KSB’s slurry dealing with success in oil sands

Alberta, Canada has the world’s third largest oil reserves within 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 in the oil sands industry.
When it involves pumping slurry, there may be very few applications which might be more challenging than the hydro-transport of industrial quality slurries in oil sands production. Not solely do the pumps should contend with the extremely aggressive nature of the fluid being pumped, they are additionally expected 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 available 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 substantial vary of industry sectors, starting from food and beverage to mining. What is common to all, is that the pumps used must have the power to transport liquids containing particles and solids of varying sizes and viscosities. In mining, dredging and oil sands manufacturing, the biggest 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 damage to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump should be able to delivering high flows and in a place to stand up to harsh working 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 challenging, involving the removal of bituminous ore which is transported to a crushing plant. The crushed ore is then mixed with heat water to kind a dense slurry that can be transported in the pipeline towards extraction, where the bitumen is separated from the sand and rock. After extraction, the remaining solids (or tailings) are often transported through completely different pumps to settling ponds.
The processes require in depth use of slurry and water transportation pumps capable of handling vast portions of liquids at excessive pressures and excessive 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 latest of which is the TBC-92.
Meeting challenges Mollie Timmerman, GIW enterprise improvement supervisor, explains more: “Our consumer needed the next capacity pump which was capable of 10,000–11,000 m3 per hour of output at almost 40 m of developed head and a maximum working stress of 4000 kPa. The pump also needed to be able to pass rocks of roughly 130 mm in diameter with a complete passage measurement requirement of 10 in (or 254 mm) and handle slurry densities in excess of 1.5 SG.
In addition, the customer was concentrating on a upkeep interval (operational time between planned maintenance) of around three,000 hours. They had expressed an curiosity in maximising the maintenance intervals and based on initial put on indications, they’re presently hoping to achieve round 6,000 hours between pump overhauls (i.e. 6–8 months).”
The instant utility for the primary batch of GIW’s TBC-92 pumps in Alberta is in hydro-transport service the place they’re used to maneuver bitu- minous ore from the crusher to the extraction plant. The liquid pumped is a mixture of water, bitumen, sand, and huge rocks. Screens are in place to maintain these rocks to a manageable size for the process, however the prime measurement can still often reach up to a hundred thirty mm in diameter or larger.
The abrasive nature of the slurry is what separates a slurry pump from other pumps used within the industry. Wear and erosion are information of life, and GIW has a long time of expertise within the design of slurry pumps and the development of materials to assist extend the service life of these critical components to match the planned 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 measurement in mill duties for almost 10 years through- out Central and South America,” explains Mollie Timmerman. ”However, the customer’s application required a pump with higher strain capabilities and the capability of handling larger rocks so we responded with the development of the TBC-92 which offered one of the best answer for maximised manufacturing.”
The TBC series The construction type of GIW’s TBC pump vary features massive, ribbed plates held together with tie bolts for very high-pressure service and maximum put on performance. First developed for dredge service, then later launched into the oil sands within the Nineties, the TBC pump sequence has grown into a completely developed range of pumps serving the oil sands, phosphate, dredging and exhausting rock mining industries for tailings and hydrotransport functions.
The pumps are often grouped collectively in booster stations to construct strain as excessive as 750 psi (5171 kPa) to account for the pipe losses encountered over such lengthy distances. The sturdy development of the TBC pump is well suited to do the job, while guaranteeing maximum availability of the tools beneath heavily abrasive wear.
Capable of delivering pressure as much as 37 bar and flows of more than 18,200m³/h and temperatures up to 120o C, the TBC range is a horizontal, end suction centrifugal pump that provides maximum resistance to put on. Simple to maintain up, the pump’s tie-bolt design transfers stress hundreds away from the put on and tear resistant white iron casing to the non- bearing facet plates without the usage of heavy and unwieldy double-wall development.
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 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 equivalent to a fully-loaded Airbus A321 aeroplane. The casing alone weighs 34,000 lbs (15,500 kg). Key options of the pump include a slurry diverter that dramatically increases suction liner life by lowering particle recirculation between the impeller and the liner. The giant diameter impeller permits the pump to run at slower speeds in order that put on life is enhanced. The decrease pace also provides the pump the ability to function over a wider range of flows in order to accommodate fluctuating flow circumstances.
To make maintenance simpler, the pump is fitted with a special two-piece suction plate design which helps to cut back device time and provide safer lifting. Customers obtain pump-specific lifting gadgets to facilitate the secure removal and set up of wear and tear comp- onents. The pump also includes a longlasting suction liner that might be adjusted without having 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 in any respect working Canadian oil sands vegetation for hydrotransport purposes. The TBC-92 has been designed to sort out heavy-duty slurry transport whereas offering a low whole value of ownership. Minimal labour and upkeep time help to maximise manufacturing and revenue.
“This new pump incorporates the lessons learned from operating within the oil sands over a few years, and features our latest hydraulic and put on applied sciences,” says Mollie Timmerman. “Because that is the heaviest TBC pump we now have ever designed, particular attention was given to maintainability, as properly as material choice and building of the pressure-containing parts.”
That GIW has established itself as a major force in pumping options for the oil sands business is much from surprising on situation that it has been growing pumping applied sciences and wear resistant materials within the world mining business since the Nineteen Forties.
These pumps have had a substantial impression 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 turns into extremely environment friendly 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 is the extra benefit of removing the usage of vehicles.
GIW has estimated that เพรสเชอร์เกจวัดแรงดันน้ำ of moving oil sand on this means can minimize prices by US$2 a barrel, and it is far more environmentally friendly. These pumps also play a serious function in transporting the coarse tailings to the tailings ponds. GIW supplies pumps used within the extraction course of 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 fundamental to the development of these products. GIW has been obtaining slurry samples from prospects over a few years for testing hydraulics and materials both for pumps and pipelines. Research & Development amenities embody a quantity of slurry test beds on the campus, together with a hydraulics laboratory that is devoted to pump performance testing.
These actions are central to the company’s pump development programmes. If companies are experiencing problems the GIW R&D personnel can see where the issue lies and supply advice for remedial motion. Experience does indicate that in many circumstances the issue 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 recent instruments and pump designs. By bringing to- gether prospects and teachers from everywhere in the world to share their expertise and research with in-house specialists, the large investment in research, growth and manufacturing has superior the design of the entire GIW pump merchandise,materials and wear-resistant elements.
The future “There is a transparent trend toward bigger pumps in mining and dredging and oil sands are no exception,” comments 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 amenities for larger and better production and demanding the identical of the equipment that keeps their production shifting. While these larger pumps demand extra energy, additionally they allow for greater manufacturing with less downtime required for upkeep. Overall, the efficiency improves when in comparison with the same output from a larger quantity of smaller pumps. “
In conclusion, he says: “Larger pumps go hand-in-hand with bigger amenities, larger pipelines, and increased production, all of which continue to trend greater year after 12 months. Other prospects and industries have additionally shown an curiosity in this dimension, and it might be no shock in any respect to see extra of these pumps built in the near future for related functions.”
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