9 Jeff PDF

THE PERFORMANCE OF
CENTRIFUGAL PUMPS
WHEN PUMPING ULTRA
VISCOUS PASTE SLURRIES
J. Crawford FLSmidth Krebs, USA
F. van Sittert Paterson & Cooke Consulting Engineers, South Africa
M. van der Walt Paterson & Cooke Consulting Engineers, South Africa
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
This paper demonstrates that it is possible to pump
very viscous, high yield stress slurries with limited
head and efficiency de-rating using centrifugal
pumps, provided that positive suction conditions are
maintained at all times.
Talk Outline
§  Background
§  Rheology
§  Kaolin material proper6es
§  millMAX 6” x 4”
§  Pump test rig and procedure
§  Clear water test data
§  Kaolin paste test data
§  Pump performance
§  Summary of findings
§  Acknowledgements
Background
§  Measure centrifugal pump performance when pumping ultra viscous paste slurry
§  kaolin paste slurry
§  Yield Stress Range: 580 Pa to 1 120 Pa
§  FLSmidth Krebs millMAX centrifugal pump
Rheology
§  Anton Paar RheoLAB QC

§  Rota6onal Bob, Sta6onary Cup
§  Temperature control bath
§  Herschel–Bulkley model

§  Bingham plas6c: n = 1
𝜏0 = 𝜏𝑦 + 𝐾𝛾 𝑛
𝜏0 = 𝜏𝑦 + 𝐾𝐵𝑃 𝛾
Kaolin Rheology
1800
Bingham yield stress
1600
τy = 8.20 × 104 Cw
9.6

1400
1200
Bingham Yield Stress, τy (Pa)
1000
800
Tested Range
600
400
200
0
35%m 40%m 45%m 50%m 55%m 60%m 65%m 70%m
Mass Solids Concentration, Cw
Pump Test Data Kaolin @ Ambient Temp Data
Kaolin @ 50°C Data Kaolin Rheology

Kaolin Rheology
3.00
Plastic viscosity
K BP = µμw + 1.56 × 102 Cw
10.4

2.50
Plastic Viscosity, KBP (Pa.s) .
2.00
1.50
1.00 Tested Range
0.50
0.00
35%m 40%m 45%m 50%m 55%m 60%m 65%m 70%m
Mass Solids Concentration, C w .

Pump Test Data Kaolin @ Ambient Temp Data
Kaolin @ 50°C Data Kaolin Rheology

Kaolin Material Properties
§  Solids Density: 2.6 t/m3

§  d90 Par6cle size: 34.5 µm
§  d50 Par6cle size: 2.2 µm
100%
90%
80%
Cumulative Percentage Passing
70%
60%
50%
40%
30%
20%
10%
0%
1 10 100
Particle Size (µm)

§  Paste Kaolin: Yield Stress = 1120 Pa
§  75 mm Boger slump cylinder
millMAX Pump
Attribute millMAX Pump
Suction Size 100 NB
Discharge Size 150 NB
Impeller Size 400 mm
Impeller Tipe Closed
Number of Vanes 4
Max. Solids Passing 45 mm
Pump Test Rig
TAG DESCRIPTION COMMENTS
KGV KNIFE GATE VALVE
BFV BUTTERFLY VALVE
50 NB BV
BV BALL VALVE
FIT FLOW INDICATING TRANSMITTER
PT PRESSURE TRANSMITTER
150 NB KGV TT TEMPERATURE TRANSMITTER

