Dec 9, 2015

Metso pumps keep the heart of a Siberian coal mine pumping

When the Russian coal producer KTK needed pumps for its new Kaskad 2 plant in southwestern Siberia, Metso was the natural choice.

TEXT: Yana Merkulova

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

The coal processed in the company’s Kaskad 2 plant is mined from the Vinogradovsky open pit, one of the coal strip mines of KTK. The total installed capacity of its three coal strip mines is 11 million tons of coal per year. Open-cast mining is used because the coal is low in ash and sulfur with a relatively high calorific value, making it well-suited for power plant fuel. The plant is the first one to combine two enrichment methods into an integrated production process. It uses both high-angle separators for scalping and dense medium separation. Together, these two methods help reduce gangue from 50% to 12% as well as adjust the ash content. 

To save water and reduce environmental impact, Kaskad 2 employs a closed process water circuit where water is recycled and reused in the process. This allows for lower water costs and prevents harmful discharges that pose risks to the environment. Because of an increased earthquake hazard in the region, the plant has implemented some additional safety measures. Special sensors deliver real-time data to the EMERCOM duty officer, helping monitor the operating environment and status of the facilities on site.  

“We launched a bid and selected Metso as the only supplier of pumping equipment for all of the plant’s 
operational needs. This includes slurries, circulating water and dense medium. With its equipment, Metso is a world leader in terms of liner durability, particularly in the area of slurry pumps. The equipment was installed in 2012, and the plant was commissioned in 2013. All pumps operate normally and comply with our production objectives.” 

VIKTOR GRIBANOV, Chief Mechanic, Kaskad 2 coal plant

Longer operation and ease of use

It took merely a year and a half to establish this new industrial facility on a previously undeveloped site. The project was strategically important for KTK, because it is 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.

To operate, the plant required a number of different pumps for slurry and water transport and for the dense medium separation. The pumps play a key role and have to be able to handle abrasive slurry and dense media. To meet production goals, Metso experts suggested horizontal and vertical pumps designed for heavy and super-heavy duty. In total, Metso delivered 70 units. 

For the dense media separation, KTK chose Metso’s НM200 pumps. Made of high-chrome alloy, they provide excellent durability and good resistance to abrasive media. Well-balanced pump hydraulics, together with the advanced application analysis and optimized pump selection through Metso Pumpdim™ for Windows, greatly increased the operating life of the wet-end parts. All the delivered Metso pumps are characterized by ease of maintenance, repair and scheduling of preventive inspection. 

Working together to ensure performance

The pumps were delivered to the site completely pre-assembled. The critical areas were fitted with pumps mounted on a maintenance slide base, which significantly simplifies maintenance and reduces downtime. Proximity of services to the production site makes it possible to provide technical support promptly, increasing the efficiency of the pumps and minimizing total cost of ownership. 

“Our equipment in the coal plant allows the customer to reach its production targets while minimizing operating costs. This project is a good example of cooperation between Metso and Kaskad 2 employees, extending from the design stage to its full commissioning,” explains Dmitry Maygatov, Chief Technical Support Engineer responsible for pumps at Metso.  


Published in Results flow control customer magazine 2/2015.

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