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Dewatering in Depth: The Advent of Super High-Head Pumps for Mining Operations

June 25th, 2025

PAC H range Mining Dewatering

Mining involves harsh and difficult operating conditions. The presence of water in mines can lead to operational delays, safety hazards, and increased costs.

Dewatering pumps are therefore essential for managing the relentless ingress of water. However, dewatering pumps must overcome many challenges, including water with high corrosive and abrasive materials content, remote working in confined environments, and extreme head and flow requirements. These pumps must exhibit certain key criteria if they are to perform consistently and efficiently over time.

 

1. Pump robustness

Dewatering pumps must withstand the abrasive and harsh conditions of the mining environment. Their physical design must be sufficiently robust to cope with the rough and tumble of an operational mine. The choice of materials in pump construction is also critical. High-wear resistance materials extend the pump's life and maintain performance in the presence of abrasive particles. Corrosion-resistant materials are necessary to withstand the chemically aggressive environments found in some mines.

Atlas Copco’s new PAC SH (super high head) surface dewatering pump working in mining operations

 

2. Pump performance

Dewatering requirements will change as the mine evolves. Initially, water levels may be quite low, but as excavations deepen, the demands on the pump increase significantly. Dewatering pumps, therefore, need to have the capacity to lift growing volumes of water to ever greater heights. This requires high head and high flow rates.

 

3. Ease of maintenance

In safety-critical applications like dewatering, minimizing downtime of vital equipment is a priority. The ease with which the pump can be maintained or repaired is, therefore, important. Accessibility to wear parts for routine inspection and replacement, and whether any special tools are required, are key considerations. Complexity is another: dismantling sections of the pump to replace seals, drive trains, or lubricants in cramped conditions and poor light is not ideal, as components could easily be fitted incorrectly or lost. Adjustable wear parts are also desirable because they can be used to recover performance and extend service intervals.

 

4. Ease of deployment

Water levels can rise rapidly, so dewatering pumps should be portable and easy to deploy. The physical dimensions and weight of the pump, particularly in confined conditions that impede normal handling, are important factors. In addition, electric submersible pumps need power cables and, in some cases, start and motor protection panels. These can add to the complexity of moving a pump around in confined spaces, so their design and portability must also be considered.

 

5. Overall pump efficiency

Mines are often located in remote areas without a permanent power supply. Dewatering pumps must therefore offer optimal performance over time without being too power-hungry. Initially, there may be very little water, but as the mine deepens, water displacement requirements will increase. In addition, the water will become dirtier, more acidic, and more viscous. Pump hydraulics should meet the range of volumes and lifting heights that arise during the mine’s operational life without compromising energy efficiency. Nor should the dewatering pumps create any power spikes that could compromise other equipment's performance.

 

All these techniques have been applied in the evolution of Atlas Copco’s new PAC SH (super high head) dewatering pumps. These heavy-duty automatic self-priming pumps perform well with all media. They feature cartridge seals, which not only extend the mean time to repair (MTTR) but also make servicing much quicker and easier because there is only one component – the cartridge – to swap out. The use of link belts adds to their ease of serviceability. A further feature is the mechanical seal oil bath, which ensures sufficient lubrication and extends the pumps’ dry running capabilities. 

 

New design techniques are also facilitating customization so that pumps can be more closely matched to specific mining conditions. The PAC SH range offers various impeller options to optimize performance, materials upgrades for enhanced wear resistance in particularly abrasive conditions, and various control options to give mine operators full access and control over pump and engine parameters.

6. New pump design

Meeting all these criteria is not a simple matter, because the technical solution for one challenge may cause issues elsewhere. For example, the pump casing can be made of thick metal to improve robustness, but this adds significantly to the weight, making the pump less portable.

 

Fortunately, modern technology is providing new ways to optimize pump design and deliver the high heads and flow rates that dewatering operations demand. The progression of cloud computing has significantly enhanced the scalability of Computational Fluid Dynamics (CFD) simulations, allowing for more extensive and complex analyses. Concurrently, advancements in 3D printing have revolutionized prototyping, enabling more development cycles within tight design timelines. Moreover, intricate geometries that were once challenging or unfeasible to cast a decade ago are now achievable with high reliability, thanks to modern casting methods that incorporate cores and moulds fabricated using 3D printing technology.

All these techniques have been applied in the evolution of Atlas Copco’s new PAC SH (super high head) dewatering pumps. Depending on the model, PAC SH dewatering pumps can achieve a maximum head of up to 200 m (656 ft) and flow rates up to 1980 m3/h (8710 usgpm).

 

These heavy-duty automatic self-priming pumps perform well with all media. They feature cartridge seals, which not only lowers the mean time to repair (MTTR) but also make servicing much quicker and easier because there is only one component – the cartridge – to swap out. The use of link belts adds to their ease of serviceability. A further feature is the mechanical seal oil bath, which ensures sufficient lubrication and extends the pumps’ dry running capabilities. Galvanized skids and beams further extend the durability of the PAC SH range.

 

New design techniques are also facilitating customization so that pumps can be more closely matched to specific mining conditions. The PAC SH range offers various impeller options to optimize performance, materials upgrades for enhanced wear resistance in particularly abrasive conditions, and various control options to give mine operators full access and control over pump and engine parameters.   

 

7. Extracting the best value

To achieve optimal performance, choosing a pump on its technical merits is only part of the equation. The supplier's expertise and support are equally important. Dewatering pumps are required to run for long periods, so access to spares and engineering back-up throughout their life is important. As we have mentioned, technologies are evolving rapidly, and a reliable supplier will keep you informed about developments and upgrades that can improve pump performance even further. It is therefore advisable to check pump supplier’s credentials, ensuring that they have an established reputation and a strong presence in all the territories in which you operate. Other key characteristics to look for in a supplier include their commitment to ongoing research and development, the pre-sales advice available, the ability to support with technical training and post-sales assistance, and warranty support. 

 

8. Final word

Selecting the best dewatering pump is not just a capital expenditure: it is a strategic decision that can significantly impact operational efficiency and safety.  When selecting a pump and supplier, consider the full spectrum of needs – from the product's performance to the post-purchase support. The right choice of pump partner will not only optimize dewatering operations but also contribute to the overall success of your mining operation.