WARMAN® mill circuit pumps (MCR²®, MCR®, MCR®-M, MCU®)

About this product

Our range of WARMAN® mill circuit pumps are designed to provide superior performance, wear life and reliability in aggressive slurry applications. Overview Able to process large particles in highly abrasive slurries, WARMAN® mill circuit (MC) pumps are specifically designed for severe mill circuit duties and aggressive slurry applications (Service Class 3 & 4). These types of horizontal centrifugal slurry pumps are renowned for their performance with ball and SAG mill discharge and cyclone feed applications in mineral processing plants. Today, the WARMAN® MCR²® mill duty pump represents the latest generation of this technology leadership, extending the performance, wear life and reliability that have made WARMAN® MC pump series the industry benchmark. Compared to other mill circuit pumps, WARMAN® MC pumps offer the following benefits: • Hydraulics are based on more than 30 years of fundamental and applied research including various wear performance field trials • Superior reliability, performance and wear life due to their advanced hypereutectic alloy and elastomer technology, unique design and wear evaluation software • A flexible design that comes in a variety of sizes and has lined or unlined options available • Large, open internal passages and expelling vanes that improve flow within the pump and reduce internal velocities and wear • Features a reversible casing (open back design) that allows the discharge orientation to be positioned either right vertical (standard Clock Wise - CW) or left vertical (Counter Clock Wise - CCW) providing greater layout flexibility • The two-piece cover plate provides easy access to the pump internals for replacement of the impeller and throatbush • The low flow design stuffing box improves packing life and decreases gland seal water consumption by up to 50% • Their quick wet-end change-out helps to reduce mill downtime • Made with the latest wear-resistant material technology which results in increased pump wear life In addition to the above, WARMAN® mill pumps feature: • A large-diameter, low-speed, high-efficiency impeller, manufactured from a wide range of abrasion-resistant alloys • Heavy-duty roller bearings housed in a low-profile fixed assembly (or a removable bearing cartridge) • Patented shrouds that extend past the periphery of the impeller • Increased throatbush adjustment with the WARMAN® XA throatbush For more information about WARMAN® mill discharge pumps, get in touch with our team. WARMAN® MCR²® rubber-lined mill pump​ The WARMAN® MCR2® mill duty pump builds on the proven performance of WARMAN® mill circuit pumps, extending capability for today’s high-intensity grinding circuits. Designed for severe-duty mill discharge and cyclone feed applications, it delivers greater operational outcomes through improved durability, predictability and performance. Key benefits include: • Reduced Total Cost of Ownership (TCO) • Increased production opportunity • Improved wear performance • Reduced maintenance requirements • Designed with integrated NEXT condition and performance monitoring solutions Material: Elastomer (rubber) liners within a ductile iron outer casing Sizes available: 250 to 550 mm discharge WARMAN® MCR® rubber-lined pump The use of rubber in large mill pumps was pioneered in South American copper mines, and a significant number of the plants worldwide now use WARMAN® MCR® rubber-lined pumps for mill discharge (cyclone feed) applications. The WARMAN® MCR® mill circuit pump is a rubber-lined horizontal slurry pump for severe-duty applications. It contains thick, heavy-duty elastomer liners that can be worn down fully before replacement thanks to the split ductile iron outer casing which provides structural integrity, high operating pressure capability and greater safety. It also consists of a metal impeller, metal or elastomer throatbush, and metal or elastomer frame plate liner insert. The WARMAN® MCR®pump offers the following benefits: • A high-resilience elastomer lining that is able to handle fine to coarse particles and ball scats with ease • A lightweight liner design that is safer for maintenance compared to heavy metal liners • Cost savings as rubber lining costs less than heavy metal liners • Improved wear life Material: Elastomer (rubber) liners inside a ductile iron outer casing Sizes available: 125 to 760mm discharge WARMAN® MCR®-M all-metal pump The WARMAN® MCR®-M mill circuit pump is the metal-lined version of the traditional Warman® MCR® horizontal slurry pump. It consists of high chrome iron metal liners inside a ductile iron outer casing and also contains a metal impeller, throatbush and frame plate liner insert. The WARMAN® MCR®-M pump offers the following benefits: • An outer casing that provides slurry containment and allows safe shutdown in the event of a liner cracking • It is a safer alternative for plants where casing breakage (due to ball mill overflow) is a concern • Improved throughput and wear life Material: Hard white iron metal liners inside a ductile iron outer casing. WARMAN® MCU® unlined pump The WARMAN® MCU® mill circuit pump is the all-metal unlined version of the traditional WARMAN® MCR® horizontal slurry pump. Similar to the WARMAN® MCR® and MCR®-M, this pump contains a high chrome iron casing with metal impeller, throatbush and frame plate liner insert. However, unlike the others, it only contains a single wall. The WARMAN® MCU® pump offers the following benefits: • Long-lasting