PUMPS & PIPELINES
Pumping efficiency- mining’ s most ignored lever for sustainability
Mining’ s sustainability narrative has been dominated by highvisibility initiatives such as electrified fleets, renewable energy integration and hydrogen pilots; Divyanshu Shrivastava, Global Product Manager – Industrial Fluids at Armstrong Industrial, a division of Armstrong Fluid Technology, argues that while these are important, they are also long-cycle, capital-intensive and often slow to scale.
“ What is less discussed and arguably more actionable is the inefficiency embedded within fluid systems that run continuously across mining operations. Dewatering, slurry transport and process water circulation quietly consume significant energy and water, yet remain largely underoptimised.” He adds:“ As the industry moves toward 2030 targets for emissions and water reduction, this oversight is becoming harder to justify. Pumping systems may not attract the same attention as electrification strategies, but they represent one of the fastest pathways to measurable gains in both energy efficiency and water stewardship.”
In many operations, inefficiencies in pumping and water management have persisted for decades. Oversized pumps, throttled flows, fixed-speed operation and poorly integrated controls are still common.
Shrivastava:“ The reality is that sustainability in mining will not be achieved through isolated interventions. Energy, water and process efficiency are interdependent, yet too often it is managed in silos. This is where a systems-level approach becomes critical.”
He says closed-loop water systems, for example, do more than reduce freshwater intake; they directly reduce pumping energy, treatment loads and thermal losses across the circuit. Likewise, intelligent pumping systems that respond to real-time demand and energy availability can unlock efficiencies that static systems simply cannot deliver.
“ Dewatering is a case in point. It is treated as a necessary operational activity – critical, but rarely strategic. The objective is typically to‘ keep the mine dry’ rather than optimising how that is achieved. This mind-set results in systems that are overdesigned, energy-intensive and largely unresponsive to changing site conditions. Pumps run longer than required and at higher loads than necessary, simply because the system lacks visibility and control.”
He argues that modern dewatering systems do not need to operate this way. High efficiency pumps equipped with IE5 ultra-premium motors and variable speed drives( VSDs) can dynamically adjust flow and head based on real-time demand.“ When dewatering is combined with sensor-driven monitoring; tracking water levels, inflows and system pressures become demand-based rather than schedule-based. The result is energy savings in the range of 30-40 %.”
If dewatering is under-optimised, Shrivastava argues that slurry transport is often underestimated.“ Moving abrasive, high-density material over long distances is inherently energy-intensive, but inefficiencies amplify this burden significantly. Worn hydraulic profiles, incorrect pump sizing and lack of control flexibility result in excessive energy consumption and frequent maintenance interventions.”
Over time, this erodes both productivity and reliability. Improving slurry transport efficiency is not simply about selecting more durable materials. It requires maintaining hydraulic efficiency across the lifecycle of the pump, supported by optimised flow paths and operating strategies that minimise recirculation losses and turbulence.
He continues:“ Mineral processing highlights the need for integration even more clearly. High-pressure pumping systems used for washing, circulation and descaling sit at the intersection of water and energy use, yet are rarely managed as such. Closedloop systems demonstrate what is possible when this changes. By recirculating process water effectively, operations can reduce freshwater intake by 50-80 % while simultaneously lowering the
When dewatering is combined with sensor-driven monitoring; tracking water levels, inflows and system pressures become demand-based rather than schedule-based
energy required for pumping and treatment.”
Translating systems thinking into measurable outcomes requires the right engineering decisions at the equipment level. Here, Shrivastava says design philosophy influences both performance and sustainability outcomes.
Armstrong’ s 4300 vertical in-line( VIL) pump range, for instance, eliminates the need for inertia bases, housekeeping pads and flexible connectors. This simplifies installation while reducing civil scope and footprint. More importantly, the inline design improves hydraulic alignment, minimising piping losses and contributing to higher system efficiency over the operating lifecycle.
Building on this, the Design Envelope 4300 platform integrates intelligent, sensorless variable speed control directly within the pump system. Instead of operating at fixed speeds and relying on throttling, these systems continuously adjust to real demand conditions.“ When coupled with IE5 ultra-premium efficiency motors, this approach can deliver operating cost reductions in the range of 35-65 % compared to conventional configurations.”
For high-flow requirements, Armstrong’ s 4600-series horizontal split-case( HSC) pumps remain a robust solution. Their doublesuction design supports stable hydraulic performance at scale, while also enabling easier maintenance access – a critical factor in reducing lifecycle costs in continuous operations.
In high-pressure applications, the 4700-series vertical multistage pumps extend system capability further. With multiple stages delivering pressures beyond 300 psi, and advanced impeller designs that minimise axial thrust, these systems are engineered for reliability and extended bearing life under demanding duty conditions.
International Mining | JUNE 2026 63