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Jeffery Mason
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Feb 17,
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Pumps are devices used to transport fluids by mechanical means. They are used in a wide range of applications in various industries, such as mining, wastewater treatment, agriculture, and many others. However, not all pumps are created equal, and selecting the correct type of pump for a particular application is crucial to ensuring optimal performance and efficiency. In this context, two types of pumps that are often compared are slurry pumps and normal pumps.
A slurry pump is a type of centrifugal pump explicitly designed to handle abrasive or corrosive slurries, which are mixtures of liquids and solids. On the other hand, a normal pump is a general-purpose pump used for transporting clean fluids, such as water or oil, without solid particles.
Slurry pumps are designed to handle abrasive and corrosive slurries that are typically encountered in mining, construction, and other industrial applications. Slurries can contain various solid particles, such as sand, gravel, coal, and minerals, which can cause wear and tear on the pump and its components. Slurry pumps are specifically designed to handle these types of challenging conditions, and they feature a robust construction with materials that can withstand abrasion and corrosion.
There are several types of slurry pumps, including horizontal, vertical, submersible, and recessed impeller pumps. Horizontal slurry pumps are the most common type used for general-purpose applications. In contrast, vertical slurry pumps are used for applications where space is limited or the fluid needs to be lifted to a higher elevation. Submersible slurry pumps are designed to operate while submerged in the liquid, while recessed impeller pumps are used for applications that require low flow rates and high heads.
Slurry pumps are used in various applications, including mining, dredging, sand and gravel, construction, and oil and gas. They are critical components in these industries, and selecting the right type of slurry pump is essential for maintaining high levels of productivity and efficiency.
Normal pumps, also known as clean water pumps, are used for transporting clean fluids without solid particles. They are designed for applications that require low to moderate pressure and flow rates, such as water supply, irrigation, HVAC, and circulation. Normal pumps are typically less expensive than slurry pumps and have a simpler design and construction, making them easier to maintain and repair.
There are several types of normal pumps, including centrifugal, positive displacement, and axial flow pumps. Centrifugal pumps are the most common type and are used for general-purpose applications. Positive displacement pumps are used for applications that require high pressure and low flow rates, while axial flow pumps are used for applications that require high flow rates and low pressure.
Normal pumps are used in many applications, including water supply, irrigation, heating and cooling systems, wastewater treatment, and many others. They are critical components in these industries, and selecting the correct type of normal pump is essential for maintaining high levels of performance and efficiency.
The main differences between slurry pumps and normal pumps lie in their design, materials, performance, and maintenance requirements.
Slurry pumps are designed to handle abrasive or corrosive slurries. They are typically made of materials that can withstand wear and tear, such as high-chrome white iron, rubber, and other special alloys. They also have a robust construction with thicker casings, impellers, and liners to protect the pump from damage.
Normal pumps, on the other hand, are designed to handle clean fluids and are typically made of materials such as cast iron, stainless steel, or plastic. They have a more straightforward construction with thinner casings and impellers, which makes them lighter and easier to handle.
Slurry pumps require specialised materials that can withstand abrasive or corrosive slurries. High-chrome white iron is the most common material used for slurry pump components because of its exceptional wear resistance. Rubber and other special alloys are also used for specific applications requiring chemical resistance or other properties.
On the other hand, normal pumps do not require specialised materials because they handle clean fluids. Common materials used for normal pump components include cast iron, stainless steel, and plastic.
Slurry pumps are designed to handle abrasive or corrosive slurries and are typically selected based on the percentage and size of solids in the slurry, as well as the required flow rate and head. Slurry pumps have a lower efficiency than normal pumps because of the additional friction and wear caused by the solid particles.
On the other hand, normal pumps are designed to handle clean fluids and are typically selected based on the required flow rate and head. Normal pumps have a higher efficiency than slurry pumps because they do not have to overcome the additional friction and wear caused by solid particles.
Slurry pumps require more maintenance than normal pumps because of the wear and tear caused by abrasive or corrosive slurries. The pump components must be inspected and replaced more frequently to ensure optimal performance and efficiency.
