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Copyright FELUWA Pumpen GmbH Applied Bionics in Pumps for Hydrotransport Rudolf Gänsl – Managing Director

Feluwa applied bionics in pumps for hydrotranport & process

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Postitive Displacement Diaphragm Piston Pumps engineered and made by FELUWA in Germany

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Page 1: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH

Applied Bionics in Pumps for Hydrotransport

Rudolf Gänsl – Managing Director

Page 2: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH2

Basics for Hydrotransport

Page 3: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH3

Basics for Hydrotransport

• Our customers handle and transport through pipes

heterogeneous, abrasive and corrosive media with a defined viscosity

• The Competing Systems are:

• train

• truck

• belt

• and comes to pipelines – centrifugal pumps

Page 4: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH4

Displacement vs. Centrifugal Pumps

• Centrifugal Pumps

• use excess water to transport solids

# Dealing with the rescource WATER

# Excessive energy consumption due the excess WATER

• have a hydraulic efficiency of 70% (if new)

Double Hose-Diaphram Pumps have 97%

# energy consumption of PD pumps is 15-25% better

• due to up to 35 m/s impellers and wear plates are worn within 2000h

Double Hose-Diaphragm will stand 8000 h and more.

# cost for the parts, recycling cost, environm., CO2, (pro PD)

# operation safty and reliability (pro PD see Multisafe)

Page 5: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH5

Pump Characteristic- Centrifugal versus PD Pump -

Pre

ssu

re[b

ar]

Capacity [m³/h]

He

ad

[b

ar]

Capacity [m³/h]

Centrifugal Pump-Train Positive Displacement Pump

Speed

Page 6: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH6

Displacement vs. Centrifugal Pumps

• Decission Process

• In case the question of the owner is:

„when do I have the first ROI“

– Centrifugal Slurry Pumps will be the choice

• In cases the question is:

„what is the total ROI for the livetime of the mine and equipment“

- the first choice in any case is the

Piston-Diaphragm-Pump

Page 7: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH7

Project Dimensions

Slurry capacity pressure distance Pumps/P.Station

(m³/h) (bar) (km) (Nos.)

• Bauxit 2000 90 240 1

• Cu/Zn 2500 140 300 4

• Bauxit 500 250 150 1

• Cu/Ni/Co 2250 50 10 1

• Minerals 1500 130 700 6

Page 8: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH8

Evolution and Characteristics of Hose-Diaphragm Pumps

Bionics in Pumps

or the

Page 9: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH9

Piston

Evolution of Hose-Diaphragm Pumps- Piston Pump -

Inlet

Outlet

Check valve

(One-way valve)

Page 10: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH10

Evolution of Hose-Diaphragm Pumps - Piston Pump -

Piston

Inlet

Outlet

Suction stroke

Piston

Inlet

Outlet

Discharge stroke

Page 11: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH11

Piston Pump and Hose-Diaphragm Pump

Piston

Inlet

Outlet

Piston

Inlet

Outlet

Flexible hose

Hydraulic liquid

Page 12: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH12

Evolution of Pumps- Hose-Diaphragm Pump -

Piston

Inlet

Outlet

Piston

Inlet

Outlet

Piston in rear position

=

End of suction stroke

Piston in front position

=

End of discharge stroke

Page 13: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH13

Evolution of Pumps- Hose-Diaphragm Pump -

Piston

Inlet

Outlet DiaphragmHousing

Pumped medium

Hydraulic liquid

Page 14: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH14

MULTISAFE Pumps- Double Hose-Diaphragm Pump -

End of suction stroke End of discharge stroke

Second

diaphragm

Page 15: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH15

Evolution of Pumps- Hose-Diaphragm Pump -

• Hydrostatic Pressure by

surrounding hydraulic liquid

• Pressure inside and outside

the diaphragm is equal

• Hose-diaphragm is not

covering any pressure,

except for static load

• Medium in contact with

diaphragm only

Page 16: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH16

Evolution of FELUWA MULTISAFE Pumpthe unique MULTISAFE Double-Hose-Diaphragm Pump since 2000

FELUWA 1960 traditional design

FELUWA from 1970hose diaphragm

FELUWA - MULTISAFE Double-Hose-Diaphragm

Page 17: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH17

MULTISAFE Pumps- Double Hose-Diaphragm -

Inner

diaphragm

Outer

diaphragm

Both hose-diaphragms

are in direct contact

Double safety

Hose-diaphragms are

never stretched!

