📋 Case Study

Slurry Transport Optimization in Iron Ore Pipeline (Brazil)

Unstable flow causing intermittent blockages and excessive pump wear

🏗️ Project Overview

520 km, 450 mm diameter pipeline transporting hematite slurry (62% w/w) from mine to port

🎯 Challenge

Unstable flow causing intermittent blockages and excessive pump wear

🔧 Design Approach

Rheological characterization → Bingham plastic model calibration → CFD-based velocity profile tuning to maintain minimum transport velocity

📐 Design Diagram

CharacterizationBingham Model
CalibrationCFD Velocity
Tuningτ₀ = 38 PaHe = 7,200Min. Transport
Velocity ≥ 2.1 m/sSlurry Transport OptimizationIron Ore Pipeline • BrazilPipeline Incline θD = 0.35 m

AI-generated project design illustration

📐 Key Calculations

Yield Stress Threshold

τ₀ = ρgD sinθ / 4

Result: 38 Pa

Minimum shear to initiate motion on incline

Hedstrom Number

He = ρD²τ₀/μ²

Result: 7,200

Confirmed laminar-dominated flow regime requiring precise yield control

📊 Results

Zero unplanned shutdowns over 24 months, 22% reduction in specific energy consumption

💡 Lessons Learned

• •Yield stress must be measured at pipeline temperature
• •Particle size distribution directly affects τ₀ and μ

✅ Key Takeaways

• 1Yield stress must be measured at pipeline temperature
• 2Particle size distribution directly affects τ₀ and μ