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KSB’s slurry handling success in oil sands

Alberta, Canada has the world’s third largest oil reserves in the type of oil sands. Extracting and processing the oil from the sands and bedrock is a challenging course of and requires the biggest slurry pump in the oil sands trade.
When it comes to pumping slurry, there could be only a few purposes which are more challenging than the hydro-transport of professional quality slurries in oil sands production. Not solely do the pumps have to 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 92 in (2337 mm) impeller, the TBC-92 is the most important and heaviest slurry pump out there in the oil sands trade and the most recent in a line of highly effective high-pressure pumps supplied by GIW.
Slurry transportation Slurry transport covers a considerable vary 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 various 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 important that the slurry passes through the pump with the minimal amount of put on and tear to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump must be able to delivering excessive flows and capable of withstand harsh working environments.
Alberta in Canada has extensive oil reserves and these are in 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 mixed with heat water to form a dense slurry that may be transported in the pipeline in course 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 capable of handling huge quantities of liquids at high pressures and excessive temp- eratures. Drawing on its long expertise of designing slurry pumps for mining, GIW has custom-engineered slurry pumps that combine superior materials, hydraulics and patented mechanical designs, the newest of which is the TBC-92.
Meeting challenges Mollie Timmerman, GIW business improvement manager, explains more: “Our client wanted a higher capacity pump which was capable of 10,000–11,000 m3 per hour of output at nearly 40 m of developed head and a maximum working pressure of 4000 kPa. The pump additionally wanted to be able to move rocks of approximately one hundred thirty mm in diameter with a complete passage size requirement of 10 in (or 254 mm) and deal with slurry densities in excess of 1.5 SG.
In addition, the client was concentrating on a maintenance interval (operational time between planned maintenance) of round three,000 hours. They had expressed an interest in maximising the upkeep intervals and primarily based on preliminary wear indications, they are currently hoping to achieve round 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 where 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 keep these rocks to a manageable measurement for the process, but the high measurement can nonetheless typically attain as much as one hundred thirty mm in diameter or larger.
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 decades of experience in the design of slurry pumps and the development of materials to assist prolong the service life of those critical components to match the planned upkeep cycles within the plant.
“GIW already had a pump capable of the output requirement, this being the MDX-750, which has been a popular size in mill duties for practically 10 years through- out Central and South America,” explains Mollie Timmerman. ”However, the customer’s utility 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 answer for maximised production.”
The TBC series The construction type of GIW’s TBC pump vary features large, ribbed plates held along with tie bolts for very high-pressure service and maximum wear efficiency. First developed for dredge service, then later launched into the oil sands within the Nineties, the TBC pump series has grown into a totally developed vary of pumps serving the oil sands, phosphate, dredging and exhausting rock mining industries for tailings and hydrotransport applications.
The pumps are often grouped together in booster stations to build stress as excessive as 750 psi (5171 kPa) to account for the pipe losses encountered over such lengthy distances. The sturdy construction of the TBC pump is nicely suited to do the job, whereas making certain most availability of the equipment under 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 range is a horizontal, end suction centrifugal pump that provides most resistance to put on. Simple to maintain, the pump’s tie-bolt design transfers stress masses away from the wear and tear resistant white iron casing to the non- bearing facet plates with out using heavy and unwieldy double-wall building.
The TBC-92 combines one of the best parts of earlier TBC models, together with 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 used in heavy-duty mining circuits throughout the world of exhausting rock mining.
In complete, 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 embody a slurry diverter that dramatically will increase suction liner life by decreasing particle recirculation between the impeller and the liner. The giant diameter impeller permits the pump to run at slower speeds in order that wear life is enhanced. The decrease speed additionally gives the pump the flexibility to operate over a wider range of flows so as to accommodate fluctuating circulate circumstances.
To make upkeep simpler, the pump is fitted with a special two-piece suction plate design which helps to reduce device time and provide safer lifting. Customers receive pump-specific lifting gadgets to facilitate the safe removal and installation of wear comp- onents. The pump additionally contains a longlasting suction liner that can be adjusted without needing 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 at all working Canadian oil sands crops for hydrotransport purposes. The TBC-92 has been designed to sort out heavy-duty slurry transport while offering a low complete price of ownership. Minimal labour and maintenance time help to maximise manufacturing and profit.
“This new pump incorporates the teachings realized from working in the oil sands over a few years, and features our latest hydraulic and wear applied sciences,” says Mollie Timmerman. “Because that is the heaviest TBC pump we’ve ever designed, specific attention was given to maintainability, as well as materials selection and construction of the pressure-containing elements.”
เกจวัดถังแก๊ส has established itself as a big drive in pumping options for the oil sands business is far from stunning on situation that it has been creating pumping technologies and put on resistant materials within the world mining industry because the 1940s.
These pumps have had a substantial 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 extremely efficient to pump the slurry along a pipeline to the upgrader. The pipeline agitation assists in separating the bitumen from the sand as it is transported, plus there might be the extra good factor about eradicating using 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 pleasant. These pumps also play a serious position in transporting the coarse tailings to the tailings ponds. GIW supplies pumps used in the extraction course of 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 event of these merchandise. GIW has been obtaining slurry samples from prospects over a few years for testing hydraulics and supplies each for pumps and pipelines. Research & Development facilities embrace 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 improvement programmes. If firms are experiencing problems the GIW R&D personnel can see where the issue lies and supply advice for remedial action. Experience does indicate that in many instances the issue lies not with the pump however, however in the interplay between the pipeline and the pump.
Feedback from customers about appli- cations helps in the growth of recent instruments and pump designs. By bringing to- gether customers and lecturers from all over the world to share their experience and analysis with in-house specialists, the huge investment in research, development and manufacturing has superior the design of the entire GIW pump merchandise,supplies and wear-resistant components.
The future “There is a transparent trend toward larger pumps in mining and dredging and oil sands are not any exception,” comments Leo Perry, GIW lead product manager. “The first TBC pump within the oil sands industry was the TBC-46 (46 in being the diameter of the impeller). Customers are designing their facilities for larger and higher production and demanding the identical of the gear that retains their manufacturing shifting. While these larger pumps demand extra power, additionally they enable for greater manufacturing with less downtime required for upkeep. Overall, the effectivity improves when in comparability with the identical output from a bigger quantity of smaller pumps. “
In conclusion, he says: “Larger pumps go hand-in-hand with larger amenities, bigger pipelines, and increased production, all of which proceed to development greater 12 months after 12 months. Other clients and industries have additionally proven an curiosity on this dimension, and it would be no shock in any respect to see extra of those pumps constructed within the near future for related applications.”
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