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The 4th Annual Slurry Pipelines Conference is the world's only event wholly dedicated to the operational challenges, design questions, innovations, pumps and tailings related to slurry pipelines in the mining and resources sectors. For more information on the event, please visit: http://bit.ly/1xvoBPT
Citation preview
Large piston diaphragm pumps
A feasible alternative for multistage centrifugal pumps Wirth TDPM 2500
November 11, 2014 Slide 2
About MHWirth
Aker Wirth GmbH MHWirth GmbH
The demand for high volume piston diaphragm pumps is increasing § Pipeline slurry transportation is increasing § Pipelines are getting longer § Flow rates are getting higher
§ Flow rate of traditional piston diaphragm pumps is limited § An impractical number of traditional piston diaphragm pumps in parallel
are required to produce high flow rates
§ MHWirth develops a high capacity piston diaphragm pump § Based on established technology § Proven feasibility
Background
Proven technology
++
700 m³/hr at 120 bar 750 m³/hr at 50 bar
Triplex double-‐ ac=ng pump
1400 m³/hr at 80 bar
Triplex single-‐ ac=ng pump
=+
Duplex double-‐ ac=ng pump
=
Hein Krimpenfort (Aker Solutions, Germany)
Triplex double ac=ng pump
Proven technology
Commercial feasibility
Proven feasibility
Project descrip=on
Existing slurry pipeline conceptual design in Angola, Africa § Type of slurry : iron ore tailings § Length of pipeline : approx. 12 km § Pipe diameter : 450 mm (OD) § SG of slurry : 1,4 § Slurry velocity : approx . 4,07 m/sec § Flow rate : 2.015 m³/hr § Required pressure : approx 6 MPa
§ Cost of energy : € 0,057/kWhr
Pipeline profile
Project descrip=on
Centrifugal pump system
Design parameters
Centrifugal pump system
Main pump sta7on Booster pump sta7on
Pipeline profile and hydraulic grade line
Process requirements § Pump stations : 2 § Agitated tailings tank : 2 (1 per station) § GSW tank : 2 (1 per station) § Potable GSW supply : 2 (1 per station) § Nr. of slurry pumps : 24 (6 operating + 6 standby, per station) § Nr. of GSW pumps : 4 (2 per pump station) § Slurry pipeline (4 MPa) : 12 km
Centrifugal pump system
Process requirements
Centrifugal pump system
Operating train § 1 slurry feed tank § 12 slurry pumps § 2 gland seal water pumps
Standby train § 1 slurry feed tank § 12 slurry pumps § 2 gland seal water pumps
Centrifugal pump description § Pump size : 16 x 14 § Nr. of pumps required : 12 § Derated head per pump : 36 m § Derated efficiency : 63% § Impeller tip speed : 24,5 m/sec § Motor shaft power : 427 kW § Total required power : 5.124 kW
§ Annual parts consumption : 25% of pump capital cost
Centrifugal pump system
Piston diaphragm pump system
Design parameters
Piston diaphragm pump system
Main pump sta7on
Pipeline profile and hydraulic grade line
Piston diaphragm pump system
Process requirements § Pump stations : 1 § Agitated tailings tank : 1 § GSW tank : 1 § Potable GSW supply : 1 § Nr. of slurry pumps : 3 (2 operating + 1 standby) § Nr. of charge pumps : 2 (1 operating + 1 standby) § Nr. of GSW pump : 2 (1 operating +1 standby) § Slurry pipeline (8 Mpa) : 12 km
Process requirements
Operating pumps § 1 slurry feed tank § 2 slurry PD pumps § 1 charge pump § 1 gland seal water pump
Standby pump § 1 slurry PD pumps § 1 charge pump § 1 gland seal water pump
Piston diaphragm pump system
Piston diaphragm pump system
Piston diaphragm pump description § Pump size : Wirth TDPM 2500 § Nr. of pumps required : 2 § Derated head per pump : 432 m § Derated efficiency : 92% § Stroke rate : 42 per minute § Motor shaft power : 1.807 kW § Total required power : 3.614 kW
§ Annual parts consumption : 5% of pump capital cost
Cost comparison
Capital costs
Cost comparison
Annual operating costs
§ Excluding costs of gland water § Excluding maintenance labour costs
Cost comparison
Payback time
§ Excluding costs of gland water § Excluding maintenance labour costs
Sensi=vity analysis
