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 course of and requires the most important slurry pump within the oil sands business.
When it comes to pumping slurry, there can be very few functions which are more challenging than the hydro-transport of industrial quality slurries in oil sands production. Not solely do the pumps have to deal with the highly aggressive nature of the fluid being pumped, they’re also anticipated to function in a few of the harshest environments on the planet.
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 within the oil sands trade and the latest in a line of highly effective high-pressure pumps provided by GIW.
Slurry transportation Slurry transport covers a considerable vary of industry sectors, starting from food and beverage to mining. What is common to all, is that the pumps used should be capable of transport liquids containing particles and solids of various sizes and viscosities. In mining, dredging and oil sands production, the most important challenge is to accommodate excessive density slurry and extremely abrasive grits.
It is crucial that the slurry passes via the pump with the minimal amount of wear and tear to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump must be able to delivering high flows and in a position to withstand harsh working environments.
Alberta in Canada has intensive oil reserves and these are in the type of oil sands. Extracting and processing the oil from the sands and bedrock is difficult, involving the removing of bituminous ore which is transported to a crushing plant. The crushed ore is then blended with warm water to kind a dense slurry that can 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 sometimes transported by way of completely different pumps to settling ponds.
The processes require extensive use of slurry and water transportation pumps able to dealing with huge quantities of liquids at high pressures and excessive temp- eratures. Drawing on its long expertise of designing slurry pumps for mining, GIW has custom-engineered slurry pumps that combine superior supplies, hydraulics and patented mechanical designs, the newest of which is the TBC-92.
Meeting challenges Mollie Timmerman, GIW business development supervisor, explains more: “Our shopper wanted a higher 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 stress of 4000 kPa. The pump also needed to have the flexibility to move rocks of approximately 130 mm in diameter with a total passage measurement requirement of 10 in (or 254 mm) and handle slurry densities in extra of 1.5 SG.
In addition, the client was concentrating on a maintenance interval (operational time between deliberate maintenance) of around 3,000 hours. They had expressed an interest in maximising the maintenance intervals and based mostly on initial wear indications, they’re presently hoping to achieve round 6,000 hours between pump overhauls (i.e. 6–8 months).”
The instant application for the primary batch of GIW’s TBC-92 pumps in Alberta is in hydro-transport service where they’re used to maneuver bitu- minous ore from the crusher to the extraction plant. The liquid pumped is a mix of water, bitumen, sand, and large rocks. Screens are in place to maintain these rocks to a manageable measurement for the method, but the top measurement can nonetheless usually 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 within the business. Wear and erosion are details of life, and GIW has many years of experience within the design of slurry pumps and the development of supplies to help lengthen the service life of these important components to match the deliberate maintenance cycles within the plant.
“GIW already had a pump able to the output requirement, this being the MDX-750, which has been a well-liked size in mill duties for practically 10 years through- out Central and South America,” explains Mollie Timmerman. ”However, the customer’s software required a pump with higher pressure capabilities and the potential of handling larger rocks so we responded with the event of the TBC-92 which provided the most effective answer for maximised production.”
The TBC series The development type of GIW’s TBC pump range features massive, ribbed plates held together with tie bolts for very high-pressure service and maximum put on efficiency. First developed for dredge service, then later launched into the oil sands in the Nineties, the TBC pump sequence has grown into a completely developed vary of pumps serving the oil sands, phosphate, dredging and exhausting rock mining industries for tailings and hydrotransport functions.
The pumps are often grouped together in booster stations to construct stress as high as 750 psi (5171 kPa) to account for the pipe losses encountered over such lengthy distances. The strong construction of the TBC pump is well suited to do the job, whereas making certain maximum availability of the gear under heavily abrasive wear.
Capable of delivering pressure as much 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 offers maximum resistance to put on. Simple to keep up, the pump’s tie-bolt design transfers stress loads away from the wear resistant white iron casing to the non- bearing facet plates without the usage of heavy and unwieldy double-wall construction.
