KSB’s slurry dealing with 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 difficult process and requires the biggest slurry pump in the oil sands industry.
When it comes to pumping slurry, there may be very few functions that are more challenging than the hydro-transport of industrial quality slurries in oil sands production. Not only do the pumps should deal with the highly aggressive nature of the fluid being pumped, they’re additionally expected to operate in a few of the harshest environments in the world.
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, specifically the Tie Bolt Construction (TBC-92). Named after its 92 in (2337 mm) impeller, the TBC-92 is the biggest and heaviest slurry pump available in the oil sands industry and the newest in a line of highly effective high-pressure pumps supplied by GIW.
Slurry transportation Slurry transport covers a substantial vary of trade sectors, ranging from meals and beverage to mining. What is frequent to all, is that the pumps used must be able to transport liquids containing particles and solids of various sizes and viscosities. In mining, dredging and oil sands manufacturing, the largest problem is to accommodate high density slurry and highly abrasive grits.
It is crucial that the slurry passes via the pump with the minimum amount of put on and tear to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump have to be able to delivering high flows and capable of face up to harsh working environments.
Alberta in Canada has in depth oil reserves and these are within the form of oil sands. Extracting and processing the oil from the sands and bedrock is difficult, involving the removal of bituminous ore which is transported to a crushing plant. เกจ์วัดแรงดันลม crushed ore is then mixed with warm water to form a dense slurry that might be transported within the pipeline in the course of extraction, the place the bitumen is separated from the sand and rock. After extraction, the remaining solids (or tailings) are sometimes transported through different pumps to settling ponds.
The processes require in depth use of slurry and water transportation pumps able to handling huge portions of liquids at high pressures and excessive temp- eratures. Drawing on its long experience of designing slurry pumps for mining, GIW has custom-engineered slurry pumps that combine advanced materials, hydraulics and patented mechanical designs, the newest of which is the TBC-92.
pressure gauge ออก หลัง challenges Mollie Timmerman, GIW business improvement manager, explains more: “Our client wanted a better capacity pump which was capable of 10,000–11,000 m3 per hour of output at almost 40 m of developed head and a most working stress of 4000 kPa. The pump additionally needed to find a way to move rocks of roughly 130 mm in diameter with a complete passage measurement 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 maintenance interval (operational time between deliberate maintenance) of around three,000 hours. They had expressed an interest in maximising the upkeep intervals and based mostly on preliminary put on indications, they’re presently hoping to attain round 6,000 hours between pump overhauls (i.e. 6–8 months).”
The instant utility for the first batch of GIW’s TBC-92 pumps in Alberta is in hydro-transport service where they’re 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 maintain these rocks to a manageable measurement for the process, but the prime dimension can still usually reach as a lot as a hundred thirty mm in diameter or larger.
The abrasive nature of the slurry is what separates a slurry pump from different pumps used in the trade. Wear and erosion are information of life, and GIW has a long time of experience within the design of slurry pumps and the development of materials to help prolong the service life of these crucial parts to match the planned maintenance cycles in the plant.
“GIW already had a pump capable of the output requirement, this being the MDX-750, which has been a popular size in mill duties for almost 10 years through- out Central and South America,” explains Mollie Timmerman. ”However, the customer’s software required a pump with greater stress capabilities and the aptitude of dealing with bigger rocks so we responded with the event of the TBC-92 which provided the most effective solution for maximised production.”
The TBC series The construction fashion of GIW’s TBC pump vary options massive, ribbed plates held along with tie bolts for very high-pressure service and maximum wear performance. First developed for dredge service, then later introduced into the oil sands in the Nineteen Nineties, the TBC pump sequence has grown into a completely developed vary of pumps serving the oil sands, phosphate, dredging and hard rock mining industries for tailings and hydrotransport purposes.
The pumps are sometimes grouped collectively in booster stations to build pressure as high as 750 psi (5171 kPa) to account for the pipe losses encountered over such lengthy distances. The robust construction of the TBC pump is nicely suited to do the job, while guaranteeing maximum availability of the equipment underneath heavily abrasive put on.
