Paterson and Cooke Slurry Notes

University of the Witwatersrand: The Centre
for Mechanised Mining Systems

Pipeline Conveying of Bulk Materials Course:
Slurry Pipelines (20 – 24 April 2015)
University of the Witwatersrand: The Centre for
Mechanised Mining Systems
Slurry Pipelines
20 – 24 April 2015
Presented by Nic Marais and Angus Paterson
Contents Page
Monday: Session 1 – Water Systems Nic Marais 1.1
Session 2 – Pipeline Hy draulics Nic Marais 2.1
Session 3 – Introducti on to Slurry Angus Paterson 3.1
Session 4 – Settling Slurries Angus Paterson 4.1
Tuesday: Session 5 – Slurry Pipeli ne Hydraulics Nic Marais 5.1
Session 6 – Non-Newtonian Slurry Behaviour Angus Paterson 6.1
Session 7 – Mixed Regi me Slurries Angus Paterson 7.1
Session 8 – Slurry Pipeli ne Design Nic Marais 8.1
Wednesday: Session 9 – Applications : Mine Backfill Angus Paterson 9.1
Session 10 – Review and Task Discussion Nic Marais 10.1
Appendices : A.1
Although due care has been taken in the preparation of these notes, Paterson & Cooke shall not be responsible for any
liability, injury, loss or damage suffered by any party as a result of the use or implementation of the information
contained herein.
Copyright © 1996 to 2015 Paterson & Cooke
Phone +27 21 531 2955, Fax +27 86 546 9876, PO Box 38045, Pinelands, 7430, South Africa. All rights reserved. These
course notes may not be reproduced in any form without permission of Paterson & Cooke.
www.PatersonCooke.com
University of the Witwatersrand: The Centre for
Mechanised Mining Systems
Slurry Pipelines
20 – 24 April 2015
Presented by Nic Marais and Angus Paterson
Appendices A.1
General:
Nomenclature
Water Properties
Sea Water Properties
Minor Loss Coefficients
Solids Densities
Diagrams:
Wilson Nomogram for s ettling slurries
ANSI/HI 12.1 – 12.6 Soli ds-Effect Diagram for Settling Slurry Head Derati ng
Piping:
SANS 719 Pi pe Sizes and Thicknesses Sheet
HDPE PE 100 Pipe Sizes and SDRs Sheet
Pump Performance Curves:
Warman 8/6 AH Pump Curve – Weir E-Curve
Warman 10/8 AH Pump Curve – Wei r E-Curve
Warman 12/10 AH Pump Curve – Wei r E-Curve
Typical 4-pole Motor Lis t to IEC standards – Zes t/WEG

Page iv Paterson & Cooke Slurry Pipeline Design Course
Nomenclature
Units
A area m2
Aa area above bed m2
Ab area occupied by bed m2
C mass solids concentration %
CD drag coefficient
Cbfree freely settled solids packing volumetric concentration %
Cbmax maximum solids packing volumetric concentration %
Cv volumetric solids concentration %
d particle size, sphere diameter m
d50 particle size at which 50% of the particles by mass are smaller than d50 m
drep representative particle size m
D internal pipe diameter m
Do outside pipe diameter m
E energy N.m
E Young’s modulus of elasticity Pa
ER pump efficiency derating ratio
f Fanning friction factor
F force N
g acceleration due to gravity m/s2
h, H head m
Hatm atmospheric pressure head m of mixture
Hvap vapour pressure head m of mixture
He Hedström number
HR pump head derating ratio
iw hydraulic gradient (water flow) m water/m
jm hydraulic gradient (slurry flow) m mixture/m
k hydraulic pipe roughness m
K bulk modulus Pa
K fluid consistency index Pa.sn
K fitting or minor head loss coefficient
KBP Bingham plastic viscosity Pa.s
L length m
M mass kg
M mass flow rate kg/s
N rotational speed RPM
mc moisture content (% by wet mass) %
n flow behaviour index
p local pressure Pa
P pressure Pa
Patm atmospheric pressure Pa absolute
Pvap vapour pressure Pa absolute
P power N.m/s, W
Q volumetric flow rate m3/s
R gas constant J/kg.K
Re Reynolds number
Rep particle Reynolds Number
© Paterson & Cooke 2014 Revision 8.0

