Slurry

Slurry Pipeline Design,
Testing and Practice

Presented by:
Graeme Addie and Lee Whitlock

GIW Industries, Inc.
Bob Hagler
Hagler Systems
Slurry Pipeline Design
 FIRST NEED TO KNOW
• CONCENTRATION FIXED OR CAN BE VARIED
• IS PIPELINE EXISTING DIAMETER CAN IT BE VARIED
• IS SLURRY SETTLING OR NON-SETTLNIG TYPE
HOW MUCH CAN

SLURRY SIZE
TYPE
CONCENTRATION,
ETC.
VARY/ CHANGE
Prepared by: CRA GIW Industries, Inc. 2

Solids Transport Rate
for Different Pipe Diameters, Velocities and Concentrations

Demarcation Between Settling and Non-Settling

Slurry System Characteristics

When the solids are less than 80
micron, the slurry is usually non-settling

For Non-Settling Slurry
Design flow can theoretically be very low but

energy dictates need be higher
capital cost also
Also, if laminar, any large particles may settle

Non-Settling Slurry Analysis
Rabinowitsch and Mooney have shown that the rate of strain of a fluid particle adjacent to
the pipe wall can be expressed as
 dv   1  3n  8 V 
     (11)
 dr r =ro  4n  D 
for all laminar flows in a pipe. In eq. 11 d ln   

n (12)
d ln 8V/D 
The importance of the Rabinowitsch and Mooney proof is that of establishing the scaling law
 8V 
    
 D  (13)
for all steady uniform laminar flows in a pipe. In other words, both T 0 and 8V/D can be
determined from experiment with the result that the experimentally determined friction,
eq. 13, can be applied to other pipe sizes and/or velocities provided that the same
non-Newtonian fluid is involved in both the test are the design.
Here, the shear stress distribution is linear varying from a maximum at the boundary to zero
at the centerline of the pipe, that is,
dp r
 (3)
dx 2
In which dp/dx = the pressure gradient along the axis of a horizontal pipe.
Where We Can Only Get a
Small Sample, We Can Use
 Rotating Viscometer
 Extrusion Rheometer

Extrusion
Rheometer

Non-settling slurries have a zero flow wall shear
stress and a laminar and turbulent region.
(a) Test 303 -81

Symbol
D (in)
ALCAN Red Mud 4.026
No Sand Added 6.065
7.981
S = 1.597
m
Turbulent Flow
S m = 1.597
m = B = 1.9 (10 -4 ) lb-sec/ft 2
k/D = 1(10 -4 )
D = 4.026 in.

(PSI)
Turbulent Flow
S m = 1.597
-3 2
m = w = 1.7 (10 lb-sec/ft
k/D = 1(10 -4 )
D = 4.026 in.

Non-settling slurries are
very concentration dependent
100 Pa
1.45 Red Mud Alcan

1.13 Phosphate Slimes
1.366
1.366
1.528
1.528
1.471

Settling Slurries
Settling slurries of 100 micron to 5 mm size solids,
have a minimum head loss and a deposit velocity

The deposit velocity can be calculated

Pipeline Deposit Velocity

Settling Slurry Modeling Approach
Wilson and Clift used the concept of a stratification
ratio R and the threshold of turbulent suspension to
show that the total excess friction pressure gradient
(im - if) is Smd  1  BR  Aif (1  R )
where the stratification ratio

n
V 
R   u 
 Vm 
and
A' and B are properties of the slurry

Smd = specific gravity of the delivered mixture
if = pipe friction due to carrier liquid only.
Stratification in Settling Slurries
To estimate the variation of R with pipe size and mixture velocity, we
return to the work of Wilson (5). Wilson and Watt proposed that, below a
particular mixture velocity termed the threshold of turbulent suspension,
Vs, the solids are fully stratified. If the mixture velocity is increased above
Vs, then part of the solids pass into pseudohomogeneous suspension.
The value of Vs is estimated as
8  45d  (9)
Vs  0.6 Vt exp 
w  D 
where Vt and d are the terminal velocity and diameter of a conveyed

particle, and λw is the (Moody) friction factor for flow of the carrier liquid
alone (i.e. 2gDiw/V2m). For mixture velocities below Vs, flow is fully
stratified and R = 1. For Vm > Vs, R can be estimated
R  Vs / Vm 
m
(10)
where values of m close to 1.7 have been determined (6). For particles
which are sufficiently fine to ensure Vs < Vm over the whole.
Settling Slurry Transport Mechanisms
Sliding
Lifted

