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    Iron Ore Drainage System Renovation Case: Breakthrough in Efficiency and Practical Application of Self-Balancing Multistage Centrifugal Pumps

    Publication Date:

    2025-09-12

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    In the field of deep metal mining, the stability of the drainage system is directly related to production safety and operational efficiency. In this article, professionals with mining safety and coal safety certificates Mining Drainage Pump Manufacturer Changsha Zhonglian Pump Industry , take a large domestic iron mine 825 deep well drainage project as an example to deeply analyze the self-balancing Mining Multistage Centrifugal Pump how structural innovation, material upgrades, and intelligent management solve the drainage problems under high lift and strong acidic environments, providing a replicable technical model for ultra-deep iron mines.

     

    1. Mining Drainage Conditions and Limitations of Traditional Systems

    This iron mine adopts " shaft + belt inclined shaft " combined development method, mining depth reaches 825 meters, with a maximum daily water inflow of 5000 cubic meters, requiring full lift transportation to the surface treatment system. The mine's hydrological conditions are complex, with groundwater containing high concentrations of iron ions and iron oxide particles with a diameter ≤ 2mm . pH value as low as around 5, showing acidic corrosion characteristics, posing a severe challenge to drainage equipment.

     

    MD Mining Wear-Resistant Multistage Pump

    Please click the image to learn about the model parameters and product details of Changsha Zhonglian Pump Industry's [MD Mining Wear-Resistant Multistage Centrifugal Pump].

     

     

    The originally used MD type balance disc multistage centrifugal pump has three major operational pain points: first, balance disc and balance ring are prone to wear, causing shutdowns for maintenance every 3 month, creating production bottlenecks; second, volumetric losses caused by the balance return water pipeline keep efficiency only around 65% %, resulting in high energy consumption; third, continuous erosion of the strong acidic medium on flow parts leads to a pump body lifespan of less than 2 years, with annual maintenance costs exceeding 20 ten thousand yuan, seriously affecting mining plan execution.

     

    2. Selection Optimization and Technical Breakthrough of Self-Balancing Multistage Pump

    Targeting extreme working conditions, the technical team conducted hydraulic model simulations and field tests, selecting the MD600-95*10P type self-balancing wear-resistant multistage centrifugal pump. This model adopts 10 stage impellers symmetrically arranged, designed lift of 950 meters, flow rate of 600 cubic meters per hour, specially designed for transporting high-solid-content acidic media. Its modular structure allows flexible adjustment of stages according to mining depth. / Please click the image to learn about the model parameters and product details of Changsha Zhonglian Pump Industry's [Corrosion-Resistant Mining Self-Balancing Multistage Centrifugal Pump].

     

    Corrosion-Resistant Mining Self-Balancing Multistage Centrifugal Pump

    Structural innovation is the core of performance improvement: the traditional

     

    pump's balance disc device is removed, achieving axial force self-balance through symmetrical arrangement of forward and reverse impellers, completely eliminating wear risks of balance parts and extending fault-free operation time by more than MD times; optimizing hydraulic flow path design, removing the balance return water pipeline, volumetric efficiency increased by 3 5-14% , and energy consumption significantly reduced. Targeted material system upgrade: impellers are made of

    duplex stainless steel forging, verified by laboratory tests to reduce corrosion rate in iron ion acidic media by 2205 times compared to ordinary stainless steel; the pump casing is lined with a high-chromium cast iron wear-resistant layer (hardness 8 ), effectively resisting erosion by iron oxide particles, extending the service life of flow parts to more than HRC58-62 months. 18 Cavitation resistance performance simultaneously enhanced: a low-cavitation inducer is added at the inlet, controlling the required net positive suction head (NPSHr) within

    meters; equipped with an intelligent booster device to adjust inlet pressure in real time, ensuring it is always higher than the medium vapor pressure, completely solving cavitation problems under high suction lift conditions. System collaborative optimization and intelligent operation and maintenance system To fully leverage equipment efficiency, a full system matching retrofit was implemented. The pipeline system uses flange-connected duplex stainless steel seamless pipes, with pressure rating increased to 3.2 ; pipeline slope precisely controlled at

    °, utilizing gravity effect to reduce iron oxide deposition and lower pipeline blockage risk.

    Constructing a 25MPa perception 3 diagnosis

    early warning " intelligent management system: multi-parameter sensors for vibration, temperature, and pressure are deployed at key pump components, combined with online - monitoring instruments to capture operating status in real time; data is integrated into the mine's IoT platform, establishing a machine learning-based fault prediction model. When bearing temperature exceeds - ℃ or vibration amplitude is abnormal, a graded warning is automatically triggered, reducing technical response time from " hours to pH hours. 85℃或振动幅值异常时自动触发分级预警，技术响应时间从48小时缩短至3小时。

     

    3. Analysis of Transformation Results and Comprehensive Benefits

    Through technological upgrades and management optimization, the performance of the drainage system has achieved a qualitative leap. Implementing quarterly high-pressure water jet cleaning and standardized inventory management of vulnerable parts has improved the overall equipment efficiency ( OEE ) from 62% to 89% ; a single pump operating independently can meet the entire well drainage demand, replacing the original three-stage relay drainage mode. The system's continuous operation time has been extended from 500 hours to 3200 hours or more.

    Significant economic benefits: annual electricity consumption reduced by 28 ten thousand kWh, equivalent to electricity cost savings of 22.4 ten thousand yuan; maintenance costs decreased from an annual average of 80 ten thousand yuan to 32 ten thousand yuan, a reduction of 60% ; failure downtime rate decreased by 75% , indirectly reducing mining interruption losses by more than 300 ten thousand yuan / per year.

    Comprehensive environmental and safety improvements: optimized sealing structure reduced leakage points by 92% and completely eliminated the risk of acidic wastewater pollution; adopting low-noise design and vibration-damping foundations reduced operating noise from 108dB to 82dB , meeting the occupational exposure limit requirements of GBZ2.2-2007 .

     

    4. Technical Experience and Future Development Directions

    Project practice has established three major principles for selecting ultra-deep well iron ore drainage equipment: first, the head design must retain a safety factor of 1.2 times to cope with increasing mining depth; second, material selection must simultaneously meet acid resistance and solid particle wear requirements of ≤ pH ; third, priority should be given to self-balancing structures to maximize maintenance-free periods. 3 Intelligent upgrades have become an inevitable trend. Through big data analysis, potential failures above

    can be identified in advance. As iron ore mining develops to depths of 80% meters and beyond, future breakthroughs need to focus on the application of titanium-based composite materials (which can achieve 1500 weight reduction) and digital twin technology to build a virtual-real mapping 40% intelligent control system that provides core support for the construction of green intelligent mines. The self-balancing multistage centrifugal pump is a key piece of equipment for deep mine drainage. Its technological upgrades will continue to drive cost reduction, efficiency improvement, and enhanced safety and environmental protection in the mining industry. 作为深部矿山排水的关键装备，其技术升级将持续推动采矿行业降本增效与安全环保水平提升。

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