Slurry Pumps MCU Introduction (English)

Technical Learning Program Centrifugal Slurry Pump Introduction
Mill Circuit University

Centrifugal Slurry Pump Introduction
Version 2.0
Developed by
Centrifugal Pump Technology Group
Presented by
Learning and Development
Weir Minerals Division
Outline
1. Product Information
2. Product Terminology
3. Product Types or Variations
4. Product Selection Methodology
5. Product Performance
6. Competition
Version 2.0 20 September, 2018 IP Category: Confidential Page 1

Warman® MCR®, MCR-M®, MCU®
 For the most severe services

 SAG, ball, rod mill discharge service
 MCR® - rubber lined
 MCR-M® - metal lined
 MCU® - metal unlined
 Product Overview:
 Flow
 Up to 10,220 m3/hr (45,000 USGPM)
 Pressure
 Up to 55 m (180 ft) of Head 900 kPa
(~130 Psi)
 Size
 125 -760 mm discharge
 Power
 Up to 4,025 KW (5,400 HP)
Warman® AH®
 Suitable for most applications

 Flow
 Up to 5,000 m3/hr (22,000 USGPM)
 Pressure
 Up to 73 m (240 ft) of Head 2,070 kPa
(~300 Psi)
 Size
 Up to 18 inch discharge
 Power
 Up to 2,015 KW (2,700 HP)

WRT® – Wear Reduction Technology

Discharge guide vanes from
WBH® development
Born from the WBH development

program, this new technology was
retrofitted into the most popular
Warman AH, L and M models to
give your existing installations a
face lift in performance! Matching
throatbush
Warman® AHP / AHPP
 Suitable for tailings or staged applications

 Flow
 Up to 5,000 m3/hr (22,000
USGPM)
 Pressure
 Up to 73 m (240 ft) of Head
 AHP 3,450 kPa (~500 Psi)
 Some high pressure sizes AHPP
6,900 kPa (~1000Psi)
 Size
 4-18 inch discharge

Warman® WBH® Slurry Pumps
 The next generation of the AH

 Suitable for most applications
 Flow
 Up to 2,725 m3/hr (12,000 USGPM)
 Pressure
(~300 Psi)
 Size
 50 – 300 mm discharge
 Power
 Up to 1,045 KW (1,400 HP)
Warman® Froth Pumps: AHF, LF, MF
 Froth Slurry, Flotation, Chemical, Pulp &

Paper
 Flow
 Up to 4,525 m3/hr (20,000 USGPM)
 Pressure
(~500 Psi)
 Size
 Power
 Up to 1,420 KW (1,900 HP)

 Easily retrofits existing AH®, L orM

installations by replacing:
 Cover plate
 Throatbush
 Impeller
 Intake joint ring
Warman® XU
 Suitable for most applications, generally sold into

Coal and Aggregate
 Metal unlined configuration
 Flow
 Up to 2,270 m3/hr (10,000 USGPM)
 Pressure
(~150 Psi)
 Size
 Power
 Up to 560 KW (750 HP)

Warman® HTP
 High pressure Hydrotransport and

tailings
 Only available with metal liners and
impeller
 Flow
 Up to 9,085 m3/hr (40,000
USGPM)
 Pressure
 Up to 67 m (220 ft) of Head
4,400 kPa(~580 Psi)
 Size
• 500, 600, 650 mm discharge

Power
 Up to 4,025 KW (5,400 HP)
Warman Bearing Assemblies

Warman® Bearing Assemblies Terminology;
 Defined by letter designation A (smallest)

through V (largest)
 Grease lubricated as a standard
 Includes grease purged labyrinth type shaft

seals
 Inpro-Seals available upon request
U, V

Warman Bearing Assemblies

Warman® Bearing Assemblies

 Bearing assemblies supplied with grease zerk fittings for the
labyrinth shaft seals
 Recommended greasing intervals in IOM
 Bearing assemblies supplied with pipe plugs in the bearing grease

holes
 Greasing frequency/amount requirements in IOM manual
 Provided with plugs vs. grease zerks in order to minimize
possibility of site over greasing the bearings when greasing the
shaft seals daily.
Warman® Horizontal Slurry Pumps

