SECTION 2 - Water and Slurry Basics All matter in tho universe exits in one or more of thee states Solid, liquid of gaseous and each state is determined by its body temperature and pressure. The best known example of a substance withthe thece states is ‘Water which in humas-survivable imperatures and pressures ca exis as ice, water and vapour, FLUIDS. Liquids and gases are calle fluids because they can flow and can take the shape of any container into which they are poured. There are however also considerable diferences between liquids and gases, A liquid can have separating upper and lower surfaces with oer liquids ~if hey do aot mix — of with gases bute gw cannot have 2 separating surfce with another gus. Som liguids mix widh other liguids (water and wine) some do-no (ater tnd ol), All gosos mix with each other and some gases ean dissolve in some liquids, Liquids are virustly incompressible whereas gases ae compeessible. Many physical, chemical or other properties idemify all substanoss. In pumping we are mainly converned with propertos associated with mass. A force imparts acceleration to.a mass. Weight, as particular form a fore, imparts pravitational acceleration to a mass. Foe easy Comparison of various materials, we usualy expeess their masses telative 10 a unit volume. This physical property is called Density p [kg/m]. Occasionally density is expressed in tonnes per cubic mate [vim] or ky per litre [kg/L], which are numerically qual, Liauios The most common liquid handled by centifugal pumps is water. AC nocmal ambient pressure and at sieezing point (°C), water and ice have densities of 999 and 895 kg/m’ respectively, whieh explains why ice Moats on water. At the same pressure but at boiling point (100°C), water and saturated vapour have densities of 957 and 0.590 gin? respectively, which shows that water expands approximately 1600 times after boiling, The most common solid material handled by centifugal pumps is silica in the form of saad or rock, whose density is seound 2650 kg/m ‘Very often wo expeoss unit mass of a material by is Specie gravity oF SG, a dimensionless mumbor, which we obeain by dividing the density ofthe material by the density of water. For this particular purpose, we usually take the density of water as 1000 kgia? and so the SG of any material is simply equal to is density divided by 1000, By this reasoning, the SG of waters 1 and that of Silica 2.65 SLURRIES In solids handling by pumping, we mix some solid mater with some liquid carrer to form a slucry, ic. mixture of a lguid and solid paroles, large or small. In calculations associated with slury pumping in this “Manual be use the following symbols: the SGi of the solids is S, the SG of the liquid is Sw. (Note that SL is, prefered by some engincers but the letter “I” can be confused with the digit" in some printing fons). The SG. of the mixture is Sm. Often mixtures of solids and liquids can be teated as an equivalent Duid with dhe same SG-Sm. Two additional parameters are used, namely Concentatoa of solids inthe mixture by weight Cw [6] and Concentration of solids in the misture by true volume Cv [%. The word true is often omited. To underszand its meaning, consider the following Allow cube with sides D has a volume of D?. A solid sphere of diameter D has a volume of 0.520? and. ‘would ake up $2% of de eube's volume I eight smaller spheres were added with centres ac the eight corners fof the cube and tonehing the large sphere the volume ofthe portions of these spheres inside the cube would be (0.2007 and the combined volume of the nine spheres would be 72% a the cube, A progresive similar fitment fof moce smaller spctes of corset number and size would make their combined volumes converge quickly to an, asymptotic value of around 74%. If we had spheres ofthe same dianctr or if we had solid particles of varieus spes and sizes, che tue volumes filled would vary trom $0°% wo 80%, For loose beach sand its uround 73% There ar, as we have seen, five inter-elated variables, which we use with sluries Table 2.1 om acxt page lists all the equations for calculating any one ofthe variables from other known values, For yater use Sw=1|Cw and Cy values are express as percentages (9), divide them by 100 before using them in the tabulate equations. Table 2.1~ Specitic gravity and Concentration equations for Shires Sw_[=SiSmCw- Su) /SmCw-s) | = CVS) (CN = siCuCw-1}/ (wey) S_[=sucw(Cv-ty/fcucw-i1 | =sw+tSm-Sw)/ Ce = SwCw /(Cw=14Sw/Sin} Sin_[ >See [-Cwll Swi) = SwiCMS SH) = SmCHY/ CWI) (Gx [=SiSm- Se) (Sms SH] |= SC [SHES Se] = sMGv-)/8a cy [Fism sw) $0) = Sw sw S#9C8) = FsmiGw_1)/ 957 For any slurries, when any thece of the five variables tabulated a left are known, the fourth and fifth may be calculated from the equations shown. Allematively the Diagram Al-3 ia Appendix Al may be used forthe same purpose although that Diagram cannot be uscd to calculate Sw Another useful lationship is wits = 8!8m 20) As ean bo renily seen, this equation is independent of liquid density Sw and it hold tre for solids mixed with ‘any lguid. In oice words, when the ratio Cw'C¥ for a shury has been given 8 value, the ratio ‘Sm must have the same valuo and the