Blog: Go with the flow

New pumps offer coal mine excellent durability and abrasive media resistance

The Kuznetsk Basin in Siberia is one of the largest coal mining areas in the world. Among the major companies in the area is KTK, Kuzbasskaya Toplivnaya Company, the largest producer of thermal coal in western Siberia.

Kaskad 2, the company’s open-cast coal mining plant, has been built with some of the most advanced technological solutions. For instance, the plant has a closed process water circuit that recycles water to help lower the water costs and prevent harmful discharges into the environment. Additionally, special sensors deliver real-time data to help the staff monitor the operating environment and status of the facilities.

KTK chose to use open-cast mining because the coal is low in ash and sulfur with a relatively high calorific value, which is well-suited for power plant fuel. This plant is the first ever to combine two enrichment methods into an integrated production process, using both high-angle separators for scalping and dense medium separation. Together, these two methods help reduce gangue from 50% to 12% and adjust the ash content.

It took only 1.5 years to build this new industrial facility, which now boasts a total installed capacity of 11 million tons of coal per year, on a previously undeveloped site. The project was strategically important for KTK, because it is now able to enrich up to 70% of the coal as a result. This provides the company with high-quality coal that meets global standards and market demand.

Pumps with super-heavy-duty advantages

Kaskad 2 required a number of pumps for slurry and water transport as well as for the separation of the dense media. The pumps play a key role in handling the abrasive slurry and dense media. To meet production goals, Metso experts suggested horizontal and vertical pumps designed for heavy and super-heavy use.

KTK chose Metso’s НM200 pumps for the dense media separation, thanks to their ability to provide excellent durability and good resistance to abrasive media. In total, 70 Metso units were delivered. The operating life of the wet-end parts has been greatly increased due to well-balanced pump hydraulics and advanced pump analysis through the Metso PumpDim™ application for Windows. All of the pumps offer easy maintenance, repair and scheduling of preventive inspection.

Reaching targets while minimizing costs

The pumps were delivered completely preassembled to the site. The critical areas were fitted with pumps mounted on a maintenance slide base, which significantly simplifies maintenance and reduces downtime.

Metso services are located in close proximity to the production site. This makes it possible for KTK to get technical support promptly, thereby increasing the efficiency of the pumps and minimizing the total cost of ownership.

This project is a good example of cooperation between Metso and KTK employees, which has extended from the design stage all the way through to the full commissioning. Today, the Metso equipment at the Kaskad 2 coal plant is enabling the customer to reach its production targets while minimizing operating costs.

You can read the article  'Metso pumps keep the heart of a Siberian coal mine pumping'  in Metso Showroom.


Pavel Cherepanov

Chief Technical Support Engineer for Pumps

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