Cemented high-concentration backfill (CHB) is an indispensable solution for mitigating risks associated with underground mining voids and surface tailings ponds. The accurate prediction of pressure drop of CHB in pipe flow is crucial for the design of backfilling systems. In this study, full factorial loop tests were conducted to obtain observed pressure drop data and rheological parameters of CHB, while considering the variables of binder content, solid fraction, and flow velocity. The rheometer method was also utilized to acquire the rheological parameters of CHB for comparison. Three analytical models and one numerical simulation method, which are considered highly accurate in the literature, were employed to predict the pressure drop of CHB in pipe flow. The findings indicate that the Buckingham model and the Darby–Melson model produce identical results as they are fundamentally equivalent. The Swamee–Aggarwal model and the single-phase flow simulation employ a similar mechanism as the Buckingham model, albeit with minor variations in mathematical treatment. The rheological parameters of CHB obtained through the rheometer method are considerably greater than those acquired by the loop test method, leading to significantly higher predicted pressure drop values from both the three analytical models and single-phase flow simulation when compared to the measured values. Whereas the mean deviation of the three analytical models is within 6.5% when employing rheological parameters of CHB determined by the loop test, with the Swamee–Aggarwal model being the most accurate, the mean error of single-phase flow simulation remains within 10%. It is suggested that the rheological parameters of CHB be determined through small-diameter loop testing. The Buckingham model and single-phase flow simulation are subsequently recommended for predicting pressure drop in industrial straight horizontal pipelines and complex piping systems, respectively. The results of this study facilitate the selection of the simplest method for accurately predicting the pressure drop of CHB in pipe flow.
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