Centrifugal Slurry Pumps

for Hydrotransport Tailings

Prepared by:
Aleks Roudnev, Chief Engineer Hydraulic Design
John Otten, Global Product Manager

Presented by:
October 2016
Concentrator Plant
Concentrator Plant

Tailings Pumps
Pipeline Transport
Mine Removal Options
Pipeline Transport
Long distance Pipeline trends
Long distance Pipeline trends
Pumping Equipment Options
Selection Credentials
Double Walled Pumps are safe
Design Features of High Pressure centrifugal Slurry Pumps

Double walled pumps are safer

Unlined pumps are lower pressure, casings a

wearing component & potential cracking issue!
 Slurry Pumps for Tailings and Hydrotransport Service

• The following features ensure safe, reliable and economic operation of the
Weir Minerals pumps:

• Encased liner design: This is an important safety feature when handling

abrasive and corrosive slurries.

• Ability to interchange pump liners: This is a major benefit when selecting the
most suitable material to resist abrasion.

• Heavy duty pump bearings: These are required as the axial thrust in the last
stages of a multi-staged scheme will be of high value, due to the combined
discharge pressures of the previous pumps acting over the shaft area (taken at the
stuffing box).Caution: Be mindful of the axial thrust reversal at an intermediate
stage.

• Ability to accept either packed gland or mechanical seal.

Transport Pumps in Operation – Oil Sands
Transport Pumps in Operation – Concentrates
Transport Pumps in Operation – Tailings
Transport Pumps in Operation – Tailings
Transport Pumps in Operation – Tailings
Pump Wearing Materials
Best Practise Pump Selection
Multi-Stage Applications for Centrifugal Slurry Pumps
Multi-stage pumping refers to two or more pumps used in series for heads exceeding single
stage limits for long distance pipelines.
Two basic pump arrangements may be used for pipeline transportation duties :
▪ Low pressure pumps spaced evenly along the pipeline in more stations

▪ High pressure pumps multi-staged in one station

High Pressure staged pumping is more common with lower Capital Cost.
Design and Selection
Design and Selection
Design Features of High Pressure centrifugal Slurry Pumps

Full range for high pressure pumps multi-stage operation

Design and Selection
 Important considerations for selection and operation
• Main factors influencing selection of the pipe size – tonnage throughput, slurry rheology,
particle size distribution and line velocity to keep solids suspended along the pipeline.
• Pipe wall thickness could vary along the pipeline to match maximum pressure. May include
diameter options depending upon the application.
• Pipeline velocities, routing over the terrain, method of installation (above or below ground),
access for maintenance (reviewing erosion and corrosion), starting-up procedures,
emergency shut down procedures and re-starting the system needs careful planning.
• Optimum configurations for centrifugal pumps in series requires review of inter-stage piping
arrangements, foundation loadings and pipe anchors together with maintenance issues e.g.
overhead crane access.
• Multi-stage pump installations require careful analysis of the system pipeline curve and the
intersection with each stage pump curve to define operating pump ranges.
• Start-up of the pipeline requires particular attention in order that the motors are not
overloaded due to high flowrates and / or to avoid pump cavitation.
• For a multi-staging installation, it is recommended to allow for the first and final stage pumps
to be driven by variable speed drives. First stage is to allow for gradual filling of the pipeline
while the final stage is to allow for pressure variations when pumping along the dam
perimeter.
• Pipeline starting and stopping is recommended to be carried out with water or dilute slurry.
Variable speed drives assist these operations due to density changes and pressure drops.
• Wear of centrifugal pump parts are generally equal for pumps operation in series. Pump
liners and impeller wear life can vary between 6 to 18 months depending upon the
application.
Design and Selection
Selection Criteria - Avoiding Problems
• Pipeline friction loss considerations and Over Pumping

• Impeller peripheral speed limits

• Air problems & Sump design

• Settling Velocity in pipelines

• Hydraulic Profiles

• System Head Curve

• Inter-stage adjustable piping to solve loading issues

• Variable speed pumping

• Variable Speed control advantages

• Prime References – Tailings Transportation

Selection Criteria - Avoiding Problems
Selection Criteria - Avoiding Problems
Selection Criteria - Avoiding Problems
Selection Criteria - Avoiding Problems
Selection Criteria - Avoiding Problems
Selection Criteria - Avoiding Problems
Selection Criteria - Avoiding Problems
Prime References - Tailings Transportation
Prime References - Tailings Transportation
Prime References - Tailings Transportation
Prime References - Tailings Transportation
Prime References - Tailings Transportation
Prime References - Tailings Transportation
Constancia – Tailings
Warman High Pressure Pumps, 20x18 U-AHPP
 Owner: Hudbay Minerals
 Mine: Constancia
 Location: Chumbivilcas Province, Cuzco, Peru
4,100 masl., 180 km of Arequipa (6 hours drive)
 Operation Date: November, 2014
 Application: Copper Tailings
 Throughput: Design 76,000 tpd, today 80,000 to 85,000 tpd Constancia
 Pumps: Warman 20x18 U-AHPP Service Center

 Motor Power: 1850 HP (1380 kW)

 Gear Box: Flender, Ratio 3.59
 VFD: 5, one per pump
Constancia – Tailings 43

Warman High Pressure Pumps, 20x18 U-AHPP ̶ Layout

Stand-By Train, Future

Constancia – Tailings
Warman High Pressure Pumps, 20x18 U-AHPP ̶ Discharge Pipeline

Description 1 Description 2
Tailings Pipeline (Steel)

Nominal Diameter = 30” API 5L Grado B OD = 30”

Pipe, Nominal Wall Thickness 0.375”

HDPE Lining, Nominal Wall Thickness 1.5”

Length (estimated) 6443 m

Tailings Pipeline, (HDPE)

HDPE, Nominal Diameter = 32” PE4710 OD = 32”

Nominal Wall Thickness, SDR 11

Length (estimated) 3395 m

Ton per Day Ton per Hour Flow (m3/Hr) Cw TH (m)

62 ktpd 2591 tph 2828 58% 88.5

87 ktpd 3625 tph 3953 58% 132.5

95 ktpd 3988 tph 4348 58% 160.5

113.35 ktpd 4722 tph 5148 58% 205.5

Constancia – Tailings 45

Warman High Pressure Pumps, 20x18 U-AHPP

Seal Water piston pumps,

Prime References – Long List for Tailings Transportation
Summary

• Pipeline transportation of mineral slurries is a viable alternative to other modes of

transportation.

• Demand for multi-staged centrifugal slurry pump/pipeline installations have

increased due to environmental pressures.

• Slurry pump/pipeline installations are becoming more popular as mineral

reserves are located in isolated regions.

• Tailings pipelines are particularly suited for multi-stage centrifugal slurry pumping.

• Centrifugal slurry pumps are suited to the presence of coarse/abrasive solids and
high flow rates.

• For remotely located disposal areas, references are now numerous for long
distance pipelines, with multi-stage centrifugal pumps operating in excess of 50
Bar pressure.
Vulco S.A.
Av. San José 0815
San Bernardo, Santiago
Chile

T +56 2 2754 2100

F +56 2 2859 5686

weirminerals.com
ventas@weirminerals.cl

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