Traditional pump stations in underground mining are typically constructed within large, excavated chambers where multistage pump sets or large progressive cavity pumps and extensive pipework are one of the most expensive and maintenance heavy parts of underground operations.
But what if a mine could simplify its entire dewatering setup and cut costs?
The Flygt 2450 from Xylem Water Solutions – the first 300-metre high head submersible pump built for abrasive and high solids conditions – offers a new way forward.
The problem: Traditional dewatering is too costly, too complex with large pump stations
Traditional pump stations typically demand:
1. Large and expensive underground excavation
2. Multiple pumps, more failure points
Achieving high head normally requires multiple pumps in series or large progressive cavity pumps, driving up capital costs and complicating maintenance. Each additional pump represents another potential failure point, reducing system reliability and increasing the risk of unplanned downtime when something goes wrong.
3. Complex piping and sedimentation system
Traditional systems require separate sedimentation tanks, large manifolds and valve assemblies, long pipe runs, access platforms, steelwork, and concrete – which all add layers of infrastructure.
Wear accelerates in dirty water conditions, where many systems struggle with solids, leading to rapid impeller degradation and increased maintenance requirements. Frequent servicing, combined with difficult access, can result in lost production time, particularly for fixed installations that require disassembly or cranage.
The result? High cost, low uptime, ongoing operational drag.
The solution: A single high head pump that simplifies everything
The Flygt 2450 replaces entire multi‑stage pump stations with a single high‑head submersible pump – significantly reducing cost, complexity, and infrastructure in both underground and deep open‑pit operations.
1. Massive Infrastructure Savings
With a compact size (1.5m high × 0.7m wide) and hopper‑based installation, the 2450 removes the need for large chambers, sedimentation zones, multi‑stage pump sets and complex pipework.
The outcome: lower capital cost, faster installation, a smaller excavation footprint and far greater flexibility underground.
2. Lower maintenance costs through long service intervals
Extended 6000‑hour inspection intervals reduce planned maintenance and callouts. When servicing is required, the 6‑bolt hydraulic access allows quick disassembly (in under 15 minutes) without heavy lifting or full teardown.
3. Handles abrasive, dirty water without sacrificing life
Hard‑Iron™ impellers, Dura‑Spin™ diffusers and 10 per cent solids‑handling capability allow the 2450 to operate reliably in harsh mining water. These mining‑specific hydraulics reduce wear, prevent clogging, and extend component life.
4. Energy efficiency built for underground mining
With an IE3‑rated motor the 2450 reduces energy usage – even at high head or in sediment‑rich water.
5. Reliability and uptime gains through simplicity
Every hour of downtime impacts production. A single high-head pump reduces the number of components that can fail. With fewer moving parts, fewer pumps, less pipework, and minimal infrastructure, the system becomes inherently more reliable.
For fast-advancing underground operations, the portable, modular hopper system adds another advantage: it can move with the mine, rather than locking infrastructure into one place.
| Feature | Traditional Dewatering | Flygt 2450 System |
| Excavation | Large chamber | Small sump/hopper |
| Sedimentation | Separate tank | Integrated (basic) |
| Pumps | 2-3 stages | 1 pump |
| Pipework | Complex | Simple |
| Mobility | Fixed | Portable/modular |
| Maintenance | Frequent | 6,000-hour intervals, fast access |
| Head capability | Requires pumping in series | 300m from one pump |
| Solid handling | Limited | 10% solids |
| Total operational cost | High | Lower |
Together, these improvements result in major cost savings across the full life cycle of the dewatering system – from installation through to long-term operation.
A shift towards smarter and more efficient water management
Mining operations looking for lower cost, reduced infrastructure, and higher uptime are turning to more efficient, modular dewatering strategies. The Flygt 2450, purpose-built for the challenge of modern underground mining.
With significantly lower CAPEX, reduced maintenance, improved energy efficiency, and simplified operation, the Flygt 2450 helps mines:
- Cut costs
- Increase uptime
- Reduce infrastructure footprint
- Improve overall operational efficiency
One pump. Fewer assets. Lower lifetime cost.