Nickel mine sought durable flow control to tackle harsh slurry

Jan 25, 2026

Back in 2018, we helped Australia’s largest nickel mine overcome a critical slurry challenge — a solution that remains a trusted choice years later. This case highlights a common issue in mining operations, where abrasive slurries place high demands on equipment. Handling tailings and concentrate pipelines requires flow control solutions that keep operations safe and efficient.

During a site visit to meet our existing pump customer, our team identified a recurring issue: conventional valves on the customer’s slurry transfer lines were seizing during long periods of inactivity. These failures increased maintenance needs, caused delays, and raised total ownership costs – giving the customer plenty of headaches.

Challenge

Across the site, particularly in tailings dam operations, the end user had been relying on conventional slurry knife gate and diaphragm valves, which suffered from:

Seizure during non-actuation
Corrosion of the knife and body due to harsh environmental exposure
Slurry settling on the seat, preventing full closure after long intervals
Heavy, complex construction, making handling and maintenance difficult

These challenges resulted in reliability concerns and continuous maintenance demands.

Solution: Flowrox™ pinch valves

Flowrox PVEG pinch valve is a robust and low‑maintenance choice for slurry transfer and spigot isolation, offering reliable performance even during long periods of non‑actuation.

Flowrox pinch valves are engineered for abrasive slurry environments, offering proven reliability and low total cost of ownership. They feature a full-bore design for unobstructed flow, only the rubber sleeve in contact with the medium, and bubble-tight shut-off even with solids present. These qualities make them ideal for demanding mining applications.

For this special customer case our experts proposed the Flowrox PVEG series pinch valve as a robust but cost-effective alternative for their slurry transfer and spigot isolation applications. After initial trials, the end user quickly recognized several key advantages:

Lightweight polyamide body for easy handling and installation
Fully enclosed design that keeps the actuator spindle protected from contamination
Rubber sleeve as the only wetted component, minimizing wear and eliminating corrosion risks
Reliable performance even during extended periods of non‑actuation
Low total cost of ownership thanks to minimal maintenance requirements

Flowrox hose pumps, delivered before 2018 when Flowrox products were still red, used in onstream analyzer sample lines.

Over the following years, the mine progressively installed PVEG valves across the tailings dam infrastructure, confirming their performance consistency and operational benefits. In total, this results in a substantial installed base of our flow control solutions, with over 160 PVEG DN100 pinch valves supported by Flowrox LPP-T hose pumps used in demanding applications such as thickener underflow (LPP-T100) and onstream analyzer sample lines (LPP-T50 pumps). The installed base also includes approximately fifty Flowrox heavy‑duty valves in filtration processes, forming a broad portfolio of our technologies across key areas of the plant.

Customer Impact

The transition to PVEG pinch valves significantly improved reliability in critical slurry isolation points, reduced downtime, and simplified field operations. The mine now benefits from a valve solution engineered specifically for abrasive and demanding environments.

“We focus on providing the best customer service by having the customer at the center of our operations. With local stock and assembly, our experienced team has been helping mining customers across Oceania for the past 15 years.”
— Santo Varghese Rajan, Regional Sales Director

Reliable flow control is essential for mining operations worldwide, where handling abrasive slurries in tailings and concentrate pipelines directly impacts safety, efficiency, and sustainability.

Key outcomes:

Improved reliability in slurry transfer and isolation
Reduced maintenance and operational delays
Lower total cost of ownership

Summary of the content

A major nickel mine in Australia was struggling with seizing, corroding slurry valves that caused delays and high maintenance costs. During a site visit, our team recognized the issue and recommended Flowrox™ PVEG pinch valves as a more durable and low‑maintenance alternative for their slurry transfer and spigot isolation needs. The valves’ lightweight construction, enclosed design, and rubber sleeve ensured reliable operation even after long idle periods, quickly proving their value in harsh slurry conditions. Over the years, the mine expanded the installation to more than 160 PVEG DN100 valves supported by Flowrox hose pumps and additional heavy‑duty valves across key process areas. The upgrade significantly improved reliability, reduced downtime, and lowered overall operating costs while strengthening the customer’s confidence in our long‑term flow control solutions.

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