Tag Archives: slurry pumps

FLSmidth reflects on KREBS slurry pump dominance in Africa

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KREBS® slurry pumps have become leaders in mill discharge applications in Africa, with the latest Ultimate Mill Discharge (UMD) pump leading the way in these heavy-duty applications, according to FLSmidth.

Andre Hall, FLSmidth Regional Product Line Manager — Pumps, Cyclones and Valves, said: “West African gold mines and the copper operations of Zambia and Democratic Republic of Congo are among the areas where these robust pumps dominate.

“Their popularity,” he says, “is based on their long wear life and high efficiency.”

Ghana is a particular success story for UMD pumps, according to Hall, with nearly all gold mines there using the equipment manufacturer’s pumps to discharge slurry from their mills, he added.

“The KREBS UMD is popular at these mines largely because it lowers the total cost of ownership due to the millMax™ proprietary design that eliminates inefficient recirculation and grinding of slurry within the pump,” FLSmidth said.

“Prior to the millMAX wear ring design, slurry pumps experienced two major problems: mechanical grinding of solids between the suction liner and impeller, and flow recirculating back to the impeller eye on the suction side. Both of these problems decrease pump life and increase power consumption.”

The wear ring stops recirculation by closing the suction-side gap, while still allowing for a large clearance between the impeller and the suction liner, according to FLSmidth. This eliminates the grinding of solids. Adjusting the wear ring while the pump is running, meanwhile, restores performance and provides longer wear life and higher continuous efficiency, in all, lowering the total cost of ownership.

Hall says: “The UMD’s casing symmetry also means less inventory for customers. Mines that have pumps rotating in both left-hand and right-hand orientations must stock different casings, liners and impellers, adding to the operational costs.”

The advantage of the UMD is that it uses the same casing, suction liner, wear ring and back liner, which reduces overall net working capital.

The KREBS gravelMAX™ pumps continue to do well in the Mpumalanga coal sector of South Africa, according to FLSmith, where 14 of these pumps recently replaced competitor units on a single site.

Commonly applied in a cyclone feed application within the dense medium separation (DMS) circuit, the pump’s wider passage allows pumping of larger solids.

“We are also active in iron ore in South Africa with pumps in the DMS circuit,” Hall says. “A Lesotho diamond mine also operates KREBS pumps, which have demonstrated a four-fold increase in wear life compared to a competitor’s previous units.”

In sump pumps, FLSmidth has the vMAX™ range, which features a recessed impeller design allowing the pumps to run dry.

The company explains:“When the sump has been emptied of slurry, the recessed impeller allows the slurry to return safely down the discharge pipe without contacting the impeller, ensuring that it does not vibrate when dry.”

Another recent innovation in the KREBS slurryMAX range of pumps is being introduced to the Africa market after an enthusiastic response in the US and Australia, FLSmidth said. With multiple liner and impeller material options, the slurryMAX split-case pump can handle the majority of applications for any plant across multiple industries.

GIW MDX-750 keeps slurry moving at Panama copper mine

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GIW Industries says its recent success with a customer at a Panama copper mine bodes well for the future of copper mining in Central America and the pump manufacturer’s potential for business in this area and beyond.

The Panama copper mine customer needed to ensure continuous and efficient operation of its mine and, according to GIW, was looking for a dependable partner with experience in the market, a good track record in similar applications and excellent technical support.

Reliable parts supply was at the top of the priority list, GIW said, while it also needed a company that could help solve their system challenges and offer continuous improvements.

GIW said: “The customer was familiar with GIW’s success in Chile with the MDX-750 slurry pump and wanted to achieve the same performance.”

GIW supplied a customised MDX-750 pump – one of the world’s the largest mill pumps – featuring all the latest slurry handling technology, it said. In addition to GIW’s long-lasting wear materials, the company included technology to allow the company to monitor vibrations and check the temperature of the bearings.

The company added: “GIW design engineers converted our traditional imperial threads to metric, and all seal configurations have been customised to the customer’s specifications. In the future, the customer will have the capability to test the oil quality and assess parts’ wear life. They also have the ability to optimise their pump by adding GIW’s remotely adjusted mechanical suction liner (RAMSL) feature.”

The RAMSL function allows for efficient pump operation in aggressive wear applications, according to GIW.

Benefits of the MDX pump include increased output, reduced downtime and easier maintenance, the company says. This increased efficiency and a longer wear life results in a lower total cost of ownership.

This success is an example of GIW’s ability to provide reliable service around the world, it said, with GIW collaborating with its parent company’s (KSB) teams in Australia and Central America to coordinate the engineering and delivery of the pumps to site.

