50 HP Tesla Disc Pump vs Discflo Interpolation Performance Envelopes 30 ft Head

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50 HP Tesla Disc Pump vs Discflo Interpolation Performance Envelopes 30 ft Head

Below is a recalculated, engineering-consistent comparison at a fixed target head of 30 ft for 50 HP class pumps, followed by a complete mining-ready article.

All values are based on:

• Target total dynamic head: 30 ft (9.1 m)

• Fluid cases:

• Wash water: SG 1.03, viscosity 1.2 cP

• Dirty slurry water: SG 1.15, viscosity 5 cP

• 50 HP shaft power limit

• Realistic overall efficiencies:

• Tesla style disc pump: 38 percent

• Discflo type Discpac pump: 48 percent

These efficiencies are consistent with wide-gap mining tolerant Tesla pumps versus engineered Discpac geometry.

Power available for pumping

50 HP = 37.3 kW

Hydraulic power:

Tesla style

37.3 × 0.38 = 14.2 kW hydraulic

Discflo type

37.3 × 0.48 = 17.9 kW hydraulic

Flow calculation at 30 ft head

Hydraulic power equation:

Power = rho × g × Q × H

Solve for Q.

Case 1 Wash water (SG 1.03)

Density ≈ 1030 kg per cubic meter

Head = 9.1 m

Tesla style

Q = 14,200 / (1030 × 9.81 × 9.1)

Q ≈ 0.153 cubic meters per second

Q ≈ 2,420 gpm

Q ≈ 549 m3 per hour

Discflo type

Q = 17,900 / (1030 × 9.81 × 9.1)

Q ≈ 0.193 cubic meters per second

Q ≈ 3,050 gpm

Q ≈ 694 m3 per hour

Case 2 Dirty slurry water (SG 1.15)

Density ≈ 1150 kg per cubic meter

Tesla style

Q = 14,200 / (1150 × 9.81 × 9.1)

Q ≈ 0.139 cubic meters per second

Q ≈ 2,200 gpm

Q ≈ 500 m3 per hour

Discflo type

Q = 17,900 / (1150 × 9.81 × 9.1)

Q ≈ 0.176 cubic meters per second

Q ≈ 2,790 gpm

Q ≈ 634 m3 per hour

Summary table at 30 ft head

| -----------------• | -----------• | --------• | ---------------• |

Mining interpretation

At a 30 ft system head, the Discflo type pump moves approximately:

• 26 percent more wash water

• 27 percent more dirty slurry

for the same 50 HP input power.

This is the practical value of the stiffer curve and higher hydraulic efficiency at mining duty points.

Article

Page Title

50 HP Disc Pump Performance at 30 Ft Head for Gold Wash Plant Water Supply

Meta Description

This article compares Tesla style disc pumps and Discflo type disc pumps at a 30 ft head for gold wash plant water supply. Flow rates, efficiency, and mining duty performance are analyzed for 50 HP class pumps handling dirty water and slurry.

Teaser

Gold wash plants require high water flow at moderate head while handling abrasive dirty water. This analysis shows how two disc pump architectures perform when both are constrained to the same 30 ft system head and 50 HP power input.

Why 30 ft head is a realistic mining target

Most gold wash plants operate with total dynamic heads between 20 and 40 ft. This includes elevation changes, hose friction, manifold losses, and spray bar restrictions. Designing to a 30 ft target provides a realistic basis for comparing pump technologies in the field.

At this head, pumps are power limited rather than speed limited, making hydraulic efficiency the dominant factor in how much water reaches the plant.

50 HP Tesla style disc pump performance

A Tesla style disc pump configured with mining tolerant disc gaps favors solids passage and reliability. At 30 ft head, a 50 HP unit delivers approximately:

• 2,420 gpm of wash water

• 2,200 gpm of dirty slurry water

Metric equivalents:

• 549 m3 per hour wash water

• 500 m3 per hour slurry water

The reduction in slurry flow reflects higher density and internal slip caused by abrasive fines.

50 HP Discflo type disc pump performance

A Discflo type Discpac pump uses engineered disc spacing and optional high head disc geometry to retain more head and efficiency. At the same 30 ft head and 50 HP input, expected performance is:

• 3,050 gpm of wash water

• 2,790 gpm of dirty slurry water

Metric equivalents:

• 694 m3 per hour wash water

• 634 m3 per hour slurry water

This represents roughly a 26 to 27 percent flow advantage over a Tesla style disc pump at the same duty point.

What this means for wash plant design

For a plant requiring 3,000 gpm at 30 ft head:

• One Discflo type 50 HP pump can meet the requirement with margin.

• A Tesla style system would require either one larger pump or two smaller pumps in parallel.

For a plant requiring 2,000 gpm at 30 ft head:

• Either pump type can supply the flow, but the Discflo type operates at lower relative load and offers greater future margin as wear increases clearances.

Reliability and wear considerations

Mining water gradually increases internal clearances due to abrasion. As clearances grow:

• Tesla style disc pumps lose head faster because viscous coupling declines with gap growth.

• Discflo type pumps retain performance longer due to engineered Discpac geometry and lower sensitivity to clearance growth.

This difference becomes more important over long service intervals.

System architecture implications

Using fewer 50 HP pumps instead of many smaller pumps:

• Reduces suction and discharge header complexity

• Lowers valve and fitting count

• Simplifies VFD control and staging

• Improves overall system reliability

For critical plants, a two duty plus one standby 50 HP configuration is often more reliable than six to eight smaller pumps in parallel.

Final engineering conclusion

At a realistic mining duty of 30 ft head:

• A 50 HP Tesla style disc pump delivers about 2,200 to 2,420 gpm depending on slurry loading.

• A 50 HP Discflo type disc pump delivers about 2,790 to 3,050 gpm under the same conditions.

The Discflo architecture provides approximately 26 to 27 percent higher usable flow at the same power input, which directly reduces the number of pumps required in large wash plant systems.