Long-Distance Pipelines
We have over 35 years of experience designing overland pipeline systems and are global leaders in this field.
Long-distance slurry pipeline systems are a safe, reliable, and economically viable alternative to conventional bulk transport and are particularly well suited for projects located in mountainous terrain or in regions with limited existing transport infrastructure.
Our engineers have experience in all aspects of slurry pipeline system design and operation, ranging from laboratory test work, hydraulic analysis, pipeline routing, and pipeline construction, to the detailed design and engineering of pump, valve, and choke stations.
This expertise extends to other long-distance pipelines such as concentrate, ore, tailings and water systems. We have executed numerous slurry pipeline projects, from pre-feasibility to detailed engineering design, construction assistance, commissioning, and operator training. We help owners of existing pipeline systems implement operational improvements to increase pipeline capacity, and to extend the operating life of their pipeline assets using integrity management programs.
Transient flow simulation has become an essential requirement for understanding the response of a piping system under various scenarios for normal operation and upset conditions. We collaborated with Deltares to extend their WANDA software capacity for flow simulation of pipelines with slurry and water batches, such as during flushing or for long-distance pipeline operation.
NOTABLE PROJECTS
Long-Distance Pipeline Projects from around the world
We completed the detailed design, engineering and commissioning support of the 186 km long phosphate ore pipeline from Khouribga Mine to Jorf Lasfar, and the feeder pipeline systems from the process plants to the pump head station. The head station receives ore of different grades from the feeder stations and pumps the ore in separate batches via the main DN 900 pipeline to the terminal that delivers different grades of ore to dedicated storage tanks. A choke station at the terminal ensures that the system remains at fully pressurised flow at all times to prevent slack flow.
Commissioned in 2014, the system transports 38 MTA of phosphate ore and is the highest capacity ore slurry pipeline in the world, providing a significant proportion of global phosphate demand.
We provided ongoing technical and management support to IMERYS that operates a long-distance kaolin transport pipeline in Brazil.
The support included annual management, training, technical audits, and identification and implementation of technical projects. These projects included ongoing maintenance and system upgrades as required, including the detailed design, construction support, and commissioning of a 23 km section of replacement pipeline.
Since 2014, Anglo American has been operating the 520 km long Minas Rio iron ore concentrate pipeline - the longest slurry pipeline in the world. We provided ongoing support for pipeline integrity activities, planning and providing invaluable insight into the unique operation of this long-distance pipeline system with tight-lined positive displacement pump booster stations.
Hydro has been operating the 244 km long Paragominas bauxite pipeline for over 10 years, the first bauxite transportation pipeline in the world. We were engaged on this project to support pipeline integrity activities which included operational recommendations, pipe rehabilitation, and a full in-line inspection pig campaign.
In 2020 we completed a third-party review of the transient analysis and pipeline hydraulics for the desalination and copper concentrate pipeline systems for this client. The following year we completed a study optimising the 165 km long, concentrate and desalination water pipeline systems for the proposed expansion.
CMA have been operating the world’s first multi-product pipeline for nearly 20 years. We were engaged to study and evaluate the 300 km long pipeline’s availability and expansion capabilities. The study included an extensive evaluation of pump maintenance and pipeline historic operational performance.
We were engaged by the Galore Creek Mining Company to develop a conceptual level ore slurry transport system for the Galore Project. The project is expected to advance to feasibility level in the near future.
The MARA (Minera Agua Rica Alumbrera) project intends to integrate the retired Alumbrera concentrate slurry pipeline with the Agua Rica project in Argentina. The Alumbrera concentrate transport system comprised a 317 km slurry pipeline from the mine site to a filter plant at Tucumán. A pipeline condition assessment site visit, rheology test work, hydraulic assessment and strategies to increase pipeline capacity were within the project scope.
We completed the concept study design review, laboratory test work and basic engineering for a 10 Mtpa and 90 km iron ore slurry pipeline in Maharashtra. Our work established a robust and technically grounded basis for the implementation of this large-scale slurry transport system. The pipeline was executed in record time and forms a critical part of Lloyds Metals’ investment in lower-impact transport of iron ore concentrate between sites.
