Applied Bionics in Pumps for Hydrotransport

Copyright FELUWA Pumpen GmbH

Basics for Hydrotransport

Copyright FELUWA Pumpen GmbH

Who is FeLuWa ?

Fe

: Feuer ( Fire )
Lu

: Luft

( Air )

Wa : Wasser ( Water )

Copyright FELUWA Pumpen GmbH

Market Segments

Minerals & Mining

Power & Energy
Oil & Gas
Food & Pharmacy
Chemical Industry

Copyright FELUWA Pumpen GmbH

Applications

Hydrotransport
Fly & Bottom Ash
Tailingstransfer
Gasifier / Autoclave Feeding
Mine Dewatering
Digester Feeding
Spray Dryer Feeding
Abrasive, corrosive, viscose, homogeneous and especially heterogeneous media
5

Copyright FELUWA Pumpen GmbH

History of FELUWA
Founded in 1901 as pump manufacturer
Mrlenbach New Works in 1982
Flat & Hose-diaphragm pumps since the 1970ties
Joining the ARCA Flow Group in the year 2000
MULTISAFE double hose-diaphragm pumps from 2001
Design and Innovation Awards in 2003 till 2010
New Office Building and Training Center in 2009

Copyright FELUWA Pumpen GmbH

FELUWA Pumpen GmbH

Quality Designed and Made in Germany

No. E 004.009-1

Copyright FELUWA Pumpen GmbH

Basics for Hydrotransport

Our customers handle and transport through pipes

heterogeneous, abrasive and corrosive media with a defined viscosity

The Competing Systems are:

train
truck
belt
and comes to pipelines centrifugal pumps

Copyright FELUWA Pumpen GmbH

Displacement vs. Centrifugal Pumps

Centrifugal Pumps
use excess water to transport solids
# Dealing with the rescource WATER
# Excessive energy consumption due the excess WATER
have a hydraulic efficiency of 70% (if new)
Double Hose-Diaphram Pumps have 97%
# energy consumption of PD pumps is 15-25% better
due to up to 35 m/s impellers and wear plates are worn within 2000h
Double Hose-Diaphragm will stand 8000 h and more.
# cost for the parts, recycling cost, environm., CO2, (pro PD)
# operation safty and reliability (pro PD see Multisafe)

Copyright FELUWA Pumpen GmbH

Pump Characteristic
- Centrifugal versus PD Pump Centrifugal Pump

Positive Displacement Pump

Head [bar]

Pressure [bar]

Speed

Capacity [m/h]
10

Capacity [m/h]
Copyright FELUWA Pumpen GmbH

Displacement vs. Centrifugal Pumps

Decission Process

In case the question of the owner is:

when do I have the first ROI
Centrifugal Slurry Pumps will be the choice

In cases the question is:

what is the total ROI for the livetime of the mine and equipment
- the first choice in any case is the
Piston-Diaphragm-Pump

11

Copyright FELUWA Pumpen GmbH

Project Dimensions

Slurry

capacity

pressure

distance

(m/h)

(bar)

(km)

Bauxit

2000

90

240

Cu/Zn

2500

140

300

Bauxit

500

250

150

Cu/Ni/Co

2250

50

10

Minerals

1500

130

700

12

Copyright FELUWA Pumpen GmbH

No. of PS

Bionics in Pumps

or the
Evolution and Characteristics
of Hose-Diaphragm Pumps

13

Copyright FELUWA Pumpen GmbH

Evolution of Hose-Diaphragm Pumps

- Piston Pump Outlet
Check valve
(One-way valve)

Piston

Inlet
14

Copyright FELUWA Pumpen GmbH

Evolution of Hose-Diaphragm Pumps

- Piston Pump Outlet

Outlet
Suction stroke

Discharge stroke

Piston

Inlet

Piston

Inlet

15

Copyright FELUWA Pumpen GmbH

Piston Pump // Hose-Diaphragm Pump

Outlet

Outlet

Flexible hose

Piston

Piston

Hydraulic liquid

Inlet

Inlet

16

Copyright FELUWA Pumpen GmbH

Evolution of Pumps
- Hose-Diaphragm Pump Outlet

Outlet

Piston in rear position

=
End of suction stroke

Piston in front position

=
End of discharge stroke

Piston

Inlet

Piston

Inlet

17

Copyright FELUWA Pumpen GmbH

Evolution of Pumps
- Hose-Diaphragm Pump Housing

Outlet

Piston

Diaphragm

Pumped medium

Inlet

Hydraulic liquid
18

Copyright FELUWA Pumpen GmbH

Evolution of FELUWA MULTISAFE Pump

the unique MULTISAFE Double-Hose-Diaphragm Pump since 2000
FELUWA - MULTISAFE
Double-Hose-Diaphragm

