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 within the oil sands industry.
When it involves pumping slurry, there may be only a few purposes which would possibly be more challenging than the hydro-transport of heavy-duty slurries in oil sands production. Not only do the pumps need to contend with the extremely aggressive nature of the fluid being pumped, they’re additionally anticipated to operate in a few of the harshest environments on the earth.
In January 2020, GIW Industries, Inc., a KSB firm, 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 largest and heaviest slurry pump out there in the oil sands business and the latest in a line of powerful high-pressure pumps offered by GIW.
Slurry transportation Slurry transport covers a considerable range of trade sectors, ranging from meals and beverage to mining. What is widespread to all, is that the pumps used must have the power to transport liquids containing particles and solids of various sizes and viscosities. In mining, dredging and oil sands manufacturing, the largest challenge is to accommodate excessive density slurry and highly abrasive grits.
It is important that the slurry passes via the pump with the minimal amount of damage to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump must be able to delivering excessive flows and able to stand up to harsh operating environments.
Alberta in Canada has extensive oil reserves and these are within the type of oil sands. Extracting and processing the oil from the sands and bedrock is challenging, involving the removal of bituminous ore which is transported to a crushing plant. The crushed ore is then combined with warm water to kind a dense slurry that could be transported in the pipeline in course of extraction, where the bitumen is separated from the sand and rock. After extraction, the remaining solids (or tailings) are often transported by way of totally different pumps to settling ponds.
The processes require intensive use of slurry and water transportation pumps capable of handling huge quantities of liquids at high pressures and high temp- eratures. Drawing on its lengthy expertise of designing slurry pumps for mining, GIW has custom-engineered slurry pumps that combine superior supplies, hydraulics and patented mechanical designs, the latest of which is the TBC-92.
Meeting challenges Mollie Timmerman, GIW enterprise development supervisor, explains more: “Our consumer wanted a higher capacity pump which was able to 10,000–11,000 m3 per hour of output at practically 40 m of developed head and a most working strain of 4000 kPa. The pump also needed to have the ability to cross rocks of approximately a hundred thirty mm in diameter with a complete passage size requirement of 10 in (or 254 mm) and handle slurry densities in extra of 1.5 SG.
In addition, the shopper was focusing on a upkeep interval (operational time between deliberate maintenance) of round three,000 hours. They had expressed an curiosity in maximising the maintenance intervals and primarily based on initial wear indications, they are currently hoping to attain round 6,000 hours between pump overhauls (i.e. 6–8 months).”
The immediate application for the first batch of GIW’s TBC-92 pumps in Alberta is in hydro-transport service the place 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 large rocks. Screens are in place to maintain these rocks to a manageable measurement for the process, however the high measurement can still often attain up to one hundred thirty mm in diameter or bigger.
The abrasive nature of the slurry is what separates a slurry pump from different pumps used within the industry. Wear and erosion are details of life, and GIW has a long time of experience in the design of slurry pumps and the event of supplies to help extend the service life of those important elements to match the planned upkeep cycles within the plant.
“GIW already had a pump capable of the output requirement, this being the MDX-750, which has been a well-liked size in mill duties for almost 10 years through- out Central and South America,” explains Mollie Timmerman. ”However, the customer’s utility required a pump with higher stress capabilities and the capability of handling larger rocks so we responded with the event of the TBC-92 which supplied one of the best solution for maximised production.”
The TBC collection The building type of GIW’s TBC pump vary options giant, ribbed plates held together with tie bolts for very high-pressure service and most wear efficiency. First developed for dredge service, then later introduced into the oil sands in the 1990s, the TBC pump sequence has grown into a completely 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 together in booster stations to construct strain as excessive as 750 psi (5171 kPa) to account for the pipe losses encountered over such lengthy distances. The strong building of the TBC pump is nicely suited to do the job, while ensuring most 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 as a lot as 120o C, the TBC vary is a horizontal, end suction centrifugal pump that offers most resistance to wear. Simple to hold up, the pump’s tie-bolt design transfers stress masses away from the wear resistant white iron casing to the non- bearing facet plates without using heavy and unwieldy double-wall development.