 Standard Design Features

 Heavy duty construction
 Cast/ductile iron outer casing
 Interchangeable thick elastomer or metal

liners and impellers
 Large diameter impeller
 Large internal passages
 Cartridge style bearing assembly
 Shaft sealing options: gland, low flow

gland, dry running centrifugal seals and
mechanical seals
 Warman® pattern flanges
We have come a long way from the

original design…

Product Terminology
Bearing Assembly Volute Liner Seal Frame Plate Liner Rubber Lined
Metal Lined
Frame Plate Liner Seal
Impeller Cover Plate Liner
Unlined
One-Piece Frame Volute Liner seal Casing
OH0 – Unlined Pump
Volute Liner Impeller Throatbush Intake Joint Ring
Warman® Liner Interchangeability

Product Core Part numbers
Part Description Basic Part # Material Code Basic Part Number

Cover Plate Liner 018 Abrasion or Erosion/Corrosion Resistant Alloys A
Expeller 028 Corrosion Resistant Alloys C
Expeller Ring 029 SG Cast Irons D

Frame Plate Liner 036/043 Engineering Alloys E
Frame Plate Liner Insert 041 Grey Irons G

Gland / Bolts 044/045/126 Heat Resistant Alloys H
Impeller 056/058/145/147 Coper Base Alloys K

Intake Joint Ring 060 Aluminum Base Alloys L
Lantern Ring 063 Special Alloys M
Impeller Sealing O Ring 064 Nickel Base Alloys N

Neck Ring 067 Coatings
Shaft Sleeve 075/076 Spray / Cladding J
Stuffing Box 078 Polymers
Throatbush 083 Plastics P

Shaft O Ring 109 Gland Packings Q
Volute liner 110 Natural Rubbers R

Shaft Spacer / Sleeve Spacer 117/179 Synthetic Bushings T
Lantern Restrictor 118 Synthetic Elastomers S
Expeller Ring Seal 122 Polyurethanes U

Volute Seals 124/125 Combinations
Discharge Joint Ring 132 Multi-material Combinations Z
Warman® Materials
 A05 – 27% Hi Chrome

 The standard metal offering for
Warman® pump product
 A61 – 30% HyperChrome®

 Utilized when a greater level of wear
resistance vs A05 is required
 A68 – 36% HyperChrome®

 Utilized when a greater level of wear
resistance vs A61 is required
 R55 – 47 ShoreA
 The standard elastomer offering for
Warman® pump product

Types of Slurry Pumps – MCU, MCR-M, MCR 19

Courtesy of ANSI/HI 12.1-12.6 - 2016
Rubber
Unlined
Metal
Unlined
OH0 – Unlined Pump
Unlined
Weir Minerals MC Pumps: MCU Unlined Metal Design 20
Available 125, 150, 200, 250, 350, 450, 550, 650

Option for very course particles > 10 mm and ball scats
Same piping locations as MCR
Interchangeable throatbush, impeller, FPLI with the MCR
Ability to increase casing wall thickness on pattern

Weir Minerals MC Pumps: MCR-M, Metal Lined Design
Option to convert MCR to a High Chrome Iron Volute Liner

Available 400, 450, 550, 650, 750, 760
Ability to mix rubber and metal side liners
Weir Minerals MCR Pumps: 2 Piece Design
A 2-piece design Cover plate – size 300 and larger

Allows access to replace the impeller or throatbush without disconnecting the
discharge piping or splitting the casings

Two Piece Cover Plate

Remove Suction Cover and Throatbush subassembly

Suction Cover lifting beam has pick points for rubber or metal
Throatbush


Impeller lifting beam has moveable lower jaw for new vs worn
impeller

Provides ability to replace Throatbush or Impeller without
removing discharge piping or removing the Cover Plate