Analysis of Settling Slurry Test Data
Behaviour of masonry-sand slurry (d50 = 0.42 mm)

Prepared by: CRA GIW Industries, Inc. In 203 mm and 440 mm pipe, after Clift et al. (1982) 19
Settling Slurry Pipe Friction Approach
m
(im  i w )  Vm 
  
(Sm  1)  Uu 

Pipe Friction Constant From Pipe Tests

Wilson Book Method
The equation for the approximating power law is readily
obtained in terms of V50, giving the relative solids effect as
M
(im  i f )  Vm 
 0.22 
V 
 (6.3)
(Sm  S f )  50 
The coefficient 0.22 represents the value of the relative

solids effect at the point where Vm equals V50, as
mentioned previously. The power M is about 1.7 for
slurries with a narrow particle grading (Clift et al., 1982)
Based on data obtained for various slurries tested at the

GIW Hydraulic Laboratory, the resulting expression is
2
M  (0.25  13 s ) 0.50 (6.16)
GIW has Developed Different Models for
Predicting Head Loss
Definition sketch for limit of stationary deposit zone.

The GIW Models are Some of the Best Available.
In a Long Pipeline with Difficult Slurry, it is Best to do Tests.

GIW Slurry Test Loops
3”, 4”, 6”, 8”, 12”, 18” and 20”

Observing Deposit Velocity at Glass Pipe Section

US Army Corps. of Engineers
Slurry Tests
 Tests Run in 4” Loop
 Used Three Different Sand Sizes
• 650 micron
• 1250 micron
• 2250 mircon
 4 Concentrations of each Sand
(5, 10, 20, and 30% Cv)
 5 Concentrations Clay for Each
(0, 2, 4, 5, and 6% Cv)
 Total Number of Tests - 60
US Army Corps. Of Engineers Sand Results

Argyle Diamond
Simulated Slurry Pipe Test
in 250 and 300 mm Loop

Plugged Pipeline
While Running at CV=49%

Energy vs. Transport Rate for a 250 mm Pipe

Schematic of Hibernia Oil Platform

Hibernia Slurry Tests
 Phase 1: Determine the head loss characteristics of
pumping magnetite ore in various pipelines. Results to
be used to design distributor system.
Average Solids S.G. = 4.392

Average Particle Size = 25 mm
A. Tests in combo 254 / 305 mm loop at

0%, 4%, 8%, and 16% by volume.
Flow rates up to 550 L/sec.
B. Tests in combo 406 / 457 / 508 mm loop at

0%, 6%, 8%, and 10% by volume.
Flow rates up to 1250 L/sec
 Phase 2: Test Full Scale Mock-up of Actual

Distributor at concentrations of
0%, 4%, 8%, and 12% by volume.
Prepared by: CRA GIW Industries, Inc.
Flow rates up to 1800 L/sec. 33
Hibernia Distributor Slurry Test

Hibernia Slurry Tests
Hibernia Head Loss Results
12" Pipe With Magnetite Ore
7
5
Relative Head Loss (m/m)
4
Cv = 5%
Cv = 8%
Cv = 16%
3
0
0 1 2 3 4 5 6 7 8 9
Velocity (m/s)

Syncrude Coarse Rock
Ready for Loading in 450 m Loop
Sliding
Lifted

Tar Sands Slurry Pipe Friction
Delivered concentration Frictional headlosses

for coarse rock in water, for tar sand slurries at
Cr = 0.066, D = 490 mm 40°C, as determined
in two laboratories

Dallas White Rock Lake
 20 Mile Transportation of Sediment
 Slurry Analysis Performed by GIW for Terra-Mar,
Consulting Engineers
 GIW Extrusion Rheometer tests performed to
predict pipeline friction
 Silt NOT Sand
 Double Velocity required for Sand
 3.25 times Friction for Sand
 3.25 x 2 = 6.5 times the power
 Results = (3) Pumps rather than (9) Pumps
 Results = 5,000 HP rather than 27,000 HP
 Huge Project $$Savings$$