FELUWA 1960
traditional design
19

FELUWA from 1970

hose diaphragm
Copyright FELUWA Pumpen GmbH

Hermetically Sealed Process Pumps

Double Hose-Diaphragm and Its Benefits
Hydraulic actuation of MULTISAFE hose-diaphragms

20

Copyright FELUWA Pumpen GmbH

v
v vv v vv
v
v
v
v
v

v
vv v
v v
v v vv v v
v

Maximum contraction during the discharge stroke

v v

v
v
v
v v
v v
v
v
vv
v
v v
vv
v
v

Initial situation

MULTISAFE Pumps
- Double Hose-Diaphragm -

Double safety
Inner
diaphragm

Both hose-diaphragms
are in direct contact

Outer
diaphragm

21

Copyright FELUWA Pumpen GmbH

Hose-diaphragms are
never stretched!

Double Hose-Diaphragm Pumps

- Working Principle -

22

Copyright FELUWA Pumpen GmbH

Double Hose-Diaphragm Pumps

- Advantages Double safety due to two hose-diaphragms
Hermetically sealing between medium,
hydraulic drive system and environment
Linear flow path without deviations
Less or no sedimentation
No dead pockets
Pump housing is never in contact with the
medium
Small and compact pump head
Fast volume exchange in pump head
High efficiency high energy savings
Hydraulic Efficiency: > 97%
Overall Efficiency: > 85%
23

Copyright FELUWA Pumpen GmbH

FELUWA Standard Range

24

Copyright FELUWA Pumpen GmbH

FELUWA MULTISAFE Quintuplex

Double Hose-Diaphragm Pump
MULTISAFE Quintuplex
pumps provide
lowest pulsations

Up to 1000m/h 4400gpm
Up to 320bar 4640psi

5 Heads
25

Copyright FELUWA Pumpen GmbH

Cost Efficiency of MULTISAFE Pumps

Investment
Lifetime
Energy

MULTISAFE
Double Hose-Diaphragm Pump

Efficiency

Efficiency

Energy

Lifetime
Availibility

Changing Time
Downtimes

Investment
&
Operating Exp.

26

Costs for Spares

Maintenance

Copyright FELUWA Pumpen GmbH

Spares
Maintenance
Availibility

Valve System
Ball Valves
Quick Change
Diagnostic
Downflow
Multiple Pump
Control

Double Hose-Diaphragm Pumps

- Pressure sensor -

Pressure detection of the area in

between the two hose-diaphragms
Normally pressure free
Pressure increases if one diaphragm
fails
Alarm is set if one hose-diaphragm
fails
Pump operation can be continued
without any restriction until the
system allows for a shutdown and
repair.

Foliennr.

27

Copyright FELUWA Pumpen GmbH

Double Hose-Diaphragm Pumps

- Flat vs. Hose-Diaphragm Flat diaphragm

Double hose-diaphragm

Pump head volume

about 40% smaller
3 times higher
filling ratio
About 5%
higher efficiency
Pumped medium is
in contact with
diaphragm housing

filling ratio =
28

pumped volume
max medium volume

Copyright FELUWA Pumpen GmbH

Pumped medium is
in contact with
diaphragm, only

Unique MULTISAFE design

- Comparison of Fluid Wetted Items -

Example: ZGL 300/250 2K 180 4 SM 460 HD Example: TGK 300/250 K 180 DS 100 HD

Weight of wetted parts: 6,400 kg

29

29

Weight of wetted parts:

150 kg
-97,7%

Copyright FELUWA Pumpen GmbH

Valve Types
- Corner vs. Linear Valves -

30

Copyright FELUWA Pumpen GmbH

MULTISAFE Check Valves

- Ball Valve Open position

No. E 2201103-2

31

Closed position

Copyright FELUWA Pumpen GmbH

Heinz M. Ngel

Valve Types
- Ball Valve Assembly -

steel sealing

Foliennr.

32

revearsable
valve seat

Copyright FELUWA Pumpen GmbH

MULTISAFE Check Valves

- Quick Change System -

Foliennr.

33

Copyright FELUWA Pumpen GmbH

Special Configurations
- Double Valves -

Double Valves
Double valves are used for
critical processes, which do not
allow an interrupted flow.
Double valves provide doublesafety against smallest leakages.
Double valves reduce the wear of
the valves and increase
maintenance intervals.

