Meet the solution for higher capacities in pumps: Metso MD Series

This demand is driven by depreciating ore bodies and the need for large production on SAG and ball mills. On top of that, higher efficiencies, longer service life and improved digital technology have become crucial in mining operations. The intensity and the size of mines is growing, and with that, operations must keep up with the amount requirements and procedures. With the focus on sustainability and energy costs, customers are struggling to find the optimal solution – until now.

Challenge: Ensuring accurate pump size

When it comes to slurry pumps, having the correct size for your feed is undoubtably very important. Since mill discharge is a class 3 or class 4 application, we follow use the following selection criteria:

For a class 4 service, the pump is generally recommended to be picked between 60% and 100% of its best efficiency performance point. The reason behind that is with a class 1 slurry, which has a wider band off selection of 30% to 130%, the location of where the pump actually operates, does not affect its life cycle.

When you operate towards the left of the BEP, (see Fig.1) the fluid within the pump stays there. It recirculates, and if it doesn’t have enough particles inside, it’s not abrasive enough for the pump to experience wear. Thus, the pump remains suitable. However, using that same scenario but applied to a class 4 application, there will be particle laden fluid sitting and spinning within the pump. This will create a lot of turbulence and wear, thus further highlighting the importance of having a much tighter bandwidth.

“When we select a pump for class 4, we usually recommend staying within a very tight bandwidth because you want to be towards the right of the BEP. Initial selections very often end up to the left of the BEP, due to multiple levels of factor of safeties applied at different equipment selection levels,” says Diwakar Aduri, Global Product Manager, Mill Discharge Pumps.

Solution: Metso MD Series slurry pumps

Metso launched the and in 2022. The numbers – 800 and 900 – are referring to the inlet size of the pump, which dictates the amount of flow that passes through. For the MDM800, this is approximately 12,000m3/hour. For the MDM900, this is more than 13,000m3/hour.

“To put these numbers into context, an American football field is 120 yards,” says Diwakar. “If you use the height of the goal - almost 10 feet high - and cover the field with slurry, the MDM900 can empty that entire field in just over an hour.”

The Metso MD Series pumps have been designed for efficient operation and longest wear life in grinding mill circuits to match the mill’s uptime. With excellent resistance to abrasion and erosion, the MD series pumps are known for their durability in highly abrasive slurries with the latest in wear reduction technology.

“Efficiencies are high by design because we used CFDs to perfect the hydraulic, so we’re looking at very high efficiencies compares to competitors and low water consumption,” says Alan Varghese, Product Manager, Digital Products, Pumps. “All of which minimize the footprint of the pump and adhere to our global sustainability targets.”

Benefits: Adaptability is key

One of the key factors in finding the right pump is ensuring you have upsizing/upgrading options. Therefore, it is important to always select a pump that can be upsized for new and/or greenfield installations.

“It’s very beneficial if you have a modular design, because then you can upsize the wet end with a little amount of piping changes, spool pipes, and more,” says Diwakar. “An operational tip from me is to always keep that upsize capability and flexibility when selecting a mill discharge pump – you won’t regret it.”

The modular design of the MD Series allows for easy interchangeability of all metal and rubber parts, which reduces the need for component changes when up- or down-sizing the pump. The ability to maintain individual elements of the pumps is a key feature of the MD Series. The back pull-out feature also includes an optional maintenance slide base for fast, easy, and safe inspection.

“Pumps are designed to operate at a certain point with a given efficiency – they’re fixed,” says Alan. “Sometimes process changes can happen, and with that, you need to have the adaptability to resize your pump if needed.”

Metso also has a sizing and selection tool, PumpDim™, that can help make this process seamless and simple.

Investing in digitalization

Digitalization is one of the top priorities for the mining industry, driven by stricter safety requirements, higher production efficiency, cost-saving targets and sustainability goals.

By leveraging more automated and digitalized elements in our pumps, Metso is in the unique position to ensure improved process efficiency, increased pump uptime and reduced energy and water consumption.

You can’t fight facts, and due to the aggressive nature of slurry, the internal wear parts of the slurry are going to deteriorate. However, with the ability to monitor internal wear rates of pumps and incorporating predictive maintenance capabilities, this allows customers to plan and avoid unnecessary failures. By utilizing this technology, they can inevitably experience less downtime for their operations.

“For a long time, we’ve invested in condition monitoring devices and technology which makes the maintenance, the operation and upkeep of our equipment easier,” says Diwakar. “We are incorporating these technologies as they emerge into our product line.”

Not just a part supplier, but a life-cycle partner

Metso Life Cycle Services (LCS) for pumps is a comprehensive and customizable solution designed to improve the performance and reliability of pumps throughout their entire life cycle. One of the key benefits of LCS is that it can be tailored to meet the specific needs of each customer, ensuring that they get the support they need to optimize the operation and maintenance of their pumps.

“Services and aftermarket are at the heart of Metso pumps culture, as it is where we can make the big difference to our customers,” says Diwakar. “Our global services and supply chain networks include foundries, rubber factories, assembly parts, R&D centers, warehouses, repair service centers and field services groups. They all work together to allow Metso pumps to meet all needs of its customers by providing full coverage on parts and service supply.”

The LCS program provides a range of services that includes technical support, performance consultancy, operation and maintenance training, troubleshooting and more. These services aim to help customers reduce downtime, increase productivity and extend the life of their pumps.

“LCS contracts can simplify your maintenance, improve your pump reliability, minimize downtime and maximize pump life – all at the same time,” says Tiago Oliveira, VP, Pumps Services.

Metso’s LCS program also includes comprehensive monitoring and reporting tools that enable customers to track the performance of their pumps and identify opportunities for further improvement. By providing customers with the tools and support they need to optimize the performance and sustainability of their pumps, Metso is helping to drive positive change in the mining industry.

Sustainability at a lower cost

Here at Metso, we recognize the importance of reducing the environmental impact of mining operations. With the MD Series pumps, customers can achieve this goal.

The pumps have been developed to minimize water consumption, which is becoming a scarce resource in many mining regions. By utilizing the EnviroSet™ gland as a standard feature, they can reduce water consumption by up to 50%.

The MDM800 and MDM900 pumps have been designed to meet the demands of higher capacities required by expanding mine sites. Their robust and modular nature makes them efficient and durable, with the ability to be upsized and adapted for new and/or greenfield installations. With sustained efficiency and performance, all whilst providing the lowest total cost of ownership, Metso is proud to boast such a versatile and proven application.

“With this unique combination of pumps engineering developments and services offerings, we can ensure that we walk the walk and talk the talk on asset life cycle management,” says Diwakar. “By having swift and supported access to our new and innovative technologies, we can support customers in both their production and sustainability goals – regardless of the pumps fleet they already have installed.”