Dallas Process Concept
Make Up Water
0 ston/hr 0% cw
2000-10000 1.0
gpm SG
Transportation System
20% Cv
595 yd/hr
Slurry Transfer System Soil
Tank 10000 gpm
1.08
Approx 30,000gpm SG
(only 10000req’d)
6 miles 14 miles
40 ft 40 ft
20000HP 1500HP 1500HP
54" 46" 46"
DC Drive AC Constant Speed AC Constant Speed Disposal Area
Dredge Slurry (Soil insitu SG 1.4)

25% Cv
595 yd/hr
Soil
1.10
8000 gpm SG
Dredge
Dredge and Transfer System

White Rock Lake
Drawn RSH Reference
Approved
Project
Scale None
Date Drawing 01

Flow Properties of
White-Rock-Lake-Sediment Slurries
For
Terra-Mar Consulting Engineers

Determined at
GIW Hydraulic Laboratory

Four tests were performed in the GIW Hydraulic Laboratory
for the Terra-Mar, Consulting Engineers. These four test
were carried out in the .43” ID Extrusion Rheometer and are
designated and differentiated as follows:
Test no. Specific Gravity (Sm)
4-97 1.30
5-97 1.30
6-97 1.35
7-97 1.32
0.43” ID Extrusion Rheometer Test
tau0 = fn(8V/D)
Test 4-97; Sm = 1.30

Scaled Test Results
-dp/dx = fn(V)
Terra-Mar; ID = 19in.

Application of GIW Test Data
Dallas White Rock System/Pump Analysis
103,350 Feet of 23.25" ID Pipe, 0K Fitting and Entrance loss, -99 feet static ,
Loss Based on Water Smooth Steel (e=.00005), GIW Laminar Flow Tests #4-97,6-97,7-97
1500
1400 800
1300 750
1200 700
650
1100
600
1000
550
TDH - Feet of Slurry
PSI @ 1.3 SG
900
500
800 Test 6-97, 1.35 SG
450
700
400
600
350
500 2 Pum ps
300
400 Test 7-97, 1.32 SG
250
300 200
1 Pum p
200 150
100 100
Test 4-97, 1.30 SG
0 50
-100 0
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000 12,000 13,000 14,000 15,000 16,000
Flow Rate - Gallons per Minute

Filename - 72034 70728

Hydraulic Gradeline
24 inch 20 Mile System
Dredge, Unmanned Booster, and Instruments

Radio Link to Dredge

Main Control
Radio Link to Dredge, Phone Line Link to Remote Booster

Remote Booster – 6 miles

System Make Up Water

Automatic Flow Control

Dredge SG Approx 1.1

Four Corners Mine Transportation Analysis
Four Corners
Hp-Hr 21-1/4" Pipe
Ton-Mile
*Water
.45
Only
.4
16514
.35
.3
*
.25
11839
.2
*
.15
1600 1800 2000 2200 2400 2600
Tons Per Hour (Dry Solids)
Long Distance Pipeline
Pumps are Usually Not
This Large
Centrifugal Pumps are

Usually Limited to 6 in
Series in One Location

In Florida, Up to 11 Pumps in Series May be
Located Along a 21” Pipeline, 8.5 Miles Long

Phosphate Pump and Pipe Tests in the Field

Florida Phosphate Matrix Transport Costs
Existing Matrix Train 17, with 19” ID Pipe, Except 10 WBC 46 (49)’s + LSA 62 Pit Pump
Costs at Different Concentrations (and TPH), 45,200 Feet
(Same Motors, V.S. Pumps @ Max Speed, 300 Micron D50)
(Assumes 1" Suction Liner Wear, 2" Casing Belly Wear)
* All costs are figured at 6000 hours unless specified otherwise

Kaolin Hydro-transport Pipeline Design
Kaolin Product: 37 miles of 12” pipeline;
d50 = 8 µm; 98-99% < 50 µm
Some 200 µm quartz;
Cw = 24% & 36%
Closed Test Loop Setup: 400 feet long; 12” steel pipeline loop;
Observation section in inclinable pipe
Fully instrumented to measure both
pipeline and pump characteristics.