Preface Page v
Rer roughness Reynolds number

S relative density
Sf particle shape factor
T temperature K, °C
T torque N.m
u,v local velocity m/s
Vtrans transition velocity between laminar and turbulent flow m/s
Vdep stationary deposit velocity m/s
Vm mean mixture or bulk velocity m/s
Vt particle terminal settling velocity m/s
Vt´ hindered particle settling velocity m/s
V* shear velocity m/s
w moisture content (% by dry mass) %
Wa absolute wear rate mm/year
Ws specific wear rate μm/1 000 tonnes
z elevation m
α Richardson & Zaki exponent

β half angle defining bed load component rad
γ shear rate s-1
Γ pseudo shear rate s-1
η efficiency
θ angle defining position at pipe wall rad
ρ density kg/m3
κ von Karman constant
μ dynamic coefficient of viscosity kg/m.s, Pa.s
μs coefficient of sliding friction between solid particle and pipe wall
υ coefficient of kinematic viscosity m2/s
τo pipe wall shear stress Pa
τy mixture yield stress Pa
τyB mixture Bingham yield stress Pa
φ pipeline slope rad
ω rotational speed radians/s
 volume m3
Subscripts
N Newtonian
NN non-Newtonian
d delivered
f vehicle
m mixture
s solids
t in situ
w conveying liquid

Appendix Page A.7
B Water Properties

Page A.8 Paterson & Cooke Slurry Pipeline Design Course
C Sea Water Properties

Appendix Page A.9
D Minor Head Loss Coefficients

Page A.10 Paterson & Cooke Slurry Pipeline Design Course

Appendix Page A.13
F Typical Solids Densities

Wilson Deposition Velocity Nomogram
ANSI/HI 12.1 – 12.6 Solids-Effect Diagram for Settling Slurry Head Derating
SABS 719 Grade A B C
SMYS (MPa) 207 241 290
HDPE PE100 Design Sheet
STD HDPE SIZES (NS or OD) AND NOMINAL THICKNESSES THICKNESS TABLE
Source: SANS/ISO 4427-1 : 2007 thickness = NS / SDR
SDR 7.35 9 11 13.6 17 21 26

OD (mm) \ PN (kPa) 2500 2000 1600 1270 1000 800 640
90 12.2 10.0 8.2 6.6 5.3 4.3 3.5
110 15.0 12.2 10.0 8.1 6.5 5.2 4.2
125 17.0 13.9 11.4 9.2 7.4 6.0 4.8
140 19.0 15.6 12.7 10.3 8.2 6.7 5.4
160 21.8 17.8 14.5 11.8 9.4 7.6 6.2
180 24.5 20.0 16.4 13.2 10.6 8.6 6.9
200 27.2 22.2 18.2 14.7 11.8 9.5 7.7
225 30.6 25.0 20.5 16.5 13.2 10.7 8.7
280 38.1 31.1 25.5 20.6 16.5 13.3 10.8
315 42.9 35.0 28.6 23.2 18.5 15.0 12.1
355 48.3 39.4 32.3 26.1 20.9 16.9 13.7
400 54.4 44.4 36.4 29.4 23.5 19.0 15.4
450 61.2 50.0 40.9 33.1 26.5 21.4 17.3
500 68.0 55.6 45.5 36.8 29.4 23.8 19.2
560 76.2 62.2 50.9 41.2 32.9 26.7 21.5
630 85.7 70.0 57.3 46.3 37.1 30.0 24.2
710 96.6 78.9 64.5 52.2 41.8 33.8 27.3
800 108.8 88.9 72.7 58.8 47.1 38.1 30.8
900 122.4 100.0 81.8 66.2 52.9 42.9 34.6
1000 136.1 111.1 90.9 73.5 58.8 47.6 38.5
1200 163.3 133.3 109.1 88.2 70.6 57.1 46.2
DERATING FACTORS AND PIPE DERATINGS DERATED PRESSURE TABLE

