KSB’s slurry dealing with success in oil sands

Alberta, Canada has the world’s third largest oil reserves within the type 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 trade.
When it involves pumping slurry, there can be very few functions which are tougher than the hydro-transport of skilled quality slurries in oil sands production. Not only do the pumps should contend with the highly aggressive nature of the fluid being pumped, they’re also anticipated to operate in a variety of the harshest environments on the earth.
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, namely the Tie Bolt Construction (TBC-92). Named after its ninety two in (2337 mm) impeller, the TBC-92 is the biggest and heaviest slurry pump obtainable in the oil sands trade and the latest in a line of powerful high-pressure pumps provided by GIW.
Slurry transportation Slurry transport covers a substantial vary of industry sectors, starting from food and beverage to mining. What is widespread to all, is that the pumps used should be in a position to transport liquids containing particles and solids of various sizes and viscosities. In mining, dredging and เครื่องมือวัดความดัน manufacturing, the largest problem is to accommodate excessive density slurry and extremely abrasive grits.
It is crucial that the slurry passes by way of the pump with the minimum quantity of wear to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump should be able to delivering high flows and able to withstand harsh operating environments.
Alberta in Canada has in depth oil reserves and these are in the type of oil sands. Extracting and processing the oil from the sands and bedrock is challenging, involving the elimination of bituminous ore which is transported to a crushing plant. The crushed ore is then mixed with heat water to type a dense slurry that may be transported within the pipeline in the direction of extraction, the place the bitumen is separated from the sand and rock. After extraction, the remaining solids (or tailings) are often transported through completely different pumps to settling ponds.
The processes require in depth use of slurry and water transportation pumps capable of handling huge portions of liquids at high pressures and high temp- eratures. Drawing on its long experience of designing slurry pumps for mining, GIW has custom-engineered slurry pumps that mix superior materials, hydraulics and patented mechanical designs, the most recent of which is the TBC-92.
Meeting challenges Mollie Timmerman, GIW business development manager, explains extra: “Our consumer needed a better capacity pump which was capable of 10,000–11,000 m3 per hour of output at nearly 40 m of developed head and a most working strain of 4000 kPa. The pump also needed to have the power to move rocks of approximately 130 mm in diameter with a total 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 maintenance interval (operational time between deliberate maintenance) of around 3,000 hours. They had expressed an curiosity in maximising the maintenance intervals and primarily based on initial put on indications, they’re presently hoping to achieve around 6,000 hours between pump overhauls (i.e. 6–8 months).”
The immediate application for the primary batch of GIW’s TBC-92 pumps in Alberta is in hydro-transport service the place they’re used to maneuver 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, however the top measurement can still usually attain as much as 130 mm in diameter or larger.
The abrasive nature of the slurry is what separates a slurry pump from different pumps used within the business. Wear and erosion are information of life, and GIW has a long time of expertise within the design of slurry pumps and the event of materials to help extend the service life of those crucial elements to match the deliberate maintenance cycles in the plant.
“GIW already had a pump capable of the output requirement, this being the MDX-750, which has been a preferred dimension in mill duties for almost 10 years through- out Central and South America,” explains Mollie Timmerman. ”However, the customer’s application required a pump with larger pressure capabilities and the potential of dealing with bigger rocks so we responded with the event of the TBC-92 which supplied one of the best resolution for maximised manufacturing.”
The TBC series The development fashion of GIW’s TBC pump vary features large, ribbed plates held along with tie bolts for very high-pressure service and most wear performance. First developed for dredge service, then later launched into the oil sands within the 1990s, the TBC pump collection has grown into a completely developed range of pumps serving the oil sands, phosphate, dredging and hard rock mining industries for tailings and hydrotransport functions.
The pumps are often grouped collectively in booster stations to construct pressure as high as 750 psi (5171 kPa) to account for the pipe losses encountered over such lengthy distances. The robust development of the TBC pump is properly suited to do the job, while guaranteeing maximum availability of the equipment under heavily abrasive wear.
