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 biggest slurry pump in the oil sands industry.
When it comes to pumping slurry, there could be very few applications that are tougher than the hydro-transport of industrial quality slurries in oil sands manufacturing. Not solely do the pumps have to cope with the highly aggressive nature of the fluid being pumped, they are additionally anticipated to operate in a number of the harshest environments in the world.
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, specifically 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 business and the newest in a line of powerful high-pressure pumps supplied by GIW.
Slurry transportation Slurry transport covers a substantial vary of trade sectors, ranging from food and beverage to mining. What is frequent to all, is that the pumps used must be capable of transport liquids containing particles and solids of varying sizes and viscosities. In mining, dredging and oil sands manufacturing, the most important problem is to accommodate excessive density slurry and extremely abrasive grits.
It is crucial that the slurry passes through the pump with the minimal quantity of wear to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump should be able to delivering excessive flows and capable of withstand harsh working environments.
Alberta in Canada has in depth oil reserves and these are in the form 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 heat water to form a dense slurry that can be transported in 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 often transported by way of totally different pumps to settling ponds.
The processes require intensive use of slurry and water transportation pumps capable of dealing with huge quantities of liquids at excessive pressures and excessive temp- eratures. Drawing on its lengthy experience of designing slurry pumps for mining, GIW has custom-engineered slurry pumps that mix advanced materials, hydraulics and patented mechanical designs, the most recent of which is the TBC-92.
Meeting challenges Mollie Timmerman, GIW business growth manager, explains more: “Our client wanted the next capability pump which was able to 10,000–11,000 m3 per hour of output at almost 40 m of developed head and a maximum working pressure of 4000 kPa. The pump additionally needed to have the ability to cross rocks of approximately 130 mm in diameter with a complete passage dimension requirement of 10 in (or 254 mm) and handle slurry densities in extra of 1.5 SG.
In addition, the client was focusing on a upkeep interval (operational time between deliberate maintenance) of around 3,000 hours. They had expressed an interest in maximising the upkeep intervals and primarily based on preliminary put on indications, they’re at present hoping to attain around 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 where they are used to move bitu- minous ore from the crusher to the extraction plant. The liquid pumped is a mix of water, bitumen, sand, and enormous rocks. Screens are in place to keep these rocks to a manageable size for the process, however the top size 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 details of life, and GIW has many years of experience within the design of slurry pumps and the development of supplies to assist lengthen the service life of these critical elements to match the planned upkeep cycles in the plant.
“GIW already had a pump capable of the output requirement, this being the MDX-750, which has been a well-liked 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 strain capabilities and the potential of dealing with bigger rocks so we responded with the event of the TBC-92 which supplied the most effective solution for maximised production.”
The TBC sequence The building fashion 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 in the Nineties, the TBC pump collection has grown into a totally developed range of pumps serving the oil sands, phosphate, dredging and exhausting rock mining industries for tailings and hydrotransport applications.
The pumps are sometimes grouped collectively in booster stations to construct stress as high 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, whereas ensuring maximum availability of the tools under heavily abrasive wear.
Capable of delivering stress up to 37 bar and flows of greater than 18,200m³/h and temperatures up to 120o C, the TBC range is a horizontal, finish suction centrifugal pump that gives most resistance to put on. Simple to take care of, 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 with out the utilization of heavy and unwieldy double-wall building.
The TBC-92 combines the most effective parts of earlier TBC models, including the TBC-84 oil sands tailing pump, also called 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 onerous rock mining.
In complete, 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 options of the pump include a slurry diverter that dramatically increases suction liner life by decreasing particle recirculation between the impeller and the liner. The massive diameter impeller allows the pump to run at slower speeds in order that wear life is enhanced. The decrease velocity also provides the pump the power to operate over a wider vary of flows to have the ability to accommodate fluctuating move conditions.
To make maintenance simpler, the pump is fitted with a special two-piece suction plate design which helps to reduce back software time and supply safer lifting. Customers obtain pump-specific lifting units to facilitate the safe removal and set up of put on and tear comp- onents. The pump additionally includes a longlasting suction liner that can be adjusted while not having to shut 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 operating Canadian oil sands vegetation for hydrotransport applications. The TBC-92 has been designed to tackle heavy-duty slurry transport while offering a low whole price of possession. Minimal labour and upkeep time help to maximise production and profit.
“This new pump incorporates the lessons realized from working in the oil sands over a few years, and features 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 well as material choice and development of the pressure-containing elements.”
That GIW has established itself as a significant drive in pumping options for the oil sands business is way from surprising on condition that it has been growing pumping applied sciences and put on resistant materials in the world mining industry because the Forties.
These pumps have had a substantial impact 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 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’s the additional benefit of removing the use of trucks.
GIW has estimated that the price of moving oil sand in this means can minimize costs by US$2 a barrel, and it is much more environmentally pleasant. These pumps also play a major role in transporting the coarse tailings to the tailings ponds. GIW supplies pumps used within the extraction course of and different areas of production (HVF, MDX, LSA).
Understanding slurries Understanding the character of slurries and how they behave when being pumped has been basic to the development of those merchandise. GIW has been acquiring slurry samples from customers 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 performance testing.
These actions are central to the company’s pump improvement programmes. If firms are experiencing problems the GIW R&D personnel can see where the problem lies and provide recommendation for remedial motion. Experience does indicate that in many cases the issue lies not with the pump nonetheless, but within the interplay between the pipeline and the pump.
Feedback from prospects about appli- cations helps within the improvement of recent instruments and pump designs. By bringing to- gether prospects and academics from all round the world to share their expertise and research with in-house specialists, the massive investment in analysis, improvement and manufacturing has advanced the design of all the GIW pump merchandise,materials and wear-resistant elements.
pressure gauge trerice ราคา There is a transparent trend toward bigger pumps in mining and dredging and oil sands aren’t any exception,” feedback Leo Perry, GIW lead product supervisor. “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 manufacturing and demanding the identical of the gear that retains their production moving. While these bigger pumps demand more power, additionally they enable for greater manufacturing with much less downtime required for maintenance. Overall, the effectivity improves when in comparability with the same output from a bigger quantity of smaller pumps. “
In conclusion, he says: “Larger pumps go hand-in-hand with larger facilities, bigger pipelines, and increased production, all of which continue to trend higher 12 months after 12 months. Other prospects and industries have additionally shown an interest in this size, and it will be no shock in any respect to see more of these pumps built within the near future for related applications.”