1. Client & Project Background
A prominent zinc mining company in Eritrea embarked on an expansion project to increase processing capacity. A critical bottleneck was identified in the tailings disposal system. The existing pipeline was failing prematurely due to the combined effects of high-pressure pumping (6 MPa), highly abrasive zinc tailings slurry, and a corrosive mine water chemistry. This led to frequent leaks, unplanned maintenance shutdowns, and rising operational costs, threatening the project's productivity and economic viability.
2. Core Challenges & Technical Requirements
The client outlined a set of stringent requirements for the new pipeline system:
Ultra-High Pressure Resistance: Consistently withstand a sustained operating pressure of 6 MPa (870 psi) with safety margins for pressure surges.
Superior Abrasion & Corrosion Resistance: The internal lining must resist the scouring effect of dense, hard mineral particles. Externally and internally, the material must withstand corrosive elements in the soil and slurry.
Optimized Hydraulic Design: Precise pipe diameter selection was crucial to maintain an optimal flow velocity – high enough to prevent particle settling and pipeline clogging, yet low enough to minimize abrasive wear and energy consumption.
Ruggedness & Reliability: Adapt to a harsh, remote mining environment with temperature variations, rough terrain, and minimal on-site repair infrastructure. Installation needed to be straightforward and reliable.
Long Service Life & Low TCO: Reduce the total cost of ownership by minimizing maintenance interventions, replacement frequency, and production downtime.
3.SIFFO’s Customized Solution
SIFFO, a global leader in industrial piping systems, proposed a tailored HDPE Steel Wire Skeleton Composite Pipe System with the following specifications:
Material: High-density polyethylene (HDPE) reinforced with a steel wire mesh framework, combining flexibility with rigidity.
Dimensions: 125–160 mm outer diameters, engineered to balance flow velocity and pressure resistance.
Pressure Rating: Designed for 6 MPa (60 bar) continuous operation, exceeding project requirements.
Connection Method: Flange joints for secure, leak-proof assembly and easy disassembly during maintenance.
4.Why This Solution Worked
Dual Resistance:
The HDPE layer resisted chemical corrosion, while the steel wire skeleton absorbed pressure stresses, preventing deformation.
Tested to withstand abrasion rates 3x lower than conventional steel pipes in simulated tailings flow conditions.
Flow Efficiency:
Custom sizing (125–160 mm) maintained optimal flow velocity (≥2.5 m/s), minimizing sedimentation risks.
Smooth inner wall reduced friction loss by 40% compared to rubber-lined pipes.
Installation & Maintenance:
Lightweight design (30% lighter than steel) simplified transportation and installation in rugged terrain.
Flange connections enabled rapid replacement of damaged sections without system shutdown.
5.Project Outcomes
Zero Pressure Failures: The pipeline operated at 6 MPa for 18 months without leaks or bursts.
Reduced Downtime: Flow efficiency improvements cut cleaning cycles by 60%, saving $120,000 annually in maintenance costs.
Longevity: Projections indicate a 15-year service life, outperforming the initial 10-year target.
6.Client Testimonial
"SIFFO’s composite pipes addressed all our challenges—pressure, corrosion, and blockages. The flange system’s ease of use was a game-changer for our remote site. We’ve since adopted this solution across three other mine projects."
— Mr. Tewolde Gebremariam, Project Manager, Eritrean Zinc Mining Co.
Conclusion
SIFFO’s HDPE steel wire composite pipes provided a cost-effective, durable solution for high-pressure tailings transportation in abrasive environments. By combining material innovation with custom engineering, the project achieved uninterrupted operations and significant lifecycle cost savings, setting a benchmark for mining infrastructure globally.
