Pexgol Solution for Iron Ore Slurry

Improved Slurry Transportation significantly reduced scaling.

Case Study Nº

186 Customer

Jindal Steel – DRI Plant

India

2025

Working Conditions

Temperature: 70°–80°C / 158°-176°F | Flow rate: 65 m³/h, 150 m³/h, 300 m³/h | Pressure: 6 bar | Fluid components: 50% iron ore + 50% water. Solids composition includes Fe, C, SiO₂, Al₂O₃, CaO, MgO (balance water)

Pexgol Pipes

Pexgol 140 mm, 180 mm, 250 mm

Application

Iron Ore Slurry Transportation

Lenght

900 m + 250 m + 200 m / 2952 ft + 820 ft + 656 ft

The Challenge

Jindal Steel, one of India’s foremost integrated steel producers, required a reliable solution for the transportation of 40–50% iron ore slurry under demanding operating conditions.
The existing pipeline system, manufactured from HDPE and carbon steel, was exposed to high solids concentration, operating temperatures of 70–80 °C, and continuous service. As a result, the system suffered from:

Severe internal scaling, progressively reducing the effective internal diameter.
Frequent clogging and line blockages, leading to unstable ﬂow.
Repeated downtime and production losses.
Flow ﬂuctuations, limiting ﬂow output and operational efﬁciency.

The client required a piping system capable of eliminating scaling, ensuring stable and continuous ﬂow, and supporting higher production volumes with reduced maintenance.

The Solution

For Jindal Steel DRI (Direct Reduced Iron Plant), Pexgol piping was selected to replace the existing system due to its smooth internal surface, high resistance to scaling, and excellent performance in high-temperature slurry applications.
Key elements of the solution included:

Less scaling performance, completely eliminating internal buildup and ﬂow obstructions.
Continuous, stable ﬂow without ﬂuctuations, signiﬁcantly improving operational reliability. Flow rate increased by more than two times compared to the previous system, directly enhancing production output volume and contributing to the overall success of the project.
Natural bending radius of the Pexgol pipeline, allowing the line to follow the required route without excessive ﬁttings. This ﬂexibility avoided the use of a high number of 45° and 90° elbows, reducing pressure losses and potential wear points.
Each circuit executed with more than 70 meters as a single-length pipeline installation, minimizing the number of joints and improving system integrity.
Mechanical Double Connectors used to ensure safe, reliable, and efﬁcient connections.
Lightweight pipes and longer sections, simplifying handling and accelerating installation.

The long pipe sections, together with the Pexgol material characteristics, allowed a fast installation with minimal pump shut down.