Slurry Pump

Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005

How to Specify the Operating Conditions for a Slurry Pump

J. A. Sharpe

President

J.A.S. Solutions Ltd.

Presentation Outline

• Background to the use of slurry pumps in oil sands processing

• Particle size and settling velocities

• Range of flows and pressure drops

• ANSI/HI Standard for Slurry Pumps

• Wear rates

• Conclusions

In the beginning was the dragline

Followed by the bucketwheel

Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 200514 – 2.4 m3 buckets

And then miles of conveyors

Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Dumping onto a surge pile

Finally into a tumbler, where the oil sand meets hot water

Trucks and ShovelsIn the mid 1990s trucks and shovels replaced the draglines and bucketwheels

Additional capacity is readily available

Maintenance of haul roads

Flexible for blending ore composition to extraction

High unit cost ($/tonne_km)

Ability to switch units between ore and waste

Labour intensiveLower capital cost

ConcernsBenefits

Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Hitachi Shovel at Albian Sands Muskeg River Mine

Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Shovel Loading a 320 T truck

Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Double truck dump into the crusher feed hopper

Conveyor from Crusher to Surge Pile

Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Hydrotransport replaced tumblers - Slurry Preparation Towers

Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Conveyor Discharging Oil Sand into the Cyclofeeder

Hydrotransport feedPumpbox

Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Weir Hydrotransport Pumps at Syncrude’s North Mine

Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 20053 km later the final destination, the primary separation cell

Particle Size and Settling Velocities

Deposition velocity in a pipeline is a function of:

D50 of the particles in the slurry

Pipe diameter

Particle size distribution

Slurry density

Typical Particle Size Distribution

1 10 100 1000 10000

Particle Size (microns)

Average

Coarse High

Calculation of Deposition Velocity (based on D50 and dia.)

“Deposition-Limit Nomograms for Particles of VariousDensities in Pipeline Flow”, K.C. Wilson, Queen’s University,

Hydrotransport 6, September 1979

Saskatchewan Research Council Pipeflow ProgrammeInputs

FlowratePipe - internal diameter, wall roughness and slopeSlurry - specific gravity and temperatureSolids densityWater - density and viscosityD50 of coarse particles > 75 µFraction of fines < 75 µCarrier fluid viscosity

OutputsPipeline velocityDeposition velocityPressure gradientSolids volume fractionParameters outside the range of the database

Fines % vs Deposition Velocity(29" I.D. pipe, data from SRC Pipeflow 2003 Programme )

0 5 10 15 20 25 30

Fines %

) D50 = 400

D50 = 300

D50 = 250

D50 = 200D50 = 150

Slurry Density vs Deposition Velocity( 2 9 " id l ine, f ines f ract ion = 2 0 %, D 50 = 2 0 0 micron

SR C Pip ef low prog ramme)

4.60 4.65 4.70 4.75 4.80 4.85 4.90 4.95 5.00

D eposit ion V elocit y ( m/ s)

Reduction in density of 0.1 t/m3results in approximately 3%increase in deposition velocity

Range of Flows and Pressure Drops

Need to strike a balance between:

Exceeding the deposition velocity in the worst case scenario,which is usually the highest d50 with the lowest fines (MUST)

Minimizing the overall wear, which has to take into accountthe relative concentrations of the different ores and minimizing the overall pressure drop and therefore the powerrequired for the transportation. That is minimize velocity.

Maximizing the allowable turndown to achieve flexible operation

Optimizing the overall processing capability balanced against the capital and operating costs

38,130 m3/h

8,535 t/h oil sand5.3Coarse high

D50 400, 5% fines

176,750 m3/h

7,087 t/h oil sand4.4High

D50 250, 10% fines

604,295 m3/h

4,510 t/h oil sand2.8Average

D50 180, 15% fines

203,068 m3/h

3,220 t/h oil sand<2Low

D50 80, 30% fines

% of ore body

Flow rate at deposition velocity

Deposition velocity m/s

Ore Grade

29” id pipe, slurry density 1.55 t/m3

MUST provide sufficient pumping capacity to process thecoarse high grade 400 µ at a velocity of 5.3 m/s

Capital requirements are based on oil sand tonnage processed,therefore reduce rate on coarse high grade to 8,000 t/h bydecreasing the slurry density, maintaining the same velocity

Increase the slurry density on other grades to minimize flow requirements and increase available turndown

Increase tonnage processed to 8,000 t/h on all grades so thatoverall throughput is maximized and turndown increased

Resultant design basis, 8,000 t/h all grades, 29” id pipe

(8,130 m3/h)

1.52Coarse high

D50 400, 5% fines

125.0(7680 m3/h)

1.55High

D50 250, 10% fines

(7,230 m3/h)

1.58Average

D50 180, 15% fines

(7,230 m3/h)

1.58Low

D50 80, 30% fines

Turndown

Operating velocity m/s

Slurry density t/m3

Ore Grade

Pressure Drop in a Hydrotransport Pipeline

SG = 1.5k = 70 µPipe id =29”