Normal pumps require less maintenance than slurry pumps because they handle clean fluids. The pump components need to be inspected and replaced less frequently, which makes them more accessible and less expensive to maintain.
Choosing the correct type of pump for a specific application is critical to ensuring optimal performance and efficiency. When selecting a pump, several factors should be considered, such as the type of fluid, the flow rate and head, the percentage and size of solids, and the required materials and properties.
Slurry pumps have the advantage of being able to handle abrasive or corrosive slurries, which normal pumps cannot handle. However, they have the disadvantage of being less efficient and requiring more maintenance than normal pumps.
Normal pumps have the advantage of being more efficient and requiring less maintenance than slurry pumps. However, they have the disadvantage of not being able to handle abrasive or corrosive slurries.
To select the right pump for a particular application, the pump needs to be compared to the specific requirements of the application. This includes considering the fluid type, flow rate, head, percentage and size of solids, and required materials and properties.
In conclusion, slurry and normal pumps are two types used in various industries for different applications. Slurry pumps are designed to handle abrasive or corrosive slurries, while normal pumps are designed to handle clean fluids. Understanding the differences between these two types of pumps is crucial to selecting the right pump for a specific application and ensuring optimal performance and efficiency. It is essential to consider the materials used for the pump components and the performance and maintenance requirements when selecting the right pump. Slurry pumps typically require specialised materials, have lower efficiency, and require more maintenance than normal pumps. On the other hand, normal pumps can handle a broader range of fluids and have higher efficiency with lower maintenance requirements.
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Choosing the right pump for a specific application requires careful consideration of all the factors involved. The type of fluid being pumped, the flow rate and head, the percentage and size of solids, and the required materials and properties must all be considered to ensure optimal performance and efficiency.
When selecting a pump, it is important to work with a trusted supplier who has experience in the specific application and can provide expert advice and guidance. Proper pump selection can minimise downtime, reduce maintenance costs, and maximise overall system efficiency.
In summary, while both slurry and normal pumps have their advantages and disadvantages, understanding the differences between them and selecting the right pump for a specific application is crucial to achieving optimal performance and efficiency. With proper selection and maintenance, pumps can be a reliable and efficient component in a wide range of industrial processes.
From motor size and pump speed to wear life and operating costs, an imposing array of choices face a buyer intent on reaching and maintaining optimum pump performance. Here are some tips from experts.
by russell a. carter, contributing editor
Slurry pumps are essential for moving hard-to-handle, high solids-content fluids and sludge, and annual demand for these pumps reflects just one aspect of the significant space they occupy in several industry sectors. The global market for all types of slurry pumps is estimated at well more than a billion dollars each year, and although those sales represent only a single-digit portion of overall pump sales, slurry pumping costs take up a lot of space in mining&#;s collective energy budget. Process equipment supplier Metso estimated that slurry pumps account for only about 5% of centrifugal pumps &#; the most common type used for this purpose &#; installed throughout the mining industry, yet this small segment represents up to 80% of the industry&#;s total operational pumping costs.
The space they physically inhabit in a mining operation is typically harsh &#; at the bottom of a sump, a prep plant or thickener-underflow discharge point, or serving a pipeline carrying abrasive slurry. Their duty cycles range from continuous to sporadic depending on the application, often with highly variable flow rates and particle sizes. Internal wear can be severe in some applications, with as much as 2 mm of material a day disappearing from crucial component surfaces. Due to the increased probability of high wear rates from the materials being transported, pump builders add thicker, heavier components and/or internal liners, making slurry models larger and heavier than their water-pump brethren.
The wide range of pump-performance requirements encountered at thousands of mine, mill and other industrial sites requires an equally wide variety of pump types, sizes and mounting configurations. Two recent product introductions illustrate the range of available choices.
Going Big, Going Mobile
Late last year GIW Industries announced that it had developed the TBC-92 slurry pump specifically for use in oil sands operations. Named for its 92-in.-diam (234 cm) impeller, GIW claims the TBC-92 is the largest and heaviest slurry pump available in the mining industry.
