KSB’s slurry dealing with success in oil sands

Alberta, Canada has the world’s third largest oil reserves within the form of oil sands. Extracting and processing the oil from the sands and bedrock is a difficult process and requires the most important slurry pump within the oil sands industry.
When it involves pumping slurry, there may be very few applications that are more challenging than the hydro-transport of industrial quality slurries in oil sands manufacturing. Not only do the pumps should deal with the extremely aggressive nature of the fluid being pumped, they are also anticipated to function in some of the harshest environments on the planet.
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, specifically the Tie Bolt Construction (TBC-92). Named after its ninety two in (2337 mm) impeller, the TBC-92 is the most important and heaviest slurry pump obtainable in the oil sands business and the latest 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 food and beverage to mining. What is frequent to all, is that the pumps used should have the flexibility to transport liquids containing particles and solids of various sizes and viscosities. In mining, dredging and oil sands manufacturing, the largest challenge is to accommodate excessive density slurry and highly abrasive grits.
It is important that the slurry passes via the pump with the minimal amount of damage to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump have to be able to delivering excessive flows and in a position to face 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 removing of bituminous ore which is transported to a crushing plant. The crushed ore is then combined with heat water to form a dense slurry that can be transported within the pipeline in the course 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 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 long experience of designing slurry pumps for mining, GIW has custom-engineered slurry pumps that mix superior supplies, hydraulics and patented mechanical designs, the most recent of which is the TBC-92.
Meeting challenges Mollie Timmerman, GIW business development manager, explains more: “Our consumer wanted a higher capacity pump which was able to 10,000–11,000 m3 per hour of output at almost forty m of developed head and a most working stress of 4000 kPa. The pump additionally wanted to find a way to cross rocks of approximately one hundred thirty mm in diameter with a complete passage size requirement of 10 in (or 254 mm) and handle slurry densities in extra of 1.5 SG.
In addition, the shopper was targeting a maintenance 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 wear indications, they’re presently hoping to realize 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 where they’re 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. digital pressure gauge ราคา are in place to keep these rocks to a manageable size for the process, but the top measurement can still usually attain up to 130 mm in diameter or larger.
The abrasive nature of the slurry is what separates a slurry pump from other pumps used in the industry. Wear and erosion are facts of life, and GIW has many years of experience in the design of slurry pumps and the event of supplies to assist lengthen the service life of those critical parts 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 size in mill duties for practically 10 years through- out Central and South America,” explains Mollie Timmerman. ”However, the customer’s application required a pump with greater strain capabilities and the potential of dealing with bigger rocks so we responded with the development of the TBC-92 which provided the best resolution for maximised production.”
The TBC sequence The construction style of GIW’s TBC pump vary options massive, ribbed plates held along 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 completely developed range of pumps serving the oil sands, phosphate, dredging and onerous rock mining industries for tailings and hydrotransport functions.
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 long distances. The sturdy development of the TBC pump is nicely suited to do the job, while ensuring maximum availability of the tools under heavily abrasive put on.
Capable of delivering pressure up to 37 bar and flows of more than 18,200m³/h and temperatures as much as 120o C, the TBC vary is a horizontal, finish suction centrifugal pump that provides maximum resistance to put on. Simple to keep up, the pump’s tie-bolt design transfers stress loads away from the wear resistant white iron casing to the non- bearing facet plates with out the usage of heavy and unwieldy double-wall construction.
The TBC-92 combines the best parts of earlier TBC fashions, together with the TBC-84 oil sands tailing pump, also called the Super Pump. The pump additionally incorporates features from GIW’s MDX product line, which is utilized in heavy-duty mining circuits all through the world of hard 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 will increase suction liner life by decreasing particle recirculation between the impeller and the liner. The large diameter impeller permits the pump to run at slower speeds so that put on life is enhanced. The decrease pace also gives the pump the flexibility to function over a wider range of flows to have the ability to accommodate fluctuating circulate situations.
To make upkeep simpler, the pump is fitted with a special two-piece suction plate design which helps to reduce software time and supply safer lifting. Customers receive pump-specific lifting units to facilitate the protected elimination and installation of wear comp- onents. The pump also includes a longlasting suction liner that can 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 operating Canadian oil sands crops for hydrotransport purposes. The TBC-92 has been designed to tackle heavy-duty slurry transport whereas providing a low complete value of ownership. Minimal labour and maintenance time help to maximise manufacturing and revenue.
“This new pump incorporates the teachings realized from working within the oil sands over a few years, and features our latest hydraulic and wear technologies,” says Mollie Timmerman. “Because this is the heaviest TBC pump we’ve ever designed, specific attention was given to maintainability, as nicely as material choice and development of the pressure-containing elements.”
That GIW has established itself as a significant force in pumping options for the oil sands trade is way from shocking provided that it has been creating pumping applied sciences and put on resistant supplies within the international mining business because the Nineteen Forties.
These pumps have had a considerable impact on the way that excavated sand, rock and bitumen are transported to the upgrader plant. By including water to the excavated materials it turns into 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 extra benefit of eradicating using trucks.
GIW has estimated that the value of shifting oil sand on this method can minimize costs by US$2 a barrel, and it’s much more environmentally pleasant. These pumps also play a serious role 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 the way they behave when being pumped has been fundamental to the development of those products. GIW has been acquiring slurry samples from clients over many years for testing hydraulics and supplies each for pumps and pipelines. Research & Development amenities embody multiple slurry check beds on the campus, along with a hydraulics laboratory that is dedicated to pump efficiency 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 issue lies and offer advice for remedial action. Experience does indicate that in many circumstances the problem lies not with the pump nonetheless, but in the interaction between the pipeline and the pump.
Feedback from clients about appli- cations helps in the improvement of new tools and pump designs. By bringing to- gether customers and academics from everywhere in the world to share their experience and analysis with in-house consultants, the large funding in analysis, development and manufacturing has superior the design of all the GIW pump products,materials and wear-resistant components.
The future “There is a transparent trend towards larger pumps in mining and dredging and oil sands aren’t any exception,” comments Leo Perry, GIW lead product manager. “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 greater and better production and demanding the same of the tools that keeps their manufacturing moving. While these larger pumps demand extra power, they also permit for larger manufacturing with much less downtime required for maintenance. Overall, the effectivity improves when in comparability 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 proceed to development higher yr after year. Other clients and industries have also proven an curiosity on this measurement, and it might be no shock in any respect to see more of these pumps constructed in the near future for related applications.”

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