In mining operations, few environments are as demanding and unforgiving as tailings systems. These systems are responsible for handling waste slurry — a combination of water, fine particles, chemicals, and residual materials — under constant pressure and flow.
Monitoring these systems accurately is not just important — it is critical for safety, efficiency, and compliance.
Fox Global recently supplied 2 x 100mm 0–600 kPa pressure gauges complete with diaphragm seals to a mine site, where they will be installed on an 8-inch tailings outlet pipeline to provide reliable pressure monitoring in a harsh and abrasive environment.
This project highlights the importance of selecting the right instrumentation and reinforces Fox Global’s position as a trusted supplier of pressure gauges and diaphragm seal assemblies across Australia.
The Application: Mine Tailings Pressure Monitoring
Tailings pipelines are used to transport waste slurry from processing plants to storage facilities such as tailings dams.
These pipelines typically handle:
- Abrasive slurry mixtures
- Chemically active materials
- High solid content fluids
- Continuous flow under pressure
The 8-inch pipework in this application forms part of a tailings outlet system, where maintaining correct pressure is essential to:
- Prevent blockages
- Avoid pipeline failure
- Maintain consistent flow rates
- Ensure operational safety
Without accurate pressure monitoring, operators risk:
- Overpressure events
- Equipment damage
- Environmental hazards
- Costly downtime
The Solution: Fox Global Pressure Gauge Assemblies
Fox Global supplied:
Gauge Specifications
- 100mm (4-inch) dial face
- 0–600 kPa pressure range
- Industrial-grade construction
- Designed for accuracy and durability
Diaphragm Seal Specifications
- Stainless steel diaphragm
- Designed for slurry and contaminated media
- Installed between the process and gauge
- Prevents direct contact with tailings material
Together, this combination provides a robust, long-lasting, and highly accurate pressure monitoring solution.
Why Diaphragm Seals Are Critical in Tailings Applications
Standard pressure gauges are not designed to handle abrasive or viscous media like tailings slurry.
Without protection, the internal bourdon tube can:
- Become blocked
- Corrode
- Wear prematurely
- Fail entirely
This is where diaphragm seals become essential.
How Diaphragm Seals Work
A diaphragm seal acts as a protective barrier between the process media and the pressure gauge.
Operation:
- A thin, flexible diaphragm is exposed to process pressure
- Pressure causes the diaphragm to deflect
- This movement is transferred through a filled fluid to the gauge
- The gauge displays the pressure without direct contact with the media
Key Benefits of Diaphragm Seals
1. Protection Against Abrasive Media
Tailings slurry contains fine solids that can destroy standard gauges. The diaphragm seal prevents this contact entirely.
2. Resistance to Corrosion
Mining environments often involve chemically aggressive materials. Stainless steel diaphragm seals provide excellent resistance.
3. Improved Reliability
By isolating the gauge, the system operates more consistently and requires less maintenance.
4. Extended Equipment Life
Protecting the gauge reduces replacement frequency and lowers long-term costs.
5. Accurate Readings in Harsh Conditions
Even in viscous or contaminated media, diaphragm seals ensure stable and reliable pressure readings.
Pressure Gauge Selection: Key Considerations
Selecting the right pressure gauge involves more than just choosing a pressure range.
Fox Global works closely with clients to ensure every factor is considered.
1. Process Media
The type of fluid or material being measured is critical.
For tailings:
- Abrasive
- Contaminated
- Slurry-based
👉 Requires diaphragm seals and corrosion-resistant materials.
2. Pressure Range
A general rule:
👉 Gauge range should be 2x the operating pressure
In this case:
- Operating conditions suited a 0–600 kPa gauge range
- Provides accurate readings without overstressing the gauge
3. Environmental Conditions
Mining sites expose equipment to:
- Dust
- Vibration
- Temperature fluctuations
- Moisture
Fox Global gauges can be:
- Liquid-filled for vibration resistance
- Sealed to prevent contamination
4. Accuracy Requirements
Accuracy is measured as a percentage of full-scale deflection (FSD).
For industrial applications:
- Typical accuracy ranges from ±1% to ±3% FSD
Fox Global supplies gauges to suit both critical and non-critical applications.
5. Mounting & Installation
For this application:
- Installed on 8-inch pipeline outlet
- Requires secure and stable mounting
- Diaphragm seal ensures compatibility with process conditions
Why 100mm Gauges?
The 100mm (4-inch) gauge size is widely used in industrial environments because it offers:
- Clear readability from a distance
- Better accuracy compared to smaller gauges
- Robust construction for heavy-duty use
For mining applications, visibility and durability are key.
The Importance of Accurate Tailings Monitoring
Tailings management is one of the most critical aspects of mining operations.
Accurate pressure monitoring helps to:
- Maintain safe pipeline operation
- Prevent leaks or ruptures
- Ensure environmental compliance
- Optimise system efficiency
Failure in tailings systems can have serious consequences, making reliable instrumentation essential.
Fox Global: Pressure Gauge Specialists
Fox Global supplies a complete range of pressure gauges and instrumentation solutions, including:
- General-purpose gauges
- Heavy-duty industrial gauges
- Liquid-filled gauges
- Vacuum gauges
- Dual-scale gauges
- Test and calibration gauges
Custom Solutions Available
We also provide:
- Diaphragm seal assemblies
- Custom dial configurations
- Special materials and coatings
- Oxygen-cleaned gauges
- Remote-mounted systems
Applications Across Industries
Fox Global pressure gauges are used in:
- Mining and resources
- Tunnelling and construction
- Food and beverage processing
- Chemical handling
- Oil and gas
- Water treatment
Fast Supply When It Matters
This project demonstrates Fox Global’s ability to:
✔ Supply specialised instrumentation quickly
✔ Provide complete, ready-to-install solutions
✔ Support critical operations across Australia
When downtime is not an option, Fox Global delivers.
Australian Owned. Family Operated. Trusted Nationwide.
Fox Global is proudly Australian owned and family operated, committed to supporting local industries with:
- Fast response times
- Reliable supply
- Technical expertise
- High-quality products
We understand the pressures of Australian industry — because we are part of it.
Why Choose Fox Global?
- Extensive stock availability
- Complete hose, valve, and instrumentation solutions
- In-house assembly and expertise
- Fast dispatch across Australia
- Proven track record in mining and infrastructure
Contact Fox Global
Need pressure gauges, diaphragm seals, or complete instrumentation solutions?
📞 Call: 1300 852 795
📧 Email: sales@foxglobal.com.au
🌐 Website: www.foxglobal.com.au
Final Word
In demanding environments like mine tailings systems, accuracy, durability, and reliability are non-negotiable.
Fox Global continues to deliver high-quality pressure monitoring solutions that keep operations safe, efficient, and compliant.
Fox Global — Family-owned. Australian-owned. Built for industry.
