Project Overview

Efficient slurry transportation is essential for stable mineral processing operations. However, abrasion, scaling, and chemical corrosion are common causes of pipeline failure in grinding and flotation circuits, resulting in frequent maintenance, unplanned downtime, and high operating costs.

To address these challenges, Guangdong Kejin New Materials Co., Ltd. partnered with the beneficiation plant of Fankou Lead-Zinc Mine to conduct a 400-day field trial of customized reinforced nylon slurry pipes under actual production conditions.

The project evaluated the long-term performance of nylon pipes in three critical slurry transportation applications: sulfur ore feeding, concentrate flotation, and hydrocyclone overflow. The trial successfully demonstrated outstanding wear resistance, anti-scaling performance, corrosion resistance, and long service life under demanding mining conditions.

Today, this project serves as a proven reference for mining companies seeking reliable pipeline solutions for mineral processing plants, flotation systems, grinding circuits, and slurry transportation.

Project Snapshot

Item	Details
Industry	Lead-Zinc Mining
Application	Mineral Processing Pipeline
Project Type	Field Trial
Trial Duration	400 Days
Installation Date	June 2007
Completion Date	August 2008
Pipe Material	Reinforced Nylon
Pipe Diameter	DN150 (ID150 mm)
Operating Slurry Concentration	40%–53%
Operating pH Range	6.8–12.5
Maximum Operating Pressure	Approximately 0.15 MPa

Customer Challenges

The grinding and flotation section of the beneficiation plant experienced several long-standing pipeline problems that affected production efficiency and maintenance costs.

1. Severe Scaling and Pipeline Blockage

High-density mineral slurry continuously adhered to the inner surface of conventional steel pipelines. Over time, scale accumulated inside the pipe, reducing flow capacity and eventually causing blockages.

Operators were forced to stop production frequently for manual cleaning, leading to significant downtime and increased labor costs.

2. Rapid Abrasive Wear

The slurry contained large quantities of hard mineral particles moving at high velocity.

Traditional metal pipelines suffered severe internal abrasion, especially in elbows and high-flow sections, resulting in wall thinning, leakage, and frequent pipe replacement.

3. Corrosion Under Complex Chemical Conditions

Different flotation processes operated under different chemical environments.

Operating conditions ranged from:

• Weakly acidic slurry (approximately pH 6.8)

• Strongly alkaline slurry (approximately pH 12.5)

Conventional metal pipes were vulnerable to corrosion in both environments, reducing service life and increasing maintenance requirements.

4. High Total Cost of Ownership

Frequent shutdowns for cleaning, pipe replacement, welding, and maintenance created high lifecycle costs.

The mine required a pipeline solution capable of reducing maintenance while improving production reliability.

Project Objectives

The objectives of the field trial were to verify whether reinforced nylon slurry pipes could:

• Reduce internal scaling

• Improve wear resistance

• Resist acidic and alkaline corrosion

• Extend pipeline service life

• Lower maintenance frequency

• Reduce overall operating costs

Customized Nylon Pipe Solution

Guangdong Kejin designed customized reinforced nylon pipe assemblies according to the operating conditions of each process.

Application 1 – Sulfur Ore Feeding

Pipe Type

• Reinforced Nylon Straight Pipe

Specifications

• Length: 370 mm

• Inner Diameter: 150 mm

Installation Position

• D1 Slurry Pipeline

• D3 Slurry Pipeline

Application 2 – Flotation Concentrate Pipeline

Pipe Type

• Reinforced Nylon Straight Pipe

Specifications

• Length: 2000 mm

• Inner Diameter: 150 mm

Installation Position

• System II Fourth Foam Concentrate Pipeline

Application 3 – Hydrocyclone Overflow Pipeline

Pipe Type

Customized Nylon Assembly

Including:

• Two 90° elbows

• Two straight pipe sections

Inner Diameter:

150 mm

Application:

No.7 Ball Mill Hydrocyclone Overflow Pipeline

Operating Conditions

The trial covered three different production environments.

Application	Slurry Concentration	pH	Operating Condition
Sulfur Feeding	Approximately 53%	6.8	Weakly Acidic
Concentrate Foam	Approximately 45%	12.5	Strongly Alkaline
Cyclone Overflow	Approximately 40%	12.5	High Velocity Slurry

The cyclone overflow system also transported slurry with:

• Particle fineness: 85% passing 74 μm

• Internal pressure: approximately 0.15 MPa

Field Trial Results After 400 Days

1. Sulfur Ore Feeding Pipeline

Operating Conditions

• Slurry concentration approximately 53%

• Weakly acidic environment

Inspection Results

• Only a very small amount of scale adhered to the pipe wall.

• Scale was easily removed by light hammer tapping.

• After water flushing, the internal surface returned to a nearly new condition.

• No noticeable abrasive wear was observed.

• Scaling was significantly lower than conventional metal pipelines.

