KSB’s slurry handling success in oil sands

Alberta, Canada has the world’s third largest oil reserves in the form of oil sands. Extracting and processing the oil from the sands and bedrock is a challenging process and requires the most important slurry pump within the oil sands business.
When it involves pumping slurry, there may be only a few applications which are tougher than the hydro-transport of skilled quality slurries in oil sands manufacturing. Not only do the pumps need to cope with the highly aggressive nature of the fluid being pumped, they’re also anticipated to operate in a number of the harshest environments on the planet.
In January 2020, GIW Industries, Inc., a KSB company, commissioned its largest ever heavy-duty centrifugal slurry pump for operation in Canada’s oil sands, namely the Tie Bolt Construction (TBC-92). Named after its 92 in (2337 mm) impeller, the TBC-92 is the most important and heaviest slurry pump obtainable in the oil sands business and the latest in a line of highly effective high-pressure pumps supplied by GIW.
Slurry เกจวัดแก๊ส covers a considerable range of trade sectors, starting from food and beverage to mining. What is frequent to all, is that the pumps used must be succesful of transport liquids containing particles and solids of various sizes and viscosities. In mining, dredging and oil sands production, the largest problem is to accommodate excessive density slurry and highly abrasive grits.
It is essential that the slurry passes via the pump with the minimum quantity of wear and tear to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump should be able to delivering high flows and capable of face up to harsh working environments.
Alberta in Canada has intensive oil reserves and these are within the form of oil sands. Extracting and processing the oil from the sands and bedrock is challenging, involving the removing of bituminous ore which is transported to a crushing plant. The crushed ore is then blended with heat water to type a dense slurry that can be transported within the pipeline towards extraction, the place the bitumen is separated from the sand and rock. After extraction, the remaining solids (or tailings) are sometimes transported via totally different pumps to settling ponds.
The processes require intensive use of slurry and water transportation pumps capable of handling huge portions of liquids at high pressures and excessive temp- eratures. Drawing on its long expertise of designing slurry pumps for mining, GIW has custom-engineered slurry pumps that combine superior materials, hydraulics and patented mechanical designs, the latest of which is the TBC-92.
Meeting challenges Mollie Timmerman, GIW business development manager, explains more: “Our client wanted a better capability pump which was capable of 10,000–11,000 m3 per hour of output at nearly 40 m of developed head and a most working strain of 4000 kPa. The pump additionally wanted to be able to pass rocks of approximately 130 mm in diameter with a complete passage dimension requirement of 10 in (or 254 mm) and deal with slurry densities in extra of 1.5 SG.
In addition, the customer was concentrating on a upkeep interval (operational time between planned maintenance) of around 3,000 hours. They had expressed an interest in maximising the upkeep intervals and based on preliminary put on indications, they’re at present hoping to achieve around 6,000 hours between pump overhauls (i.e. 6–8 months).”
The immediate utility for the primary batch of GIW’s TBC-92 pumps in Alberta is in hydro-transport service where they are used to move bitu- minous ore from the crusher to the extraction plant. The liquid pumped is a mix of water, bitumen, sand, and huge rocks. Screens are in place to keep these rocks to a manageable measurement for the method, however the high size can nonetheless typically reach as much as 130 mm in diameter or larger.
The abrasive nature of the slurry is what separates a slurry pump from other pumps used in the trade. Wear and erosion are details of life, and GIW has many years of experience in the design of slurry pumps and the event of materials to assist prolong the service life of those critical elements to match the deliberate maintenance cycles in the plant.
“GIW already had a pump able to the output requirement, this being the MDX-750, which has been a preferred dimension in mill duties for nearly 10 years through- out Central and South America,” explains Mollie Timmerman. ”However, the customer’s software required a pump with higher strain capabilities and the aptitude of handling bigger rocks so we responded with the event of the TBC-92 which offered one of the best resolution for maximised manufacturing.”
The TBC collection The building type of GIW’s TBC pump vary features massive, ribbed plates held along with tie bolts for very high-pressure service and maximum put on performance. First developed for dredge service, then later introduced into the oil sands within the Nineties, the TBC pump series has grown into a totally developed range of pumps serving the oil sands, phosphate, dredging and hard rock mining industries for tailings and hydrotransport applications.
The pumps are sometimes grouped collectively in booster stations to build stress as excessive as 750 psi (5171 kPa) to account for the pipe losses encountered over such lengthy distances. The robust building of the TBC pump is well suited to do the job, while ensuring maximum availability of the equipment under closely abrasive wear.
