Numerical simulations of comminution slurries over complex topographies: Putting together CFD and pipeline integrity

• Long distance ore concentrate pipeline leaks represent an environmental concern.
• Numerical simulations have been done to anticipate the progression of the leak.
• The effect of fluid rheology is studied for two distinct topographies.
• Results reveal major differences between simulations using water and slurries.
• The implementation is a promising tool for spill response forecasting.

The use of computational fluid dynamics gives new and interesting insights for risk analysis of cross-country ore hydraulic transport operations. In particular, they offer the possibility to predict, with reasonable accuracy, the progression and final condition of spills driven by pipeline leaks at selected locations, at a relatively modest computational cost. In this work, a depth-averaged, two-dimensional numerical model is used to simulate an ore concentrate pipeline rupture and subsequent spill, reproduced as a constant flow condition at the leak point. Although the model is well suited to solve the governing flow equations on arbitrary topographies by means of digital elevation models, two specific locations featuring relatively mild and steep slopes, are analysed with regard to their implications on the potential requirements for emergency team response. Results, obtained using different slurry rheologies, are compared with those obtained using a simpler, common flow resistance model derived for water flowing over rough surfaces.