Pump Maintenance
Lifting Beam for 4 & 5 vane Impellers

Beams can safely lift both new and worn parts
Bottom hook (blue piece) is unbolted and rotated as needed
Preswirl
Localised wear of vane under front shroud (550MC)
Boddington
Ernest Henry
Cadia

Preswirl
Hypothesis for wear pattern
Recirculating flow across wear ring interacts
with gross flow onto leading edge of vane
causing vortex at inside of front shroud and
behind leading edge
Difficult to change amount of recirculation, so change angle of flow

onto leading edge by using pre-swirl vanes in inlet of throatbush
Pre-swirl vanes
Pre-swirl vanes developed

to give slurry a rotational
velocity ahead of the
impeller leading edge to;
a)Reduce the relative

velocity of the slurry onto
the vane, and
b) Lower the angle of

incidence to ensure the
flow is close to the
“shockless” entry angle

Conventional Centrifugal Pumps 31
Centrifugal, or radial flow pumps comprise a part of very wide class of rotodynamic pumps in
which pumping of liquids or generation of pressure is effected by a rotary motion of one or
several impellers, or blade cascades.
Predominantly radial direction of pumped liquid creates conditions of some centrifugal force
action.
Most rotodynamic slurry pumps are of centrifugal type.
Centrifugal Pump Impeller – Characteristic Dimensions
Note that vane angles are measured from

radial (meridional) direction. Another
convention is to measure vane angles from
tangential direction.
Centrifugal Pump Function 32
The main function of a pump intake is to provide for a uniform liquid velocity distribution at the
impeller eye.
The main function of a pump impeller is to transfer mechanical energy of a driver to the hydraulic
energy of liquid.
The function of a discharge collector (volute and diffusion chamber) is to convert the kinetic energy
imparted to the liquid by the impeller into pressure. The discharge collector takes no part in the
generation of head and therefore deals only with minimizing losses.
Conventional End-suction Pump Schematic
1 - Intake
2 - Impeller
3 - Volute
4 – Diffusion
chamber
5 - Cutwater
6 - Vane

Centrifugal Pumps of Conventional Design – Specific Speed

33
The physical meaning of specific speed (in US units):

revolutions per minute to deliver 1 gpm at 1-foot head with an impeller
similar to one under consideration but reduced in size.
Ns  n Q 3/ 4
H
The specific speed as a type number is constant for all similar pumps and
does not change with speed for the same pump.
US units to metric units conversion for specific speed:
Ns  51.6n s
Centrifugal Slurry Pumps
Variety of Pump Types for Different Applications
ANSI/HI 1.3 (2009). American National Standard for Centrifugal Pumps For Design and Application.

Centrifugal Pumps of Conventional Design 35
Pump Efficiency versus Specific Speed and Pump Size
Centrifugal Pumps of Conventional Design
Conventional Pump Design – Performance Curves for Various Ns

Slurry Classification 37
HI 12.1-12.6 – Service Class for Heterogeneous Slurries
 Based on Specific Gravity and d50 Particle Size

 Larger solids, or higher concentrations will result in a more erosive slurry
Slurry pump service can be

classified by “standard” slurry
application
• Severe
• Heavy
• Medium
• Light
Corresponding ANSI/HI Slurry

Pump Standard service classes
4,3,2,1
HI Head Recommendations Based on Slurry Classification 38
Class 1: 105 m
Class 2: 73 m
Class 3: 55 m
Class 4: 40 m
Wear history has shown these recommendations are not conservative

Weir’s Slurry Wear Type Classification is a more in-depth methodology which is
discussed in advanced modules

What is Tip speed? 39
Recommended Tip Speed & Head Limits for Slurry Type
Tip speed is the tangential component of an impeller rotation at a

specific diameter.
Tip speed at OD
Tip speed at ID
Units:
Diameter in Meters to get m/s

