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 difficult process and requires the biggest slurry pump in the oil sands trade.
When it comes to pumping slurry, there can be very few applications which may be more difficult than the hydro-transport of industrial quality slurries in oil sands manufacturing. Not only do the pumps need to cope with the highly aggressive nature of the fluid being pumped, they are additionally anticipated to operate in a few of the harshest environments on the earth.
In January 2020, GIW Industries, Inc., a KSB company, 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 largest and heaviest slurry pump available in the oil sands business and the newest in a line of highly effective high-pressure pumps provided by GIW.
Slurry transportation Slurry transport covers a substantial vary of industry sectors, ranging from meals and beverage to mining. What is widespread to all, is that the pumps used must be able to transport liquids containing particles and solids of varying sizes and viscosities. In mining, dredging and oil sands production, the most important challenge is to accommodate high density slurry and highly abrasive grits.
It is crucial that the slurry passes by way of the pump with the minimum amount of damage to the pump casing, impeller, shaft and sealing mechanism. Furthermore, the pump have to be capable of delivering high flows and capable of stand up to harsh working environments.
Alberta in Canada has in depth oil reserves and these are in 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 heat water to type a dense slurry that can be transported in 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 through completely different pumps to settling ponds.
The processes require intensive use of slurry and water transportation pumps able to handling vast quantities 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 combine advanced 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 needed 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 most working strain of 4000 kPa. The pump additionally needed to be able to pass rocks of roughly one hundred thirty mm in diameter with a complete passage measurement requirement of 10 in (or 254 mm) and deal with slurry densities in extra of 1.5 SG.
In addition, the customer was targeting a maintenance interval (operational time between planned maintenance) of round 3,000 hours. They had expressed an interest in maximising the upkeep intervals and based mostly on preliminary put on indications, they’re at present hoping to achieve round 6,000 hours between pump overhauls (i.e. 6–8 months).”
The immediate application 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 combination of water, bitumen, sand, and large rocks. Screens are in place to maintain these rocks to a manageable dimension for the process, but the high measurement can still usually attain as a lot 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 within the business. Wear and erosion are facts of life, and GIW has many years of experience within the design of slurry pumps and the development of supplies to assist prolong the service life of these important components to match the deliberate maintenance cycles within the plant.
“GIW already had a pump capable of the output requirement, this being the MDX-750, which has been a popular dimension in mill duties for almost 10 years through- out Central and South America,” explains Mollie Timmerman. ”However, the customer’s utility required a pump with larger strain capabilities and the capability of handling larger rocks so we responded with the development of the TBC-92 which provided the most effective resolution for maximised manufacturing.”
The TBC sequence The construction fashion of GIW’s TBC pump range options large, ribbed plates held along with tie bolts for very high-pressure service and most put on efficiency. First developed for dredge service, then later launched into the oil sands within the Nineties, the TBC pump sequence has grown into a fully developed vary of pumps serving the oil sands, phosphate, dredging and hard rock mining industries for tailings and hydrotransport functions.
The pumps are sometimes grouped together in booster stations to build pressure as high as 750 psi (5171 kPa) to account for the pipe losses encountered over such long distances. The robust development of the TBC pump is well suited to do the job, while guaranteeing maximum availability of the equipment under closely abrasive wear.
Capable of delivering pressure up to 37 bar and flows of greater than 18,200m³/h and temperatures up to 120o C, the TBC range is a horizontal, end suction centrifugal pump that gives maximum resistance to wear. Simple to take care of, the pump’s tie-bolt design transfers stress loads away from the wear resistant white iron casing to the non- bearing side plates without the usage of heavy and unwieldy double-wall building.
เกจวัดแก๊สlpg -92 combines one of the best components of earlier TBC fashions, including 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 onerous rock mining.
In whole, 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 large diameter impeller permits the pump to run at slower speeds so that wear life is enhanced. The decrease velocity additionally provides the pump the power to function over a wider range of flows in order to accommodate fluctuating circulate conditions.
To make maintenance 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 units to facilitate the protected removal and set up of put on and tear comp- onents. The pump additionally contains 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 essential milestone for GIW, which now has pumps in service at all working Canadian oil sands crops for hydrotransport functions. The TBC-92 has been designed to tackle heavy-duty slurry transport whereas providing a low complete value of possession. Minimal labour and upkeep time help to maximise manufacturing and profit.
“This new pump incorporates the teachings learned from operating within the oil sands over many years, and options our newest hydraulic and wear applied sciences,” says Mollie Timmerman. “Because that is the heaviest TBC pump we have ever designed, particular consideration was given to maintainability, as well as materials selection and development of the pressure-containing parts.”
That GIW has established itself as a big force in pumping options for the oil sands industry is much from stunning provided that it has been developing pumping applied sciences and wear resistant supplies within the global mining industry because the Forties.
These pumps have had a considerable impact on the way that excavated sand, rock and bitumen are transported to the upgrader plant. By adding water to the excavated materials it becomes extremely efficient to pump the slurry alongside 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 removing the utilization of trucks.
GIW has estimated that the value of shifting oil sand on this method can cut prices by US$2 a barrel, and it’s far more environmentally friendly. These pumps also play a major function in transporting the coarse tailings to the tailings ponds. GIW provides pumps used in the extraction process and other areas of production (HVF, MDX, LSA).
Understanding slurries Understanding the nature of slurries and how they behave when being pumped has been fundamental to the development of these products. GIW has been acquiring slurry samples from clients over a few years for testing hydraulics and materials both for pumps and pipelines. Research & Development facilities embody a number of slurry test beds on the campus, together with a hydraulics laboratory that’s devoted to pump performance testing.
These activities are central to the company’s pump growth programmes. If companies are experiencing problems the GIW R&D personnel can see where the issue lies and supply advice for remedial action. Experience does point out that in plenty of instances the problem lies not with the pump nonetheless, but in the interaction between the pipeline and the pump.
Feedback from prospects about appli- cations helps in the growth of latest tools and pump designs. By bringing to- gether customers and lecturers from everywhere in the world to share their experience and research with in-house specialists, the huge funding in analysis, growth and manufacturing has superior the design of all the GIW pump merchandise,materials and wear-resistant components.
The future “There is a transparent pattern towards larger pumps in mining and dredging and oil sands are no exception,” comments Leo Perry, GIW lead product manager. “The first TBC pump within the oil sands trade was the TBC-46 (46 in being the diameter of the impeller). Customers are designing their services for higher and better manufacturing and demanding the same of the equipment that retains their manufacturing transferring. While these larger pumps demand more energy, they also enable for greater manufacturing with less downtime required for upkeep. Overall, the effectivity improves when compared to the same output from a bigger 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 trend greater 12 months after yr. Other customers and industries have additionally shown an curiosity in this measurement, and it would be no shock in any respect to see more of those pumps built in the close to future for similar purposes.”