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Case Study: Capstone Pinto Valley Copper Mine Warman® MCR Pump Upgrade
Case Study: How a Warman® mill circuit pump saved our customer AUD$150,000
Since their introduction, Warman® mill circuit pumps have maintained their status as the undisputed world leader in arduous mill circuit applications.
This enviable reputation has been well-earned and proven through numerous trial installations that showed our Warman® MC pump range consistently outperforming other brands within the same application.
The high efficiency, flexibility, superior wear life and low maintenance cost of our Warman® mill discharge pumps has made us global leaders in many critical pumping applications.
Engineered for severe mill circuit duties, the Warman® mill pump draws on years of proven research and application experience to improve wear life, reduce downtime and provide superior reliability.
Its innovative, adjustable and patented Warman® throatbush design features deep pre-swirl vanes that:
Expelling vane tip turbulence is also minimised by the patented shroud feature that traps tip vortices and prevents localised scouring on the throatbush face.
Additionally, the full face adjustment feature improves wear life by minimising the impeller-throatbush gap across the whole face of the throatbush. This provides gradual pressure reduction and minimal recirculation so any possible wear is distributed evenly, unlike sacrificial wear rings used by some manufacturers at the impeller eye that may focus wear and cause premature failure.
The full face double adjustment of the throatbush and frame plate liner is easy to perform, even during operation. Once clamping screws are released, adjusting screws can be rotated sequentially to move the liner closer to the impeller face.
Our range of Warman® mill circuit pumps have interchangeable materials from a wide range of hard alloy and compression moulded elastomers. This enables optimum material selection for each specific application ensuring the wear characteristics for each component are balanced.
It also means that if process conditions change, you can interchange the pump's wet end components.
At Weir, we offer a diverse range of horizontal slurry pumps to ensure that you receive the optimal cost solution for your application.
Depending on your needs, we can provide lined or unlined mill pump solutions that provide superior reliability and performance.
Our range of lined mill circuit pumps (i.e. Warman® MCR® and MCR®-M) contain a replaceable inner liner that is made from a resilient elastomer or a very hard cast alloy, housed within an outer supporting casing.
The casing provides the overall structural strength of the pump allowing the inner liners to be worn to their fullest without compromising the strength and pressure rating of the pump.
Our unlined single-wall mill circuit pumps (i.e. Warman® MCU®) are manufactured in hard cast alloys that provide adequate wearing capability and maintain sufficient pressure ratings, even when in a weakened or worn condition.
For more information about our range of liners, please get in touch with our team.
Warman® mill discharge pumps are available in a wide range of sizes to suit a variety of different needs and applications.
Due to the nature of planned maintenance cycles, most pump maintenance and overhauling is done during a very short mill shutdown period. As a result, mill pumps must be easy to maintain, with readily available replacement parts to carry the pump through to the next maintenance cycle.
On our larger Warman® MC pumps, the wet ends can be removed and replaced as one piece, allowing the complete maintenance to be performed in just a few hours.
By adjusting the throatbush to clamp the impeller tight against the frame plate liner insert, the frame plate mounting bolts can be removed. The wet end (with the clamped impeller) can then be unscrewed from the shaft resulting in the outer casing, liners and impeller being removable as one piece.
This is convenient when rapid change-outs are required to meet plant maintenance requirements or to allow the impeller and liner to be inspected at a more convenient time.
Warman® MC pumps come with a two-piece cover plate that provides easy access to the pump internals for replacement of the impeller and throatbush.
They also contain single-point gland adjustment, which is a design feature allowing safe packing adjustment from outside the stuffing box guard, while the pump is still in operation.
All Warman® mill pump designs are available with our improved Warman® XA (extra adjustment) throatbush. This offers improved sealing and easier installation of the intake joint ring into both elastomer and metal throatbushes.
Compared to a standard throatbush design, the Warman® XA throatbush allows a total axial adjustment of up to 80-100% of its total thickness. This means that most of the available material thickness can be used before needing to be replaced.
Our range of Warman® mill discharge pumps come with a low flow design stuffing box which allows for improved centring of the stuffing box and lantern restrictor to the shaft sleeve. It also improves packing life and decreases the gland seal water consumption by up to 50%, compared to designs without this feature.
The low flow stuffing box is made with tungsten-carbide-coated shaft sleeves and features close clearance split lantern restrictors with a harder non-galling coated inside diameter.
Warman® MCR Mill Circuit Pumps Features and Benefits
Warman® Mill Circuit Pumps (MCR®, MCR®-M, MCU®)
Hydraulic Institute 6, ISO 9001, ISO 14001, OHSAS 18001 and CE certified
Discharge sizes - 125mm to 760mm (5” to 30”)
Heads to 180 ft (55m) | Pressures to 130 psi (900 kPa)
1 to 100°C
Capacities to 55,000 gpm (12,500 m3/hr)
Lined Warman® mill discharge pumps contain a ductile iron outer casing with metal impeller, throatbush and frame plate liner insert. The internal liners will depend on the model chosen. Unlined designs allow for a metal casing.
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Warman® Heavy-duty Slurry Pumps (AH® and AHPP)
Hydraulic Institute 6, ISO 9001, ISO 14001, OHSAS 18001 and CE certified
Discharge sizes - 100mm to 450mm (4" to 18")
Heads to 240ft (73m) | Pressures to 1,000 psi (6,900 kPa)
1 to 90°C
Capacities up to 8600 m3/hr
Warman® AH® horizontal centrifugal pumps contain a ductile-iron outer casing, high-chrome white-iron impeller and high-chrome white-iron or elastomer wear liners.
Up to 2000 kW
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