specific gravity of the liguid Sw can then be changed at will widhout affecting the said value The equation is used to caloulate any one ofits four vaeiables when th other thre ae known, Sal [Dacipior Dinenione Carats of irs Sparen ary gh snalNOT Pe Sanction of iso pain Sy By NTT ee Ac ae Thaler dela Sontie syessTa Mexicans gy cao Veter Te i ys ip alr iar ow Ao = Finetes modulus FM) Teon booed tom ooncite miing indus Tt ity |indeaes paticiesize dsrouton na sample, eg sample wun FAI=3 tas | aimensintess ‘wide variety of soe sample with FM has anarou vary of 288 ss son, 7 | Dares pie con for nats Gravationalaoseration oat Etcency of pnp when banding uy Eisiency of punp won banling waterHere is « mini-dictionary of terms and definitions used in Slurry Pumping and in Minerals Process Industries Affinity Laws (also Affinity Rules) — Mathematical relationships of pump speed to low rate, developed head tnd input power. When speed changes from N, to N;, low rate changes from Q, to Q.=Q,NyN,), head from Hy (oH-Hy(NyNi) and power fom Pi, co Pi-Piy(NYN,) Beneficiation — The process of refining ores and naw materials, Carrying Medium, in a slurry ~ Any hornogenowsMuid used to suspend sols during flow Character le Curve A curve showing the relationship between pump heads and flow rates ata given speed, ‘Comminution — The reduction of size of solids particles by means of mill grinding, attrition or any ether size rection process. ‘Concentrates The valuable postions of ores and raw materials obtained by a benecition process ‘Concentration by Weight (or Mass) ~ The weight (mass) of solids present in a two-phase mixture taken as 2 percentage of the weight (mass) of the total mixture Concentration by Volume The volume of solids presont in a two-phase mixture taken asa percentage oF the ‘volume ofthe total mixture Comistency — A measure of the resistance of a susry to shear. As with non-Newtonian Muids, the dynamic viscosity (being the ratio between shearing stress and rate of shearing strain) is not constant and must be determined forany particular flow rte Density of Material — Moss of material in kilograms per cubic metre. Material may refer to uid, solid or Drag Coefficient — A measure ofthe forces resisting the movement ofa solid particle ina uid, [Efficiency ~ The ratio of energy transferred to a pumped fluid and energy supplied to the pump shal Fines Small particles of ore or metal Flocculation - The use of high molecular weight synthetic organic polymers which are added to a suspension of Finely divided solids in water, in very small quantities, which increase the sotling rate ofthe suspended material bby combining fine partices together wo form a lager agglomerate. Flotation — A continuous process in which eels are arranged in svies forming a bank. Pulp enters dhe fist cell of the bank and gives up some ofits valuable mincral asa froth, Air bubbles overflow from this cell taking the desired mineral with them. The underflow from ths cell passes tothe second cel where more mineralized froth is remove, continuing down the bank, until barren tailings overflow and the underfTow passes to the last ell in the bank. Pulp passing through each cell is drawn upwards ino the rotor by the suction ereated by the rotation. Slurvies are heroughly mixed withthe air before being broken imo small, Gm bubbles by the disperser, whieh surrounds te rotor, by abrupdly diverting te whirling motion of the pulp.Flow by Saltation — Turbulent flow of a shy with soles too coarse to be fully suspended by turbulence, The solid particles travel by consecutive bounces and leaps on the bottom of the pipe Flow with Stationary Bed The flow ofa slurry in a pipe with restricted area due to a deposit of solid particles ‘on the bottom ofthe pipe. The deposits often have dunes, both stationary and moving, Flow rate (also Rate of Flow, Discharge and Capacity) ~ The volume of fui» pump delivers during a certain period af time, This can be expressed in a variety of way’, such as litres per second, cubic metres per hos, gallons per minute, &. Slurry pump applications are often specified in terms of tonnes of solids per hour and in such cases they must be converted to the appropeiate volumetric units, Friction loss —The resistence to low within a pipe and fiuings. Ics a function of the rate of Tow, vseosity of ‘the liquid, and pips diameter and is express mettes of oid pummpe Head — The potential andior kinetic energy that exists im a fluid. Ie is usually expressed in metres of uid pumped, Heterogeneous Slurry ~ A flowing slurry in which the concentration of solid particles is not uniform but increases iowards the botiom ofthe pipe Homogenous Mixture or Slurry — A two-phase misrure of solid particles and fluid in which the two phases cannot be separated by mechanical means and in which the distribution or concentration of solid particles is ‘uniform across the soetion ofthe pipe. In practice this is really n “model” shay with uniform properties that we assume in order Co simplify system calculations Hydraulic Gradient — The sretion heed loss pee unit length of pip. Laminar Flow ~ In laminae flow, all the fluid particles proceed along paralle! paths and there is no