Weir Minerals takes a load off slurry pump maintenance

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An often-overlooked component, lifting tools help keep workers safe, maximise equipment life and can reduce pump rebuild times, according to Weir Minerals.

These tools have become increasingly important for handling slurry pump parts during maintenance as processing equipment has become larger and larger.

David Russell, Trials Manager for Weir Minerals Australia, says: “We have a duty of care to our customers to ensure they remain safe when operating and maintaining our equipment. Adopting our uniquely engineered lifting tools for our slurry pumps mean that when the correct procedures are followed, it’s very safe.”

It was only in the 1990s when a Warman® AH® 20/18 pump, was one of the largest available on the market. Now, it is regarded as a medium-sized model, outdone by the likes of the Warman® MCR® 760 pump.

Weir said: “As equipment has rapidly increased in scale over the past couple of decades, Weir Minerals has developed specially engineered tools to safely disassemble and reassemble machinery, reducing the risks associated with lifting components.”

In the case of slurry pumps, Weir Minerals’ range of lifting tools are designed for use when performing wet-end overhauls. Specific lifting tools are used for impellers, throatbushes, suction covers, frame plate liner inserts, stuffing boxes, casings and volutes.

These tools have also been designed to lift multiple components together to make rebuilds easier and quicker. For example, a lifting beam has been developed that lifts a suction cover squarely with the throatbush still attached to it.
“Using purpose designed assembly equipment in accordance with OEM lifting procedures can reduce rebuild time, in some cases by up to 50%, leading to increased plant uptime and availability,” the company said.

Russell said: “When lifting pump parts weighing more than two tonnes in restricted areas, there is little room for error. Often, the components will be worn and it is crucial they can still be secured and lifted safely in accordance with the strict global standards that Weir Minerals adheres to.”

When designing lifting equipment, Weir Minerals says it also carefully considers the mechanical strength and the stresses placed on the components being lifted, since worn parts are likely to be weaker and more brittle than new parts.

When it comes to impeller lifting tools, some competitors may employ a simple hook design, increasing the risk of the impeller falling off. Weir Minerals has developed a tool with a fixed locking jaw so that the impeller eye is locked in position and the component is properly secured prior to being lifted, the company says. “This positive engagement across two points of contact ensures that components are lifted evenly and securely with minimal risk of injury,” it said.

Independently certified in each region, the tools are manufactured and sold to meet local health and safety requirements, according to the company.

Joel Goodwin, Weir Minerals’ Aftermarket Manager for Warman pumps, said: “Safety is central in everything we do at Weir Minerals.

“We are an OEM supplier who complies with global safety standards and we adopt a stage-gated development process incorporating risk assessments and product stewardship best practice for equipment design and lifting.”

Weir’s Warman AHF slurry pumps cut through the froth in South Africa

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Weir Minerals’ Warman® AHF pumps have been put to the test at two mines in South Africa’s Limpopo Province, the company said.

The pumps were tasked with pumping frothy, high density and viscous slurries at the platinum and phosphate mines.

Weir said: “Handling froth in some process circuits can be very challenging, as froth will air-bind a conventional slurry pump. In froth applications, the Warman AHF inducer impeller solves this problem, producing far less surging. The inducer impeller and oversized inlet enhance the movement of the froth, high density or viscous slurries into the impeller, facilitating effective transportation.

“In addition, its higher efficiencies mean a smaller pump will deliver the required results.”

At the platinum operation, a Warman AHF 2 pump was commissioned in early 2016. It has met the specified flow rate of 40 m3/h with no pump-related stoppages, repairs or replacements, according to Weir.

A 12-month trial period showed the unit saved the mine over R200,000 ($14,153) when compared with the cost of the competitor pump installed previously. Based on this, the mine replaced another eight competitor products with Warman AHF pumps, Weir said. It has approved the Warman AHF 3 pumps as standard for all frothy applications at the plant’s first flotation section, and Warman AHF 2 pumps for the second flotation section, the company added.

The Warman AHF pumps – with Hi Seal® expeller (dry gland) design – were also tested in a viscous slurry application at the phosphate mine in Limpopo for six months. According to Weir, they demonstrated they could continuously pump the high-density viscous underflow slurry at relative densities above 1.9. “As a result, the customer purchased the pump and began upgrading all the remaining concentrate thickener underflow pumps to the Warman AHF pump technology,” Weir said.

This reduced the plant’s operational costs significantly, decreased dewatering and concentrate moisture extraction operations, improved filtration efficiency and increased concentrate throughput to the dryers, according to Weir. The Warman AHF pump also extended the underflow pumping boundaries and the overall reliability of the thickener underflow pumping system.

