Which Size & Type Suits Your Mining Operation?
Ever asked yourself: “Which pump type and size provides the pressure and flow I need for my operations?”
If you’re managing a mining operation, you know pump selection is a strategic decision. Choosing the wrong pump can result in lost production, rising maintenance costs or operational shutdowns. But if you get it right, you’ll enjoy reliable mine dewatering, slurry transfer or fluid handling with minimal hassle.
In this article we’ll explore how to match pump flow and pressure to your site’s exact requirements. You’ll learn what flow and pressure mean in mining applications, how they interplay and how to select the right pump size from our model range at Prestige Universal Mining Pumps. We’ll also walk you through simple calculations, common pitfalls and best practices for sizing your pump correctly.
Read on and you’ll walk away with:
- a clear understanding of flow and pressure in pump sizing,
- the ability to interpret your site requirements and match a pump,
- insight into what our pump models deliver in terms of flow and pressure, and
- a confident checklist you can use to select (or verify) your pump sizing.
Key Takeaways
- Flow (volume per unit of time) and pressure (head or height/force) are both critical when sizing a mining pump; ignoring one often leads to inefficiency or failure.
- Total Dynamic Head (TDH) is the key pressure metric in mining: static lift + pipe friction + velocity losses.
- Pump selection should start with site data: required flow rate and required head pressure. From there you can map the data against a pump’s performance curve.
- Oversizing or under sizing a pump both carry risks: higher energy costs, increased wear, poor performance or downtime.
- Our product range (Force 5, Force 8, Force 15, Force 20, Force 37) offers different flow and pressure combinations to meet varied mining requirements.
- After installation, ongoing monitoring and mining pump maintenance are essential: flow and head often change over the lifecycle of a mine and external factors (abrasion, solids, pipe layout) impact performance.
- If you’re in doubt, consult a pump specialist early. The right sizing saves cost, reduces risk and improves operational reliability.
Why Flow & Pressure Matter
In the context of a mining operation, imagine you have two tasks:
- Remove 50,000 litres per hour from a sump at 20 metres below the surface, and
- Transfer slurry uphill of 60 metres over a long pipeline.
In task one your flow is high but head is moderate. In task two head pressure is high but flow may be lower. If you pick a pump only because it looks big and powerful you may fail to get the flow you need. If you pick a pump only by flow rating (ignoring head) you may lack the pressure to lift the fluid. This results in poor performance, premature wear or even total system failure.
That’s why understanding both flow and head pressure, as well as how they apply to your mining pump system is crucial.
Understanding Flow (Volume) – How Much Fluid You Need To Move
What Is Flow?
Flow rate is the volume of fluid moved by the pump in a given time — typically expressed as litres per second (L/s), cubic metres per hour (m³/h) or litres per minute (L/min). It tells you how much fluid your system must handle.
Why Is Flow Important?
- If flow is too low for your application, the system may choke; the mine sumps may overfill, slurry transport may bottleneck.
- Oversizing for flow (without checking head) can lead to wasted energy, high velocities (causing erosion) or the pump operating far from its optimum duty point.
Mining Examples
- A dewatering sump in a shallow open cut mine might need a flow of 300 L/min (≈ 18 m³/h).
- A tailings line may require 60 m³/h of slurry transfer.
In either case you must select a pump capable of these flows, but you must also select for the correct head.
Flow In The Context Of Our Models
For example, the Force 15 pump (our snort type pump) is specified with flows between about 2 L/s and 15.5 L/s for its operating pressure range of 30 70 m head (300 700 kPa). That means if your application demands, say, 60 L/min (≈ 1 L/s) you’re outside its ideal range. You’d either need a smaller unit or one with better low flow capability.
Checklist For Flow
- Determine the volume per hour or per minute your operation must transfer.
- Convert units so you can match to pump performance curve (often in L/s or m³/h).
- Consider variations: Is the duty constant or will it fluctuate? Do you have to maintain a minimum flow even during low demand periods?
- Double check fluid characteristics: heavy solids or high viscosity reduce effective flow capacity.
Understanding Head Pressure (How Hard You Must Push The Fluid)
What Is Head Pressure?
In mining pump terms, “head” is the height the pump must raise the fluid, or the equivalent pressure the pump must overcome. It’s commonly expressed in metres (m) of water column. Pressure, in kPa or bar, is closely related (1 m head ≈ 9.81 kPa water column).
Total Dynamic Head (TDH)
TDH = Static Head + Friction Losses + Velocity Head.
