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KSB’s slurry dealing with success in oil sands

Alberta, Canada has the world’s third largest oil reserves within the form of oil sands. Extracting and processing the oil from the sands and bedrock is a challenging course of and requires the biggest slurry pump within the oil sands trade.
When it comes to pumping slurry, there could be only a few purposes which are more challenging than the hydro-transport of heavy-duty slurries in oil sands manufacturing. Not solely do the pumps have to cope with the extremely aggressive nature of the fluid being pumped, they are 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, specifically the Tie Bolt Construction (TBC-92). Named after its 92 in (2337 mm) impeller, the TBC-92 is the most important and heaviest slurry pump out there in the oil sands industry and the newest in a line of highly effective high-pressure pumps supplied by GIW.
Slurry transportation Slurry transport covers a considerable vary of industry sectors, ranging from meals and beverage to mining. What is frequent to all, is that the pumps used should be capable of transport liquids containing particles and solids of varying sizes and viscosities. In mining, dredging and oil sands manufacturing, the most important problem is to accommodate excessive density slurry and highly abrasive grits.
It is important that the slurry passes through the pump with the minimum quantity of wear to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump have to be able to delivering high flows and able to withstand harsh operating environments.
Alberta in Canada has intensive 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 removal 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 might be transported within the pipeline in the path of extraction, the place the bitumen is separated from the sand and rock. After extraction, the remaining solids (or tailings) are often transported via totally different pumps to settling ponds.
The processes require intensive use of slurry and water transportation pumps able to dealing with vast quantities of liquids at excessive 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 materials, hydraulics and patented mechanical designs, the latest of which is the TBC-92.
Meeting challenges Mollie Timmerman, GIW business growth manager, explains more: “Our shopper wanted the next capacity pump which was capable of 10,000–11,000 m3 per hour of output at nearly forty m of developed head and a maximum working pressure of 4000 kPa. The pump additionally needed to have the ability to cross rocks of approximately a hundred thirty 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 concentrating 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 primarily based on preliminary wear indications, they are at present hoping to achieve round 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 combination of water, bitumen, sand, and large rocks. Screens are in place to keep these rocks to a manageable size for the method, however the top size can nonetheless typically attain up to 130 mm in diameter or bigger.
The abrasive nature of the slurry is what separates a slurry pump from other pumps used in the trade. Wear and erosion are information of life, and GIW has decades of expertise within the design of slurry pumps and the development of supplies to help lengthen the service life of those important elements to match the planned upkeep cycles in the plant.
“GIW already had a pump capable of the output requirement, this being the MDX-750, which has been a popular 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 larger strain capabilities and the potential of dealing with larger rocks so we responded with the development of the TBC-92 which offered one of the best answer for maximised manufacturing.”
The TBC series The building fashion of GIW’s TBC pump vary options giant, ribbed plates held together with tie bolts for very high-pressure service and maximum wear performance. First developed for dredge service, then later introduced into the oil sands within the Nineties, the TBC pump collection has grown into a fully developed vary of pumps serving the oil sands, phosphate, dredging and exhausting rock mining industries for tailings and hydrotransport purposes.
The pumps are often grouped together in booster stations to construct pressure as high as 750 psi (5171 kPa) to account for the pipe losses encountered over such long distances. The robust building of the TBC pump is well suited to do the job, whereas ensuring most availability of the gear under heavily abrasive wear.
Capable of delivering stress up to 37 bar and flows of more than 18,200m³/h and temperatures as much as 120o C, the TBC vary is a horizontal, end suction centrifugal pump that gives maximum resistance to put on. Simple to take care of, the pump’s tie-bolt design transfers stress hundreds away from the wear and tear resistant white iron casing to the non- bearing aspect plates without the utilization of heavy and unwieldy double-wall development.
The TBC-92 combines the best parts of earlier TBC models, together with the TBC-84 oil sands tailing pump, also recognized as the Super Pump. The pump additionally incorporates options from GIW’s MDX product line, which is utilized in heavy-duty mining circuits throughout the world of hard rock mining.
In complete, 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 embody a slurry diverter that dramatically will increase suction liner life by lowering particle recirculation between the impeller and the liner. The massive diameter impeller allows the pump to run at slower speeds in order that wear life is enhanced. The lower velocity additionally offers the pump the power to function over a wider range of flows in order to accommodate fluctuating flow circumstances.
To make maintenance simpler, the pump is fitted with a particular two-piece suction plate design which helps to minimize back software time and provide safer lifting. Customers receive pump-specific lifting gadgets to facilitate the secure removal and installation of wear and tear comp- onents. เกจ์ลมsumo includes a longlasting suction liner that may be adjusted while not having to shut the pump down.
New milestone The commissioning of the TBC-92 marks an necessary milestone for GIW, which now has pumps in service in any respect operating Canadian oil sands crops for hydrotransport purposes. The TBC-92 has been designed to tackle heavy-duty slurry transport while offering a low total price of ownership. Minimal labour and maintenance time help to maximise manufacturing and profit.
“This new pump incorporates the lessons realized from working within the oil sands over many years, and features our newest hydraulic and put on applied sciences,” says Mollie Timmerman. “Because that is the heaviest TBC pump we’ve ever designed, specific attention was given to maintainability, in addition to material selection and development of the pressure-containing parts.”
That GIW has established itself as a major pressure in pumping options for the oil sands trade is much from shocking on circumstance that it has been creating pumping technologies and put on resistant supplies in the world mining industry because the Forties.
These pumps have had a substantial impact on the way that excavated sand, rock and bitumen are transported to the upgrader plant. By including water to the excavated materials 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 is the extra benefit of eradicating the use of vans.
GIW has estimated that the value of transferring oil sand in this means can reduce prices by US$2 a barrel, and it is way more environmentally pleasant. These pumps also play a major position in transporting the coarse tailings to the tailings ponds. GIW supplies pumps used within the extraction process and other areas of production (HVF, MDX, LSA).
Understanding slurries Understanding the nature of slurries and how they behave when being pumped has been fundamental to the event of these merchandise. GIW has been acquiring slurry samples from prospects over a few years for testing hydraulics and materials both for pumps and pipelines. Research & Development facilities include multiple slurry take a look at beds on the campus, together with a hydraulics laboratory that’s devoted to pump efficiency testing.
These actions 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 offer advice for remedial action. Experience does point out that in plenty of cases the problem lies not with the pump nonetheless, however within the interaction between the pipeline and the pump.
Feedback from customers about appli- cations helps within the development of new instruments and pump designs. By bringing to- gether prospects and teachers from everywhere in the world to share their expertise and research with in-house experts, the huge investment in research, development and manufacturing has advanced the design of all the GIW pump products,materials and wear-resistant elements.
The future “There is a transparent trend towards larger pumps in mining and dredging and oil sands aren’t any exception,” comments Leo Perry, GIW lead product manager. “The first TBC pump within the oil sands trade was the TBC-46 (46 in being the diameter of the impeller). Customers are designing their facilities for greater and better manufacturing and demanding the identical of the tools that retains their production transferring. While these bigger pumps demand extra energy, they also allow for higher 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 larger facilities, larger pipelines, and elevated production, all of which continue to pattern larger year after 12 months. Other clients and industries have also shown an curiosity on this dimension, and it would be no surprise in any respect to see more of those pumps constructed in the close to future for similar purposes.”
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