Reducing water usage doesn’t have to break the bank
In mineral processing, slurry pumps are among the most water-intensive and maintenance-heavy assets in operation. Maintaining adequate flush water to protect sealing systems often comes at the cost of excessive water consumption, accelerated wear, and frequent maintenance interventions. A recent field installation on a Warman slurry pump demonstrated how a change in sealing support technology can significantly reduce water usage while improving reliability.
The challenge
The pump in question was operating under typical abrasive slurry conditions, requiring continuous flush water to prevent solids ingress into the stuffing box. Prior to intervention, the system consumed approximately 3.44m3 of water per hour. Over a 75-day operating period, this translated to a total consumption of 6,192m3 of water.
Despite this high flush rate, the pump required frequent maintenance. Critical components – including shaft sleeves, packing sets and lantern rings – were being replaced every eight days. Each maintenance cycle required significant labour input, contributing to operational downtime and increased cost.
The solution
To address these issues, a composite bearing support system was introduced into the stuffing box. The bearing was designed to stabilise the shaft and restrict the migration of solids into the sealing area, allowing for more efficient use of flush water.
A key advantage of this approach was that the system could be installed without any modification to the existing pump. The bearing was engineered to fit within the standard stuffing box configuration, enabling a straightforward retrofit using existing equipment. This eliminated the need for machining, redesign or extended downtime, allowing the upgrade to be implemented quickly during a routine maintenance interval.
Following installation, flush water requirements dropped to 1.68m3/hr. Over the same 75-day period, total water consumption was reduced to 3,022m3.
Results
The reduction in flush water usage resulted in a total savings of 3,170m3 over the evaluation period — representing nearly a 50% decrease in water consumption. In operations where water availability and cost are critical, this level of reduction has meaningful environmental and economic implications.
Equally important were the improvements in equipment reliability and maintenance frequency. Prior to the upgrade, the pump required eight full maintenance cycles within the 75-day window. Each cycle involved the replacement of liners, packing kits, and lantern rings, along with approximately 100 man-hours of labour for disassembly, installation, and reassembly.
Since the installation on 25th August, 2022, the system has remained in continuous operation without requiring the same level of intervention. This represents an approximate eightfold increase in component service life.
Operational Impact
The stabilisation of the shaft within the stuffing box reduced dynamic movement and minimised wear pathways for abrasive solids. As a result, the sealing environment became more controlled, allowing operators to reduce flush rates without risking packing failure or excessive leakage.
This case highlights a broader trend in slurry pump optimisation: rather than relying solely on increased flush water to compensate for instability and wear, addressing the root mechanical conditions within the pump can yield more sustainable results.
Conclusion
The introduction of a bearing-supported sealing approach in this Warman slurry pump delivered measurable benefits across multiple performance metrics. Water consumption was reduced by over 3,000m3 in just 75 days, while maintenance frequency and associated labour were dramatically decreased.
For mining operations seeking to reduce water usage, improve equipment reliability, and lower total cost of ownership, this case demonstrates the value of rethinking traditional sealing strategies in favour of more stable, mechanically supported systems.
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