“Other field and laboratory tests have proven that the Warman AHF pump has largely overcome the problem of high-density viscous underflow slurries, with negligible effects on head at slurry yield stresses up to 200 Pa,” the company said.

Jacques Pretorius, Weir Minerals Africa’s Pump Product Development Specialist, said the approach to solving any thickener underflow pumping problem must be based on a thorough understanding of the entire application, the mineralogy and rheological behaviour of the slurry.

“Successful thickener underflow pumping projects are only achievable through involving a team of thickener engineers, pumping engineers and rheological consultants,” he said. “Weir Minerals’ pump trial campaigns confirm the successful operability of the Warman AHF pumps in viscous slurry applications.”

Weir Minerals Warman WBH pumps make the most of slurry handling tech

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Weir Minerals Africa says its locally manufactured Warman ® WBH® range of pumps provide access to the latest slurry pumping technology, helping ensure productivity demands are met.

Typically used in heavy duty applications such as mill discharge, slurry transfer and process pumping applications, the Warman WBH is suitable for both greenfields and brownfields installations, according to the company.

With a “revolutionary” one-piece frame for correct alignment of bearings, seal and impeller to front liner, the Warman WBH is engineered for enhanced efficiency and operational savings in mind, the company says. “The pump incorporates a fully-adjustable and rotatable throatbush to more evenly spread the wear and maintain the pump’s performance for longer periods.”

The ‘One Point’ front liner adjustment feature allows both rotation and axial movement to minimise front impeller gap to reduce wear and maintain performance. “Significantly, this adjustment can be made while the pump is running, eliminating the need to stop production resulting in cost savings for the plant,” Weir says.

The company continued: “The streamlined impeller inlet of the Warman WBH pump facilitates enhanced handling of even the most difficult slurries. While the low-flow gland seal, expeller seal and mechanical seal options on the pump mean there is less dilution of the slurry and lower required flow of gland water.”

Equipped with large capacity bearings, the pump can withstand high loads without affecting bearing life, according to the company. “The impeller and volute flow paths are streamlined to enhance efficiencies and extend component wear life,” Weir says.

GIW pumped with Anglo American Quellaveco copper project order

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GIW Industries says it is to deliver four MDX 600 cyclone feed pumps to Anglo American’s Quellaveco copper project in Peru.

GIW, a subsidiary of KSB, won the order based on the reputation of its centrifugal slurry pumps and the firm’s commitment to customer support, it said. “Decades of experience in slurry transport means GIW is in the perfect position to partner with Quellaveco.”

Anglo American plans on first copper production coming out of Quellaveco in 2022, which, with a reserve of 1,300 Mt at 0.58% Cu, is expected to have a 30-year mine life at an average production capacity of 127,500 t/d. This could see the mine produce around 300,000 t/y of copper.

The Quellaveco project marks a significant milestone for GIW as it continues to invest in the region, the company said. In 2018, it expanded its service capabilities in South America to meet the needs of current and future customers.

Local GIW technicians will be on-site to assist Quellaveco for the installation, commissioning, and start-up of the four MDX 600 cyclone feed pumps, according to the company.

“The MDX pump was selected for the Quellaveco project because of its success in copper and gold applications around the world,” GIW said. “The MDX product line has undergone extensive development; in fact, the latest technology features a remotely adjusted mechanical suction liner.

“The pumps for Quellaveco are specially designed to operate in the most extreme duty conditions. Critical wear parts are made of GIW’s proprietary white-iron alloy, Endurasite. This material extends wear life and optimises pump performance.

“These features combined have a direct impact on Quellaveco’s total cost of ownership – proving the MDX is the most reliable pump on the market.”

Hernan Palavecino, South America Region Manager for GIW, said economic stability and continuous growth in the country have facilitated the investment of new mining projects in Peru, with the country, over recent years, becoming a key player in the global market.

“GIW recognises the importance of the Quellaveco mine to the region,” he said. “The greenfield project solidifies Peru’s position as a substantial player in the South American and global mining markets. The award is a result of GIW’s drive for continuous improvements in slurry technologies. We are committed to offering high-quality service while building a long-term partnership with Quellaveco.”

Atlas Copco extends WEDA dewatering range to slurry pump applications

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Atlas Copco Power and Flow has completed its portfolio of WEDA electric submersible dewatering pumps, in the process adding a new range for slurry applications.

The range now comprises three families; the expanded WEDA D for dewatering, WEDA S – also expanded – for sludge, and the entirely new WEDA L slurry family.

WEDA D pumps handle either clean or dirty water, even with small solids, while the WEDA S range supports dewatering of liquid sludge containing larger solids. The WEDA L products are the toughest, Atlas Copco says, having the largest apertures to facilitate handling of slurry with the most challenging solids.