Page 18: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH18

Double Hose-Diaphragm Pumps - Working Principle -

Copyright FELUWA Pumpen GmbH

Page 19: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH19

• Double safety due to two hose-diaphragms

• Hermetically sealing between medium,

hydraulic drive system and environment

• Linear flow path without deviations

• Less or no sedimentation

• No dead pockets

• Pump housing is never in contact with the medium

• Small and compact pump head

• Fast volume exchange in pump head

• High efficiency – high energy savings

Hydraulic Efficiency: > 97%

Overall Efficiency: > 85%

Double Hose-Diaphragm Pumps - Advantages -

Page 20: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH20

FELUWA Standard Range

Page 21: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH21

FELUWA MULTISAFE QuintuplexDouble Hose-Diaphragm Pump

MULTISAFE Quintuplexpumps provide

lowest pulsations

5 Heads

Up to 1000m³/h – 4400gpm

Up to 320bar – 4640psi

Page 22: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH22

Cost Efficiency

Energy

Efficiency Availibility

Investment

Maintenance

SparesLifetime

Page 23: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH23

Cost Efficiency of MULTISAFE Pumps

EnergyEnergyEfficiencyEfficiency

AvailibilityAvailibility

InvestmentInvestmentand

Operating Exp. MaintenanceMaintenance

Costs for SparesCosts for Spares

LifetimeLifetime

Changing TimeChanging Time

Valve SystemValve System

Ball ValvesBall Valves

Quick ChangeQuick Change

DiagnosticDiagnostic

Multiple PumpMultiple PumpControl

DowntimesDowntimes

DownflowDownflow

MULTISAFE

Double Hose-Diaphragm Pump

Page 24: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH24

Double Hose-Diaphragm Pumps- Pressure sensor -

Foliennr.

• Pressure detection of the area in

between the two hose-diaphragms

• Normally pressure free

• Pressure increases if one diaphragm

fails

• Alarm is set if one hose-diaphragm

fails

• Pump operation can be continued

without any restriction until the

system allows for a shutdown and

repair.

Page 25: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH25

Double Hose-Diaphragm Pumps- Flat vs. Hose-Diaphragm -

Flat diaphragm Double hose-diaphragm

Pumped medium is in contact with

diaphragm housing

Pumped medium is in contact with

diaphragm housing

Pump head volume about 40% smaller

3 times higher filling ratio

volume mediummax

volumepumped ratio filling =

Pumped medium is in contact with

diaphragm, only

Pumped medium is in contact with

diaphragm, only

About 5%

higher efficiency

Page 26: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH26

Unique MULTISAFE design - Comparison of Fluid Wetted Items -

26

Example: ZGL 300/250 – 2K 180 – 4 SM 460 HD

Weight of wetted parts: 6,400 kgExample: TGK 300/250 – K 180 – DS 100 HD

Weight of wetted parts: 150 kg ���� -97,7%

Page 27: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH27

Valve Types- Corner vs. Linear Valves -

Page 28: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH28

MULTISAFE Check Valves- Ball Valve -

Heinz M. NägelNo. E 2201103-2

Open position Closed position

Page 29: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH29

Valve Types- Ball Valve Assembly -

Foliennr.

steel sealingrevearsing

seal ring

Page 30: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH30

MULTISAFE Check Valves- Quick Change System -

Foliennr.

Page 31: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH31

Special Configurations- Double Valves -

Double Valves

• Double valves are used for critical processes, which do not allow an interrupted flow.

• Double valves provide double-safety against smallest leakages.

• Double valves reduce the wear of the valves and increase maintenance intervals.