thick metal casings for rugged applications • Able to manage large-sized particles in dense abrasive slurries • Reduced operating costs • Improved plant availability Material: All metal, unlined (single wall) hard white iron casing Sizes available: 125 to 650mm discharge Frequently Asked Questions What can I do to find the best pump for my mill circuit application? In order to find the best mill circuit pump for your application, we recommend contacting your local Weir representative for a comprehensive analysis of your site and process. Our experts will take into account technical factors such as flow, head, solids concentration, NPSHA, particle properties as well as any commercial and planning considerations in order to specify the correct pump. Doing so will ensure that wear life is maximised and downtime minimised. How do I fix my Net Positive Suction Head (NPSH) issues? The first step is to analyse the system to calculate what the Net Positive Suction Head (NPSH) available is and to compare that to the NPSH required from the pump curve, or as stated by your Weir representative. If there is less NPSH available than required (or a very small margin <1m between the two), there are a few steps that can be taken. For example, you can increase the slurry level in the pump box, ensure that there are no blockages or valves closed in the suction line or carefully increase the diameter of the suction line to reduce friction losses. If there are no system modifications that are able to help, a pump performance analysis should be performed to determine whether a different mill pump would help. We recommend reaching out to your local Weir representative to organise an on-site analysis. My current pump supplier only provides mill circuit pumps with a single-wall casing and metal internal parts. Are there better options? WARMAN® MCR® and MCR-M mill circuit pumps are designed with interchangeable rubber and metal casing liners, throatbushes and frame plate liner inserts, matched to a metal impeller. This allows for combinations of materials to be chosen to optimise the wear life and economics of your slurry pump. If the simplicity of a single wall pump is a top priority, the WARMAN® MCU® pump is the ideal choice, with a metal casing, impeller and throatbush. How do I minimise wear between my throatbush and impeller? It is critical to maintain the recommended clearance between the two parts, as specified by the manufacturer. To maintain a consistent clearance, the throatbush must be regularly adjusted throughout the life of the parts. The WARMAN® XA throatbush allows for the adjustment of 80-100% of the throatbush thickness, ensuring that the part life is maximised, whereas competitors may only allow for partial wear before replacement, or may not even allow for adjustments. Why is my mill discharge pump not performing at its design conditions? It is advised to begin with an analysis of the system to ensure that the system curve and corresponding system head at your desired flow matches the original design. It is possible that your system has changed over time, which could be due to such things as changing cyclones and/or modifying the piping. Once the system curve is calculated, it can then be compared to the pump curve at the speed which your mill pump is running to determine the intersection of the two lines, which would be the operating point of your pump. If the operating point corresponds to a different flow than desired, the pump speed may be modulated to adjust to the desired flow. There are several details that need to be taken into account, such as the slurry properties and how they affect pump performance, as well as the mechanisms for modulating the pump speed. It is advised to reach out to your local Weir representative who can help you perform these calculations and get your mill pump running as it should. Features and benefits Next-generation mill circuit pump technology​ The WARMAN® MCR²® mill circuit pump expands on the proven MC pump architecture with patented hydraulic and wear innovations, helping operators improve efficiency, maximise component life and increase confidence in mill circuit performance. Market-leading design Since their introduction, WARMAN® mill circuit pumps have maintained their status as the undisputed world leader in arduous mill circuit applications. This enviable reputation has been well-earned and proven through numerous trial installations that showed our WARMAN® MC pump range consistently outperforming other brands within the same application. The high efficiency, flexibility, superior wear life and low maintenance cost of our WARMAN® mill discharge pumps has made us global leaders in many critical pumping applications. Superior performance, reliability and wear life Engineered for severe mill circuit duties, the WARMAN® mill pump draws on years of proven research and application experience to improve wear life, reduce downtime and provide superior reliability. Its innovative, adjustable and patented WARMAN® throatbush design features deep pre-swirl vanes that: • Reduce the wear effect due to recirculation at the impeller-throatbush interface • Create a smoother entry for the slurry into the impeller Expelling vane tip turbulence is also minimised by the patented shroud feature that traps tip vortices and prevents localised scouring on the throatbush face. Additionally, the full face adjustment feature improves wear life by minimising the impeller-throatbush gap across the whole face of the throatbush. This