Case Study: Paste Tailings Transport Optimization, Model Calibration and Concentration Sensitivity
Authors: Cristian Giner1, Gonzalo Laciar1, Cristian Bertolo1, Alexander Manos2
Conference: 12th International Congress on Tailings Management
Date: September 29–October 1, 2026
1 Knight Piésold, Argentina
2 Knight Piésold, USA
ABSTRACT
This paper presents a case study on the optimization of a paste tailings transport system for a tailings storage facility located in Zacatecas, Mexico. The study focuses on hydraulic performance, model calibration using field data, and sensitivity to solids concentration under varying operating conditions. The system consists of a combined pipeline configuration, including a 12-inch HDPE ramp section and 10-inch HDPE distribution lines delivering tailings to multiple discharge points across two storage cells. A steady-state hydraulic analysis was carried out over a wide operational envelope defined by variations in throughput and solids concentration to determine the operating pressures. Although laboratory testing suggested a Bingham fluid model, field measurements showed stronger agreement with a Casson-based approach. Hydraulic loss models were therefore calibrated against field data, yielding improved head loss prediction reliability. The study also highlights the influence of field data in calibrating the hydraulic gradient models and slurry properties. Calibrating the model with operational data provided the technical justification to safely maintain the existing HDPE infrastructure for new TSF elevations, avoiding a costly upgrade to carbon steel piping. Ultimately, the outcomes of this study supported informed decision-making, allowing capital investments to be minimized while maximizing the utility of the existing pumping system.
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