Alberta, Canada has the world’s third largest oil reserves in the type of oil sands. Extracting and processing the oil from the sands and bedrock is a challenging process and requires the biggest slurry pump within the oil sands trade.
When it involves pumping slurry, there can be very few functions that are more difficult than the hydro-transport of professional quality slurries in oil sands manufacturing. Not solely do the pumps need to contend with the extremely aggressive nature of the fluid being pumped, they are additionally expected to operate in some of the harshest environments in the world.
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, specifically the Tie Bolt Construction (TBC-92). Named after its 92 in (2337 mm) impeller, the TBC-92 is the largest and heaviest slurry pump obtainable in the oil sands industry and the newest in a line of powerful high-pressure pumps supplied by GIW.
Slurry transportation Slurry transport covers a considerable range of trade sectors, ranging from meals and beverage to mining. What is เกจวัดแรงดันแก๊สco2 to all, is that the pumps used should be able to transport liquids containing particles and solids of various sizes and viscosities. In mining, dredging and oil sands production, the largest problem is to accommodate high density slurry and extremely abrasive grits.
It is essential that the slurry passes by way of the pump with the minimal quantity of put on and tear to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump should be capable of delivering excessive flows and capable of withstand harsh working 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 difficult, involving the elimination of bituminous ore which is transported to a crushing plant. The crushed ore is then combined with warm water to type a dense slurry that may 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 intensive use of slurry and water transportation pumps able to dealing with huge portions of liquids at excessive pressures and high 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 most recent of which is the TBC-92.
Meeting challenges Mollie Timmerman, GIW enterprise development supervisor, explains extra: “Our shopper needed the next capability pump which was capable of 10,000–11,000 m3 per hour of output at practically forty m of developed head and a maximum working strain of 4000 kPa. The pump additionally wanted to have the ability to cross rocks of approximately one hundred thirty mm in diameter with a total passage dimension 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 planned maintenance) of around 3,000 hours. They had expressed an curiosity in maximising the upkeep intervals and based on initial wear indications, they are at present hoping to attain round 6,000 hours between pump overhauls (i.e. 6–8 months).”
The quick software for the primary 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 mixture of water, bitumen, sand, and large rocks. Screens are in place to keep these rocks to a manageable measurement for the method, but the high size can nonetheless typically reach up to a 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 business. Wear and erosion are facts of life, and GIW has a long time of expertise within the design of slurry pumps and the event of supplies to assist prolong the service life of those critical elements to match the deliberate upkeep cycles in the plant.
“GIW already had a pump capable of the output requirement, this being the MDX-750, which has been a well-liked measurement 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 greater pressure capabilities and the capability of dealing with bigger rocks so we responded with the development of the TBC-92 which supplied one of the best solution for maximised production.”
The TBC series The development style of GIW’s TBC pump range options large, ribbed plates held together with tie bolts for very high-pressure service and most wear efficiency. First developed for dredge service, then later launched into the oil sands in the 1990s, the TBC pump collection has grown into a completely developed vary 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 high 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, whereas ensuring maximum availability of the equipment beneath heavily abrasive wear.
Capable of delivering stress up to 37 bar and flows of greater than 18,200m³/h and temperatures up to 120o C, the TBC vary is a horizontal, finish suction centrifugal pump that gives maximum resistance to wear. Simple to maintain, the pump’s tie-bolt design transfers stress loads away from the wear resistant white iron casing to the non- bearing side plates without using heavy and unwieldy double-wall construction.
The TBC-92 combines one of the best elements of earlier TBC models, including the TBC-84 oil sands tailing pump, also called the Super Pump. The pump additionally incorporates options from GIW’s MDX product line, which is utilized in heavy-duty mining circuits all through the world of exhausting 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 include a slurry diverter that dramatically will increase suction liner life by reducing particle recirculation between the impeller and the liner. The massive diameter impeller allows the pump to run at slower speeds so that wear life is enhanced. The decrease velocity additionally provides the pump the flexibility to operate over a wider vary of flows so as to accommodate fluctuating circulate conditions.
To make upkeep simpler, the pump is fitted with a special two-piece suction plate design which helps to scale back device time and supply safer lifting. Customers obtain pump-specific lifting units to facilitate the protected removing and installation of damage comp- onents. The pump also features a longlasting suction liner that may be adjusted while not having 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 in any respect working Canadian oil sands vegetation for hydrotransport purposes. The TBC-92 has been designed to tackle heavy-duty slurry transport while providing a low whole price of ownership. Minimal labour and maintenance time assist to maximise production and revenue.
“This new pump incorporates the lessons learned from working within the oil sands over many years, and features our latest hydraulic and put on applied sciences,” says Mollie Timmerman. “Because this is the heaviest TBC pump we’ve ever designed, specific consideration was given to maintainability, as properly as material choice and building of the pressure-containing components.”
That GIW has established itself as a major pressure in pumping solutions for the oil sands trade is far from stunning on condition that it has been growing pumping applied sciences and wear resistant supplies in the international mining trade because the Forties.
These pumps have had a substantial influence on the way that excavated sand, rock and bitumen are transported to the upgrader plant. By adding water to the excavated material it turns into highly 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 might be the additional benefit of removing using trucks.
GIW has estimated that the price of transferring oil sand in this way can reduce costs by US$2 a barrel, and it is far more environmentally friendly. These pumps also play a significant role in transporting the coarse tailings to the tailings ponds. GIW provides pumps used within the extraction process and different areas of manufacturing (HVF, MDX, LSA).
Understanding slurries Understanding the character of slurries and how they behave when being pumped has been basic to the event of these merchandise. GIW has been obtaining slurry samples from customers over a few years for testing hydraulics and supplies both for pumps and pipelines. Research & Development facilities embrace a number of slurry take a look at beds on the campus, along with a hydraulics laboratory that is dedicated to pump performance testing.
These actions are central to the company’s pump development programmes. If corporations are experiencing issues the GIW R&D personnel can see the place the issue lies and supply recommendation for remedial motion. Experience does point out that in many cases 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 in the growth of new instruments and pump designs. By bringing to- gether prospects and academics from all over the world to share their experience and research with in-house consultants, the large investment in analysis, development and manufacturing has superior the design of all of the GIW pump products,supplies and wear-resistant components.
The future “There is a clear trend toward bigger pumps in mining and dredging and oil sands are not any exception,” feedback Leo Perry, GIW lead product supervisor. “The first TBC pump in the oil sands business was the TBC-46 (46 in being the diameter of the impeller). Customers are designing their services for higher and higher manufacturing and demanding the identical of the tools that retains their production transferring. While these larger pumps demand more power, in addition they enable for larger production with less downtime required for upkeep. 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 facilities, larger pipelines, and elevated production, all of which continue to pattern greater year after 12 months. Other clients and industries have additionally shown an curiosity in this measurement, and it will be no surprise at all to see more of these pumps constructed in the near future for similar functions.”