provides gradual pressure reduction and minimal recirculation so any possible wear is distributed evenly, unlike sacrificial wear rings used by some manufacturers at the impeller eye that may focus wear and cause premature failure. The full face double adjustment of the throatbush and frame plate liner is easy to perform, even during operation. Once clamping screws are released, adjusting screws can be rotated sequentially to move the liner closer to the impeller face. Flexible and interchangeable components Our range of WARMAN® mill circuit pumps have interchangeable materials from a wide range of hard alloy and compression moulded elastomers. This enables optimum material selection for each specific application ensuring the wear characteristics for each component are balanced. It also means that if process conditions change, you can interchange the pump's wet end components. Lined and unlined options are available At Weir, we offer a diverse range of horizontal slurry pumps to ensure that you receive the optimal cost solution for your application. Depending on your needs, we can provide lined or unlined mill pump solutions that provide superior reliability and performance. Our range of lined mill circuit pumps (i.e. WARMAN® MCR® and MCR®-M) contain a replaceable inner liner that is made from a resilient elastomer or a very hard cast alloy, housed within an outer supporting casing. The casing provides the overall structural strength of the pump allowing the inner liners to be worn to their fullest without compromising the strength and pressure rating of the pump. Our unlined single-wall mill circuit pumps (i.e. WARMAN® MCU®) are manufactured in hard cast alloys that provide adequate wearing capability and maintain sufficient pressure ratings, even when in a weakened or worn condition. For more information about our range of liners, please get in touch with our team. Wide range of sizes WARMAN® mill discharge pumps are available in a wide range of sizes to suit a variety of different needs and applications. Reduced mill downtime Due to the nature of planned maintenance cycles, most pump maintenance and overhauling is done during a very short mill shutdown period. As a result, mill pumps must be easy to maintain, with readily available replacement parts to carry the pump through to the next maintenance cycle. On our larger WARMAN® MC pumps, the wet ends can be removed and replaced as one piece, allowing the complete maintenance to be performed in just a few hours. By adjusting the throatbush to clamp the impeller tight against the frame plate liner insert, the frame plate mounting bolts can be removed. The wet end (with the clamped impeller) can then be unscrewed from the shaft resulting in the outer casing, liners and impeller being removable as one piece. This is convenient when rapid change-outs are required to meet plant maintenance requirements or to allow the impeller and liner to be inspected at a more convenient time. Safer packing adjustment, inspection and maintenance WARMAN® MC pumps come with a two-piece cover plate that provides easy access to the pump internals for replacement of the impeller and throatbush. They also contain single-point gland adjustment, which is a design feature allowing safe packing adjustment from outside the stuffing box guard, while the pump is still in operation. Improved throatbush sealing and installation All WARMAN® mill pump designs are available with our improved WARMAN® XA (extra adjustment) throatbush. This offers improved sealing and easier installation of the intake joint ring into both elastomer and metal throatbushes. Compared to a standard throatbush design, the WARMAN® XA throatbush allows a total axial adjustment of up to 80-100% of its total thickness. This means that most of the available material thickness can be used before needing to be replaced. Low flow design stuffing box Our range of WARMAN® mill discharge pumps come with a low flow design stuffing box which allows for improved centring of the stuffing box and lantern restrictor to the shaft sleeve. It also improves packing life and decreases the gland seal water consumption by up to 50%, compared to designs without this feature. The low flow stuffing box is made with tungsten-carbide-coated shaft sleeves and features close clearance split lantern restrictors with a harder non-galling coated inside diameter. Why Weir? At Weir, we have been market leaders in centrifugal and horizontal slurry pump manufacturing for over 60 years. Our continued commitment to research, development and innovation means that we are constantly bringing new products and materials to the market with the objective of improving performance, extending wear life, simplifying maintenance practices and delivering the lowest total cost of ownership to our customers. Given the size and type of particles that need to be pumped by a mill circuit pump, erosive wear is one of the most critical design considerations. Unlike some mill pumps that only last up to 500 hour cycles (due to the extreme wear experienced), our WARMAN® MC pumps can achieve over 5,000 hour cycles in SAG and ball mill applications. Renowned for our world-class range of WARMAN® pumps, we also manufacture valves, hydrocyclones, spools, mill lining, hoses and high pressure grinding rolls in order to provide complete end-to-end mill circuit solutions to customers all around the globe. Applications WARMAN® mill circuit (MC) pumps are specifically designed for highly abrasive and corrosive slurry applications