Presentación Técnica #06 - Roudnev Aleks - Weir Minerals PDF

Date: August 1, 2013
Weir Minerals Division
MINEPUMP 2013
August 1 - 2, 2013
Centrifugal Slurry Pumps

for Mining Industry of Today
Prepared by: Aleks Roudnev, Manager of R&D, WMNA
Confidential Information
This document contains information which is confidential to companies forming the Weir Minerals Division.
It should not be disclosed in whole or in part to parties other than the recipient without the express written
permission of Weir Minerals Division authorized personnel.
*KHD is a Humboldt Wedag GmbH brand used under licence by The Weir Group
Weir Minerals Division MINEPUMP 2013
Concentrator Plant 2
Presentation Outline
 Pumps for Mill Circuits
 Pumps for Hydrotransport and Tailings
 Pumps for Frothy Mixtures

Mill Circuit Pump

Slurry Pumps for Mill Circuits 5
Presentation Outline
 Pump Classification
 Design Criteria and Specifications
 Design Features
 Assembly and Maintenance
 Application Evaluation
Weir Minerals - FULL HOUSE Solution

Rubber lined piping
Rubber lined tanks
Cyclones
Hoses & Spools
Valves
Mill Circuit Pumps

type MCR
Mineral Processing – Mill Circuit Area
%TOC vs Useful Life 2c/kWhr Energy

Materials
80 Capital
% Total Ownership Cost

70
60
50
40
30
20
10
0
0 5000 10000 15000 20000 25000
Useful Life (Hrs)

Materials
120 Capital
100
80
Parity of Production on 60
Power Consumption 40
20
0
0 5000 10000 15000 20000 25000
Useful Life (Hrs)
MCR / MCM Mill Circuit Pumps

Pump Classification 9
 Pumps can be classified by “Standard” slurry application (Severe,

Heavy, Medium, Light)
(Corresponding ANSI/HI Slurry Pump Standard service classes 4,3,2,1)
 Life of pump in any application depends on

 Impeller outlet/inlet diameter ratio
 Impeller diameter/width ratio
 Volute cutwater/impeller clearance
 Thickness of wearing sections
10
ANSI/HI 12.1–12.6 - 2011 Service class/Materials

11
WMD – Mill Circuit Pumps are for Severe Duty

12
WMD – Mill Circuit Pumps are for Severe Duty
 Severe Duty Pump Range is called MC (Mill Circuit)

series :
 MCR (Mill Circuit Rubber Lined with Metal Impeller)
 MCR-U (Mill Circuit Metal Unlined)
 MCM (Mill Circuit Metal Lined)
13
Mill Circuit Pump – Design Criteria
 Maximum Wear Life while Maintaining Pump Efficiency
 Predictable Wear Life - Exclude Catastrophic Failures
 Equal/Multiple Wear Life of Wet End Components
 Ability to Handle Coarse Solids and Mill Tramp
 Ability to Operate Over Range of Mill Duty Flow Rates
 Ability To Handle High Slurry Concentrations of 45-65 %

MC Pump – The Range 14

Severe duty - Pump Plan Summary 15
 Severe duty – MC range

 Mill circuit, water flush crushers, coarse tailings
 Unlined metal or cased rubber with interchangeable metal
 Size range: 125-750/760 (850?)
 Features
 Adjustable throatbush for all sizes
 Extra thick rubber liners
 Extra thick metal casing
 Extended impeller shrouds (patented)
16
Larger Mill Circuit Pumps
 To meet the mill circuit severe duty

