GIW® MDX L Series: Longer Wear Life for Demanding Mill Circuit Applications
In mill duty applications, a pump’s hydraulic efficiency is only part of the performance equation. Factors like wear life, maintenance intervals and uptime all play a key role in preserving or improving production.
KSB GIW developed the GIW® MDX L Series pump range to offer extended wear life in severe-duty mill circuit applications, including cyclone feed, screen feed, SAG mill discharge, ball mill discharge, and rod mill discharge. Based on the proven hydraulics of the GIW® MDX pump, the GIW® MDX L provides longer service life in demanding slurry conditions while maintaining the performance customers rely on.
Built Around Customer Challenges
The GIW® MDX L builds on the GIW® MDX platform with small but impactful design changes to areas within the pump known for aggressive and accelerated wear.
For the first phase of the GIW® MDX L range’s development, covering GIW® MDX-400 through GIW® MDX-850 pumps, KSB GIW upgraded part thickness in key wear areas including the impeller and casing. The new design increased critical nose thickness on the impeller for improved wear and optimized the quantity, height and shape of the clearing vanes to minimize recirculation and maintain nose clearance over a longer period of time. When paired with regular nose clearance adjustments, these changes help delay the onset of gouging wear patterns and significantly extend the life of wet end parts.
The GIW® MDX L Phase I design also increased suction inlet length to allow different inlet geometries, helping to counter the effects of sliding bed wear that can occur with low flow rates or large particle sizes.
The result is a stronger, more wear-resistant wet end designed to support longer run times in demanding mill circuit applications, with little or no change to head, efficiency, best efficiency flow, NPSHR and specific speed.
Continuing to Advance the GIW® MDX L
KSB GIW has continued to expand and improve the GIW® MDX L range. The GIW® MDX-750 L design is now complete and installed at several customer sites. KSB GIW is also currently implementing Phase II of the GIW® MDX L range by developing L Series designs for smaller pump sizes, from GIW® MDX-350 through GIW® MDX-100.
For these smaller sizes, design updates include reductions in specific speed and best efficiency flow to better match pump hydraulics to branch sizes. This allows KSB GIW to extend the benefits of the GIW® MDX L design into smaller pump sizes while maintaining the performance customers expect.
Hydraulic lab testing of the GIW® MDX-250 L pump confirmed that the Phase II design has minimal impact on pump hydraulics. During testing, NPSHR remained close to the original GIW® MDX-250 design, efficiency exceeded pre-test estimates, best efficiency flow was right-sized for the updated hydraulics, and the head curve matched the pre-test estimate.
Additional advances include:
- Completion of the GIW® MDX-200 L, GIW® MDX-250 L and GIW® MDX-300 L designs
- Introduction of four-vane impellers for GIW® MDX-350 through GIW® MDX-100 sizes, where smaller pump geometry makes them a good fit
- Completion of designs for RAMSL, KSB GIW’s remotely adjustable mechanical suction liner system, for select GIW® MDX L sizes to make nose gap adjustments easier for customers
Proven Wear Life Gains in the Field
Field results for the GIW® MDX L have been strong, with customers experiencing significant improvements in pump service life.
At one customer site in Indonesia:
- A GIW® MDX-650 L achieved 5,975 hours on both the impeller and casing
- Some GIW® MDX-650 L casings have exceeded 10,000 hours, including one casing that reached 10,738 hours
A customer in Latin America also increased wear life from 2,880 hours with the GIW® MDX-750 to 4,240 hours after upgrading the wet end to the GIW® MDX-750 L design.
These improvements translate into extended maintenance intervals, reduced downtime, and better alignment with maintenance cycles for other critical mill equipment, helping to increase site throughput and decrease total cost of ownership.
“The GIW® MDX L includes a wet end produced from KSB GIW’s proprietary white iron metal thickened in areas susceptible to wear and advanced hydraulics to match the maintenance cycle of other critical mill equipment, maximizing the operating time of the mill,” explained Amy Lewis, Product Manager for GIW® MDX, GIW® TBC and GIW® WBC pumps.
Many existing GIW® MDX pumps are eligible for upgrades to L Series features. Customers can contact KSB GIW or their local KSB GIW representative to discuss available options.
Building the Future of GIW® MDX Performance
Looking ahead, KSB GIW will complete design work on smaller GIW® MDX L sizes. The company is also working to incorporate ramp inlet geometry suction liner designs on all GIW® MDX L sizes.
The GIW® MDX L is part of KSB GIW’s broader approach to solving customer challenges through continuous product improvement.
“KSB GIW solves problems when customers present their challenges,” said Lewis. “That includes creating new and improved GIW® MDX parts and pumps, as well as improving existing designs to make the product line stronger. This customer-driven approach will continue to shape the future of the GIW® MDX product line.”
Interested in learning more about what you read today? Speak to an expert at KSB GIW, Inc. to learn more.