VFD VARIABLE FREQUENCY DRIVE
50 NB BV
150 NB
MAG FLOW
FIT
VENTURI
TT 200 LITER DRUMS
150 NB BFV
PT
PROGRESSIVE CAVITY PUMP
VFD PT
150x100
150 NB MILD STEEL PIPE
CENTRIFUGAL
PUMP
25 NB BV
150 NB RUBBER HOSE
Clear Water Test Data – Efficiency
100%
Impellar tip speed - 29.3 m/s
90%
80%
Pump Head, (m/metres of mixture)
70%
60%
50%
40%
30%
20%
10%
0%
0 100 200 300 400 500 600 700
Flow Rate, (m3/h)
P&C Clear Water Data Published Curve @ 1400 RPM
Clear Water Test Data – Head
Clear Water Test Data – Head
Kaolin Test Data – Head
60
Head Curves Impeller tip speed - 29.3 m/s
55
50
45
Pump Head, (metres of mixture)
40
35
30
NPSHa Curves
25
Measured Slurry
20
Measured
Water BEP
15 Cw τy Cw τy
BEP Range
10 63.9% m 1120 Pa 61.5% m 766 Pa
63.4% m 1031 Pa 89.7% m 578 Pa
5
62.8% m 940 Pa NPSH r Curve
0
0 10 20 30 40 50 60 70 80 90 100 110 120
Flow Rate, (l/sec)
63.9% 63.4% 62.8%
61.5% 59.7% Water - 1400 RPM
35
Impeller tip speed - 29.3 m/s
30
NPSHa Curves
25
20
15
10
NPSH r Curve
0
0 10 20 30 40 50 60 70 80 90 100 110 120
Flow Rate, (l/sec)
63.9% 63.3% 62.7% 61.4% 59.6%
60
55
50
45
40
35
30
25
Measured Slurry
20
Measured
Water BEP
15
BEP Range
10
0
0 10 20 30 40 50 60 70 80 90 100 110 120
Flow Rate, (l/sec)
63.9% 63.4% 62.8%
61.5% 59.7% Water - 1400 RPM
Kaolin Test Data – Efficiency
80%
70%
60%
ER = 0.80
Pump Efficiency, (%)
50%
ER = 0.60
40%
30%
ER = 0.40
20%
Measured
Measured
Slurry BEP
Water BEP
Range
10%
0%
0 10 20 30 40 50 60 70 80 90 100 110 120
Flow Rate, (l/sec)
63.9% 63.4% 62.8% 61.5% 59.7% Water - 1400 RPM
Pump Performance
Cw KBP τy Pump HR data Pump ER data

63.9%m 1.491 Pa.s 1,120 Pa 0.83 0.47
63.4%m 1.363 Pa.s 1,031 Pa 0.91 0.65
62.8%m 1.234 Pa.s 940 Pa 0.88 0.62
61.5%m 0.989 Pa.s 766 Pa 0.91 0.68
59.7%m 0.728 Pa.s 578 Pa 0.97 0.78
Pump Performance
1.00 1.00
0.90 0.90
0.80 0.80
0.70 0.70
Head and Efficiency Ratio

0.60 0.60
0.50 0.50
0.40 0.40
0.30 0.30
0.20 0.20
0.10 0.10
0.00 0.00
0 200 400 600 800 1000 1200 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6
Kaolin Bingham Yield Stress (Pa) Kaolin Slurry Plastic Viscosity (Pa.s)
Pump Hr Data Pump Er Data Pump Hr Data Pump Er Data
Comparison with Walker & Goulas
1.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
Walker & Goulas Tested Rep Range
0.00
1.0E+04 1.0E+05 1.0E+06 1.0E+07
Pump Reynolds Number
Walker & Goulas Hr Walker & Goulas Er
Pump Hr Data Pump Er Data

Summary of Findings
§  Centrifugal pumps can pump very viscous high yield stress slurries
§  if sufficient NPSHa is provided
§  The slurry head curves derate more at the low flow rate than at high flow rates
§  The pump’s BEP shics to the lec of the water performance curve
§  The pump head and efficiency ra6os are calculated at the pump BEP for slurry
§  The pump head and efficiency performance decreases as the Bingham yield stress
and plas6c viscosity increases,
§  Theore6cal method provided by Walker and Goulas remains a very useful design
tool
§  over predicts efficiency dera6ng by more than 20% based on the measured data
§  provide a conserva6ve lower bound for head dera6ng es6mates
This paper demonstrates that it is possible to pump
very viscous, high yield stress slurries with limited
head and efficiency de-rating using centrifugal
pumps, PROVIDED THAT POSITIVE SUCTION
CONDITIONS ARE MAINTAINED AT ALL TIMES.
millMAX:
PATENTED ON-LINE ADJUSTABLE
WEAR RING BENEFITS
CONVENTIONAL FLOW
RECIRCULATION
Based on Clearance Versus Pump