Source: SANS/ISO 4427-1:2007 Pr = 2 x (MRS/C) x Ft / (SDR-1)
Temperature (degrees C) 20 25 30 35 40
Design Factor (Ft) 1.000 0.935 0.870 0.805 0.740
HDPE PE 100 SDR Rating P (kPa) P (kPa) P (kPa) P (kPa) P (kPa)
7.4 PN 25 2500 2338 2175 2013 1850
MRS = 10 MPa 9 PN 20 2000 1870 1740 1610 1480
C = 1.25 11 PN 16 1600 1496 1392 1288 1184
MRS/C = 8.0 MPa 13.6 PN 12 1270 1188 1105 1023 940
17 PN 10 1000 935 870 805 740
21 PN 08 800 748 696 644 592
26 PN 06 640 599 557 516 474
NJM HDPE Sizes and Ratings Rev 2.xls
Last Updated 3 April 2015

Customer Details 14 April 2015
Project:
No:
Customer:
Application:
Pump Item Number:
AH
Notes
Metal impeller
1300 r/min 50 % A05 Stuffing box limited to 700kPa
80 60 %
65 % Add 5% to power for expeller pump
68 % Duty Point Water Slurry
70 % Specific Gravity SG: 1.00 1.00
71 % Flowrate Q: 0.00 0.00 (
Total Flowrate Q: 0.00 0.00 (
70 1200 r/min BEP 71.7 %
Head H: 0.00 0.00
Total Head (1 stage): 0.00 0.00
Pumps in Series: 1 1
Pumps in Parallel: 1 1
P Absorbed: Err Err
P Required: Err Err
60 P Installed: 275.00 275.00
1100 r/min
Specified Safety Factor: 1.25 1.25
Actual Safety Factor: Err Err
Pump Speed n: 0.00 0.00 r
Efficiency: 0.00 0.00
50 Impeller Tip Speed: 0.00 0.00
1000 r/min Position From BEP: 0.00 0.00
Minimum NPSH: 0.20 0.20
Gland Service: 0.00 0.00
Expeller Head: 2.83 2.83
40
900 r/min Derating and Speed
Total Head H (m)

Head Ratio: 1.00
Efficiency Ratio: 1.00
Froth Factor: 1.00
800 r/min
Pump Information
30 Suction Diameter: 203 mm
12 m
Discharge Diameter: 152 mm
Parts Passing: 63 mm
Casing Pressure Rating: 2100 kPa
700 r/min 10 m Impeller Diameter: 510 mm
Number of Vanes: 5
20
Curve Source
8 m WPG86AH30 rev 1
Pump
500 r/min
6 m
10 4 m
8/6 AH Metal 5 van
NPSH 2 m
0
0 180 360 540 720 900
Flowrate Q (m^3/h)
Pump performance is based on clear water SG = 1.0
Duty point box indicates tolerances according to BS5316
Project:
No:
Customer:
Application:
Pump Item Number:
AH
Notes
90 1000 r/min
Metal impeller
50 %
A05 Stuffing box limited to 700kPa
64 %
Duty Point Water Slurry
67 %
Specific Gravity SG: 1.00 1.00
80 69 % Flowrate Q: 0.00 0.00 (
70 %
Total Flowrate Q: 0.00 0.00 (
Head H: 0.00 0.00
900 r/min BEP 70.9 % Total Head (1 stage): 0.00 0.00
Pumps in Series: 1 1
70 Pumps in Parallel: 1 1
P Absorbed: Err Err
P Required: Err Err
P Installed: 0.00 0.00
Specified Safety Factor: 1.25 1.25
60 Actual Safety Factor: Err Err
800 r/min Pump Speed n: 0.00 0.00 r
Impeller Tip Speed: 0.00 0.00
Position From BEP: 0.00 0.00
50 Minimum NPSH: 5.11 5.11
Expeller Head: -12.19 -12.19
700 r/min
Derating and Speed
Total Head H (m)

