KSB’s slurry dealing with success in oil sands

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 industry.
When it involves pumping slurry, there could be very few applications which would possibly be more challenging than the hydro-transport of professional quality slurries in oil sands production. Not only do the pumps have to contend with the extremely aggressive nature of the fluid being pumped, they are additionally anticipated to operate in some 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, particularly 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 obtainable in the oil sands industry and the latest in a line of powerful high-pressure pumps offered by GIW.
Slurry transportation Slurry transport covers a considerable vary of industry sectors, starting from food and beverage to mining. What is widespread to all, is that the pumps used must be in a position to transport liquids containing particles and solids of various sizes and viscosities. In mining, dredging and oil sands manufacturing, the largest problem is to accommodate high density slurry and extremely abrasive grits.
It is crucial that the slurry passes through the pump with the minimal quantity of wear and tear to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump must be able to delivering excessive flows and able to face up to harsh operating environments.
Alberta in Canada has extensive 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 elimination of bituminous ore which is transported to a crushing plant. The crushed ore is then combined with heat water to kind a dense slurry that can be transported in the pipeline in course 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 totally different pumps to settling ponds.
The processes require extensive use of slurry and water transportation pumps able to handling vast quantities of liquids at excessive pressures and high temp- eratures. Drawing on its lengthy experience of designing slurry pumps for mining, GIW has custom-engineered slurry pumps that combine superior materials, hydraulics and patented mechanical designs, the most recent of which is the TBC-92.
Meeting challenges Mollie Timmerman, GIW business growth manager, explains extra: “Our consumer wanted the next capability pump which was able to 10,000–11,000 m3 per hour of output at practically 40 m of developed head and a most working strain of 4000 kPa. The pump also wanted to be able to pass rocks of approximately a hundred thirty mm in diameter with a total passage dimension requirement of 10 in (or 254 mm) and deal with slurry densities in extra of 1.5 SG.
In addition, the shopper was concentrating on a upkeep interval (operational time between planned maintenance) of round three,000 hours. They had expressed an curiosity in maximising the maintenance intervals and based on preliminary put on indications, they are at present hoping to attain around 6,000 hours between pump overhauls (i.e. 6–8 months).”
The immediate software for the first batch of GIW’s TBC-92 pumps in Alberta is in hydro-transport service the place they are used to move bitu- minous ore from the crusher to the extraction plant. The liquid pumped is a mixture of water, bitumen, sand, and enormous rocks. Screens are in place to maintain these rocks to a manageable measurement for the method, but the prime measurement can nonetheless typically reach up to one hundred thirty 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 event of supplies to help prolong the service life of those critical components 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 popular size in mill duties for nearly 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 aptitude of handling larger rocks so we responded with the event of the TBC-92 which provided one of the best resolution for maximised production.”
The TBC sequence The construction style of GIW’s TBC pump range options giant, ribbed plates held along with tie bolts for very high-pressure service and most put on efficiency. First developed for dredge service, then later launched into the oil sands in the 1990s, the TBC pump collection has grown into a fully developed vary of pumps serving the oil sands, phosphate, dredging and hard rock mining industries for tailings and hydrotransport applications.
The pumps are often grouped collectively in booster stations to build strain as excessive as 750 psi (5171 kPa) to account for the pipe losses encountered over such long distances. The robust building of the TBC pump is nicely suited to do the job, whereas making certain maximum availability of the equipment beneath heavily abrasive put on.
Capable of delivering stress as a lot as 37 bar and flows of more than 18,200m³/h and temperatures as much as 120o C, the TBC vary is a horizontal, finish suction centrifugal pump that provides maximum resistance to wear. Simple to keep up, the pump’s tie-bolt design transfers stress masses away from the put on and tear resistant white iron casing to the non- bearing facet plates without the use of heavy and unwieldy double-wall building.
The TBC-92 combines one of the best elements of earlier TBC models, together with the TBC-84 oil sands tailing pump, also called the Super Pump. The pump additionally incorporates features from GIW’s MDX product line, which is used in heavy-duty mining circuits all through the world of onerous 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 options of the pump embrace a slurry diverter that dramatically will increase suction liner life by reducing particle recirculation between the impeller and the liner. The giant diameter impeller allows the pump to run at slower speeds so that wear life is enhanced. The lower speed also provides the pump the ability to operate over a wider range of flows to be able to accommodate fluctuating move circumstances.
To make upkeep easier, the pump is fitted with a special two-piece suction plate design which helps to scale back tool time and provide safer lifting. Customers obtain pump-specific lifting devices to facilitate the secure removal and installation of damage 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 essential 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 whereas providing a low total cost of possession. Minimal labour and upkeep time assist to maximise production and profit.
“This new pump incorporates the teachings discovered from operating within the oil sands over a few years, and options our newest hydraulic and put on technologies,” says Mollie Timmerman. “Because that is the heaviest TBC pump we now have ever designed, specific consideration was given to maintainability, as nicely as material choice and construction of the pressure-containing parts.”
That GIW has established itself as a major drive in pumping options for the oil sands trade is way from surprising given that it has been developing pumping applied sciences and wear resistant materials within the international mining trade for the explanation that 1940s.
These pumps have had a substantial impact on the best way that excavated sand, rock and bitumen are transported to the upgrader plant. By including water to the excavated materials it turns into highly efficient to pump the slurry alongside a pipeline to the upgrader. The pipeline agitation assists in separating the bitumen from the sand as it’s transported, plus there’s the extra advantage of removing the utilization of trucks.
GIW has estimated that the worth of transferring oil sand in this method can cut prices by US$2 a barrel, and it’s much more environmentally friendly. These pumps additionally play a significant function in transporting the coarse tailings to the tailings ponds. GIW provides pumps used in the extraction process and different areas of manufacturing (HVF, MDX, LSA).
Understanding slurries Understanding the character of slurries and the way they behave when being pumped has been elementary to the event of those merchandise. GIW has been acquiring slurry samples from clients over many years for testing hydraulics and materials both for pumps and pipelines. Research & Development services include multiple slurry take a look at beds on the campus, together with a hydraulics laboratory that is devoted to pump efficiency testing.
These activities are central to the company’s pump improvement programmes. If companies are experiencing problems the GIW R&D personnel can see the place the problem lies and provide recommendation for remedial action. Experience does indicate that in many cases the problem lies not with the pump however, however in the interplay between the pipeline and the pump.
Feedback from prospects about appli- cations helps in the improvement of latest tools and pump designs. By bringing to- gether customers and academics from all round the world to share their expertise and research with in-house experts, the massive investment in research, improvement and manufacturing has advanced the design of all of the GIW pump merchandise,supplies and wear-resistant components.
The future “There is a transparent trend toward larger pumps in mining and dredging and oil sands are not any exception,” feedback Leo Perry, GIW lead product supervisor. “The first TBC pump in the oil sands business was the TBC-46 (46 in being the diameter of the impeller). Customers are designing their amenities for larger and higher production and demanding the identical of the gear that retains their manufacturing shifting. While these larger pumps demand extra energy, they also enable for higher production with less downtime required for maintenance. Overall, the efficiency improves when in comparability with the same output from a larger 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 proceed to pattern greater yr after year. เกจวัดแรงดันลม10bar and industries have additionally proven an interest in this size, and it will be no shock at all to see extra of those pumps built in the near future for related functions.”
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