Lower costs, risks and environmental footprint with slurry handling

Our complete slurry handling solutions, including equipment, parts, optimization and maintenance services, can address these challenges. These services, ranging from product selection and technical support to comprehensive service agreements, can be customized to suit any customer’s specific application. The range of equipment is designed to enhance efficiency and reduce operating costs, leading to improved production and uptime. In tandem with the parts and services offering, these slurry handling solutions can increase customers’ productivity whilst decreasing their environmental footprint.

But how can this be done?

Navigating common challenges in slurry handling

Engineering slurry handling systems is a complex task. It requires precise calculation of pump discharge pressure, adaptation to varying system operating points, preparation for tenacious frothy slurries, and more.  Given the complexity of the situation, having a skilled and knowledgeable professional managing all system aspects is crucial – from design and implementation to services and beyond. Failing to choose the appropriate product for a specific application is also an issue, as this can unfortunately lead to operational failures or significant inefficiencies in the process. For example, if the wrong valve for an application is used, it can result in the main equipment not working efficiently or not operating at all. In addition to productivity loss, this poses major safety issues if the slurry valve cannot open and close properly. It is essential for all equipment in a slurry transport line to be sized and selected appropriately, as mismatched parts from various manufacturers can create excessive safety margins. Another challenge operations are facing with slurry handling is the abrasive wear and increasing energy and water costs, further complicating the system efficiency and cost-effectiveness. Wear and downtime are critical concerns – both financially and environmentally. For example, customers are looking for wear-resistant solutions that decrease pipeline downtime as much as possible. Faulty pipelines affect the entire slurry handling system, causing significant financial and operational losses.

So how can customers ensure the best production for their operations?

The key to seamless slurry operations

Metso has remained a trusted partner in slurry handling solutions for almost 70 years by emphasizing the importance of a cohesive slurry handling system with compatible components to ensure seamless operation. We have one of the most comprehensive offerings in minerals processing, with slurry handling methods used throughout the whole process. By leveraging synergies to offer unique integrated solutions, we can fulfill customer specific needs and find the right fit for any operation. We offer a full range of slurry pump sizes and aspect ratios in both high chrome and natural rubber variants, as well as multiple shaft sealing options and an advanced pump sizing tool, PumpDim. The pumps are designed with maintenance in mind, featuring both back pull-out maintenance and slide base options.

Being a one-stop-shop for slurry handling systems has its advantages, one of which being the enhanced operational efficiency. For example, our selection software, PumpDim, ensures optimal equipment choices, utilizing our extensive experience and integrated product offerings. As the sole equipment supplier, we can provide appropriate selections of individual equipment or the whole line using precise and reliable selection software. Another underestimated but crucial feature of slurry handling is pipeline configuration and wear monitoring. Aspects such as inner diameter, pipeline configuration, and lining material have significant implications in not only the pipeline wear resistance, but in process stability and energy consumption. We have a solution for this. The team studies each request to thoroughly understand where the problem is and what can be done differently to get the most efficient and reliable solution. This, in collaboration with our standardized systems, facilitates reliable planning and operation with reduced lead times and efficient spare parts management.

Minimized costs, maximized savings

Inherently, slurry systems are costly to operate. However, there is a silver lining when saving on service costs. Natural rubber-lined pipes have five times longer wear compared to typical polyethylene pipes. Thus, one annual break instead of three leads to 67% spare parts cost savings and overall reduced maintenance costs. The Metso slurry pumps, pipes, and hoses are designed for improved efficiency and lower operating costs. The services and parts work in increasing productivity by cutting maintenance costs and adding uptime. These extensive offerings – from equipment to a broad range of services – help customers improve profitability and safety, whilst at the same time reducing both operating costs and risks.

Keeping it Planet Positive

There is a clear movement towards more sustainable and responsible handling and storage of tailings, translating into higher levels of dewatering and solids concentration. Abrasive wear is ever-present, and energy and water costs are increasing in many areas. In addition to this, the importance of environmental sustainability in slurry handling is driving innovations in both plant layouts and process designs. With sustainability driving the market, slurry handling is directly affected by new types of slurry systems.