application MC pump is designed as
a “Market Specific” pump
 Large diameter impellers
 Thick liners
 Interchangeable Rubber & High Chrome
 Adjustable side liners, Throatbush & FPLI
 Centerable stuffing box
 Maintenance friendly
 Proved out design concepts in a smaller
350 MCR (16x14) pump 1995
17
450 MCR
 20”x18” pump designed 1996
 Flows to 4,620 m3/hr
(20,340 GPM)
 Pump weight 15,600 kgs, (34,400
lbs)
 High Chrome Iron 1495 mm dia.
Impeller (58.9“)
 4 Piece Thick Rubber Liners
 Split casing design, frame & cover
plate
 Minimum number of casing bolts
 First pump installed in Copper
Mine in Chile 1998
18
550 MCR
 Flows to 5,940 m3/hr (26,200
GPM)
 Pump weight 21,930 kgs,
(48,246 lbs)
Impeller (63.2”)
 Split casing design, frame &
cover plate
Mine in Chile 2001
19
650 MCR
 Flows to 10,000 m3/hr (44,000
GPM)
(66,770 lbs)
Impeller (69.3”)
 Split casing design, frame &
cover plate
 Minimum number of bolts
Mine in S.E. Asia 2004
20
750 MCR
 Flows to 15,650 m3/hr (68,900
GPM)
(99,440 lbs)
Impeller (80.3 “)
 4 Piece split casing design, frame
plate & adaptor, cover plate &
suction cover
Mine in Chile 2010
21
Pump Specifications
650MCR
Rubber Lined
Mill Circuit Pump
650MCR-U
Hard Metal Unlined
Mill Circuit Pump
Pump Specifications 22
Weir Minerals 650 MCR Severe Duty Slurry Pump

Pump Specifications 23
Weir Minerals 650 MCU Severe Duty Slurry Pump

24
MC Pump – Mill Circuit Design
 Balanced Hydraulic Design Concept. - Hydraulic design based on more than 25 years of
fundamental and applied research
 Actual wear performance studies conducted in the field. Unique

programs developed for hydraulics design and wear evaluation
 Modifying impeller hydraulics by optimising vane angles, profiling vane

tip to reduce inward spiral flow, increasing vane / shroud thickness and
correcting expelling vane height, resulting in extending Impeller wear
life.
 Volute design method based on a “constant vortex” principle.
 Design differs from the competitors and provides for longer service life
and enhanced power consumption.
25
MC – Mechanical Design Features
 Safety - Easy to fit elastomer liners. Backed by ductile iron casing halves,
this achieves durability, strength & long service life.
 Adjustable side liners maintain pump efficiency & extend wear life i.e. full
face adjustment.
 Metal side liners are interchangeable with rubber (optimisation based upon
solids type).
 Interchangeable elastomer & metal bolt-in design provide ease of

maintenance & results in less down time.
 Unique designed, centered stuffing box, reduces gland seal maintenance &
extends packing life.
26
Slurry Pump Impeller Hydraulic Design
Mill circuit pumps use large

diameter, slower rotating
impellers with thicker vanes
and shrouds.
Vane number is low to provide

for required passage size.
Despite these compromises

pump efficiency is high, up to
87% on larger sizes.
27
Pump Impeller – Flow Modelling
Vane Inlet Flow Modelling Vane Inlet Edge Velocity Profile

Typical Standard (5 vane) Impeller Wear

28
EL style (4 vane) Impeller Wear

29
Copper/Gold Mine, Australia

Pump - Volute 30
Weir Minerals 650 MCU Severe Duty Slurry Pump Volute Casing
 100 mm (4 in) thickness

 Ultrachrome and Hyperchrome
650+ BHN minimum
MC Pump - Adjustable Suction Side Liner 31
Suction side liner

(THROATBUSH)
Liner adjustment
screw
Impeller
Suction
flange seal
MC Pump – Unique features 32
 Maintain the impeller front seal face clearance

without moving bearing assembly, completely
independent of the drive
 Allows customer to maintain drive side clearance,

and expelling performance to protect the stuffing
box
 Throatbush and Frame Plate Liner Insert are

adjustable using patented
elastomer seal
 EMLTM patented technology eliminates hard iron

machining on the side liner inserts
MC Pump - Impeller Front Seal 34
Copper/Gold Mine, Australia
3000 hours
Adjustment
MC Pump - Adjustable Stuffing Box 35
Stuffing box Centering tool

