Aerial view of evaporation ponds for the extraction of lithium in Northern Argentina
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Battery metals for mobility transition: How pumps sustainably advance mining

 

Electric cars have triggered a rapid increase in demand for metals such as lithium, copper, cobalt and nickel. Covering this demand is becoming more and more difficult. How can we expand mining of these critical metals with a minimum impact on the environment? Durable and water-saving pumps make mining more efficient, safer and more environmentally friendly – contributing significantly to the sustainable future of mobility.

Infographic of the predicted rise in demand for lithium-ion batteries

Demand for electric cars is on the rise – and so is the demand for battery metals

The future of traffic is electric: Electric cars are efficient, climate-friendly and quiet. S&P Global Mobility is expecting the sales of electric cars to grow in 2025 – despite the challenging market environment and uncertainties of government subsidies. According to their forecast, sales figures may rise by 30 percent in 2025, reaching a total of 15.1 million vehicles, equalling 16.7 percent of vehicle sales worldwide. This has got some far-reaching consequences: The growing number of electric cars is rapidly increasing the demand for lithium-ion batteries. McKinsey estimates the demand for 2025 to be 1500 gigawatt hours (GWh), which may rise by 27 percent a year to about 4700 GWh by 2040. This will spur on the demand for critical metals, such as lithium, copper and cobalt, that are indispensable for the production of batteries. It is a challenge for the mining industry to keep up with the pace of this rapid development.

From lithium to cobalt: Electric cars require numerous critical metals

The materials needed for manufacturing an electric car differ from those of a combustion engine car. An internal combustion engine is a lot heavier than an electric motor, however, it is mainly made of iron alloys or aluminium alloys. By contrast, the motors of electric cars require many hundreds of metres of copper cable and frequently also permanent magnets, involving rare earths such a neodymium.

Excluding steel and aluminium, an electric car contains about six times the amount of metals and minerals of a combustion engine car, estimates the International Energy Agency (IEA). A car with a combustion engine only comprises 22 kilograms of copper and 11 kilograms of manganese, compared to an electric car with 206 kilograms of metal and minerals such as copper, manganese, lithium or graphite. The rising demand for these minerals is an enormous challenge for the mining industry. To enable the large-scale production of electric cars new pathways have to be found to secure a reliable supply with critical resources – a balancing act between technological progress and sustainable use of resources. 

 

Infographic showing the demand predicted for battery metals until 2034

Supply cannot cover demand

The rising demand for battery metals takes the global supply to its limits. Prognoses by the leading market research company Benchmark Mineral Intelligence (BMI) indicate that the demand for lithium would have more than tripled by 2034, from today's 1.1 million tonnes of lithium carbonate equivalent (LCE) to 3.8 million tonnes of LCE. This would lead to a deficit of 572,000 tonnes. The industry research company also foresees a clear deficit for cobalt, nickel and manganese. Investments in mining are further necessary to become less dependent on the market dominance of certain countries supplying individual battery metals. For instance, 60 percent of lithium is refined in China, and 70 percent of all manganese is sourced from the Democratic Republic of Congo.

Pumps are essential for satisfying resource demand

To be able to cover the demand for battery metals triggered by electric cars, major investments into mining are pivotal. Pumps play an indispensable role in this process: from draining deep mines to pumping lithium brine from salt lakes and transporting abrasive sludge in ore processing. Here are three examples of KSB innovations that make mining more efficient and sustainable.

A mine shaft filled with water and two submersible motor pumps of the UPA type series

Efficient water extraction: UPA type series

Borehole pumps are indispensable in mining. In the "lithium triangle“ of Argentina, Bolivia and Chile, for example, they extract a brine solution containing lithium from underground reservoirs. These pumps also play an essential role in transporting ore in open-cast or underground mining: Without groundwater being pumped off regularly, the mines would be at risk of flooding. When extracting brine and dewatering mines, pumps need to be robust and reliable to withstand extreme conditions as the water handled contains abrasive and corrosive materials. KSB’s UPA submersible motor pumps offer a powerful solution: With their superior design, longevity and high performance, they not only provide reliable and efficient dewatering services, they also lower the overall operating costs, i.e. the total cost of ownership.

Longevity in the milling circuit: MDX type series

Metals that are sourced from open-cast or underground mines have to be separated from the surrounding rock that cannot be used. To do so, the ore is processed into smaller particles and added to by water. Ball mills – rotating drums filled with steel balls – grind this mixture into a fine sludge, called slurry. Substances are added that make the metals attach to froth and float up – a process called flotation. These processes are kept moving by large slurry pumps that have to be extremely wear-resistant. This is where the GIW Mill Duty Extra Heavy (MDX) product line by KSB GIW sets standards. The MDX pumps stand out with their robust wear parts made of the innovative Endurasite™ white-iron alloy that can potentially double the service life of casings, impellers and linings. With their large impeller diameter they run at a lower speed than competitor models, which extends their service life and makes flow conditions more controllable.

The drum of a ball mill, and a milling circuit pump of the MDX type series
Absetzbecken zur Lagerung von Schlämmen aus dem Bergbau und eine Pump vom Typ TDW

Using water economically: TDW type series

The sludges that remain after the flotation stage are called tailings. To minimise the environmental impact and use resources efficiently, recovering as much water as possible from the tailings with filter presses is crucial. One of the main challenges mine operators face is that slurry pumps require fresh water for transporting tailings. This barrier water flushes the shaft seals to prevent the ingress of particles. As mines for battery metals are often situated in dry regions, providing barrier water can be detrimental to the environment and cause the operators high costs. The type series TDW by KSB GIW has been developed in cooperation with their customers to overcome this challenge. It is designed with an expeller shaft seal that does not require flushing. An additional vaned impeller generates pressure to keep the fluid handled away from the seal area. By making water transport to remote mining sites redundant, this pump increases the site's efficiency, lowers its operating costs and helps reach sustainability goals.

KSB's innovations make mining more efficient and sustainable

Our innovative pump solutions enhance mobility transition by minimising energy input, water consumption and wear in mining. In this way they not only protect the environment, they also lower the operating costs for the operators. A key factor is the use of specially developed materials. The Gasite® alloy family, which was created in the 1940s and has continuously been developed until today by KSB GIW, ensures the durability and resistance of mining pumps. For a plus in resistance Endurasite™ alloys are used, the standard material for wetted parts of the MDX series. IIoT (Industrial Internet of Things) technology reduces downtimes and extends the service life of the pumps by monitoring wear and signalling when maintenance is needed. It also ensures that pumps are always operated at their optimum.

Sustainability and profitability in mining are not opposites. Barrier-water-free shaft seal arrangements for slurry pumps not only spare natural resources, they also lower the total cost of ownership. With their expeller seal, pumps of the TDW type series are suitable for recovering water. For the LCC type series, KSB has developed the LAPIS mechanical seal – another seal that works without barrier water. This seal is characterised by its springs being located outside the fluid handled, where they are protected from solids by an external quench fluid, such as water or grease. A clamping collar mechanism enables maximum torque transmission and easy adjustment.

KSB GIW, Inc.'s commitment to environmental protection is not limited to innovative pump solutions – they also consistently opt for sustainable solutions for their own operations. By purchasing renewable energy certificates the company ensures that its production facilities are powered one hundred percent by renewable energies. KSB further promotes a circular economy with its comprehensive scrap metal buyback programme: Worn pumps and parts are recycled. About sixty to seventy percent of the new slurry pumps are made of recycled white iron. This is how KSB holistically contributes to a more sustainable future – from product development through to operations management.

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