Design, development and testing of a digitally instrumented slurry pump test rig enabling sustainability‑conscious pump assessment in mining

Abstract

Slurry pumps are becoming paramount for the mining and mineral processing industries that heavily rely on them to transport solid–liquid mixtures. Basic test rigs and clear water (as opposed to digitized/smart rigs and slurry) are typically used to validate the functioning of slurry pumps and generate performance curves that can be empirically adjusted for slurry conditions. However, these adjustments are rarely aligned with the actual operating conditions, which may lead to discrepancies between expected and real-world performance. This paper presents the design and development of a slurry pump test rig that is proposed to advance digitalization in the mining sector. Unlike conventional setups, this rig is meant to handle real slurry mixtures. It is equipped with a set of sensors that monitor pressure, temperature, slurry density and flow rate and capture performance continuously. The collected data will be instrumental in developing a digital monitoring of the pump condition and possibly assessing its reliability in real time. By enabling digital performance validation and condition monitoring under controlled yet realistic slurry operating conditions, the proposed test rig provides a practical experimental platform to support energy and water aware pump operation and improved maintenance decision‑making. The digitalization system, consisting of data acquisitions systematic analysis and interpretation, can enhance maintenance strategies, operational reliability, and the overall efficiency of slurry transport in mining operations.