Diameter in Ft to get ft/s
Speed in RPM (revolutions per minute)
Recommended Tip speed limits depend generally on service types to limit the wear
on the pump liners. For example: Impeller wear can exponentially increase at 2.5 to
3 exponent with an increase in Tip Speed.
Slurry Application 40
Service Class 4 Service Class 1

Slurry Pump Groups 41
Service Class 4 Service Class 1
Preferred Operating Range (POR) 42
Service Duty Preferred Operating Range

Classification General Guideline
Wet Crushing,
Mill Discharge > 1% 75% 90%
of Underflow from Severe
crusher, Oil Sands
Hydrotransport…
SAG Mill, Heavy

Media, Sand & Heavy 70% 100%
Gravel >.25”…
Ball Mill, Pebble Mill,
Sand and Gravel < Medium 65% 110%
.25”
Flotation, Dewater
Pump with SG close 50% 130%
to 1 Light
*FGD 80% to 110%
100

Performance Test
650 MCR initial validation test

▪ Used to confirm actual pump operating
condition
Customer witness tests
▪ Offsite Online viewing
MC Pump – Typical Predicted Performance Curve
Curve number
starts with a “P”
Created using
affinity rules and
scale factors
Bears a note:
“PREDICTED, USE
AS FIRST GUIDE
ONLY”

MC Pump – Typical Tested Performance Curve
Curve number
starts with a “T”
Reflects actual test

on water
Contains
information on test
date and location
Pump Curve vs. System Curve 46
Weir Minerals Division 11
 So where does the customer come up with a flow and head value in
order for us to select a pump?
 The flow is generally process driven where the customer is trying

to process so many tons per hour.
 The head requirement is completely dependent on the customers

system and the flow rate required for their process.
 A system curve would typically be generated to show the

head requirements as a function of flow rate.
 The system curve is dependent on the customer’s installation and

piping system.

System Curve Components – reintroduced for Slurry 47
Weir Minerals Division 12
 Discharge Static Head

 Elevation difference between surface of the liquid in the suction tank and discharge
point.
 Friction Losses
 Energy loss due to the affect of fluid viscosity.
 Losses are dependent on:

 Piping length, diameter, roughness, elbows, valves, entrance & exit losses
 Use Darcy-Weisbach and Hazen-Williams equations for friction losses (See section
5 – Friction Losses in Pipes of Weir Slurry Pumping Manual Pg. 25)
 Additional terminal pressure
 Feeding cyclones
 Spray nozzles
 Filter feed
 Pressurized tank
Actual Process Data – Single Pump System Variations 48

Centrifugal Pump Performance Curve 49
Pump Type Horizontal Pump

Pump Model 550 MCR
CURVE SHOWS APPROXIMATE PERFORMANCE FOR CLEAR WATER (ANSI/HI 1.6-2000 Centifugal Pump Test Standard unless otherwise specified). For media other than water,
corrections must be made for density, viscosity and/or other effects of solids. WEIR MINERALS reserves the right to change pump performance and/or delete impellers without notice. Frame
suitability must be checked for each duty and drive arrangement. Not all frame alternatives are necessarily available from each manufacturing centre.
80 Pump
Discharge 559mm
Nozzle
Suction 660mm Size
Impeller
70 Vanes 4
Vane ø 1580mm Impeller
Speed Curve Type Closed Data
50% 60% Part No Material
375 rpm 70% UMC55145EL1 Metal
75%
60 80% UMC55451EL1 Metal Bearing
84% Frame (Rating - KW) Frame Power
86% U 2000 Rating
350 rpm
86% Seal
50 84%
Gland Sealed Pump Seal Type
NPSH r
IENC Y
80%
Head, H (m)
Tip speed
E FFIC
Liner (Norm Max r/min)

limit
9.14m
40 300 rpm Elastomer 375
Min Passage Size Spherical
215.9mm Impeller
7.62m
Passage
Curve
30 Revision 2
Test Data
6.1m
250 rpm Revision Notes
Max speed changed
or Curve
Reference Reference
4.57m
20 Madison test 080302 Data
Last Issued Mar 08
200 rpm Issued May 10
3.05m
10
Curve Name:
“T” and
“WPA” are
© 3/2018 Weir Minerals North America
All Rights Reserved
Tested.
2000 4000 6000 8000 “P” and
TYPICAL PUMP PERFORMANCE CURVE
“ESY” are
Available in gpm and ft Flow Rate, Q (m³/hr) T-4943/2 Predicted