40 Head Ratio: 1.00
Efficiency Ratio: 1.00
Froth Factor: 1.00
600 r/min Pump Information
Suction Diameter: 254 mm
30 Discharge Diameter: 203 mm
18 m Impeller Diameter: 686 mm
500 r/min Number of Vanes: 5
15 m
20 Curve Source
WPG108AH30 rev 1
400 r/min 12 m Pump
9 m
10
10/8 F/G AH Metal
NPSH 3 m 6 m
0
0 180 360 540 720 900 1080 1260 1440 1620 1800 1980
Flowrate Q (m^3/h)
Project:
No:
Customer:
Application:
Pump Item Number:
90
AH
Notes
Metal impeller
900 r/min A05 Stuffing box limited to 700kPa
70 % Duty Point Water Slurry
80 74 % Specific Gravity SG: 1.00 1.00
76 % Flowrate Q: 0.00 0.00 (
78 % Total Flowrate Q: 0.00 0.00 (
79 % Head H: 0.00 0.00
Total Head (1 stage): 0.00 0.00
70 Pumps in Series: 1 1
800 r/min BEP 80.2 % Pumps in Parallel: 1 1
P Absorbed: Err Err
P Required: Err Err
P Installed: 0.00 0.00
60 Specified Safety Factor: 1.25 1.25
Actual Safety Factor: Err Err
Pump Speed n: 0.00 0.00 r
Impeller Tip Speed: 0.00 0.00
700 r/min
50
Position From BEP: 0.00 0.00
Minimum NPSH: 0.38 0.38
Expeller Head: 1.81 1.81
10 m
Derating and Speed
40
Total Head H (m)

