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How to Specify the Operating Conditions for a Slurry Pump
J. A. Sharpe
President
J.A.S. Solutions Ltd.
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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
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In the beginning was the dragline
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Followed by the bucketwheel
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And then miles of conveyors
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Finally into a tumbler, where the oil sand meets hot water
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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
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Conveyor from Crusher to Surge Pile
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Hydrotransport feedPumpbox
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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
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Typical Particle Size Distribution
0
10
20
30
40
50
60
70
80
90
100
1 10 100 1000 10000
Particle Size (microns)
Pe
rcen
t P
as
sin
g
Low
Average
High
Coarse High
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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
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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
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Fines % vs Deposition Velocity(29" I.D. pipe, data from SRC Pipeflow 2003 Programme )
2
2.5
3
3.5
4
4.5
5
5.5
0 5 10 15 20 25 30
Fines %
De
po
sit
ion
Velo
cit
y
(m/s
) D50 = 400
D50 = 300
D50 = 250
D50 = 200D50 = 150
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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)
1200
1250
1300
1350
1400
1450
1500
1550
1600
1650
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
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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
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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
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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
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Resultant design basis, 8,000 t/h all grades, 29” id pipe
05.3
(8,130 m3/h)
1.52Coarse high
D50 400, 5% fines
125.0(7680 m3/h)
1.55High
D50 250, 10% fines
404.7
(7,230 m3/h)
1.58Average
D50 180, 15% fines
574.7
(7,230 m3/h)
1.58Low
D50 80, 30% fines
Turndown
%
Operating velocity m/s
Slurry density t/m3
Ore Grade
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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
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1.00.29
(29.6)
8130 (35,800)
5.3
Coarse high
0.720.225
(22.9)
7680 (33,800)
5.0
High
0.660.19
(19.4)
7230 (31,800)
4.7
Average
0.290.085
(8.7)
4620 (20,300)
3.0
Low turndown
Relative
Pressure Drop
Pressure drop kPa/m
(m slurry/km)
Flow rate m3/h (USgpm)
Velocity m/sOre grade
Calculated Pressure Drops
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Coarse highgrade headadjusted to 40 m (131 ft) andother pointspro-rated
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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
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Pipeline profile
0
20
40
60
80
100
120
140
160
180
200
0 1 2 3 4 5 6 7 8 9 10
Distance from Plant (km)
Ele
vati
on
(m
)
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Coarse highgrade headadjusted to 50 m (164 ft) andother pointspro-rated
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ANSI/HI Standard for Slurry Pumps12.1-12.6-2005
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Standard viscosity correction procedures can be used for homogeneous non-settling slurries provided the apparent viscosity is known
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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
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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
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Suction side liner
Impeller
Shell
Main Wear Components – GIW TBC Slurry Pump
Hub liner
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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
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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
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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
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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
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Impeller Replacement on GIW Pump
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Slurry Pumps Installed in Series
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Cutaway View of a Weir 600 HTP Slurry Pump
Outer casing
Impeller
Throatbush
Volute Liner
Back liner
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Exploded View of a Weir 600 HTP Slurry Pump
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Weir 600 HTP Slurry Pump Installation
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Parts Replacement on a Weir 600 HTP Slurry Pump
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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
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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
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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.