- Static Head: vertical lift – depth below sump to discharge point.
- Friction Losses: energy loss through pipes, bends, fittings, length.
- Velocity Head: energy associated with fluid motion (often smaller but not negligible in high flow systems).
Why Head Pressure Matters
- If a pump cannot deliver the required head pressure, you won’t get the required flow (or you may cause cavitation or pump failure).
- If you oversize head pressure by selecting a pump with far greater head than required, your system may operate inefficiently, increase wear or be more costly to run.
Mining Specific Factors
In mining operations, long discharge lines, abrasive slurries, high lifts (underground mines) or deep sumps make head pressure calculations even more critical. Failing to account for friction losses in long or rough pipelines is a common error.
Example From Our Model Range
Our Force 15 pump is rated for a head pressure up to about 70 m. Its pressure operating range is given as 300 700 kPa (30 70 m) with flow 15.5 2 L/s, respectively. That means if your site has TDH of 80 m you may exceed its operating window, meaning performance or service life may be reduced.
Checklist For Head/Pressure
- Determine vertical lift (m) from sump to discharge.
- Estimate friction losses (pipe length, diameter, bends, fittings).
- Consider velocity head if flow is high and pipeline diameter small.
- Add margin for wear, solids build up and future changes.
- Match pump curve to ensure the pump can deliver required flow at that head pressure.
How Flow & Pressure Combine To Determine Pump Size
Duty Point & Pump Curves
Every pump has a performance curve showing flow (x axis) vs head pressure (y axis). The “duty point” is where your site requirement intersects the curve. Selecting based on flow or head pressure alone can miss the duty point, causing the pump to operate poorly or inefficiently.
Why Mismatch Happens
- If you require high head pressure but pick a pump optimised for high flow at low head pressure, you’ll drop over in flow, possibly overload the motor or produce low output.
- Conversely, if you pick for head pressure but ignore flow, the flow delivered may be too low for system demand.
Example Scenarios
- Suppose your site needs 100 L/min at 40 m head pressure. You must find a pump whose curve intersects around that point.
- Another site may need 50 L/min at 80 m head pressure – here the head pressure is much more demanding and you’ll need a pump built for high head pressure even if the flow is moderate.
Application To Our Pump Models
- The Force 5 (5 kW) might be suited for moderate flows and moderate lifts (built for value and portability)
- The Force 8 (8 kW) increases capacity and supports more flow or head pressure.
- The Force 15 (15 kW snort pump) is designed for deeper, higher head applications (up to ~70 m head) with flows ranging from ~2 L/s to ~15.5 L/s.
- The Force 20 and Force 37 are for larger scale dewatering, higher flows and potentially moderate to high head pressure (depending on system design).
Sizing Approach
- Start with target flow.
- Calculate TDH using your site data.
- Find a pump whose performance curve crosses or slightly exceeds your required duty point (flow + head pressure).
- Check motor power, material suitability (abrasion, solids), site constraints (lift, remote location).
- Allow margin for future changes (higher solids, greater lift, longer pipeline).
Don’t Forget: System Matters
Even the right pump can perform poorly if your system imposes high friction losses from pipe diameter, layout and fittings. You need the full loop design: suction, pump, discharge. As highlighted by our guides on understanding pump head pressure and choosing the right pump type.
Selecting The Right Pump Type For Your Needs
Your flow and pressure requirements set the duty point, but you must also choose the correct pump type for the fluid and environment. Here are some common pump types used in the mining and resources sectors:
Submersible Dewatering Pumps
Used when the pump is submerged in fluid (sumps, open cut pits, underground sumps). Advantages: no priming required, typically less risk of cavitation.
Our Force 5, Force 8, Force 20 and Force 37 units are submersible dewatering pumps built for mining use. For example, the Force 20 is a 20 kW submersible dewatering pump made in Australia.
Slurry Pumps
Used where fluid contains high concentrations of solids and risk of abrasion is significant. The material selection and internal clearances must reflect this.
If your required flow‐head duty coincides with slurry transport, ensure the pump is built for slurry (hardened materials) not just clean water.
Centrifugal Pumps
Common for high flow, lower head tasks or clean water transfer. They are versatile but may not suit high head pressure or heavy solids unless specially designed.
Positive Displacement Pumps
Used when you need constant flow regardless of pressure or when handling viscous fluids. Less common for large mining dewatering but relevant in chemical dosing or thick slurry handling.
