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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 largest slurry pump within the oil sands trade.
When it comes to pumping slurry, there could be very few purposes that are tougher than the hydro-transport of industrial quality slurries in oil sands production. Not solely do the pumps have to cope with the extremely aggressive nature of the fluid being pumped, they are also anticipated to operate in a number 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 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 highly effective high-pressure pumps supplied by GIW.
Slurry transportation Slurry transport covers a considerable vary of trade sectors, ranging from food and beverage to mining. What is common 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 manufacturing, the biggest challenge is to accommodate high density slurry and extremely abrasive grits.
It is important that the slurry passes via the pump with the minimum quantity of wear to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump should be capable of delivering high flows and able to face up to harsh operating environments.
Alberta in Canada has intensive 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 removal of bituminous ore which is transported to a crushing plant. The crushed ore is then mixed with warm water to form a dense slurry that may be transported within the pipeline in the path of extraction, where the bitumen is separated from the sand and rock. After extraction, the remaining solids (or tailings) are sometimes transported via totally different pumps to settling ponds.
The processes require in depth use of slurry and water transportation pumps able to dealing with huge quantities of liquids at high pressures and high temp- eratures. Drawing on its long experience 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 extra: “Our client needed a higher capacity pump which was capable of 10,000–11,000 m3 per hour of output at almost 40 m of developed head and a most working stress of 4000 kPa. The pump also wanted to have the ability to pass rocks of roughly one hundred thirty mm in diameter with a total passage dimension requirement of 10 in (or 254 mm) and handle slurry densities in extra of 1.5 SG.
In addition, the customer was focusing on a maintenance interval (operational time between planned maintenance) of around three,000 hours. They had expressed an curiosity in maximising the upkeep intervals and primarily based on preliminary put on indications, they’re currently 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 combination of water, bitumen, sand, and large rocks. Screens are in place to keep these rocks to a manageable dimension for the process, however the top measurement can nonetheless usually attain 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 trade. Wear and erosion are information of life, and GIW has decades of expertise within the design of slurry pumps and the event of materials to help lengthen the service life of these 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 well-liked 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 strain capabilities and the potential of handling bigger rocks so we responded with the development of the TBC-92 which supplied one of the best answer for maximised manufacturing.”
The TBC series The building fashion of GIW’s TBC pump range features large, ribbed plates held together with tie bolts for very high-pressure service and maximum wear efficiency. First developed for dredge service, then later introduced into the oil sands in the Nineteen Nineties, the TBC pump sequence has grown into a completely 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 construct pressure as high as 750 psi (5171 kPa) to account for the pipe losses encountered over such lengthy distances. The strong building of the TBC pump is properly suited to do the job, whereas ensuring maximum availability of the equipment under closely abrasive wear.
Capable of delivering pressure up to 37 bar and flows of greater than 18,200m³/h and temperatures as a lot as 120o C, the TBC vary is a horizontal, end suction centrifugal pump that provides maximum resistance to put on. Simple to take care of, 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 with out the usage of heavy and unwieldy double-wall building.
The TBC-92 combines the best parts of earlier TBC fashions, including the TBC-84 oil sands tailing pump, also recognized as the Super Pump. The pump also 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 equal to a fully-loaded Airbus A321 aeroplane. The casing alone weighs 34,000 lbs (15,500 kg). Key options of the pump embody a slurry diverter that dramatically will increase 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 so that wear life is enhanced. The decrease pace additionally provides the pump the ability to function over a wider vary of flows to have the ability to accommodate fluctuating move situations.
To make upkeep easier, the pump is fitted with a particular two-piece suction plate design which helps to minimize back tool time and provide safer lifting. Customers receive pump-specific lifting units to facilitate the secure removal and installation of damage comp- onents. The pump additionally features a longlasting suction liner that could 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 in any respect operating Canadian oil sands crops for hydrotransport purposes. The TBC-92 has been designed to deal with heavy-duty slurry transport while providing a low total cost of possession. Minimal labour and maintenance time help to maximise production 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 technologies,” says Mollie Timmerman. “Because this is the heaviest TBC pump we now have ever designed, specific attention was given to maintainability, as well as materials selection and construction of the pressure-containing components.”
That GIW has established itself as a significant drive in pumping solutions for the oil sands industry is much from shocking provided that it has been developing pumping applied sciences and wear resistant materials in the global mining trade for the explanation that Forties.
These pumps have had a considerable impact on the way that excavated sand, rock and bitumen are transported to the upgrader plant. By adding water to the excavated material it becomes 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 is transported, plus there’s the additional good factor about removing the usage of trucks.
GIW has estimated that the worth of moving oil sand in this method can minimize prices by US$2 a barrel, and it’s way more environmentally pleasant. These pumps also play a major role in transporting the coarse tailings to the tailings ponds. GIW provides pumps used in the extraction course of and different areas of production (HVF, MDX, LSA).
Understanding slurries Understanding the nature of slurries and how they behave when being pumped has been elementary to the development of these products. GIW has been acquiring slurry samples from clients over many years for testing hydraulics and supplies each for pumps and pipelines. ที่วัดแรงดัน & Development services embody multiple slurry test beds on the campus, along with a hydraulics laboratory that is devoted to pump performance testing.
These activities are central to the company’s pump growth programmes. If companies are experiencing problems the GIW R&D personnel can see the place the problem lies and supply recommendation for remedial action. Experience does indicate that in lots of circumstances the problem lies not with the pump however, however within the interaction between the pipeline and the pump.
Feedback from customers about appli- cations helps within the improvement of new instruments and pump designs. By bringing to- gether customers and teachers from everywhere in the world to share their expertise and analysis with in-house specialists, the massive investment in research, improvement and manufacturing has advanced the design of all of the GIW pump merchandise,materials and wear-resistant elements.
The future “There is a clear development towards larger pumps in mining and dredging and oil sands aren’t any exception,” feedback Leo Perry, GIW lead product manager. “The first TBC pump in the oil sands industry was the TBC-46 (46 in being the diameter of the impeller). Customers are designing their amenities for higher and better production and demanding the identical of the tools that keeps their manufacturing transferring. While these larger pumps demand more power, in addition they enable for larger production with much less downtime required for maintenance. Overall, the efficiency improves when in comparison with the same output from a larger amount of smaller pumps. “
In conclusion, he says: “Larger pumps go hand-in-hand with bigger amenities, larger pipelines, and elevated production, all of which continue to pattern larger year after 12 months. Other prospects and industries have also proven an curiosity in this dimension, and it might be no surprise at all to see extra of those pumps constructed within the close to future for similar applications.”