KSB’s slurry dealing with success in oil sands

Alberta, Canada has the world’s third largest oil reserves in the form of oil sands. Extracting and processing the oil from the sands and bedrock is a difficult process and requires the largest slurry pump within the oil sands business.
When it involves pumping slurry, there may be very few functions that are more difficult than the hydro-transport of professional quality slurries in oil sands production. Not only do the pumps have to cope with the extremely aggressive nature of the fluid being pumped, they are additionally expected 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 ninety two in (2337 mm) impeller, the TBC-92 is the largest and heaviest slurry pump out there in the oil sands business and the most recent in a line of highly effective high-pressure pumps offered by GIW.
Slurry transportation Slurry transport covers a substantial range of business sectors, ranging from meals and beverage to mining. What is widespread to all, is that the pumps used should have the ability to transport liquids containing particles and solids of various sizes and viscosities. In mining, dredging and oil sands production, the most important problem is to accommodate high density slurry and highly abrasive grits.
It is crucial that the slurry passes via the pump with the minimum quantity of wear and tear to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump have to be capable of delivering high flows and capable of withstand harsh operating 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 blended with warm water to form a dense slurry that could be transported within the pipeline towards 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 different pumps to settling ponds.
The processes require intensive use of slurry and water transportation pumps able to handling huge portions of liquids at high 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 latest of which is the TBC-92.
Meeting challenges Mollie Timmerman, GIW enterprise improvement manager, explains extra: “Our shopper wanted the next capability pump which was able to 10,000–11,000 m3 per hour of output at practically 40 m of developed head and a maximum working stress of 4000 kPa. The pump also wanted to have the ability to pass rocks of approximately a hundred thirty mm in diameter with a total passage measurement 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 upkeep interval (operational time between deliberate maintenance) of round 3,000 hours. They had expressed an curiosity in maximising the maintenance intervals and based mostly on initial wear indications, they’re currently hoping to attain around 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 the place they are used to maneuver bitu- minous ore from the crusher to the extraction plant. The liquid pumped is a combination of water, bitumen, sand, and enormous rocks. Screens are in place to maintain these rocks to a manageable size for the process, but the top dimension can nonetheless usually attain up to a 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 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 help lengthen the service life of those important elements to match the deliberate upkeep cycles within the plant.
“GIW already had a pump capable of the output requirement, this being the MDX-750, which has been a preferred size in mill duties for nearly 10 years through- out Central and South America,” explains Mollie Timmerman. ”However, the customer’s software required a pump with larger pressure capabilities and the capability of handling bigger rocks so we responded with the development of the TBC-92 which provided the best resolution for maximised manufacturing.”
The TBC sequence The building style of GIW’s TBC pump vary options giant, ribbed plates held along with tie bolts for very high-pressure service and maximum put on performance. First developed for dredge service, then later introduced into the oil sands in the 1990s, the TBC pump sequence has grown into a fully developed vary of pumps serving the oil sands, phosphate, dredging and onerous rock mining industries for tailings and hydrotransport applications.
The pumps are sometimes grouped together in booster stations to construct stress 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, while guaranteeing most availability of the gear beneath heavily abrasive wear.
Capable of delivering stress as a lot 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 most resistance to wear. Simple to hold up, the pump’s tie-bolt design transfers stress loads away from the wear and tear resistant white iron casing to the non- bearing side plates without the usage of heavy and unwieldy double-wall building.
The TBC-92 combines one of the best components 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 used in heavy-duty mining circuits throughout the world of onerous rock mining.
In total, 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 embody a slurry diverter that dramatically increases suction liner life by reducing particle recirculation between the impeller and the liner. The giant diameter impeller permits the pump to run at slower speeds so that put on life is enhanced. The lower velocity additionally provides the pump the ability to operate over a wider vary of flows so as to accommodate fluctuating flow circumstances.
To make upkeep easier, the pump is fitted with a special two-piece suction plate design which helps to reduce back software time and provide safer lifting. Customers receive pump-specific lifting units to facilitate the protected elimination and set up of wear and tear comp- onents. The pump additionally contains a longlasting suction liner that might 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 plants for hydrotransport functions. 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 help to maximise production and revenue.
“This new pump incorporates the lessons discovered from operating in the oil sands over many years, and features our newest hydraulic and wear applied sciences,” says Mollie Timmerman. “Because that is the heaviest TBC pump we now have ever designed, particular attention was given to maintainability, in addition to material choice and development of the pressure-containing parts.”
That GIW has established itself as a big drive in pumping solutions for the oil sands trade is far from shocking given that it has been growing pumping technologies and put on resistant supplies in the global mining industry 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 materials it becomes highly 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 is the additional good factor about eradicating the use of vans.
GIW has estimated that the value of transferring oil sand on this way can cut costs by US$2 a barrel, and it is far more environmentally friendly. These pumps also play a significant role in transporting the coarse tailings to the tailings ponds. GIW provides เกจวัดความดันแก๊ส used within the extraction course of and different areas of production (HVF, MDX, LSA).
Understanding slurries Understanding the character of slurries and the way they behave when being pumped has been basic to the event of those products. GIW has been obtaining slurry samples from customers over many years for testing hydraulics and supplies each for pumps and pipelines. Research & Development amenities include a number of slurry check 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 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 circumstances the problem lies not with the pump however, but within the interaction between the pipeline and the pump.
Feedback from customers about appli- cations helps in the growth of recent tools and pump designs. By bringing to- gether prospects and academics from all over the world to share their experience and research with in-house specialists, the large funding in research, improvement and manufacturing has advanced the design of all of the GIW pump merchandise,supplies and wear-resistant components.
The future “There is a transparent pattern toward larger pumps in mining and dredging and oil sands are not any 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 amenities for larger and higher manufacturing and demanding the same of the tools that retains their production shifting. While these larger pumps demand extra energy, additionally they enable for higher production with much less downtime required for maintenance. 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 larger amenities, bigger pipelines, and elevated manufacturing, all of which proceed to pattern larger 12 months after yr. Other prospects and industries have also proven an curiosity in this measurement, and it would be no surprise at all to see more of these pumps built in the close to future for comparable purposes.”

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