“The WEDA D family expansion is marked by the D80, a new model for dewatering,” Atlas Copco said. “S30, and S60, as the new models for the WEDA S sludge family, can handle thick, soft, wet mud or other similarly viscous mixtures of liquids and solids, especially the product of an industrial or refining process. The completely new WEDA L family handles semi-liquid slurry mixtures, typically of fine particles of manure, cement or coal, and water.”

Aside from optimising performance, a lot of focus has been given to making the pumps lighter, enhancing electrical safety, improving the seal design and easing installation, Atlas Copco said. All pumps in the D and S range are available with WEDA+ features, which include phase failure protection, rotation control, thermal switches and a 20 m cable with phase shifter plug for all three phase pumps. The WEDA+ features are also available as an option on the L range.

Overall, the WEDA D pumps, which use top-discharge, can handle water of specific gravity to 1,100 kg/m³, and, depending on model, solids of 4-12 mm diameter. The bottom side discharging WEDA S pumps’ capabilities extend to water with specific gravity to 1,400 kg/m³, and solids of 25-50 mm, depending on model. The WEDA L pumps, which also use bottom side discharge, handle water of specific gravity up to 1,700 kg/m³, and, depending on model, solids of 20-60 mm diameter.

The company said: “The pumps’ specifications equip them well for an extensive range of dewatering applications; they provide the performance, reliability and ease of use and maintenance essential to users across multiple industries.

“All models feature a built-in starter and motor protection system along with optional automatic level control. Adjustable wear-resistant rubber diffusors and hardened high-chrome impellers ensure durability in tough environments.”

Hrishi Kulkarni, Product Manager, Atlas Copco Power and Flow division, said: “The WEDA pumps can handle flow rates of up to 16,500 l/min, with power ratings up to 54 kW. Accordingly, they make ideal dewatering solutions across many, diverse applications within the construction, industrial, emergency and maintenance sectors. Now, our ubiquitous coverage has been highlighted by these latest additions to the range, as they make our portfolio complete.”

Handling and transportation are eased by the pumps’ weight, which is 20% lower than competitor products, Atlas Copco said, adding that this makes them especially attractive for rental use.
Ease of operation is carefully balanced with high performance, with some models’ ability to pass solids of up to 2 in (51 mm) through the pump. An improved aluminium alloy provides higher corrosion resistance over all applications, while reinforced cable entries assure higher resistance to water leakage.

“Uptime is maximised through several measures,” the company said. “All pumps have seal types appropriate to their size, and an external plug for grease filling or an oil inspection plug for easy maintenance. With many connection options and sizes, discharge connections are adjustable, with flow direction changeable from 90-180°.

Weighing up the total cost of ownership in mine slurry pump applications

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Integrated Pump Technology is stressing to Africa-based mining companies the need to ensure high-quality OEM products are specified in any slurry pumping applications on mine sites.

If incorrect pump choices are made in these demanding applications, it can lead to high maintenance and repair costs and even catastrophic failures, according to the company.

Colin Adams, Managing Director of the distributor, says the company often receives enquiries from clients that have already made the mistake of trying to cut corners by using non-OEM, low-quality products.

“Slurry pumps need to be up to the task of handling high volumes of abrasive material, and when this is not the case these failures lead to costly production downtime with the obvious knock-on effects,” he said. “For a number of years, we have been cautioning the market and urging mine operators to carefully consider the overall total cost of operating slurry pumps when making decisions on which units to install.”

Integrated Pump Technology is the authorised distributor for Grindex submersible pumps. Included in its product lineup is the Grindex Bravo range, which Adams says, offer a good return on investment as the units are engineered to achieve lower operating and maintenance costs.

Commenting on why a submersible slurry pump is a better option for slurry pumping, Adams says submersibles offer several benefits over dry-mounted pumps. They do not require any support structure, need less space for operation and are very easy to install.

The Grindex Bravo range (pictured here) is produced to operate over the complete pump curve, not just one specific duty point, according to Integrated Pump Technology. This means the pump can be used in numerous applications within its range; not a case of “one pump – one application”.

Grindex Bravo pumps are fitted with a cooling jacket and agitator for effective slurry pumping. Pumps in the range can handle slurry and fluids with a high content of highly abrasive solids in sizes up to 50 mm at maximum heads from 17-45 m. Wear is reduced by using NiHard 4 for all hydraulic components, and these pumps can handle liquids with pH values from 4-10.

Adams also points to the high level of support available to customers across Africa through Integrated Pump Technology’s distributor network, which is underpinned by the company’s experienced technically competent African team. Ready access to parts also forms part of the support system, ensuring optimum uptime for customers.