Page 32: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH32

FELUWA Check Valves in Quick Change Design with Hydraulically Supported Fastening in Single or Double Valve Design (as per Illustration)

Page 33: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH33

Diagnosis Systems- Energy Loss in Case of Leaking Check Valves -

Leakage in discharge and/or

suction valve Suction stroke

Page 34: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH34

Diagnosis Systems- FELUWA Valve Performance System (FVPMS) -

Valve

sensor

Page 35: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH35

Energy Savings byValve Wear Detection

Flo

w R

ate

Time

Po

wer

Start of valve wear

Energyloss

Page 36: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH36

FELUWA Pulsation Dampener- combined air vessel + diaphragm -

Additional

air cushion

(air vessel)

Bladder

accumulator

Page 37: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH37

Multiple Pumps- Pressure Pulse Optimisation -

Pump 1 Pump 2 Pump 3

Wrong

phaseshift

Optimized

phaseshift

Resulting pulsation on common discharge pipe

or

Page 38: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH38

Multiple Pump Control- Pressure Pulse Optimisation -

• Optimized phaseshift, when a pump is shut off

• Automatic speed increase to avoid a standby pump

Optimized

phaseshift

Pump 1

Pump 2

Pump 3

Resulting flow to pipeline

Page 39: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH39

0

1

2

3

0 100 200 300 400 500 600 700

Vo

lum

e f

low

[a.u

.]

Crankshaft angle [°]

3 triplex pumpswithout phase shift

Sum of 3 triplex pumps

3 triplex pumpswith optimized phase shift

Multiple Pump Control- Phaseshift Control of 3 Triplex Pumps -

2,2%

23,2%

23,2%

Page 40: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH40

Sedimentation

inside the

diaphragm chamber

Pumping of Heterogeneous Mixtures

Flow direction

Page 41: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH41

Transport of Solid Particles

Lowsinking

rate

Homogeneous HeterogeneousMIXTURE

Highsinking

rate

Length of discharge

stroke

Sinkingrate

Page 42: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH42

Special Configurations- Downflow Transport -

Downflow Technology in everyday life!

PD Ketchup Pump

(hand-operated)

Flow

Page 43: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH43

Pumping of Heterogeneous Mixtures

Downflow Configuration is the counteragent against

sedimentation inside the pump

Downflow Configuration=

Flow from the top to the bottom of the pump

Downflow Configuration for the handling of particulary heavy

solids and heterogeneous mixtures

Page 44: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH44

Summary

Double hose-diaphragm pumps combines lowest energy consumption and highest availability and reliability by

• Highest efficiency independent of flow

• Linear flow pass through the hose-diaphragm

• Quintuplex gear system with 5 heads up to 1000m³/h per pump

• Linear ball valves with Top Entry, Quick Change & wear detection

• Optimized phase-shift control for multiple pumps

• Downflow Technology

Page 45: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH45

Hydrotransport

Page 46: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH46

Hydro Transport

• QGK 500

750 m³/h – 54 bar

Page 47: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH47

Ready for the future

Pump type Power [kW] Pressure [bar] Flow [m³/h]

TGK 500 3.000 50 to 250 up to 750

QGK 500 3.500 50 to 250 up to 1000

(e.g. Boleo) 1.100 45 750

Page 48: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH48

Process Pumps / Feeding

Page 49: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH49

FELUWAHigh Pressure and Low Pressure Pumps

Heinz M. NägelNo. E 2201052

Page 50: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH50No. E 2201051

FELUWA Quadruplex High Pressure Hose Diaphragm Piston Pumps for Four-Burner Type Gasifiers

Heinz M. Nägel

Page 51: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH51

Quadruplex ConfigurationDouble-Acting Two-Cylinder Pump

Heinz M. NägelNr. D 2109499-21

FELUWA Hose Diaphragm Piston Pump

Page 52: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH52No. E 2201085-1 Heinz M. Nägel

FELUWA Hose Diaphragm Piston Pump

Quadruplex ConfigurationDouble-Acting Two-Cylinder Pump

Page 53: Feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH53

FELUWA Areal View

Thanking for your kind attention