Mapping To Our Product Range
- For moderate flow‐head dewatering in standard water conditions: Force 5 or Force 8.
- For deeper lifts (higher head) or higher flows: Force 15 (snort pump) for head up to ~70 m at lower flows; Force 20 or Force 37 for larger volumes.
- For slurry or abrasive fluids: ensure you choose units built for abrasion resistance (which our manufacturing covers).
Sizing Your Pump Using Your Parameters
Here’s a practical sizing walkthrough using your site data and our pump range.
Step 1: Gather Your Site Requirements
- Required flow: e.g., 60 L/min (1 L/s) or 3.6 m³/h.
- Vertical lift: e.g., water level at 25 m below discharge point.
- Pipeline length, diameter, fittings: e.g., 120 m pipeline, 90 mm diameter, 3 × 90° bends + 2 valves (estimate friction loss).
- Fluid characteristics: e.g., clear water vs slurry with solids % and abrasive nature.
- Duty cycle: continuous, intermittent, site schedule.
Step 2: Calculate Total Dynamic Head (TDH)
- Using the formula: TDH = Static Head + Friction Loss + Velocity Head.
- Say: Static Head = 25 m.
- Friction Loss (estimative): say 10 m (based on length, diameter, fittings).
- Velocity Head: say 1 m (depends on flow and pipe diameter).
- TDH = 25 + 10 + 1 = 36 m.
Step 3: Choose Flow & Check Duty Point
- Your flow requirement = 60 L/min = 1 L/s.
- Find a pump that can deliver ~1 L/s at ~36 m head (plus margin).
- From our model specs: the Force 15 pump has flows 2–15.5 L/s in head range ~30–70 m. So 1 L/s is below its posted minimum of ~2 L/s at the lower head of 30 m, meaning it would operate under its optimum duty point (which could be inefficient).
- In this case, the Force 8 or Force 5 might be better suited.
Step 4: Factor Material & Environment
If your fluid is abrasive or contains solids, select a pump model with hardened materials or slurry capable internals. Our manufacturing covers this for mining conditions.
If your duty cycle is continuous and remote, ensure you allow margin for wear and future head pressure increases (e.g., sump level falls further).
Step 5: Confirm Motor Power & Operational Fit
Ensure that your selected pump’s kW, voltage and site power supply match your installation. Check serviceability, spares availability and on site maintenance capabilities. Our business offers full service and rebuilds to support this.
Step 6: Install & Monitor
After installation, monitor actual flow and head pressure delivered, comparing to design duty point. If deviated significantly, adjust or review system (pipe size, diameter, wear) to maintain optimum duty.
Operational Tips & Monitoring After Installation
Sizing correctly is just the beginning. Dependable and optimal performance over the long term is what really matters.
Monitor Flow & Head Pressure Trends
- Use flow meters and pressure gauges to remotely monitor performance readings.
- Check that the pump is operating close to its duty point (not far off where efficiency drops).
- Monitor for erosion, wear and seal failures. These often impact the pump’s ability to deliver the required head pressure and flow.
Maintenance Drives Reliability
Our guide on optimising pump performance highlights that material compatibility, correct application and regular scheduled maintenance reduce downtime.
- Check oil levels (for submersible units).
- Inspect wear parts (impellers, volute, bearings).
- Keep spare parts onsite if remote mine.
- Address changes (higher solids content, longer pipelines) early; these impact flow/pressure.
System Design Matters
Even a correctly sized pump won’t deliver if the pipework is wrong. Use correct diameter, minimise bends/valves and maintain good suction conditions to reduce friction losses and improve head pressure margin.
Understand The Cost Of Inaction
- Undersized pumps may run flat out, overheat, seal break and experience cavitation.
- Oversized pumps waste energy, may not hit optimum duty and increase Total Cost of Ownership (TCO).
Final Thoughts
Selecting the right pump requires more than picking a big motor. It demands you understand both flow and pressure, calculate your duty point and select a pump model that fits your volume, lift requirements and the harsh mining environment you operate in. With proper sizing, you’ll gain reliable performance, lower operating cost and fewer surprise shutdowns.
The team at Prestige Universal Mining Pumps has over two decades of experience delivering purpose built mining pumps for Australian conditions. Whether you’re dewatering a shallow pit or transferring slurry up a long lift, we can help you size correctly, select the right model and support installation and maintenance.
Contact us today for a free sizing consultation. Share your required flow rate, head (lift + pipeline length/fittings) and fluid characteristics and we’ll recommend the ideal pump for your needs.