Annual operating costs variations: § Cost of energy : € 0,02 – 0,10/kWh § Cost of parts consumption : 15 – 65% (of investment of centrifugal pumps)
Payback time:
Sensi=vity analysis
Payback time:
Technical feasibility
Technical feasibility
Pressure – capacity relationship
§ Centrifugal pumps : § Capacity is pressure dependent : if pressure goes up, capacity goes down
Example slurry pipeline § Slurry flow : 1000 m³/hr § Critical velocity : 3,5 m/sec § Required ID : 30 cm § Actual velocity : 3,9 m/sec § Required pressure : 40 m
Slide 28
Centrifugal pumps
ID 30 cm
Velocity 3,9 m/sec
Pump curve
Slide 29
Centrifugal pumps
Slurry pipeline § Pressure : 50 m § Slurry flow : 800 m³/hr § Critical velocity : 3,5 m/sec § ID : 30 cm § Actual velocity : 3,1 m/sec § Settling of solids
Slide 30
ID 30 cm
Velocity 3,1 m/sec
Centrifugal pumps
Slide 31
Centrifugal pumps Pump curve
Slurry pipeline § ID : 20 cm § Pressure : 60 m § Slurry flow : 660 m³/hr § Critical velocity : 3,5 m/sec § Actual velocity : 2,9 m/sec § Settling of more solids
Slide 32
ID 20 cm
Velocity 2,9 m/sec
Centrifugal pumps
Slide 33
Centrifugal pumps Pump curve
Slide 34
Centrifugal pumps Pump curve
Slurry pipeline § ID : 0 m § Pressure : > 70 m § Slurry flow : 0 m³/hr § Critical velocity : 3,5 m/sec § Actual velocity : 0 m/sec § Blocked pipeline
Slide 35
Centrifugal pumps
Technical feasibility
Pressure – capacity relationship
§ Positive displacement pumps : § Capacity is pressure independent : if pressure goes up, capacity is constant
Capacity - pressure § Capacity is constan at all discharge pressures § Capacity depends on stroke rate § If stroke rate increases, capacity increases proportionally § No pump curve, efficiency is not affected
§ Limiting factor for pressure : § installed power § Design pressure of slurry end components (diaphragm housings,
cylinder) § rod load of crankshaft
§ Limiting factor for capacity : § Installed power § maximum stroke rate
Slide 37
Piston diaphragm pumps
Slurry pipeline example § Slurry flow : 1000 m³/hr § Critical velocity : 3,5 m/sec § Required ID : 30 cm § Actual velocity : 3,9 m/sec § Required pressure : 40 m
Slide 38
ID 30 cm
Velocity 3,9 m/sec
Piston diaphragm pumps
Pump “curve”
Slide 39
Piston diaphragm pumps
Slurry pipeline § Pressure increase : 80 m § Slurry flow : 1000 m³/hr § Critical velocity : 3,5 m/sec § ID : 30 cm § Actual velocity : 3,9 m/sec § No settling of solids
Slide 40
ID 30 cm
Velocity 3,9 m/sec
Piston diaphragm pumps
Pump “curve”
Slide 41
Piston diaphragm pumps
Slurry pipeline § Pressure increase : 400 m § Slurry flow : 1000 m³/hr § Critical velocity : 3,5 m/sec § ID : 30 cm § Actual velocity : 3,9 m/sec § No settling of solids
Slide 42
ID 30 cm
Velocity 3,9 m/sec
Piston diaphragm pumps
Pump “curve”
Slide 43
Piston diaphragm pumps
Minimized risk for pipeline blockage
Slide 44
Piston diaphragm pumps
Applica=on comparison
Concentrate pipeline § Location : Morocco § Pipeline length : 240 km § Type of slurry : phosphate concentrate § Flow rate : 5000 m³/hr § Pressure : 64 bar § Type of pump used : centrifugal § Number of stations : 3 § Number of pumps : > 30 § Absorbed power : 14.500 kW
§ Alternative : TDPM § Number of stations : 1 § Number of pumps : 6 (5 + 1) § Absorbed power : 10.000 kW
Slide 46
Applica=on comparison
Tailings pipeline § Location : Australia § Pipeline length : 8 km § Type of slurry : iron ore tailings § Flow rate : 2200 m³/hr § Pressure : 60 - 80 bar § Type of pump used : centrifugal § Number of stations : 2 § Number of pumps : 26 ((8 + 5) x 2) § Absorbed power : 7.800 kW
§ Alternative : TDPM § Number of stations : 1 § Number of pumps : 3 (2 + 1) § Absorbed power : 5.400 kW
Slide 47
Applica=on comparison
§ Large piston diaphragm pumps are a feasible alternative for many multistage centrifugal pump applications
§ Depending on conditions, payback time is less than 2 years § Wirth TDPM is based on proven technology § Piston diaphragm pumps also offer technical advantages when
compared to centrifugal pumps
Summary
Thank you