Sustainable solutions aimed at the environmental footprint, along with AI, and smart systems to optimize operations, are emerging as trends. Within the slurry handling solutions portfolio, these market needs are addressed, allowing customers to lead a more sustainable operation. This is called the Planet Positive portfolio. What makes this equipment ‘Planet Positive’? Our new pumps require 75% less maintenance, thus saving over 6 billion liters of water. They also decrease energy consumption for operations, as a 17% increase in pump efficiency reduces energy consumption by 15%. Energy efficiency is also present in the grinding circuit, with up to 10% improved energy due to reliable classification by the pump and grinding mills. Additionally, there is up to 50% reduction in water consumption with the EnviroSet™ sealing. The robust components and modular design contribute to increased sustainability as well, leading to an up to 30% reduction in both carbon footprint and embedded carbon. Along with an up to 10% reduction in carbon emissions due to the improved wear life of components when using rubber and polyurethane materials, our slurry handling solutions can lead to an overall more sustainable production – from pit to port. 

Driving progress

We incorporate sustainability metrics into all R&D projects, focusing on minimizing the impact on renewable resources through weight reduction in design, reducing water consumption for seals, modular designs, and more. The growing Planet Positive portfolio coming out of extensive R&D developments has been extremely successful and it is only getting stronger. The energy transition is emerging as an important trend within the industry, demanding more ore processing to support the increase in battery metals, especially copper. Combined with lower overall grades, this results in much higher volumes of slurry needing to be processed, thus driving a demand for bigger slurry valves capable of handling larger pressures.

Our experts are also foreseeing trends in smart pump and slurry conveyance systems that monitor the health of the equipment. The aim here is to minimize downtime and optimize efficiency. With customers looking for new and more sustainable solutions that can handle battery metals processing – which can be very different compared to conventional minerals processing – the need for a trusted partner with expertise and know-how is essential in providing the relevant products and services. The research and development efforts also focus on wear monitoring solutions for slurry hoses and high-efficiency motors and drives. We have always been strong with zero flush expeller shaft seals, and have continued to embrace this strength, while also investing in a wide range of mechanical seals to minimize water consumption and slurry leakage. As an end-to-end provider with various products throughout the minerals processing chain, we have a unique ability to utilize existing solutions whenever there is a new requirement. A strong R&D and innovation power allows us to continuously look for new ways to introduce innovations for the customers’ benefit.

Innovating for the future: What’s next in slurry handling solutions

This comprehensive approach to slurry handling addresses numerous challenges faced by customers, including engineering complexities, wear resistance, sustainability, operating costs, and more. By leveraging advanced tools, integrated systems, and ongoing R&D, we continue to lead in providing tailored and efficient slurry handling solutions – for any part of the process.  Our commitment to enhancing the slurry handling solutions includes introducing new models and materials. Our goal is to meet the specific flowsheet requirements of customers, spanning mill discharge, tailings, and various slurry transfer applications. This is also extended to hydrocyclones, valves, hoses, aftermarket, and digital solutions. Looking to the future, we have continued innovating and developing products and services to suit various customer needs. For example, there is the recently released series of high-efficiency rubber-lined pumps, the MRE, with sturdy liner thicknesses and affordable capex costs. There are also trials of ceramic-lined slurry hoses and bends ongoing worldwide, showing promising results in the toughest of applications such as SAG mill discharge and gravity flow lines. In addition to these new products, we have expanded its Knife Gate Valve offering with two new models, catering for the demand of increased pressure, sustainability, and cost-efficiency. Our slurry handling solutions can optimize plant productivity and efficiency and ensure customers can navigate the complexities of modern mining operations with confidence, lower costs, and higher sustainability. This is why, together with our customers, Metso is a partner for positive change.

This article was first published in Global Mining Review