34

Copyright FELUWA Pumpen GmbH

FELUWA Check Valves in Quick Change Design

with Hydraulically Supported Fastening in Single
or Double Valve Design (as per Illustration)

35

Copyright FELUWA Pumpen GmbH

Diagnosis Systems
- Energy Loss in Case of Leaking Check Valves Leakage in discharge and/or
suction valve

36

Copyright FELUWA Pumpen GmbH

Diagnosis Systems
- FELUWA Valve Performance System (FVPMS) -

Valve
sensor

37

Copyright FELUWA Pumpen GmbH

Energy
loss

Start of
valve wear

Time
38

Copyright FELUWA Pumpen GmbH

Power

Flow Rate

Energy Savings by
Valve Wear Detection

FELUWA Pulsation Dampener

- combined air vessel & diaphragm -

Bladder
accumulator

Additional
air cushion
(air vessel)

39

Copyright FELUWA Pumpen GmbH

Multiple Pumps
- Pressure Pulse Optimisation -

Pump 1

Pump 2

Pump 3

Resulting pulsation on common discharge pipe

Wrong
phaseshift

or

40

Copyright FELUWA Pumpen GmbH

Optimized
phaseshift

Multiple Pump Control

- Phaseshift Control of 3 Triplex Pumps Sum of 3 triplex pumps

Volume flow [a.u.]

3
2,2%

23,2%

23,2%

1
3 triplex pumps
without phase shift

3 triplex pumps
with optimized phase shift

0
0

100

200

300

400

500

Crankshaft angle []
41

Copyright FELUWA Pumpen GmbH

600

700

Multiple Pump Control

- Pressure Pulse Optimisation -

Pump 1
Resulting flow to
pipeline
Optimized
phaseshift
Pump 2

Optimized phaseshift, when a

pump is shut off
Pump 3

42

Automatic speed increase to

avoid a standby pump

Copyright FELUWA Pumpen GmbH

Transport of Solid Particles

Homogeneous

MIXTURE

Heterogeneous

Length of
discharge
stroke

Low
sinking rate

Sinking
rate
High
sinking rate

43

Copyright FELUWA Pumpen GmbH

Diaphragm Failure Caused by Sedimentation

44

Copyright FELUWA Pumpen GmbH

Special Configurations
- Downflow Transport Downflow Technology
in everyday life!

Flow
PD Ketchup Pump
(hand-operated)

45

Copyright FELUWA Pumpen GmbH

Pumping of Heterogeneous Mixtures

Downflow Configuration for the handling of
particulary heavy
solids and heterogeneous mixtures

Downflow Configuration
=
Flow from the top to the bottom
of the pump
Downflow Configuration is the
counteragent against sedimentation
inside the pump

46

Copyright FELUWA Pumpen GmbH

Hydro Transport

Boleo
750 m/h 46 bar

47

Copyright FELUWA Pumpen GmbH

Summary
Double hose-diaphragm pumps combines lowest energy consumption and
highest availability and reliability by

Highest efficiency independent of flow

Linear flow pass through the hose-diaphragm
Quintuplex gear system with 5 heads up to 1000m/h per pump
Linear ball valves with Top Entry, Quick Change & wear detection
Optimized phase-shift control for multiple pumps
Downflow Technology

48

Copyright FELUWA Pumpen GmbH

Hydrotransport

49

Copyright FELUWA Pumpen GmbH

Ready for the future

Pump type

Power [kW]

TGK 500

3.000

50 to 250

up to 750

QGK 500

3.500

50 to 250

up to 1000

(e.g. Boleo)

1.100

46

750

50

Pressure [bar]

Copyright FELUWA Pumpen GmbH

Flow [m/h]

Process Pumps / Feeding

51

Copyright FELUWA Pumpen GmbH

High Pressure and Low Pressure Pumps

No. E 2201052

52

Copyright FELUWA Pumpen GmbH

Heinz M. Ngel

FELUWA Quadruplex High Pressure Hose Diaphragm

Piston Pumps for Four-Burner Type Gasifiers

No. E 2201051

53

Copyright FELUWA Pumpen GmbH

Heinz M. Ngel

FELUWA Hose Diaphragm Piston Pump

Quadruplex Configuration
Double-Acting Two-Cylinder Pump

Nr. D 2109499-21

54

Copyright FELUWA Pumpen GmbH

Heinz M. Ngel

FELUWA Hose Diaphragm Piston Pump

Quadruplex Configuration
Double-Acting Two-Cylinder Pump

No. E 2201085-1

55

Copyright FELUWA Pumpen GmbH

Heinz M. Ngel

FELUWA Multisafe

56

Copyright FELUWA Pumpen GmbH

FELUWA Multisafe

57

Copyright FELUWA Pumpen GmbH

FELUWA Multisafe

Folio No. E 2102050

58

Copyright FELUWA Pumpen GmbH

FELUWA Multisafe

Folio No. E 2102050

59

Copyright FELUWA Pumpen GmbH

FELUWA Multisafe

Folio No. E 2102050

60

Copyright FELUWA Pumpen GmbH

FELUWA Areal View

Thanking for your kind attention

61

Copyright FELUWA Pumpen GmbH