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 largest slurry pump in the oil sands industry.
When it comes to pumping slurry, there can be very few purposes that are more difficult than the hydro-transport of heavy-duty slurries in oil sands manufacturing. Not solely do the pumps should deal with the highly aggressive nature of the fluid being pumped, they are also anticipated to function in a few of the harshest environments on the planet.
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, namely the Tie Bolt Construction (TBC-92). Named after its 92 in (2337 mm) impeller, the TBC-92 is the biggest and heaviest slurry pump available within the oil sands industry and the most recent in a line of powerful high-pressure pumps offered by GIW.
Slurry transportation Slurry transport covers a substantial vary of trade sectors, starting from meals and beverage to mining. What is frequent to all, is that the pumps used should be succesful of transport liquids containing particles and solids of varying sizes and viscosities. In mining, dredging and oil sands production, the largest challenge is to accommodate excessive density slurry and highly abrasive grits.
It is important that the slurry passes via the pump with the minimal quantity of put on and tear to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump have to be capable of delivering excessive flows and in a place to stand up to harsh operating environments.
Alberta in Canada has in depth oil reserves and these are in the type of oil sands. Extracting and processing the oil from the sands and bedrock is challenging, involving the removal 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 direction of extraction, the place the bitumen is separated from the sand and rock. After extraction, the remaining solids (or tailings) are sometimes transported via completely different pumps to settling ponds.
The processes require extensive use of slurry and water transportation pumps capable of handling 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 advanced supplies, hydraulics and patented mechanical designs, the newest of which is the TBC-92.
Meeting challenges Mollie Timmerman, GIW enterprise development manager, explains extra: “Our consumer needed a better capacity pump which was capable of 10,000–11,000 m3 per hour of output at nearly 40 m of developed head and a maximum working pressure of 4000 kPa. The pump additionally needed to have the flexibility to pass rocks of roughly one hundred thirty mm in diameter with a total passage measurement requirement of 10 in (or 254 mm) and deal with slurry densities in extra of 1.5 SG.
In addition, the shopper was targeting a upkeep interval (operational time between deliberate maintenance) of around three,000 hours. They had expressed an interest in maximising the maintenance intervals and primarily based on preliminary put on indications, they’re presently hoping to realize 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 are used to maneuver bitu- minous ore from the crusher to the extraction plant. The liquid pumped is a mixture of water, bitumen, sand, and large rocks. Screens are in place to keep these rocks to a manageable size for the method, however the high dimension can nonetheless often attain up to 130 mm in diameter or larger.
The abrasive nature of the slurry is what separates a slurry pump from different pumps used in the business. Wear and erosion are details of life, and GIW has decades of experience within the design of slurry pumps and the event of supplies to help prolong the service life of those crucial components to match the deliberate maintenance cycles in the plant.
“GIW already had a pump able to the output requirement, this being the MDX-750, which has been a preferred dimension in mill duties for nearly 10 years through- out Central and South America,” explains Mollie Timmerman. ”However, the customer’s utility required a pump with higher strain capabilities and the potential of dealing with bigger rocks so we responded with the development of the TBC-92 which supplied one of the best solution for maximised manufacturing.”
The TBC series The development type of GIW’s TBC pump vary options massive, ribbed plates held along with tie bolts for very high-pressure service and maximum put on efficiency. 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 range of pumps serving the oil sands, phosphate, dredging and hard rock mining industries for tailings and hydrotransport applications.
เกจวัดแก๊ส are often grouped together in booster stations to build pressure as excessive as 750 psi (5171 kPa) to account for the pipe losses encountered over such long distances. The sturdy building of the TBC pump is nicely suited to do the job, while guaranteeing most availability of the gear underneath heavily abrasive put on.
Capable of delivering pressure up to 37 bar and flows of more than 18,200m³/h and temperatures as much as 120o C, the TBC range is a horizontal, finish suction centrifugal pump that provides maximum resistance to wear. Simple to hold 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 aspect plates with out the use of heavy and unwieldy double-wall building.
