hein krimpenfort - mhwirth - large piston diaphragm pumps as a feasible alternative to multistage...

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

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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

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Duplex double-‐ ac=ng pump

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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


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


Process requirements


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


Piston diaphragm pump system

Design parameters


Main pump sta7on

Pipeline profile and hydraulic grade line


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 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


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

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

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


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


Pump “curve”

Slide 39


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


Pump “curve”

Slide 41


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


Pump “curve”

Slide 43


Minimized risk for pipeline blockage

Slide 44


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


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


§  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

hein krimpenfort - mhwirth - large piston diaphragm pumps as a feasible alternative to multistage...

Presentations & Public Speaking

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slurry velocity

slurry pipeline pressure

pump station slurry

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slurry pipeline id

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gsw pumps