Water is one of the mining industry’s most valuable – and increasingly constrained – resources.
From mineral processing and slurry transport to dust suppression and tailings management, water plays a critical role across nearly every stage of operations. Yet, many sites still use this finite resource inefficiently, particularly in auxiliary systems such as mechanical seal support plans.
As mining operations face rising water costs, stricter environmental expectations and rising pressure to improve sustainability, even small efficiency gains can yield substantial operational and financial benefits. One often-overlooked opportunity lies in pump sealing systems – specifically, how barrier fluids are managed in double mechanical seals.
Flexaseal Australasia offers engineered sealing solutions that reduce water consumption, enhance reliability and extend equipment life in the harshest mining environments.
The hidden cost of water in sealing systems
As mining pumps frequently handle abrasive slurries, corrosive chemicals and high-temperature fluids, double mechanical seals are often used to provide extra protection against leakage and contamination.
Many systems traditionally operate using an API Plan 54 arrangement, which continuously supplies water to the seal faces. While effective, this consumes large volumes of water – most of which is discharged during operation.
In large-scale operations, the cost of this water can be significant. Beyond direct expense, excessive water usage strains infrastructure, increases environmental impact and can complicate compliance with water regulations.
A more efficient approach
Flexaseal’s Water Conservation System, known as WCS2, offers a more efficient alternative by rethinking water use in double seal applications.
Operating similar to a Plan 53A system, the WCS2 utilises the plant’s existing water supply to pressurise a closed-loop barrier fluid in a reservoir. This eliminates the need for continuous water flow while maintaining optimal sealing conditions, dramatically reducing water consumption without compromising performance.
The WCS2 features a self-regulating design that automatically refills and re-pressurises the system during operation. The pressurised barrier fluid forms a clean, stable film across seal faces, minimising wear, reducing heat and extending mean time between failures (MTBF).
Engineered for reliability in harsh mining conditions
Mechanical seals in mining are required to perform in the harshest conditions. Equipment must operate reliably despite vibration, abrasive media, pressure fluctuations and temperature extremes.
The WCS2 includes a supply pressure regulator for precise adjustment of barrier fluid pressure, and a check valve that protects plant water supply from contamination. A bronze sight flow indicator provides a quick visual check of inboard seal leakage, allowing operators to respond before small issues become failures.
Constructed with a three-gallon stainless steel reservoir and robust bronze and brass fittings, the system is built for industrial durability. Optional stainless steel cooling coils further maintain barrier fluid temperatures in high-heat applications.
The WCS2 circulates barrier fluid via the seal’s pumping ring and natural thermosyphon effects, eliminating the need for continuous external water. This approach preserves water, stabilises the sealing environment and prevents contamination from process media.
For mining operators, this translates into fewer maintenance interventions, reduced downtime and improved overall equipment reliability.
Meeting sustainability and compliance goals
Sustainability is now central to mining operations, with water stewardship a key focus. Water-efficient sealing systems like the WCS2 contribute directly to these goals by lowering overall water usage and discharge volumes, supporting environmental objectives and simplifying compliance with regulatory requirements.
By utilising existing plant water lines instead of requiring dedicated pressurisation systems, the WCS2 also offers a cost-effective upgrade for existing infrastructure.
Water conservation is just one part of a broader approach to improving sealing reliability and efficiency. Flexaseal’s portfolio includes solutions engineered for abrasive slurries, limited maintenance access and persistent “bad actor” failures.
The RKCS flushless slurry seal operates without an external flush, cutting water usage while maintaining a stable seal film. Its robust design handles high solids content and abrasive media, making it ideal for slurry pumps where traditional flush plans are inefficient.
The Style 85 split seal is engineered for hard-to-access equipment. Installed without full pump disassembly, it reduces downtime and labour costs, making it perfect for large pumps, critical assets or remote equipment locations.
For persistent seal failures, FlexIce™ diamond bond coating improves face hardness and thermal conductivity, enabling faster heat dissipation, stable lubrication and reduced wear. Its superior thermal performance also reduces cooling water requirements and energy use.
Combined with the WCS2, these solutions form a comprehensive sealing strategy that addresses water efficiency, reliability, maintenance and total cost of ownership.
A smarter path forward
Sealing systems play a more critical role in reducing costs and optimising resources than many operators realise.
Flexaseal’s WCS2 demonstrates how targeted engineering can cut water use, improve seal performance, and leverage existing infrastructure. When paired with RKCS flushless slurry seals, Style 85 split seals and FlexIce™ diamond bond coating, operators have access to a full suite of technologies designed for abrasive, high-temperature and hard-to-reach applications.
In an industry where every dollar counts, rethinking how seals operate and conserve water can have a significant impact on both performance and sustainability.
Discover more at flexaseal.com. For Australian sales and service, contact sales_aus@flexasealau.com or 1300 762 548