At the other end of the size and portability scale, Gorman-Rupp&#;s transportable SludgeKat self-priming, positive displacement hydraulic piston pump is designed for convenient pumping of sludges and slurries from clarifying pits, wastewater treatment, mud pumping, environmental cleanup and similar applications.
The SludgeKat has 4-in. (100-mm) suction and discharge ports and is capable of flows up to 226 gpm (14.3 lps) and heads up to 390 ft (118.9 m). Depending on the product being pumped, SludgeKat can pass up to 2.4-in.-diam solids without damaging or clogging the pump. Units are equipped with Kohler Tier IV diesel engines.
Each SludgeKat comes standard with a wheel kit. The pump end frame is mounted to a 52-gallon (197-l) fuel tank base and offers a full-load run time of 25.5 hours. The pump end frame can be detached from the unit and when connected to optional 150-ft (46-m) hoses, provides increased portability around the job site.
In the space between these two very different pump solutions lies an array of conventional horizontal and vertical centrifugal models, submersibles and other types offering a wide range of performance characteristics that can be applied to specific slurry pumping requirements.
Pumps, unsurprisingly, can also fail to perform adequately if specified or installed incorrectly.
Look Beyond the Pump
The industry&#;s continuous drive to increase production from existing assets makes it important to view pump systems as one part of a much larger picture. In a recent blog post, Metso&#;s head of pump product management and marketing, Chris Wyper, outlined some important points to consider about pumps when aiming for plant-wide production increases. Among his recommendations:
Ensure motor power availability: &#;A well-designed plant has enough power allocated to mill pumps. Pumps typically operate on variable speed drives, meaning there are many process variables affecting speed and, finally, the power draw. It is a good idea to look at SCADA data on historical power drawn to better estimate the amount of power that would be available for tonnage increases. Rather than using engineering data sheets that are somewhat oversimplified, it is beneficial to use a point cloud type plot showing flow and pump pressure as a function of time. This information makes it possible to determine the optimal size of all the pumps and cyclones for the plant.&#;
Consider gearbox cooling at higher power: &#;As pump duty is increased, it usually also increases the power transmitted through the gearbox. This means that the amount of heat increases as well: a gearbox that is sized marginally for air to air cooling may overheat with higher continuous duty. Consideration must be given to the cooling capacity of the lubrication system, particularly at higher ambient temperatures and altitudes.&#;
Ensure gland seal water pressure at higher heads: &#;The pump gland seal water system should be sized so as to be able to deliver a constant flow of gland water under all operational conditions. This applies to the pump duty, including any increase in head due to tonnage increases. It should also be checked that the gland seal water system is adequate when other demands are placed on it, such as hose downs or flushing.&#;
Take a close look at pipe sizing: &#;If you double the speed, the rate of material loss increases 16-fold and the rate of abrasive wear on the surface is approximately proportional to the fourth power of velocity. If there is a significant increase in input, it is necessary to consider whether the pipe sizing is optimal. The right size allows friction losses and wear to be minimized. Of course, if there is a large variation in flow, then minimum velocity to prevent settling should be examined.&#;
Prepare for crash stops by calculating floor sumps: &#;In the case of a plant crash-stop, prepare for the maximum inflow based on calculations on the live volume of floor sumps. This may include the mill static overflow and any dump valves to empty pipes and sumps. If sump size is increased or the mill volume changed, then the sumps may be undersized. In this case, the existing sumps can be deepened or enlarged, to deal with the volume, or then additional sumps created. Typically, mill sumps should be separated from the other sumps in the plant due to the possibility of mill balls entering the sump.&#;
Expanding Future Options
As industry-wide figures indicate, slurry pumping can serve as a prime example of purchased capital equipment where operating and maintenance (O&M) costs rapidly eclipse the initial procurement cost. A myopic view of TOC (Total Cost of Ownership) factors when selecting a pump can result in a variety of bad outcomes ranging from the need to prematurely replace an inadequate unit, to sky-high maintenance costs and production losses from unscheduled downtime. Conversely, pump OEMs and aftermarket suppliers are increasingly cognizant that their customers can&#;t always predict future events and consequently are expanding their product and services portfolios to provide affordable options when mining conditions, maintenance resources or technology changes occur over time.