The TBC-92 combines the best parts of earlier TBC fashions, 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 whole, 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 embrace a slurry diverter that dramatically will increase suction liner life by lowering particle recirculation between the impeller and the liner. The large diameter impeller allows the pump to run at slower speeds so that wear life is enhanced. The lower velocity also provides the pump the ability to function over a wider vary of flows to be able to accommodate fluctuating move situations.
To make maintenance easier, the pump is fitted with a particular two-piece suction plate design which helps to reduce software time and provide safer lifting. Customers receive pump-specific lifting units to facilitate the secure elimination and installation of wear comp- onents. The pump additionally contains a longlasting suction liner that may be adjusted without having to close the pump down.
New milestone The commissioning of the TBC-92 marks an important milestone for GIW, which now has pumps in service at all working Canadian oil sands plants for hydrotransport purposes. The TBC-92 has been designed to deal with heavy-duty slurry transport whereas providing a low total value of ownership. Minimal labour and maintenance time assist to maximise production and revenue.
“This new pump incorporates the lessons realized from operating within the oil sands over a few years, and options our newest hydraulic and put on applied sciences,” says Mollie Timmerman. “Because that is the heaviest TBC pump we now have ever designed, particular consideration was given to maintainability, in addition to materials selection and development of the pressure-containing parts.”
That GIW has established itself as a big drive in pumping options for the oil sands trade is much from shocking given that it has been developing pumping applied sciences and wear resistant supplies in the international mining trade because the Nineteen Forties.
These pumps have had a considerable influence on the way that excavated sand, rock and bitumen are transported to the upgrader plant. By including water to the excavated material it turns into extremely efficient to pump the slurry along a pipeline to the upgrader. The pipeline agitation assists in separating the bitumen from the sand as it’s transported, plus there may be the additional benefit of eradicating the use of trucks.
GIW has estimated that the cost of transferring oil sand in this way can cut prices by US$2 a barrel, and it is much more environmentally pleasant. These pumps additionally play a major role in transporting the coarse tailings to the tailings ponds. GIW supplies pumps used within the extraction course of and other areas of production (HVF, MDX, LSA).
Understanding slurries Understanding the character of slurries and how they behave when being pumped has been fundamental to the development of these merchandise. GIW has been acquiring slurry samples from clients over a few years for testing hydraulics and materials each for pumps and pipelines. Research & Development facilities embrace a quantity of slurry check 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 firms are experiencing issues the GIW R&D personnel can see the place the issue lies and provide recommendation for remedial action. Experience does indicate that in lots of circumstances the problem lies not with the pump nevertheless, but within the interplay between the pipeline and the pump.
Feedback from prospects about appli- cations helps in the improvement of new tools and pump designs. By bringing to- gether prospects and teachers from all over the world to share their experience and analysis with in-house experts, the huge investment in analysis, improvement and manufacturing has superior the design of all the GIW pump merchandise,materials and wear-resistant elements.
The future “There is a clear trend towards bigger pumps in mining and dredging and oil sands are no exception,” comments Leo Perry, GIW lead product supervisor. “The first TBC pump within the oil sands business was the TBC-46 (46 in being the diameter of the impeller). Customers are designing their amenities for greater and better manufacturing and demanding the identical of the gear that keeps their production transferring. While these bigger pumps demand extra energy, additionally they permit for greater manufacturing with much less downtime required for upkeep. Overall, the efficiency improves when compared to the same output from a larger quantity of smaller pumps. “
In conclusion, he says: “Larger pumps go hand-in-hand with bigger services, larger pipelines, and elevated production, all of which continue to development greater 12 months after year. Other customers and industries have also proven an curiosity in this size, and it might be no surprise in any respect to see extra of those pumps built in the near future for similar functions.”
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