TypicalDSRC = 180 µcPf = 3Fines 23%

CoarseDSRC = 400 µ cPf = 2Fines 15%

Section AB is upstream ofsection CD

“Performance of Sand Slurry Pipelines in the Oil Sands Industry”,R. Sean Sanders, Jason Schaan, Roxby Hughes and Clifton Shook,

Canadian Journal of Chemical Engineering, Vol. 82, Aug 2004

1.00.29

(29.6)

8130 (35,800)

Coarse high

0.720.225

(22.9)

7680 (33,800)

0.660.19

(19.4)

7230 (31,800)

Average

0.290.085

4620 (20,300)

Low turndown

Relative

Pressure Drop

Pressure drop kPa/m

(m slurry/km)

Flow rate m3/h (USgpm)

Velocity m/sOre grade

Calculated Pressure Drops

Coarse highgrade headadjusted to 40 m (131 ft) andother pointspro-rated

Pump Spacing Considerations

No.of pumps required = (static head + frictional head)head developed per pump

The greater the number of close coupled pumps, the higher the required pressure rating of the pump casing

The more spaced out the pumps are the lower the required pressure rating, but the higher the infrastructure costs

Pipeline profile

0 1 2 3 4 5 6 7 8 9 10

Distance from Plant (km)

Coarse highgrade headadjusted to 50 m (164 ft) andother pointspro-rated

ANSI/HI Standard for Slurry Pumps12.1-12.6-2005

Standard viscosity correction procedures can be used for homogeneous non-settling slurries provided the apparent viscosity is known

For heterogeneous slurries use Fig 12.20 and: Correct for solids sg = Cs =

((Ss-1)/1.65)0.65

Fines fraction = Cfp =(1 - fraction<75micron)2

Solids volumetric conc. = Ccv =(Cv%/15)

Modified Rh = Rh*Cs*Cfp*Ccv

Efficiency reduction follows head reduction

Reff = Rh

Wear Rates in Slurry Pumps

Influenced by:

Rotational speedDeveloped headParticle size distributionSlurry densityFlowrate

The first two items are controllable, the last three are process design issues

Suction side liner

Impeller

Main Wear Components – GIW TBC Slurry Pump

Hub liner

Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Worn Impeller from a Hydrotransport Pump

Relative Costs

Initial Capital compared with Cost of Wear Components

Pump + gearbox + couplings + motor + baseplate = 100 units

Cost Annual usage TotalSuction side liner 3 3 9Impeller 4.5 1.5 6.8Shell 20 1 20Hub liner 2 1.5 3

Spare parts cost per year 38.8

In approximately 21/2 years spare parts cost (excl. labour and downtime) = initial capital

Cost of Downtime

Oil sand rate = 8,000 t/hOre grade = 11% bitumenRecovery = 90%Bitumen density = 1 t/m3

Conversion from m3 to barrels = 6.29 Value of bitumen = Cdn$30/bbl

One hour’s production = 8000*0.11*0.9*6.29*30

= Cdn$149,450

A four foldincrease insolids sizeresults in20x casingwear rate

“Prediction of Slurry Pump Component Wear and Cost”, A. Sellgren,G. Addie, R. Visintainer and K. Pagalthivarthi. Paper presented at Western Dredging Association Conference, Houston, 2005

Effect of Solids Size on Casing Wear Rate

Effect of Pump Head on Liner Wear Rate

“Prediction of Slurry Pump Component Wear and Cost”, A. Sellgren,G. Addie, R. Visintainer and K. Pagalthivarthi. Paper presented at Western Dredging Association Conference, Houston, 2005

85% increasein pump headresults in3x increase in suction liner wear rate

D2 = impeller outside diameterD1 = impeller inside diameter

Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Parts Replacement as per the Sales Brochure

Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005GIW TBC 57 Slurry Pump Installation

Impeller Replacement on GIW Pump

Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005GIW LSA 44 Slurry Pump

Slurry Pumps Installed in Series

Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005Calgary Pump Symposium 2005GIW WBC - 64” diameter impeller slurry pump

Cutaway View of a Weir 600 HTP Slurry Pump

Outer casing

Impeller

Throatbush

Volute Liner

Back liner

Exploded View of a Weir 600 HTP Slurry Pump

Weir 600 HTP Slurry Pump Installation

Parts Replacement on a Weir 600 HTP Slurry Pump

Conclusion

The steps required to successfully specify the operating conditions of a slurry pump are:

• Establish the particle size distribution of the ore body and split it out into suitable fractions, say 20, 60, 20

• Determine the settling velocities for the full range of slurries at the rates required in various pipe diameters

• Establish the most appropriate pipe diameter

• Adjust the flow conditions (density) to balance the conflicting requirements of settling velocity, wear rates and turndown

Conclusion (continued)

• Calculate the total pressure drop for the system using an appropriate programme

• Establish the “Service Class” for the slurry

• Specify the number of pumps required in series

• Select the pump based on: hydraulic fit anticipated wear rates time required to overhaul spare parts cost and lastly the initial capital cost

Acknowledgements

The assistance provided by the following companiesin the preparation of this presentation is greatly appreciated

Albian Sands Energy Inc.GIW Industries Ltd.Syncrude Canada Ltd.Weir Slurry Group Inc.

Slurry Pump

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