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, finish suction centrifugal pump that provides most resistance to wear. Simple to take care of, the pump’s tie-bolt design transfers stress masses away from the wear and tear resistant white iron casing to the non- bearing side plates without using heavy and unwieldy double-wall construction.
The TBC-92 combines the most effective components of earlier TBC fashions, including the TBC-84 oil sands tailing pump, also called the Super Pump. The pump additionally incorporates features from GIW’s MDX product line, which is used in heavy-duty mining circuits throughout the world of onerous 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 options of the pump embody a slurry diverter that dramatically will increase suction liner life by decreasing particle recirculation between the impeller and the liner. The giant diameter impeller allows the pump to run at slower speeds so that wear life is enhanced. The decrease velocity additionally gives the pump the power to operate over a wider vary of flows so as to accommodate fluctuating flow situations.
To make upkeep simpler, the pump is fitted with a special two-piece suction plate design which helps to reduce tool time and provide safer lifting. Customers receive pump-specific lifting units to facilitate the safe elimination and set up of wear comp- onents. The pump additionally features a longlasting suction liner that may be adjusted without needing to shut the pump down.
New milestone The commissioning of the TBC-92 marks an essential milestone for GIW, which now has pumps in service in any respect working Canadian oil sands plants for hydrotransport functions. The TBC-92 has been designed to tackle heavy-duty slurry transport while providing a low complete value of possession. Minimal labour and maintenance time help to maximise production and revenue.
“This new pump incorporates the teachings discovered from operating in the oil sands over many years, and options our newest hydraulic and wear technologies,” says Mollie Timmerman. “Because that is the heaviest TBC pump we now have ever designed, explicit consideration was given to maintainability, in addition to materials choice and construction of the pressure-containing components.”
That GIW has established itself as a significant force in pumping solutions for the oil sands business is far from shocking on situation that it has been creating pumping applied sciences and put on resistant supplies within the international mining business for the explanation that Nineteen Forties.
These pumps have had a substantial impression on the way that excavated sand, rock and bitumen are transported to the upgrader plant. By including water to the excavated material it becomes extremely environment friendly to pump the slurry along a pipeline to the upgrader. The pipeline agitation assists in separating the bitumen from the sand as it is transported, plus there is the extra benefit of eradicating using vans.
GIW has estimated that the value of shifting oil sand in this means can cut prices by US$2 a barrel, and it’s far more environmentally pleasant. These pumps also play a significant role in transporting the coarse tailings to the tailings ponds. GIW supplies pumps used within the extraction course of and different areas of manufacturing (HVF, MDX, LSA).
Understanding slurries Understanding the nature of slurries and how they behave when being pumped has been basic to the event of those products. GIW has been obtaining slurry samples from prospects over many years for testing hydraulics and supplies each for pumps and pipelines. Research & Development services include a quantity of slurry take a look at beds on the campus, along with a hydraulics laboratory that’s devoted to pump efficiency testing.
These activities are central to the company’s pump improvement programmes. If corporations are experiencing issues the GIW R&D personnel can see the place the issue lies and supply recommendation for remedial action. Experience does point out that in plenty of instances the issue lies not with the pump nonetheless, however within the interplay between the pipeline and the pump.
Feedback from customers about appli- cations helps in the development of recent instruments and pump designs. By bringing to- gether customers and lecturers from all over the world to share their expertise and analysis with in-house consultants, the huge funding in analysis, development and manufacturing has advanced the design of the entire GIW pump merchandise,materials and wear-resistant components.
The future “There is a clear trend towards larger pumps in mining and dredging and oil sands are no exception,” comments Leo Perry, GIW lead product manager. “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 facilities for higher and higher manufacturing and demanding the identical of the tools that retains their production shifting. While these bigger pumps demand more energy, they also permit for larger production with less downtime required for maintenance. Overall, the effectivity improves when compared to the same 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 manufacturing, all of which continue to pattern greater year after 12 months. Other customers and industries have also shown an curiosity in this dimension, and it would be no surprise at all to see more of those pumps built within the near future for similar purposes.”
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