2. Flotation Concentrate Pipeline

Operating Conditions

• Slurry concentration approximately 45%

• Strong alkaline environment

Inspection Results

• Only minor scaling occurred.

• Scale detached easily during cleaning.

• Internal wall remained smooth.

• No significant wear was detected.

• Slight deformation was observed after long-term service, but it did not affect operation or sealing performance.

3. Hydrocyclone Overflow Pipeline

Operating Conditions

• Slurry concentration approximately 40%

• High-speed particle flow

• Strong alkaline slurry

Inspection Results

• No visible scaling.

• No measurable wear.

• Excellent hydraulic performance.

• Pipeline remained fully operational throughout the entire trial period.

Why Reinforced Nylon Pipes Performed Better

Excellent Anti-Scaling Performance

Reinforced nylon provides a smooth, low-surface-energy internal wall.

Compared with conventional steel pipes, mineral particles are much less likely to adhere to the surface, greatly reducing scale formation and minimizing pipeline blockage.

Outstanding Wear Resistance

Continuous transportation of high-solid-content slurry normally causes rapid wear in metal pipelines.

The reinforced nylon material demonstrated excellent resistance to abrasive mineral particles during the entire 400-day trial.

Superior Chemical Resistance

The pipe operated successfully in environments ranging from weak acidity to strong alkalinity.

It maintained structural stability without corrosion or material degradation.

Lightweight Construction

Compared with steel pipelines, reinforced nylon pipes are significantly lighter.

This simplifies transportation, installation, maintenance, and replacement while reducing labor requirements.

Easy Maintenance

Any minor scale that formed during operation could be removed quickly through simple mechanical cleaning without damaging the pipe wall.

Maintenance time was significantly reduced.

Flexible Structural Design

Customized straight pipes, elbows, and pipe assemblies allowed the system to integrate easily into the existing mineral processing pipeline network.

Project Benefits

Following the successful field trial, the beneficiation plant achieved several operational improvements.

Reduced Pipeline Scaling

Less scale accumulation resulted in fewer shutdowns for cleaning and improved process continuity.

Longer Service Life

Excellent wear resistance significantly reduced pipeline replacement frequency.

Lower Maintenance Costs

Reduced cleaning requirements, fewer replacements, and simplified maintenance lowered overall operating expenses.

Improved Production Stability

Stable slurry transportation improved the reliability of grinding and flotation operations.

Verified Industrial Performance

The successful 400-day field trial confirmed that reinforced nylon slurry pipes are suitable for long-term operation in demanding mineral processing environments.

Technical Highlights

• Successfully completed a continuous 400-day industrial field trial.

• Verified performance in both acidic and alkaline slurry systems.

• Demonstrated excellent resistance to abrasion from high-density mineral slurry.

• Significantly reduced scaling compared with conventional steel pipelines.

• Proven suitability for grinding circuits, flotation systems, and cyclone overflow pipelines.

• Lightweight construction simplified installation and maintenance.

• Lower total lifecycle cost compared with traditional metal pipelines.

Applications

Based on the successful performance at Fankou Lead-Zinc Mine, reinforced nylon slurry pipes are suitable for:

• Lead-zinc beneficiation plants

• Copper concentrators

• Gold processing plants

• Iron ore beneficiation

• Phosphate processing

• Coal preparation plants

• Tailings transportation systems

• Chemical slurry pipelines

• Industrial abrasive slurry handling

Conclusion

The 400-day field trial at Fankou Lead-Zinc Mine demonstrated that reinforced nylon slurry pipes provide a reliable alternative to conventional metal pipelines in mineral processing applications.

By combining excellent wear resistance, anti-scaling properties, corrosion resistance, and lightweight construction, the reinforced nylon pipeline system significantly reduced maintenance requirements while improving production reliability.

The project provides a proven, field-verified solution for mining companies seeking longer service life, lower maintenance costs, and higher operational efficiency in slurry transportation systems.

Frequently Asked Questions

Why are reinforced nylon pipes suitable for mineral processing?

Their smooth internal surface reduces scale buildup, while their high wear resistance and chemical stability make them ideal for transporting abrasive mineral slurries.

Can reinforced nylon pipes handle alkaline flotation slurry?

Yes. This project verified stable operation under slurry conditions with pH values up to approximately 12.5 for 400 consecutive days.

Are reinforced nylon pipes suitable for hydrocyclone overflow pipelines?

Yes. During the field trial, the hydrocyclone overflow pipeline showed no noticeable scaling or wear after continuous operation.

How do reinforced nylon pipes reduce maintenance costs?

Reduced scaling minimizes cleaning downtime, while excellent abrasion resistance extends pipeline service life and lowers replacement frequency.

Which industries can benefit from reinforced nylon slurry pipes?

They are widely applicable in mining, mineral processing, metallurgy, chemical processing, coal preparation, tailings transportation, and other abrasive slurry handling systems.