Head Ratio: 1.00
600 r/min Efficiency Ratio: 1.00
Froth Factor: 1.00
Pump Information
8 m Suction Diameter: 305 mm
30 Discharge Diameter: 254 mm
500 r/min
6 m Impeller Diameter: 762 mm
Number of Vanes: 5
20 Curve Source
400 r/min WPG1210AH30 rev 1
4 m Pump
10 300 r/min
12/10 F/G AH Meta
3 m
NPSH 2 m
0
0 360 720 1080 1440 1800 2160
Flowrate Q (m^3/h)
Premium Efficiency Plus (IE2) W22 Cast Iron Frame IP66
PERFORMANCE DATA 1500 RPM - 4 Pole
Squirrel Cage Electric Motors
Full load Locked Full Locked Break- Allowed % of full load
Output current rotor load rotor down locked Weight Rated
kW Frame In (A) current torque torque torque rotor time (kg) speed Efficiency Power factor
(rpm)
400 V 525 V II/In (Nm) TI/Tn Tb/Tn (s) Hot 50 75 100 50 75 100
0.18 63 0.553 0.4 4.3 1.25 2.2 2.2 40 7.2 1380 59.0 61.0 61.0 0.55 0.68 0.77
0.25 71 0.719 0.5 4.0 1.76 2.1 2.2 68 7.0 1360 63.0 66.0 66.0 0.54 0.67 0.76
0.37 71 1.08 0.8 4.2 2.59 2.5 2.5 48 8.0 1365 65.0 68.0 68.0 0.50 0.64 0.73
0.55 80 1.27 1 5.8 3.73 2.4 2.8 18 10.5 1410 75.0 76.5 76.5 0.61 0.74 0.82
0.75 80 1.63 1.2 6.0 5.08 2.6 2.9 15 13.5 1410 79.0 79.6 79.8 0.63 0.76 0.83
1.1 90S 2.40 1.8 6.5 7.30 1.9 2.6 14 19.0 1440 81.0 81.8 81.8 0.62 0.75 0.81
1.5 90L 3.26 2.5 6.3 9.95 2.0 2.8 10 22.0 1440 81.5 83.0 83.0 0.57 0.72 0.80
2.2 100L 4.64 3.5 6.6 14.8 3.1 3.2 16 30.5 1425 84.0 84.5 84.5 0.63 0.75 0.81
3 100L 6.17 4.7 6.5 20.2 3.2 3.3 14 33.0 1420 85.0 85.6 85.6 0.64 0.76 0.82
4 112M 8.12 6.2 6.1 26.5 2.0 2.6 13 42.0 1440 86.0 86.7 86.7 0.64 0.76 0.82
5.5 132S 10.5 8 7.3 36.0 1.9 3.0 10 63.0 1460 88.0 88.1 88.1 0.69 0.81 0.86
7.5 132M 14.1 10.7 7.2 49.3 2.0 3.0 8 72.0 1455 88.7 89.0 89.0 0.71 0.81 0.86
9.2 160M 17.9 13.2 6.0 60.0 2.0 2.6 13 96.0 1465 88.5 89.5 89.2 0.66 0.77 0.83
11 160M 21.2 16.2 6.4 71.5 2.3 2.8 10 105 1470 89.0 90.2 90.2 0.65 0.76 0.83
15 160L 28.7 21.9 6.2 97.8 2.3 2.8 10 125 1465 90.6 91.0 91.0 0.66 0.76 0.83
18.5 180M 35.1 26.7 6.6 121 2.4 2.8 14 164 1465 91.5 91.8 91.6 0.68 0.78 0.83
22 180L 40.5 30.9 6.8 143 2.6 2.9 15 186 1465 92.2 92.5 92.3 0.70 0.80 0.85
30 200L 56.2 42.8 6.3 195 2.2 2.6 16 222 1470 92.6 93.0 92.8 0.68 0.78 0.83
37 225S/M 66.6 50.7 6.6 240 2.2 2.7 12 342 1475 93.0 93.2 93.2 0.74 0.83 0.86
45 225S/M 80.7 61.5 6.8 292 2.4 2.7 10 363 1475 93.2 93.7 93.6 0.74 0.83 0.86
55 250S/M 97.1 74 6.4 356 2.2 2.7 14 444 1475 93.6 93.9 94.0 0.75 0.84 0.87
75 250S/M 130 99 7.2 486 2.4 2.9 10 496 1475 94.0 94.3 94.4 0.74 0.84 0.88
90 280S/M 158 120.4 7.2 579 2.1 2.7 20 673 1485 94.1 94.7 94.7 0.76 0.84 0.87
110 280S/M 192 146.3 7.6 708 2.4 2.9 18 735 1485 94.3 95.0 95.0 0.75 0.83 0.87
132 315S/M 230 175.2 6.6 846 2.1 2.4 22 953 1490 94.6 95.2 95.2 0.76 0.84 0.87
160 315S/M 278 211.8 6.6 1030 2.2 2.4 20 1012 1490 94.8 95.4 95.4 0.77 0.84 0.87
185 315S/M 325 247.6 6.8 1190 2.4 2.4 18 1114 1490 94.9 95.6 95.6 0.75 0.83 0.86
200 315S/M 347 264.4 6.7 1280 2.4 2.4 17 1216 1490 95.0 95.6 95.6 0.77 0.84 0.87
220 315L 381 290.3 7.0 1410 2.6 2.4 14 1333 1490 95.2 95.7 95.7 0.76 0.84 0.87
220 355M/L 390 297.1 6.4 1410 2.0 2.2 18 1441 1490 95.3 95.7 95.7 0.73 0.81 0.85
250 315L 428 326.1 7.0 1600 2.6 2.4 13 1399 1490 95.3 95.7 95.7 0.77 0.85 0.88
250 355M/L 443 337.5 6.8 1600 2.1 2.4 18 1470 1490 95.4 95.8 95.8 0.73 0.82 0.85
260 355M/L 461 351.2 6.8 1670 2.1 2.4 18 1470 1490 95.4 95.8 95.8 0.73 0.82 0.85
280 315L 485 369.5 7.2 1800 2.6 2.4 12 1496 1490 95.4 95.8 95.8 0.76 0.84 0.87
280 355M/L 496 377.9 6.6 1800 2.1 2.4 14 1510 1490 95.5 95.8 95.8 0.74 0.82 0.85
300 315L 532 405.3 7.6 1920 2.5 2.5 11 1540 1490 95.4 95.8 95.8 0.72 0.80 0.85
300 355M/L 532 405.3 7.2 1920 2.2 2.4 18 1510 1490 95.5 95.8 95.8 0.74 0.82 0.85
315 315L 558 425.1 7.6 2020 2.5 2.5 11 1540 1490 95.4 95.8 95.8 0.72 0.80 0.85
315 355M/L 552 420.6 7.2 2020 2.4 2.4 14 1643 1490 95.5 95.8 95.8 0.74 0.82 0.86
330 355M/L 578 440.4 6.8 2120 2.2 2.4 17 1769 1490 95.5 95.8 95.8 0.75 0.83 0.86
355* 355M/L 622 473.9 6.9 2280 2.4 2.3 15 1752 1490 95.5 95.9 95.8 0.75 0.83 0.86
370* 355M/L 648 493.7 7.0 2370 2.4 2.4 15 1971 1490 95.5 95.9 95.8 0.75 0.83 0.86
400* 355M/L 701 534.1 7.3 2570 2.6 2.4 11 1888 1490 95.5 95.9 95.8 0.74 0.82 0.86
450* 355A/B 804 612.6 7.4 2890 2.5 2.8 20 2089 1490 95.8 96.1 96.2 0.69 0.80 0.84
500* 355A/B 882 672 7.3 3210 2.4 2.7 17 2246 1490 95.9 96.3 96.3 0.72 0.81 0.85
14

