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 difficult course of and requires the most important slurry pump in the oil sands business.
When it involves pumping slurry, there may be only a few applications which are tougher than the hydro-transport of skilled quality slurries in oil sands production. Not solely do the pumps need to deal with the extremely aggressive nature of the fluid being pumped, they are also anticipated to operate in a few 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 within the oil sands trade and the latest in a line of powerful high-pressure pumps supplied by GIW.
Slurry transportation Slurry transport covers a substantial range of industry sectors, ranging from meals 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 varying sizes and viscosities. In mining, dredging and oil sands production, the biggest challenge is to accommodate high density slurry and extremely abrasive grits.
It is essential that the slurry passes by way of the pump with the minimal quantity of damage to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump have to be able to delivering high flows and able to face up to harsh working environments.
Alberta in Canada has in depth oil reserves and these are within the form of oil sands. Extracting and processing the oil from the sands and bedrock is challenging, involving the elimination 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 path 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 intensive use of slurry and water transportation pumps capable of handling vast portions of liquids at excessive pressures and high temp- eratures. Drawing on เกจวัดแรงดันอากาศ of designing slurry pumps for mining, GIW has custom-engineered slurry pumps that mix advanced materials, hydraulics and patented mechanical designs, the latest of which is the TBC-92.
Meeting challenges Mollie Timmerman, GIW enterprise growth manager, explains more: “Our consumer needed the next capacity pump which was capable of 10,000–11,000 m3 per hour of output at practically 40 m of developed head and a most working stress of 4000 kPa. The pump additionally wanted to be able to move rocks of approximately 130 mm in diameter with a total passage size requirement of 10 in (or 254 mm) and deal with slurry densities in extra of 1.5 SG.
In addition, the customer was concentrating on a upkeep interval (operational time between planned maintenance) of around 3,000 hours. They had expressed an interest in maximising the maintenance intervals and primarily based on preliminary wear indications, they are at present hoping to realize around 6,000 hours between pump overhauls (i.e. 6–8 months).”
The instant application 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 huge rocks. Screens are in place to maintain these rocks to a manageable size for the process, but the top dimension can still typically reach as much as a hundred thirty mm in diameter or bigger.
The abrasive nature of the slurry is what separates a slurry pump from other pumps used within the trade. Wear and erosion are information of life, and GIW has many years of expertise in the design of slurry pumps and the event of supplies to help lengthen the service life of these crucial 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 software required a pump with higher stress capabilities and the aptitude of dealing with bigger rocks so we responded with the development of the TBC-92 which offered one of the best resolution for maximised production.”
The TBC series The development type of GIW’s TBC pump range features large, ribbed plates held together with tie bolts for very high-pressure service and most wear performance. First developed for dredge service, then later introduced into the oil sands within the 1990s, the TBC pump sequence has grown into a totally developed vary of pumps serving the oil sands, phosphate, dredging and hard rock mining industries for tailings and hydrotransport applications.
The pumps are sometimes grouped collectively in booster stations to build pressure as excessive as 750 psi (5171 kPa) to account for the pipe losses encountered over such lengthy distances. The sturdy building of the TBC pump is well suited to do the job, whereas making certain most availability of the equipment beneath closely abrasive wear.
Capable of delivering stress as much as 37 bar and flows of more than 18,200m³/h and temperatures up to 120o C, the TBC vary is a horizontal, finish suction centrifugal pump that provides maximum resistance to put on. Simple to maintain, the pump’s tie-bolt design transfers stress loads away from the put on and tear resistant white iron casing to the non- bearing side plates without the utilization of heavy and unwieldy double-wall construction.
The TBC-92 combines the most effective elements of earlier TBC fashions, including the TBC-84 oil sands tailing pump, also referred to as the Super Pump. The pump additionally incorporates features from GIW’s MDX product line, which is used in heavy-duty mining circuits throughout the world of onerous 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 features of the pump include 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 speed additionally offers the pump the flexibility to operate over a wider vary of flows to be able to accommodate fluctuating circulate circumstances.
To make upkeep simpler, the pump is fitted with a particular two-piece suction plate design which helps to minimize back software time and supply safer lifting. Customers receive pump-specific lifting units to facilitate the protected removing and set up of wear comp- onents. The pump additionally includes a longlasting suction liner that could be adjusted while not 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 in any respect working Canadian oil sands vegetation for hydrotransport purposes. The TBC-92 has been designed to tackle heavy-duty slurry transport while providing a low total price of possession. Minimal labour and maintenance time assist to maximise production and profit.
“This new pump incorporates the lessons discovered from operating within the oil sands over many years, and options our latest hydraulic and wear technologies,” says Mollie Timmerman. “Because that is the heaviest TBC pump we’ve ever designed, specific attention was given to maintainability, in addition to materials selection and building of the pressure-containing parts.”
That GIW has established itself as a major pressure in pumping solutions for the oil sands business is much from shocking on situation that it has been creating pumping applied sciences and wear resistant materials in the world mining business since the 1940s.
These pumps have had a considerable impact on the way in which that excavated sand, rock and bitumen are transported to the upgrader plant. By adding water to the excavated materials it turns into extremely 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’s transported, plus there may be the extra advantage of removing the use of vans.
GIW has estimated that the value of moving oil sand on this way can cut prices by US$2 a barrel, and it’s much more environmentally pleasant. These pumps additionally play a serious function in transporting the coarse tailings to the tailings ponds. GIW supplies pumps used within the extraction process 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 products. GIW has been obtaining slurry samples from prospects over a few years for testing hydraulics and supplies both for pumps and pipelines. Research & Development facilities include multiple slurry take a look at beds on the campus, along with a hydraulics laboratory that is dedicated to pump performance testing.
These actions are central to the company’s pump growth programmes. If corporations are experiencing problems the GIW R&D personnel can see the place the problem lies and provide recommendation for remedial motion. Experience does point out that in many instances the issue lies not with the pump however, however within the interplay between the pipeline and the pump.
Feedback from customers about appli- cations helps within the growth of new instruments and pump designs. By bringing to- gether clients and academics from everywhere in the world to share their expertise and research with in-house experts, the massive funding in analysis, development and manufacturing has superior the design of all of the GIW pump products,supplies and wear-resistant components.
The future “There is a clear trend toward larger pumps in mining and dredging and oil sands are no exception,” comments 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 facilities for higher and higher production and demanding the same of the equipment that retains their production moving. While these bigger pumps demand extra energy, additionally they permit for greater production with less downtime required for maintenance. Overall, the efficiency improves when compared to the same output from a bigger 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 development larger year after yr. Other prospects and industries have also shown an interest in this size, and it would be no surprise in any respect to see more of these pumps built in the near future for comparable applications.”