The TBC-92 combines the most effective parts of earlier TBC models, together with the TBC-84 oil sands tailing pump, also referred to as the Super Pump. The pump also incorporates features from GIW’s MDX product line, which is utilized in heavy-duty mining circuits all through the world of exhausting rock mining.
In complete, 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 embrace a slurry diverter that dramatically increases suction liner life by lowering particle recirculation between the impeller and the liner. The giant diameter impeller allows the pump to run at slower speeds in order that wear life is enhanced. The decrease pace additionally offers the pump the flexibility to function over a wider range of flows in order to accommodate fluctuating flow conditions.
To make maintenance simpler, the pump is fitted with a particular two-piece suction plate design which helps to scale back software time and provide safer lifting. เกจ์วัดแรงดันน้ำมันเครื่อง receive pump-specific lifting units to facilitate the secure elimination and installation of damage comp- onents. The pump additionally includes a longlasting suction liner that can be adjusted without needing 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 at all working Canadian oil sands vegetation for hydrotransport purposes. The TBC-92 has been designed to deal with heavy-duty slurry transport while offering a low complete price of ownership. Minimal labour and maintenance time assist to maximise manufacturing and profit.
“This new pump incorporates the lessons learned from working within the oil sands over a few years, and options our latest hydraulic and wear applied sciences,” says Mollie Timmerman. “Because that is the heaviest TBC pump we’ve ever designed, explicit consideration was given to maintainability, as nicely as materials choice and construction of the pressure-containing elements.”
That GIW has established itself as a major force in pumping solutions for the oil sands trade is way from shocking provided that it has been developing pumping applied sciences and wear resistant materials within the world mining business for the rationale that 1940s.
These pumps have had a substantial impact on the means in which that excavated sand, rock and bitumen are transported to the upgrader plant. By including water to the excavated material it becomes highly environment friendly 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 benefit of removing the use of trucks.
GIW has estimated that the worth of transferring oil sand in this means can minimize costs by US$2 a barrel, and it is far more environmentally pleasant. These pumps additionally play a major position in transporting the coarse tailings to the tailings ponds. GIW supplies pumps used within the extraction process and different areas of manufacturing (HVF, MDX, LSA).
Understanding slurries Understanding the nature of slurries and how they behave when being pumped has been elementary to the event of these merchandise. GIW has been obtaining slurry samples from prospects over a few years for testing hydraulics and supplies both for pumps and pipelines. Research & Development amenities embrace a quantity of slurry check beds on the campus, together with a hydraulics laboratory that’s dedicated to pump efficiency testing.
These activities are central to the company’s pump development programmes. If firms are experiencing problems the GIW R&D personnel can see the place the issue lies and provide advice for remedial motion. Experience does indicate that in many instances the issue lies not with the pump nevertheless, but in the interplay between the pipeline and the pump.
Feedback from prospects about appli- cations helps in the development of recent instruments and pump designs. By bringing to- gether prospects and teachers from all around the world to share their experience and analysis with in-house specialists, the massive funding in analysis, improvement and manufacturing has advanced the design of the entire GIW pump merchandise,materials and wear-resistant parts.
The future “There is a transparent trend toward larger pumps in mining and dredging and oil sands are no exception,” feedback Leo Perry, GIW lead product manager. “The first TBC pump in the oil sands trade was the TBC-46 (46 in being the diameter of the impeller). Customers are designing their services for greater and higher production and demanding the identical of the equipment that retains their production shifting. While these bigger pumps demand more energy, additionally they permit for higher manufacturing with much less downtime required for upkeep. Overall, the efficiency improves when compared to the identical output from a bigger quantity of smaller pumps. “
In conclusion, he says: “Larger pumps go hand-in-hand with larger amenities, bigger pipelines, and increased manufacturing, all of which proceed to trend larger year after year. Other prospects and industries have additionally proven an interest in this dimension, and it would be no shock in any respect to see extra of those pumps constructed within the close to future for related applications.”