Arcelormittal Kryvyi Rih, Ukraine Warman® AHP and GHPP Pumps

ArcelorMittal Kryvyi Rih, Ukraine Warman® AHP and GHPP pumps

Minerals

Case Study

Above: Warman® AHP

Right: Warman® GHPP 28/24 high-pressure gravel pumps

INDUSTRY Warman® pumps reduce downtime and improve Iron ore mining performance at ArcelorMittal Kryvyi Rih, CUSTOMER saving the customer US $98,000 a year ArcelorMittal Background extending pump wear life, significantly LOCATION reducing maintenance and enhancing ArcelorMittal, one of the world’s leading safety to operational personnel. Kryvyi Rih, Ukraine steel and mining companies, has been operating the Kryvyi Rih iron ore plant ArcelorMittal progressively implemented a EQUIPMENT in the Ukraine since 2005. The company pump replacement project under the Warman® AHP 20/18 operates in 60 countries, producing guidance of the Weir Minerals’ process high-pressure slurry pump and products for use in the automotive, engineering team which included, six Warman® GHPP 28/24 construction and household appliance Warman® AHP 20/18 high-pressure slurry high-pressure gravel pump industries. pumps, and nine Warman® GHPP 28/24 high-pressure gravel pumps. Weir Minerals have supported the Kryvyi Rih site for twelve years, and were The Results instrumental in supporting the Increased pressure delivered productivity improvement of the tailings pumps’ increases in excess of 60%, by 2,000m3 to performance. 5,000m3. Maintenance intervals reduced The Challenge from three times per year to a single change-out annually, thus saving some 90 The installed pumps were notorious for hours a year on maintaining the Warman® deficient performance, delivering low AHP 20/18 pumps, and 120 hours per year pressure and capacity. The average wear on the Warman® GHPP 28/24 pumps. life was between 3,000 – 4,000 hours: requiring frequent mechanical breakdown ArcelorMittal estimates this to be a saving repairs and complete pump disassembly of approximately US $98,000 per year. three times annually. Given that only partial dismantling was required to undertake maintenance, the The Solution repair process was simplified, thus also Weir Minerals’ process engineering team reducing the safety risks to maintenance proposed a solution which would increase personnel. pressure, flow-rate and productivity while Vladimir Teslyuk, Director of the Mining Department at ArcelorMittal Kryvyi Rih said: ‘The Weir service team fully understood the problem and provided a simple, yet technically good solution, which improved the efficiency of our operations while reducing maintenance costs. Our time spent on repairs has greatly reduced, bringing savings of around US $98,000, and a total reduction of 215 man-hours previously dedicated to pump repairs per year.’

Results comparison table

Warman® AHP 20/18 Competitor’s pump high-pressure slurry pump Wear life (h) 5,600 3,900

Flow rate (m3/h) 5,500 3,800

Discharge head 88 65 Approx. 95 labour hours Downtime less a year 3 rebuilds per year (decreased maintenance) 1 rebuild per year Top: Warman® GHPP 28/24 high-pressure gravel pumps Warman® GHPP 28/24 Above: Warman® AHP 20/18 high-pressure Competitor’s pump high-pressure gravel pump slurry pumps Wear life (h) 6,500 4,200 Capacity (m3/h) 10,000 7,000 – 8,000 Discharge head 85 71 Approx. 120 labour hours Downtime less a year 3 rebuilds per year (decreased maintenance) 1 rebuild per year Decrease in total cost US $98,000 of ownership

Product Summary Warman® AHP 20/18 high-pressure slurry pump Warman® GHPP 28/24 high-pressure gravel pump The Warman® AHP 20/18: The Warman® GHPP 28/24: • Delivers excellent wear life while maintaining efficiency and • Is a fully lined pump offering ease of maintenance; providing the lowest total operating cost; • Features a high pressure rating with increased safety, wear life • Offers longer bearing life; and reliability; • Features bolted liners for simpler and more efficient • Provides an efficient and durable solution for long distance replacement; hydro-transport and tailings duties; • Features various shaft seal options that provide a perfect fit • Is ideal for pumping larger particle slurries and gravel, with for a wide range of applications, including high operating discharge sizes from 100mm to 900mm; pressure capabilities; • Provides capacity up to 12,000m3/h. • Offers discharge sizes from 100mm to 300mm; • Provides capacities of up to 6000m3/h.