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University of the Witwatersrand: The Centre

for Mechanised Mining Systems

Session 2 – Pipeline Hy draulics Nic Marais 2.1

Session 3 – Introducti on to Slurry Angus Paterson 3.1

Session 4 – Settling Slurries Angus Paterson 4.1

Tuesday: Session 5 – Slurry Pipeli ne Hydraulics Nic Marais 5.1

Session 6 – Non-Newtonian Slurry Behaviour Angus Paterson 6.1

Session 7 – Mixed Regi me Slurries Angus Paterson 7.1

Session 8 – Slurry Pipeli ne Design Nic Marais 8.1

Wednesday: Session 9 – Applications : Mine Backfill Angus Paterson 9.1

Session 10 – Review and Task Discussion Nic Marais 10.1

Copyright © 1996 to 2015 Paterson & Cooke

Sea Water Properties

Minor Loss Coefficients

Wilson Nomogram for s ettling slurries

SANS 719 Pi pe Sizes and Thicknesses Sheet

HDPE PE 100 Pipe Sizes and SDRs Sheet

Pump Performance Curves:

Warman 8/6 AH Pump Curve – Weir E-Curve

Warman 10/8 AH Pump Curve – Wei r E-Curve

Warman 12/10 AH Pump Curve – Wei r E-Curve

Typical 4-pole Motor Lis t to IEC standards – Zes t/WEG

© Paterson & Cooke 2014 Revision 8.0

Rer roughness Reynolds number

α Richardson & Zaki exponent

© Paterson & Cooke 2014 Revision 8.0

© Paterson & Cooke 2014 Revision 8.0

C Sea Water Properties

© Paterson & Cooke 2014 Revision 8.0

D Minor Head Loss Coefficients

© Paterson & Cooke 2014 Revision 8.0

© Paterson & Cooke 2014 Revision 8.0

F Typical Solids Densities

© Paterson & Cooke 2014 Revision 8.0

SDR 7.35 9 11 13.6 17 21 26

DERATING FACTORS AND PIPE DERATINGS DERATED PRESSURE TABLE

NJM HDPE Sizes and Ratings Rev 2.xls

Last Updated 3 April 2015

Total Head H (m)

Total Head H (m)

Total Head H (m)

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