Manufacturers are also looking at ways to incorporate more performance flexibility into their pump models and ease some of the concerns associated with necessary pump modifications. &#;For example, we are developing a line of pumps designed with a solid casing with replaceable all-metal, liner-like elements,&#; said Will Pierce, manager of engineering, Schurco Slurry. The metallurgy for these wear components is a novel enhancement to the proven 27%-28% chrome white iron that the industry has used for decades. We have hard rock customers that started with rubber liners 20 years ago, now they&#;re in a different ore deposit at the same mine and the material is sharper or has different abrasive characteristics and the rubber isn&#;t lasting. With the shell we&#;ve developed, they&#;re able to convert to a completely metal lined pump without major impact to the overall installation through using backward compatible adapter plates,&#; Pierce explained.
The new design also offers Shurco&#;s coal clients notable benefits: &#;Our coal customers almost always use metal-lined pumps, but the industry is very price-sensitive right now, so this new development doesn&#;t have the traditional massive ductile iron outer shell and metal liner &#; instead, it has replaceable metal wear components. There&#;s no quality compromise on the pump&#;s internal components, no change in wear or hydraulic performance. It&#;s just a lower-cost alternative.&#;
Designing for Durability
A rule of thumb when selecting a slurry pump is to look for the most robust pump, in terms of performance, wear resistance, power and maintainability, that falls within the service class rating for the type of material being pumped. Even that simple process can be complicated when special circumstances arise, such as unusually high mechanical wear experienced in a specific application, or intermittent operation rather than steady running. Pump manufacturers generally have vast knowledge of what works and what doesn&#;t under many conditions, and they incorporate the features that do work into their latest designs. For example:
FLSmidth Minerals expanded its line of Krebs millMAX slurry pumps with the introduction of the millMAX-e, which features a unique wear-ring design that the company claims solves grinding and recirculation problems within the pump by maintaining clearances between the impeller and the suction side. By maintaining the design performance without increasing the speed, the wear ring extends the life of all wet end parts and reduces power consumption.
The millMAX-e model is unlined and offers a compact, space-saving exterior design aimed at reducing capital and replacement costs as well as motor-power requirements. However, according to the company, millMAX-e&#;s power frame uses the same bearing and shaft components as the equivalent millMAX power frames and is capable of handling applications requiring high speed and power. The millMAX-e is equipped with the patented Krebs pump belt tensioning system that allows users to quickly change out v-belts without having to realign the sheaves.
Tsurumi Manufacturing&#;s entries in the mining-class slurry pump market include its GPN and GSD series, rated at motor outputs of 7.5-50 hp (5.5-75 kW) kW and 50-100 hp (37-75 kW), respectively. Both series comprise submersible three-phase, high head and high volume heavy-duty slurry pumps driven by a four-pole motor. They are equipped with high-chromium cast iron agitators that the company said assist in smooth handling of settled materials. Motors are enclosed by a water jacket that assures efficient cooling even when the motor is exposed to air. Pumps in this series incorporate seal pressure relief ports that prevent pumping pressure from affecting the shaft seal.
Finland-based Flowrox&#;s heavy-duty CF-S horizontal centrifugal pump is the first in a series of centrifugal pumps to be introduced by the company and capable of continuously pumping highly abrasive and dense slurries. The company said the new pump can provide flows from as low as 2.3 m3/h to more than 4,000 m3/h at heads exceeding 76 m. The pump&#;s split-case design is claimed to provide a good balance between efficiency and wear, and models are available with a range of liner material options. The pump is compatible with Flowrox&#;s Digital Services platform, a customized IIoT-based process data collection and analysis system.
MBH Pumps unveiled the Ni-Hard series submersible slurry pumps, designed and built to pump slurries containing abrasive solids up to 65% by weight. These heavy-duty pumps, according to the supplier, are equipped with an external agitator that breaks settled or compacted solids, while its adaptive spiral plate technology delivers higher pumping with less energy consumption.
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