We move solids with centrifugal slurry pumps

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© Metso Minerals, Inc. 2003

Dale Carter

British Coal - 1970 to 1988 - Mechanical apprentice - Engineer - Workshop Engineering Supervisor Joy Process Equipment - Denver / Denver Sala - Svedala - Metso UK - 1988 to date - Service engineer - Commissioning Engineer - Product Support Engineer - UK Pump Sales Manager - Global Service Manager

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Hobbies include Golf and Flying

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Service Supply And Support Training Options
Metso Slurry Pumps Service Supply And Support Options For Vedanta November 2006 Dale Carter

Metso
Maintaining Equipment Through Service Options
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We move solids
– with centrifugal slurry pumps

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Presentation Overview
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Pump Components and Basic Designs Costs of Slurry Pumps Impeller Types and Variations Performance Curves & Best Efficiency Total Dynamic Head Calculations Material Selection

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Basic Definitions
Slurry ~ mixture of water and solids (and possibly air) Slurry Pump ~ a robust centrifugal pump, handling tough abrasive duties

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Slurry Pumps
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Distribution vs. Cost
Slurry pumps represent only 5% of all centrifugal pumps installed in industry Slurry pumps represent 80% of the operating cost of all centrifugal pumps!

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Slurry Pumps
Operation Cost

Seal WaterMaintenance Seal WaterMaintenance Wear Parts Wear Parts

Electrical Energy Electrical Energy

Goal = Total Lowest Cost

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Slurry Pump
Basic Components
1. Impeller 2. Casing 3. Sealing arrangement 4. Bearing assembly 5. Drive

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Horizontal Basic Design

1. Impeller 2. Casing 3. Seal arrangement 4. Bearing assembly 5. Drive

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Shaft Seals

Soft Packing Seal (soft packed gland) Mechanical Seal (spring loaded flat faces)

Dynamic Seal (Expeller)

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Vertical Sump Basic Design

1. Impeller 2. Casing 3. Seal arrangement 4. Bearing assembly 5. Drive

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Vertical Tank Basic Design

1. Impeller 2. Casing 3. Seal arrangement 4. Bearing assembly 5. Drive

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Slurry Pump Impeller

Impeller transfer kinetic energy to slurry mass and accelerates it.

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Slurry Pump Casing

Casing creates a desirable flow pattern. Converts kinetic energy into pressure energy.

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Semi-Open Impeller

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Less prone to clogging than closed impeller Slightly lower efficiency than closed impellers

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Closed Impeller

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More efficient than open impellers More prone to clogging Clogging is more critical with smaller impellers

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Closed Impeller

~ High Efficiency, Low Wear

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Induced Flow Impeller
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Prevents clogging of fibrous, stringy or sticky particles Gentle solids handling Lower efficiency than closed or semi-open impeller

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Number of Vanes

More vanes gives higher efficiency …but the maximum number of vanes in practice is five.

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Impeller Width

The larger the impeller WIDTH, the greater the FLOW produced at a given speed

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Impeller Diameter

The larger the impeller DIAMETER, the greater the HEAD produced at a given speed

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Pressure and Head

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Head

Flow
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Aim ~ Operate Near B.E.P.

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Radial Forces and B.E.P.

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Total Dynamic Head (TDH)

TDH = H2 - H1 + friction losses

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Friction Head Calculation
Need to consider the following:
Straight Pipes • Diameter • Length • Material (roughness) • Flow Rate Fittings • Elbows • Long / Short Bends • Valves • Tees

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The System Curve

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Impeller Wear Rate

Wear rate ∝ Speed Ratio2.5

i.e.

Half the speed = 5.7 times longer life !

Conclusion: Reduce head by selecting a larger pipe diameter. This will increase wear life and also save on electrical requirements.

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Slurry Effects on Friction Head

Head Loss

Velocity Flow
Head Correction for slurry must be made before plotting on performance curve

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Slurry Correction Factors

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The correction for head and efficiency for slurries is quite involved. Based on Particle size distribution, Particle specific gravity and % solids Today, calculated with computer software

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Critical Flow Velocity

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The solids in a slurry must be kept in suspension to avoid settling in the pipe If the flow velocity is sufficiently high, turbulence will keep solids in suspension

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Particle size ~ critical velocity increases Specific gravity ~ critical velocity increases

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What happens when the Total Dynamic Head (TDH) is OVER ESTIMATED?

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Multiple Pump Installations

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Net Positive Suction Head (NPSH)

NPSH = ATM Pressure + Static Head - System Losses - Vapor Pressure

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Cavitation
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If NPSHA (Available) < NPSHR (Required) Pressure in pump inlet drops to liquid vapour pressure. Vapour bubbles form and travel to areas of higher pressure (eye of the impeller) These bubbles or “cavities” violently collapse

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Wear Parts ~ Rubber vs. Metal

Rubber-lined Wet End

Metal Wet End

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Wear Part Material Selection

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Vertical Tank Pump

Tank, Pump and Motor in one unit “Self- Priming” Seal-less design = Easy maintenance

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Thank you for attending! Slurry Pumps Division

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