Design of the Tailings Pond Backwater System and Intelligent Safety Management for Fengshuling, Dexing
Classification:
Floating platform
Hotline:
The tailings pond backwater system at Maple Ridge consists of a floating backwater platform—constructed from HDPE modules—and a pump station. The floating-platform pump station is connected via a steel truss bridge (on which the backwater pipeline and power cables are securely mounted) to a winch house on the shoreline through a ramp, with the entire assembly being anchored and rising progressively as the pond water level increases. The backwater pipeline is a single φ530×9 straight-seam steel pipe, laid along the access road beside the pond and extending to the high-level backwater reservoir at the concentrator.
The normal water-intake capacity of the recirculation floating-platform pumping station is as follows: three double-suction horizontal split-case pumps, with the following main performance parameters for each pump: flow rate of 800 m³/h and head of 70 m. The operating conditions are as follows:
Operate one pump, with a single-pump flow rate of 800 m³/h and a maximum return capacity of 19,200 m³/d;
Operate two pumps, with each pump having a design flow rate of 800 m³/h, resulting in a maximum return water capacity of 38,400 m³/d.
Operate three pumps, with each pump delivering a flow rate of 600 m³/h (adjusted via variable-frequency drives);
The maximum backwater capacity is 43,200 m³/d , with surplus capacity; during normal production, all tailings water is pumped back to the concentrator for reuse. The main equipment of the recirculating water floating-platform pumping station is listed in the table:
Device Name |
Model |
Quantity |
Remarks |
|
Floating platform |
14.5 m × 6.5 m × 0.8 m |
1 item |
Made of HDPE, Q235 steel |
|
Recirculation pump |
DYS10-8 |
3 units |
Flow-through components 304 |
|
Matching motor |
Model YE2SP355M-4, 220 kW (380V) |
3 units |
|
The control cabinet is equipped with an intelligent PLC, which automatically controls the operation of the water pumps based on set parameters. A fiber-optic interface is provided for remote transmission of monitoring data, including pressure, flow rate, voltage, current, and power. Additionally, an optional remote signaling interface can be configured to enable unattended transmission and reception of remote signals.
The PLC can display the aforementioned data on-site and also transmit the data remotely to the control room via a reserved port. A pressure transmitter installed on the pump discharge pipeline works in conjunction with the PLC to control the opening of the pump outlet regulating valve, thereby maintaining constant pressure while varying flow rate. The set pressure value can be adjusted on-site. When the actual pressure exceeds the set value, the pump valve is partially closed to reduce the pump’s delivery flow. All electrical control equipment is distributed across one power supply incoming cabinet, three pump discharge cabinets, and one data acquisition and monitoring cabinet, all housed within a 5.5 m × 2.1 m control room. To address the high summer temperatures and low winter temperatures in the control room, a 1.5-ton air conditioner is installed to maintain an appropriate temperature.
The jetty consists of a 12-meter-long, 1.2-meter-wide bridge section. The entire structure is assembled from a modular pontoon system combined with standard steel components, with stainless-steel (304) guardrails installed on both sides. Both the pontoons and guardrails are standardized prefabricated elements that can be directly assembled on site using connecting fittings and are easy to package and transport. The jetty has a width of 1.2 meters, and the water transmission pipeline—including cable trays—passes beneath it. The track rails for the rail-guided conveyor trolley are laid above the jetty.
A 1.2-meter-high steel-structured safety guardrail is installed around the perimeter of the floating platform, with life rings and safety warning signs suspended from it. Steel-structured safety guardrails, also 1.2 meters high, are provided on both sides of the steel truss bridge; a secure gate equipped with a lock is installed at the entrance, and the winch room is fitted with surveillance cameras that allow pump station personnel to monitor the status of the floating platform, the steel truss bridge, the ramp, and personnel access and egress.
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