3 Pumps in Series
Tachonite Tails
Pump System

Power Failure Example
3.5 miles
3.5 miles
Pumps located in two pumping stations

(3 in series) with sumps
Piping Arrangements and Considerations
The simplest solution is often the best solution.
Rubber Pipe
Good only for single
stage or along a line
Expansion Joint
Must be tied with
through bolts
Rigid Pipe Support

Any thermal expansion of
pipe will go into pump
Startup on Part Full Line (or filling)
Pump comes up to speed and then operates at point where H-Q curve
of pump intersects the system resistance for the amount of line filled.
Pump Head
Quantity
NPSH Available
from System
Normal
Operation Flow During
Filling
NPHS
Required
Cavitation
System resistance while part full BHP Required
Unless throttle or controlled by reduced speed, operation will result in:

 Increased Power
 Possible Cavitation
If Pump H-Q curve is flat, increases will be larger
Startup (Sequencing) of Multiple Pumps in a Line
A. After some time (steady flow) all pumps located at pit end of line.
B. Shortly after starting all pumps located at pit end.
C. After some time (steady flow) pumps located (spaced) along line.
D. Shortly after starting pumps spaced along line.
E. Starting booster before pit pump.

Water Hammer
 Occurs when rapid change happens
 May be initiated by
• startup
• shutdown
• rapidly closing valve
• water column closure
• Blocked suction
 Disturbance coming from the change
is in the form of waves traveling outwards
H t and 
V t and 
Individual waves pass up and down at constant velocity, neither being attenuated
or undergoing shape change by each other
Waves are reflected in full or part at each change of section.
Net pressure at a section is sum of pressure heights
Maximums occur at wave crossover points or initiation or reflection locations.
Water Hammer Example
When cavitation occurs
Vapor column created can be pulled up line by inertia after pump collapses.
As line slows, pump will pick up sending a second column after the first.
Subsequent closure of two columns will result in transient.
A closure may be likened to a rapidly closing value

 a x V
The transient in this case is Hrise 
g
Which can be simplified to Hrise  100 V
[any air will cushion]
Conclusions
 It is Possible to Use Centrifugal Pumps
to Transport Solids in a Pipeline up to 30
Miles and More.
 It is Important to Categorize Slurries

Accurately in Order to Identify the Most
Energy Efficient, Lowest Wear
Operating Velocity and Concentration.
 Test Lab Pipeline Tests are Necessary

in Most Cases to Determine Pipe
Friction and Pump Performance

Slurry

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Slurry Pipeline Design,

Testing and Practice

Graeme Addie and Lee Whitlock

HOW MUCH CAN

Prepared by: CRA GIW Industries, Inc. 2

Prepared by: CRA GIW Industries, Inc. 3

Prepared by: CRA GIW Industries, Inc. 4

Prepared by: CRA GIW Industries, Inc. 5

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Design flow can theoretically be very low but

capital cost also

Also, if laminar, any large particles may settle

Prepared by: CRA GIW Industries, Inc. 7

for all laminar flows in a pipe. In eq. 11 d ln   

Prepared by: CRA GIW Industries, Inc. 9

Prepared by: CRA GIW Industries, Inc. 10

(a) Test 303 -81

Prepared by: CRA GIW Industries, Inc. 11

1.45 Red Mud Alcan

Prepared by: CRA GIW Industries, Inc. 12

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where the stratification ratio

A' and B are properties of the slurry

where Vt and d are the terminal velocity and diameter of a conveyed

Prepared by: CRA GIW Industries, Inc. 18

Behaviour of masonry-sand slurry (d50 = 0.42 mm)

Prepared by: CRA GIW Industries, Inc. 20

Prepared by: CRA GIW Industries, Inc. 21

The coefficient 0.22 represents the value of the relative

Based on data obtained for various slurries tested at the

Definition sketch for limit of stationary deposit zone.

Prepared by: CRA GIW Industries, Inc. 24

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Average Solids S.G. = 4.392

A. Tests in combo 254 / 305 mm loop at

B. Tests in combo 406 / 457 / 508 mm loop at

 Phase 2: Test Full Scale Mock-up of Actual

Prepared by: CRA GIW Industries, Inc. 34

Prepared by: CRA GIW Industries, Inc. 35

Prepared by: CRA GIW Industries, Inc. 36

Delivered concentration Frictional headlosses

Prepared by: CRA GIW Industries, Inc. 37

Prepared by: CRA GIW Industries, Inc. 38

Dredge Slurry (Soil insitu SG 1.4)

Dredge and Transfer System

Prepared by: CRA GIW Industries, Inc. 39

Terra-Mar Consulting Engineers

GIW Hydraulic Laboratory

Prepared by: CRA GIW Industries, Inc. 41

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Flow Rate - Gallons per Minute

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