Capable of delivering pressure as a lot as 37 bar and flows of greater than 18,200m³/h and temperatures up to 120o C, the TBC vary is a horizontal, end suction centrifugal pump that provides maximum resistance to put on. Simple to maintain, the pump’s tie-bolt design transfers stress masses away from the damage resistant white iron casing to the non- bearing aspect plates without using heavy and unwieldy double-wall development.
The TBC-92 combines the most effective parts of earlier TBC models, together with the TBC-84 oil sands tailing pump, also called the Super Pump. The pump also incorporates options from GIW’s MDX product line, which is used in heavy-duty mining circuits throughout the world of exhausting rock mining.
In total, 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 reducing particle recirculation between the impeller and the liner. The large diameter impeller permits the pump to run at slower speeds in order that put on life is enhanced. The lower velocity additionally gives the pump the ability to function over a wider range of flows so as to accommodate fluctuating move conditions.
To make upkeep simpler, the pump is fitted with a special two-piece suction plate design which helps to cut back device time and supply safer lifting. Customers obtain pump-specific lifting units to facilitate the protected removing and set up of wear and tear comp- onents. The pump additionally contains a longlasting suction liner that can be adjusted without having to shut 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 vegetation for hydrotransport applications. The TBC-92 has been designed to sort out heavy-duty slurry transport whereas offering a low total price of possession. Minimal labour and upkeep time help to maximise production and profit.
“This new pump incorporates the lessons learned from operating within the oil sands over a few years, and options our newest hydraulic and put on applied sciences,” says Mollie Timmerman. “Because that is the heaviest TBC pump we have ever designed, particular consideration was given to maintainability, in addition to material selection and construction of the pressure-containing parts.”
That GIW has established itself as a significant pressure in pumping solutions for the oil sands business is far from stunning given that it has been growing pumping applied sciences and put on resistant materials in the global mining trade for the rationale that Nineteen Forties.
These pumps have had a considerable influence on the greatest way that excavated sand, rock and bitumen are transported to the upgrader plant. By including water to the excavated material it turns into extremely efficient to pump the slurry alongside a pipeline to the upgrader. The pipeline agitation assists in separating the bitumen from the sand as it is transported, plus there could be the additional advantage of eradicating the use of trucks.
GIW has estimated that the price of shifting oil sand on this means can reduce prices by US$2 a barrel, and it’s far more environmentally friendly. These pumps additionally play a major position in transporting the coarse tailings to the tailings ponds. GIW provides pumps used within the extraction course of 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 these products. GIW has been obtaining slurry samples from prospects over a few years for testing hydraulics and materials both for pumps and pipelines. Research & Development services embrace a number of slurry take a look at beds on the campus, together with a hydraulics laboratory that is dedicated to pump efficiency testing.
These activities are central to the company’s pump improvement programmes. If corporations are experiencing problems the GIW R&D personnel can see where the problem lies and offer advice for remedial action. Experience does point out that in many circumstances the problem lies not with the pump nonetheless, but in the interplay between the pipeline and the pump.
Feedback from prospects about appli- cations helps in the growth of latest tools and pump designs. By bringing to- gether customers and teachers from all over the world to share their experience and analysis with in-house experts, the huge funding in analysis, improvement and manufacturing has superior the design of all the GIW pump merchandise,supplies and wear-resistant components.
The future “There is a transparent pattern toward larger pumps in mining and dredging and oil sands are no exception,” feedback Leo Perry, GIW lead product supervisor. “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 services for greater and better manufacturing and demanding the identical of the gear that keeps their manufacturing shifting. While these bigger pumps demand more energy, additionally they permit for greater manufacturing with much less downtime required for upkeep. Overall, the effectivity improves when in comparison with the identical output from a bigger amount of smaller pumps. “
In conclusion, he says: “Larger pumps go hand-in-hand with bigger amenities, bigger pipelines, and increased manufacturing, all of which proceed to pattern larger yr after yr. Other customers and industries have additionally shown an interest in this size, and it will be no shock in any respect to see extra of those pumps built in the close to future for comparable applications.”
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