New from Competitors
MCPT Meeting – What is new from our Competitors?
Presented to: MC2 7th May 2012
Prepared by: John Otten, Aleks Roudnev and Ron Bourgeois
Confidential Information
This document contains information which is confidential to companies forming the Weir Minerals Division.
It should not be disclosed in whole or in part to parties other than the recipient without the express written
permission of Weir Minerals Division authorized personnel.

GIW
GIW Industries – Market Focus
Primary activity in the following sectors:
▪ Mining (Mill Circuit & Tailings)

▪ Phosphate
▪ Iron Ore
▪ Copper/Gold
▪ Oil Sands
▪ FGD
▪ Dredging, Sand & Gravel
▪ General Industry and International
▪ ~28% Market share in US

GIW Industries – Primary Product Offerings
MDX
Designed for SAG and ball mill discharge
duties as well as cyclone feed and screen
feed applications in ore mining
- Comparable to: MC®
HVF
For use in all froth pumping applications in
both the Mineral Processing and Industrial
Minerals industries
- Comparable to: AHF
LSA-S
Pumps are widely used in ore transport,
mill discharge, cyclone feed, tailings and
plant process applications
- Comparable to: AH®
Key Competitors – KSB-GIW

Key Competitors – KSB-GIW

Past History Note: Test work done in the mid 2000’s. Appeared to have early encouraging results.
GIW Industries – General Highlights
Strengths
▪ Well designed and high performing slurry pumps
▪ Lower cost point compared to Weir
▪ Highly regarded for technical solutions
▪ Slurry testing capabilities
▪ US based foundry
▪ Large Oil Sands installation ~ 40-50% of current revenue
▪ Aggressively pursue trials
▪ Broad product offering to cover almost any application, very
similar to Weir
Weaknesses
▪ Loss of the Linatex® material for their LCC-R line
▪ Do not seem to price aggressive enough on project bids and
then have to push for installations through trials
▪ Primarily a metal unlined offering which has inherent safety risks
▪ Do not have a good offering to compete when the applications
benefits from rubber liners, especially the MCR in mill circuit
applications

FLS Krebs / millMAX
FLS – Krebs/MillMax – Market Focus
▪ Mining: Active
▪ Phosphate Limited
▪ Iron Ore Lacking Success but Active
▪ Copper/Gold Successful and Highly Active
▪ Pot Ash Successful and Active
▪ Coal: Highly Successful and Highly Active
▪ FGD/Power: Very Limited
▪ Dredging, Sand & Gravel & Oil Sands: Active
▪ General Industry: Limited

Key Competitors – FLS Krebs millMAX UMD
FLS – Primary Product Offerings (Krebs - Horizontals)
Krebs millMAX metal unlined

▪ Similar to: XU, AH®, WBH® , MCU®
Krebs slurryMAX rubber lined

▪ Similar to: AH®, L, WBH®
Krebs gravelMax metal unlined

▪ Similar to: XU, AHU, MD

FLS Summary
Strengths
▪ Successful in leveraging mill equipment to package and sell total portfolio where possible
▪ GravelMAX in Heavy Media Classification applications in Coal
▪ Pull pumps through with cyclones and/or other FLS products.
▪ Aggressive pricing, especially if mills / flotation equipment have been secured.
▪ Low Cost sourcing; primarily is China
▪ Continue to invest in product development and now offer a very complete product range
▪ Very active trial program with aggressive promises and focus on benefits
▪ Extended life of wear components
▪ Wear adjustment technology
▪ Energy savings
▪ Offer complete engineering services (Purchase of CEntry)
Weaknesses
▪ Primarily a metal unlined offering which has inherent safety risks
▪ Do not have a good offering to compete with when the applications benefits from rubber liners, especially the MCR
in mill circuit applications

