solutions for High-Pressure mining Systems

Applications with high ∆P requirements often use a controlled ‘multi-stage’ pressure reduction system.

This approach is shared across various applications, including slurry transport, hydro dams, power generation, oilsands processing, and other multi-phase flow scenarios. Because design objectives differ widely depending on the process, each pressure-reducing system must be tailored to its specific operational requirements.
In slurry transport applications, for example, the goal may be to prevent ‘Slack Flow’ within the pipeline, a condition that can cause operational instability and equipment damage. Similarly, for multi-phase fluids, avoiding turbulence, sudden pressure drops, and cavitation is paramount, as these phenomena can lead to excessive flocculation and other undesirable effects.
application #1

multi-phase oil sands tailings

In this application, a three-phase fluid (oil sands tailings) requires a significant pressure drop. Attempting to reduce this pressure within a single stage can trigger cavitation, erosion, and undesirable alterations to the fluid’s properties. Preserving the fluid’s key characteristics is essential for maximizing water and land reclamation efforts.
To mitigate these risks, the system was thoroughly analyzed, and specialized equipment and design protocols were accounted for. Due to the inherent complexity, customizing the solution to the required conditions was the most effective approach. The resulting two-stage pressure reduction method is described below:
First Stage: A Control Valve with custom-engineered trim applies the initial pressure drop while minimizing fluid shear.
Second Stage: An eccentric Orifice Plate, positioned downstream of the control valve, further reduces the pressure to the target setpoint.
For similar multi-phase applications with dispersed solids, accurately predicting shear rates during flow through valves and orifice plates is crucial. Because these fluids frequently exhibit non-Newtonian behaviour, Computational Fluid Dynamics (CFD) simulations are particularly useful.
A 3-phase CFD analysis illustrates how valve trim design influences shear rate in high-pressure drop applications.
However, accurate rheological data and mathematical models remain essential for predicting shear-sensitive behaviours. With the right inputs and techniques, CFD can help optimize valve trim designs, evaluate shear rates, and analyze turbulence and velocity gradients, ultimately enhancing flow component performance.
APPLICATION #2

SLURRY CHOKE STATIONS TO PREVENT SLACK FLOW

Mining slurry often travels through pipelines that have significant elevation changes. The resulting increase in fluid velocity from pipe inclinations can induce ‘Slack Flow’, leading to pipe damage, vibration, and erosion.

To avoid Slack Flow, discrete, staged pressure reduction systems, called ‘Choke Stations’, are incorporated into the piping design. Each choke station has specialized flow components to manage head pressure and minimize cavitation. Depending on the design objectives and process conditions, each choke station may use different flow devices.
In one application, three choke stations were installed, each with a custom SlurryFlo control valve and four orifice plates featuring progressively larger orifice diameters. A fourth and final control valve (downstream of the stations) provided additional back pressure when required.
Generally, several choke stations can be installed when a pipeline descends from high to low elevations. Because mine tailings often have high solids concentrations and flow at high velocities, this environment can be extremely abrasive on flow equipment such as control valves and orifice plates. As a result, robust designs and precise sizing calculations are critical to ensuring reliable performance and achieving the desired pressure reduction.

Why choose SlurryFlo?

SlurryFlo provides the following advantages in high pressure drop applications:
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Centered flow, protecting the valve body and downstream piping from wear.
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Optimized trim geometry.
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Continued engineering support.
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Tailored process control.
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Super hard wear components.
SlurryFlo Control Valve with Flat Bottom Gate Design and custom Orifice
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