The TBC-92 combines one of the best elements of earlier TBC models, together with the TBC-84 oil sands tailing pump, also referred to as the Super Pump. The pump additionally incorporates options from GIW’s MDX product line, which is used in heavy-duty mining circuits all through the world of onerous rock mining.
In whole, the TBC-92 weighs about 209,000 lbs (95,000 kg), which is roughly equivalent to a fully-loaded Airbus A321 aeroplane. The casing alone weighs 34,000 lbs (15,500 kg). Key features of the pump include a slurry diverter that dramatically will increase suction liner life by decreasing particle recirculation between the impeller and the liner. The massive diameter impeller permits the pump to run at slower speeds in order that wear life is enhanced. The decrease pace also offers the pump the ability to operate over a wider range of flows so as to accommodate fluctuating circulate circumstances.
To make upkeep simpler, the pump is fitted with a particular two-piece suction plate design which helps to scale back tool time and provide safer lifting. Customers receive pump-specific lifting devices to facilitate the safe elimination and set up of wear comp- onents. The pump also features a longlasting suction liner that could be adjusted without needing to close the pump down.
New milestone The commissioning of the TBC-92 marks an important milestone for GIW, which now has pumps in service at all operating Canadian oil sands plants for hydrotransport functions. The TBC-92 has been designed to tackle heavy-duty slurry transport while providing a low total cost of possession. Minimal labour and upkeep time assist to maximise production and revenue.
“This new pump incorporates the teachings discovered from working within the oil sands over a few years, and options our newest hydraulic and put on applied sciences,” says Mollie Timmerman. “Because this is the heaviest TBC pump we have ever designed, explicit consideration was given to maintainability, in addition to materials selection and construction of the pressure-containing elements.”
That GIW has established itself as a big pressure in pumping solutions for the oil sands industry is way from shocking given that it has been growing pumping applied sciences and wear resistant materials within the international mining trade since the 1940s.
These pumps have had a substantial influence on the way that excavated sand, rock and bitumen are transported to the upgrader plant. By including water to the excavated materials it becomes 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 use of vans.
GIW has estimated that the cost of moving oil sand on this method can minimize costs by US$2 a barrel, and it is way more environmentally friendly. These pumps also play a major role in transporting the coarse tailings to the tailings ponds. GIW provides pumps used within the extraction process and other areas of production (HVF, MDX, LSA).
Understanding slurries Understanding the character of slurries and how they behave when being pumped has been fundamental to the event of those merchandise. GIW has been acquiring slurry samples from customers over a few years for testing hydraulics and materials each for pumps and pipelines. Research & Development facilities embrace a number of slurry check beds on the campus, along with a hydraulics laboratory that’s devoted to pump performance testing.
เกจวัดแรงดันต่ำ are central to the company’s pump development programmes. If firms are experiencing problems the GIW R&D personnel can see where the problem lies and supply advice for remedial action. Experience does point out that in lots of instances the issue lies not with the pump nonetheless, however in the interaction between the pipeline and the pump.
Feedback from customers about appli- cations helps within the growth of recent tools and pump designs. By bringing to- gether customers and lecturers from all round the world to share their experience and research with in-house experts, the huge funding in analysis, improvement and manufacturing has superior the design of the entire GIW pump products,supplies and wear-resistant elements.
The future “There is a clear pattern towards bigger pumps in mining and dredging and oil sands are no exception,” comments Leo Perry, GIW lead product supervisor. “The first TBC pump in the oil sands industry was the TBC-46 (46 in being the diameter of the impeller). Customers are designing their services for higher and better production and demanding the same of the equipment that keeps their manufacturing transferring. While these bigger pumps demand extra power, additionally they enable for higher production with much 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 larger amenities, bigger pipelines, and increased manufacturing, all of which proceed to development larger 12 months after yr. Other prospects and industries have additionally proven an interest in this dimension, and it might be no shock at all to see extra of these pumps constructed in the close to future for similar applications.”
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