Key Competitors – Metso Minerals
• XM – eXtra heavy-duty with Metal wear parts

• XR – eXtra heavy-duty with Rubber wear part
XM Extra Heavy Duty Metal Slurry pump XR Extra Heavy Duty Rubber Lined Slurry Pump
Metso – Primary Product Offering (Horizontals)
MM – Mining-duty with Metal parts (Orion)

MR – Mining-duty with Rubber parts (Orion)
Mining & mineral processing

Industrial processing
Coal and power plant
Sand and gravel
Comparable to: L, XU
VERY LOW COST

Metso Summary
Strengths
▪ Highly recognizable and know brand names
▪ Relatively large install base
▪ Ability to package pumps with the mills
▪ Extremely aggressive on projects, when they want to be
▪ Extremely aggressive on offering no cost trials to customers
▪ Plans to introduce own cyclone line in the future to package with the rest of the mill offering
Weaknesses
 Quality issues
 Inferior wear life
 Issues supporting the aftermarket of their install base
 Little to no product development – using what they have
Questions 66

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Technical Learning Program Centrifugal Slurry Pump Introduction

Mill Circuit University

Mill Circuit University

Version 2.0 20 September, 2018 IP Category: Confidential Page 1

Weir Minerals Division

Warman® MCR®, MCR-M®, MCU®

 For the most severe services

Weir Minerals Division

 Suitable for most applications

Version 2.0 20 September, 2018 IP Category: Confidential Page 2

Weir Minerals Division

WRT® – Wear Reduction Technology

Born from the WBH development

Weir Minerals Division

Warman® AHP / AHPP

 Suitable for tailings or staged applications

Version 2.0 20 September, 2018 IP Category: Confidential Page 3

Weir Minerals Division

Warman® WBH® Slurry Pumps

 The next generation of the AH

Weir Minerals Division

Warman® Froth Pumps: AHF, LF, MF

 Froth Slurry, Flotation, Chemical, Pulp &

Version 2.0 20 September, 2018 IP Category: Confidential Page 4

Weir Minerals Division

Warman® Froth Pumps: AHF, LF, MF

Warman® Froth Pumps: AHF, LF, MF

 Easily retrofits existing AH®, L orM

Weir Minerals Division

 Suitable for most applications, generally sold into

Version 2.0 20 September, 2018 IP Category: Confidential Page 5

Weir Minerals Division

 High pressure Hydrotransport and

Warman Bearing Assemblies

Warman® Bearing Assemblies Terminology;

 Defined by letter designation A (smallest)

 Grease lubricated as a standard

 Includes grease purged labyrinth type shaft

 Inpro-Seals available upon request

Version 2.0 20 September, 2018 IP Category: Confidential Page 6

Warman Bearing Assemblies

Warman® Bearing Assemblies

 Bearing assemblies supplied with pipe plugs in the bearing grease

Warman® Horizontal Slurry Pumps

 Standard Design Features

 Cast/ductile iron outer casing

 Interchangeable thick elastomer or metal

 Large diameter impeller

 Large internal passages

 Cartridge style bearing assembly

 Shaft sealing options: gland, low flow

 Warman® pattern flanges

We have come a long way from the

Version 2.0 20 September, 2018 IP Category: Confidential Page 7

OH0 – Unlined Pump

Volute Liner Impeller Throatbush Intake Joint Ring

Weir Minerals Division

Warman® Liner Interchangeability

Version 2.0 20 September, 2018 IP Category: Confidential Page 8

Product Core Part numbers

Part Description Basic Part # Material Code Basic Part Number

Expeller Ring 029 SG Cast Irons D

Frame Plate Liner Insert 041 Grey Irons G