transverse ‘comportent of velocity. The orderly progression is such that each partile follows exactly the path ofthe particle procesding it without any deviation, Thrce-dimensional laminar flow can be viewed as concentric thin shells ‘along the pipe axis. Laminar Now is associated with low velocities and viscous sluggish Muids. Limiting settling velocity ~The velocity of heterogeneous slurry in a horizontal pipeline, according to Durand’s studies, below which solids of « certain size, density und concentration bewin to seale along the boctonn, Liner, Drive side (alo Liner, Frame Plat) ~ A cast hard alloy or moulded rubber component lining the drive side of the pump casing Liner, Suetion side (also'Thraatbush) ~ A cast hard alloy or moulded rubber component lining the suction side ofthe pump easing, Liner, Votute (also Liner, Casing Shell) A cast hard alloy or moulded rubber component lining the volute of the pump casing. Mesh — The number of openings in a sereen per linear mm (metric measurement) or inch (imperial measurement), Mill — Muchinery used for crushing and grinding ores Mixture See Slurry Mud, Paste oF Sludge ~ A two-phase misture of solid particles and fluid which is not a tue homogenous Newton ~ The force which imparts an acceleration of one metre per second squared toa mass of one kilogram. Newtonian Fluid ~A fluid exhibiting o direct relationship between shearing stress and rate of shear in laminar ow. The flow of Newonian Muids is completely characterized by a sinale property, the viscosity, which isthe ratio of shear siess and velocity gradientat any flow‘Non-Newtonian Fluid ~ A fluid exhibiting a variable relationship between shearing stress and either the rat of shearing strain Bingham Plastic, Pseudoplastic and Dilutant fluids) or the duration of shear, ie. time dependence (Thixouropic and Rucopectic Duids). The flow of nou-Newtonian Muids cannot be characterized by fa tnique property. The apparent viscosity of a non-Newtonian fluid is the ratio of shear stress and velocity gradient atone particular flow rate It has no meaning at any other flow rate. Most solutions and suspensions at Tow concentrations behave as a Newtonian fluids, changing to non-Newtonian behavior when certain critical solids concentrations are reached. Inthe ease of suspensions, critical eoncentutions depend on panicle size and shape and on the degree of dispersion of the particles. For meaningful results, Inboratory tests of None "Newtonian samples should he ears out only with iesh hurry samples fons the actsl system being evaluated PSH — Net postive suction head. The tial suetion head in absolue units tthe pump suction Mange less the absolute vapor pressure of the liquid Particle Seting Velocity ~ The terminal, fve-Fall velocity of a solid partile falling in ealm, clear water. The particle settling velocity is also used to daseribe the sting of slurries wit low concentration of solids Reynolds number ~ A dimensionless number defining a fluid Now, expressed hy the ratio of inertia forces and viscous foress Sercen Amulysis ~ The separation of solid particles imo certain size fractions by means of standard sieving Shae Steeve~ A rabular hardened metal pioce fired over the shaft co protect it from wear by the gland packing inthe stufing bos. Shear rate~ sce Velocity gradient Slimes ~ A rock product which contains particles of not more than 5% #300 um size nor less than 50% size, and which includes all fine material produced by a corminution process. 75 um Slurry - Strictly, a two-phase mixture of soli particles and fluid in which the two phases will not chemically react with each other and the two phases ean be separated readily by mechanical means. However, in this ‘Manual the terms “sluery” and “mixture” are used more loosely and interchangeably to deseribe a mix of any solids and liquids Slurry Setting Velocity ~The velocity at which solids sar o separates out of a suspension of solid particles before compaction is achieved! Solids (also Solid Particles) ~ Fragments of solid materials which are chernicaly inert and will not react sith the fli in which they ae suspended, Specific Gravity Tho ratio of the weight (oF mass) of a substance to the weight (oe mass) of an equal volume of water Specific Speed — A design index number used to classify pumps by impeller type and proportion. It is defined 1s the spced in revolutions per minute at which @ geometrically similar pump would operate to deliver one unit of low at one unit of hoad, Stuffing Box ~ A postion of the pump casing through which the shaft extends and which holds a scaling device to prevent leakage. The sealing device can be a soft packed gland ora seal adaptor fora mechanical sea System Head curve (or System Resistance curve) — A curve showing the relationship between total heads required by a pumping system and their regnestive low rats, Transition Velocity ~ The velocity at which the flow of a slaty changes from one flow regime to another, such as ftom homogenous to heterogeneous flow oc from laminar to turbulent few. ‘Turbulent Flow — Flow at high Reynolds numbers with Quid and solid panicles moving with random motion transverse tothe main flow direction,