Capable of delivering pressure up to 37 bar and flows of more than 18,200m³/h and temperatures up to 120o C, the TBC range is a horizontal, end suction centrifugal pump that provides maximum resistance to put on. Simple to maintain, the pump’s tie-bolt design transfers stress loads away from the wear resistant white iron casing to the non- bearing facet plates without using heavy and unwieldy double-wall construction.
The TBC-92 combines the best elements of earlier TBC fashions, together with the TBC-84 oil sands tailing pump, also called the Super Pump. The pump also incorporates features from GIW’s MDX product line, which is utilized in heavy-duty mining circuits throughout the world of hard rock mining.
In whole, the TBC-92 weighs about 209,000 lbs (95,000 kg), which is roughly equal to a fully-loaded Airbus A321 aeroplane. The casing alone weighs 34,000 lbs (15,500 kg). Key features of the pump embody a slurry diverter that dramatically increases suction liner life by decreasing particle recirculation between the impeller and the liner. The giant diameter impeller permits the pump to run at slower speeds so that put on life is enhanced. The decrease speed also provides the pump the ability to function over a wider range of flows in order to accommodate fluctuating move conditions.
To make maintenance easier, the pump is fitted with a special two-piece suction plate design which helps to scale back software time and provide safer lifting. Customers obtain pump-specific lifting units to facilitate the safe removal and installation of wear comp- onents. The pump additionally includes a longlasting suction liner that can be adjusted without having to close the pump down.
New milestone The commissioning of the TBC-92 marks an necessary milestone for GIW, which now has pumps in service in any respect operating Canadian oil sands crops for hydrotransport purposes. The TBC-92 has been designed to tackle heavy-duty slurry transport whereas providing a low whole price of ownership. Minimal labour and upkeep time help to maximise production and profit.
“This new pump incorporates the lessons realized from working within the oil sands over many years, and features our newest hydraulic and put on applied sciences,” says Mollie Timmerman. “Because that is the heaviest TBC pump we’ve ever designed, explicit attention was given to maintainability, in addition to material choice and development of the pressure-containing elements.”
That GIW has established itself as a big pressure in pumping solutions for the oil sands trade is way from stunning given that it has been growing pumping applied sciences and put on resistant supplies in the global mining industry because the 1940s.
These pumps have had a substantial impression on the greatest way that excavated sand, rock and bitumen are transported to the upgrader plant. By adding water to the excavated materials it turns into highly efficient to pump the slurry alongside a pipeline to the upgrader. The pipeline agitation assists in separating the bitumen from the sand as it’s transported, plus there’s the extra good factor about eradicating the utilization of vans.
GIW has estimated that the price of transferring oil sand on this method can cut costs by US$2 a barrel, and it’s far more environmentally friendly. These pumps also play a significant function in transporting the coarse tailings to the tailings ponds. GIW supplies pumps used within the extraction course of and other areas of production (HVF, MDX, LSA).
Understanding slurries Understanding the nature of slurries and how they behave when being pumped has been elementary to the event of these products. GIW has been acquiring slurry samples from customers over a few years for testing hydraulics and supplies both for pumps and pipelines. Research & Development facilities embrace multiple slurry take a look at beds on the campus, together with a hydraulics laboratory that is dedicated to pump efficiency testing.
These actions are central to the company’s pump growth programmes. If corporations are experiencing problems the GIW R&D personnel can see where the issue lies and provide recommendation for remedial motion. Experience does indicate that in plenty of instances the problem lies not with the pump however, however within the interplay between the pipeline and the pump.
Feedback from clients about appli- cations helps within the development of new instruments and pump designs. By bringing to- gether clients and academics from everywhere in the world to share their expertise and analysis with in-house specialists, the large investment in analysis, development and manufacturing has advanced the design of all of the GIW pump products,supplies and wear-resistant parts.
The future “There is a clear pattern toward larger pumps in mining and dredging and oil sands are not any exception,” feedback Leo Perry, GIW lead product supervisor. “The first TBC pump within the oil sands business was the TBC-46 (46 in being the diameter of the impeller). Customers are designing their amenities for higher and higher manufacturing and demanding the same of the gear that keeps their production transferring. While these larger pumps demand more energy, additionally they allow for larger manufacturing with less downtime required for upkeep. Overall, the efficiency improves when compared to the identical output from a larger amount of smaller pumps. “
In conclusion, he says: “Larger pumps go hand-in-hand with bigger services, larger pipelines, and elevated production, all of which proceed to pattern greater 12 months after yr. Other prospects and industries have also proven an interest on this measurement, and it would be no surprise in any respect to see extra of those pumps constructed within the near future for similar purposes.”
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