and mill duties including AG, SAG, ball and rod mill discharge, cyclone feed, tailings and water-flush crushing in mineral processing plants. These horizontal slurry pumps are also used to process, transport and distribute large-sized particles including oil sands, coal, phosphate, sand, minerals concentrate and acidic materials from within the mill circuit to tailings. Suitable to be used with the following feed materials: • Acids • Aggregate • Aluminium • Bauxite / Alumina • Chrome • Coal • Copper • Diamonds • Glass • Gold • Graphite • Gravel • Iron • Kaolin • Kimberlite • Lead • Limestone • Lithium • Mineral Sands • Molybdenum • Nickel • Oil • Oil Sands • Palladium • Phosphate • Platinum • Potash • Rare Earths • Salt • Silica/Mineral Sand • Silver • Soda Ash • Zinc Processes • AG Milling / Grinding • Ball Milling / Grinding • Heavy / Dense Medium Separation • Pumping - Cyclone Feed • Pumping - Mill Discharge • Rod Milling / Grinding • SAG Milling / Grinding Product specifications Replacement parts All WARMAN® centrifugal and horizontal slurry pumps are designed, manufactured and installed to operate under demanding conditions that place every component in the pump under a significant amount of stress. Our range of genuine WARMAN® spare parts provide the following benefits: • Made from our highest-quality, cutting-edge wear-resistant construction materials to improve reliability and peace of mind • Greater efficiency and wear life resulting in lower CO2 emissions and lifetime costs compared to non-genuine parts • Legendary wear life in harsh, abrasive and corrosive mining conditions • A lower chance of critical components failing which would result in safety risks due to high-pressure slurry spray • More predictable lifespans compared to their non-genuine counterparts Less localised wear from gaps between liners, excessive vibration during operation or fitment interference • Fewer interruptions to the hydraulic performance of the pump, improving throughput, total head and efficiency In addition to this, our team follow stringent quality control standards and extensive safety testing to ensure that each part undergoes lengthy and precise design processes. Replacement parts are built in state-of-the-art manufacturing facilities all over the globe, with specific heat treatment, proprietary moulding and high quality casting. Click here for more information about our range of WARMAN® parts. Product upgrades and modifications There are a number of mill circuit applications where rubber lining is not recommended, for example when dealing with large coarse particles, high temperatures and hydrocarbons. For these types of applications, metal alloys remain the material of choice. At Weir, we offer two types of metal alloys for horizontal slurry pumping applications - Ultrachrome® and Hyperchrome®. Ultrachrome® alloys are a series of high chromium white irons that deliver excellent wear resistance in moderate to highly corrosive environments. Our most popular alloy is Ultrachrome® A05, which contains approximately 27% chromium by weight and is known as a near eutectic alloy. This alloy provides a great balance of hardness and toughness, making it effective for general-purpose pumping applications in addition to applications with very large solids (sometimes as large as 300mm in size), or those rated pH4 or above. It also provides modest corrosion resistance to a number of components such as the impellers, casings, volute liners and throatbushes. Our Hyperchrome® alloys range consists of a number of hypereutectic iron-chrome alloys, featuring high proportions of chromium carbide to produce incredibly strong metals. Our most common Hyperchrome® alloy, A61, contains 50% chromium carbide and achieves outstanding erosion resistance. This makes it ideal for conditions with a broad particle size distribution such as mill discharge slurries. The premium Hyperchrome® A68 alloy benefits from new metallurgical advances that combine the robust wear resistance of A61 with the anti-corrosive properties of our Ultrachrome® A05 alloy. This makes it ideal for moderately corrosive environments that require a harder alloy than Ultrachrome® can provide. To read more about our range of Ultrachrome® and Hyperchrome® alloys, please click here. Services and maintenance All WARMAN® centrifugal and horizontal slurry pumps are backed by our unrivalled global support network that spans more than 60 countries world-wide. Long-term customer relationships are at the heart of our business, therefore we pride ourselves on working closely with customers and their wider teams. Our experts are here to support you, every step of the way, wherever you may be. With decades of knowledge and practical experience working with mines across the world, our skilled team: • Will work alongside you to better understand your mine in order to effectively provide tailored advice and solutions • Can deliver customised single- or multi-stage slurry pump solutions to suit your desired application • Specialise in the effective maintenance, supervision and optimisation of your equipment so that it performs better and lasts longer • Can ensure that future spares are optimised to the changing feed conditions and wear profiles experienced on your mine Should the worst come to pass (e.g. a component failure shuts down a piece of equipment), our local distribution centres and global logistics network enable us to deliver the right part quickly, with a team member close at hand to help you get back up and running.