Speed
CLEARANCE 1400 RPM 1700 RPM
.300 mm 0.012" 3.52% 4.03%
.432 mm 0.017" 6.06% 6.65%
.508 mm 0.020" 7.92% 8.62%
.737 mm 0.029" 13.20% 13.90%
1.000 mm 0.040" 18.70% 19.60%
Ref: R.J. Stepanoff – Centrifugal and Axial Flow Pumps

27
SOLIDS CONCENTRATION IS HIGHEST
AT IMPELLER SHROUDS
Concentration of
Slurry is Cv= 10%
Concentration at
Suction Shroud is
Cv= 24.6%
Reference: University of Kentucky Hydraulics Laboratory The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
28
SUCTION SIDE WEAR PATTERN
BEFORE AFTER
Suction-Side
Wear Zones
Solids Quickly
Erode Running
Clearances
29
millMAX PATENTED SOLUTION
30
EXTERNAL WEAR ADJUSTMENT SCREW
31
SETTING CLEARANCES
Adjustments Can be Done

Throughout the Service Life of the
Parts:
§  While the pump is running.
§  Without disconnecting the drive.
§  Without moving the impeller and

shaft assembly.
§  Without disturbing guards or v-belt

drive.
32
KREBS millMAX RESULTS
Wear Life Increases 11/2 to 3 Times
millMAX Impeller after GIW at 550-750 hours

1700-2000 hours
33
millMAX™ Patented Solution
Integrated in the slurryMAX, High Head and

gravelMAX designs
slurryMAX High Head
gravelMAX
Acknowledgements
§  FLSmidth
§  P&C Laboratory Personal
§  Australian Centre for Geomechanics, University of Western Australia for
permission to use paper first presented at PASTE 2012

9 Jeff PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

9 Jeff PDF

Uploaded by

Copyright:

Available Formats

THE PERFORMANCE OF

§ Anton Paar RheoLAB QC

Kaolin @ 50°C Data Kaolin Rheology

1.00 Tested Range

Mass Solids Concentration, C w .

Kaolin @ 50°C Data Kaolin Rheology

§ Solids Density: 2.6 t/m3

Particle Size (µm)

§ Paste Kaolin: Yield Stress = 1120 Pa

§ 75 mm Boger slump cylinder

150 NB KGV TT TEMPERATURE TRANSMITTER

TT 200 LITER DRUMS

150 NB RUBBER HOSE

63.9% 63.4% 62.8% 61.5% 59.7% Water - 1400 RPM

Cw KBP τy Pump HR data Pump ER data

Head and Efficiency Ratio

Pump Hr Data Pump Er Data Pump Hr Data Pump Er Data

Pump Hr Data Pump Er Data

Based on Clearance Versus Pump

Ref: R.J. Stepanoff – Centrifugal and Axial Flow Pumps

Adjustments Can be Done

§ While the pump is running.

§ Without disconnecting the drive.

§ Without moving the impeller and

§ Without disturbing guards or v-belt

Wear Life Increases 11/2 to 3 Times

millMAX Impeller after GIW at 550-750 hours

Integrated in the slurryMAX, High Head and

slurryMAX High Head

You might also like

§  Anton Paar RheoLAB QC

§  Solids Density: 2.6 t/m3

§  Paste Kaolin: Yield Stress = 1120 Pa

§  75 mm Boger slump cylinder

§  While the pump is running.

§  Without disconnecting the drive.

§  Without moving the impeller and

§  Without disturbing guards or v-belt