Shaft
sleeve
Shaft
MC Pump - Stuffing box arrangement 36
 Adjustable stuffing box assures concentricity to shaft sleeve
 Close tolerance
lantern restrictor
 Minimum gland
water consumption
 Longer sleeve life
 Forgiving design
allows adjustment to
compensate for
piping loads
650 to 760 MC split stuffing box 37
 Split stuffing box to allow replacement without removing wet end

 Split lantern restrictor, now o-ring mounted
 Impeller release collar with two

taper angles
 Complete disassembly to
release impeller not required
Weir Minerals MC Pumps: Design 39
Throatbush
Throat wear – 15mm
Average wear 40mm to 45mm (33 weeks)
Preventive Maintenance
Wear Adjustment Table 40
X
Template
Wear (mm / week) = (X(mm) / Number of weeks)
Alignment notch
Throatbush Adjustment 41
Back the throatbush puller stud nuts off the desired amount of adjustment based on Table
from previous slide. This will control the throatbush movement towards the impeller.
NOTE: Using shims or a feeler gage under the washer to control the offset is
recommended as shown below.
Shim
Throatbush 42
Adjustment
Pump Size (MM) Maximum Adjustment for
MC Pumps in (MM)
150 20
200 30
250 30
350 45
400 40
450 45
550 80
650 80
750 75
43
Weir Minerals MC Pumps: Design
Volute Liner Wear Template
44
Volute Liner Wear Template
Volute Liner Wear 45mm
50mm
55mm
45
How to Assemble MCR Pumps

250 – 750/760 MCR
 Typical wet end assembly 450 MCR frame plate

 Install FPLI studs
 Lift FPLI with tool
46

250 – 750/760 MCR
 Lower FPLI into frame plate

 Strap frame plate liner
47

250 – 750/760 MCR
 Lower frame plate liner over FPLI

48

400 – 750/760 MCR
 Initial pump assembly 550 MCR example

 Components typically shipped as shown
49
400to Assemble
How – 750/760MCR MCR
Pumps
 FPLI & throatbush lifting tool used to lift up into frame plate vs
lowering into frame plate
 Easier to install studs into liners
50

400 – 750/760 MCR
 Pick up frame plate using a three point pick

400 – 750/760 MCR 51

 Lower frame plate over FPLI & lifting tool sub assembly
52
400to Assemble
Pumps
 Lift FPLI up into frame plate and tighten FPLI nuts

 Install pusher bolts
53
400to Assemble
Pumps
 Lift up frame plate & FPLI subassembly

54
400to Assemble
Pumps
 Lower frame plate over frame plate liner

 Install liner nuts
55
250to Assemble
Pumps
 Using two point pick install frame plate sub assembly on to base
56

 A 2 piece design coverplate - 400 and
larger
 Allows access to replace the impeller or
throatbush without disconnecting the
discharge piping or splitting the casings
57
Two Piece Cover Plate
 Remove Suction Cover

and Throatbush
subassembly
58
 Suction Cover lifting beam has pick

points for rubber or metal Throatbush
59
 Impeller lifting beam has

moveable lower jaw for new vs
worn impeller
60
 Provides ability to replace Throatbush or

Impeller without removing discharge
piping or removing the Cover Plate
61

 Left Hand or Reverse
Rotation Option
 Common parts, only
requires a new shaft
and impeller due to
the thread
 4 piece design on
750/760 MCR
 4 & 5 vane impeller
options
 Back Filled option
62

 High Chrome Iron Liner option
 Designed 400, 450, 550, 650, 750
 400 MCM operating at IOCC
 Ability to mix rubber and metal side
liners
63
MC Mechanical Ends
Non Adjustable Frames 64
M100, M150, M200 & M240

Diameter of shaft at drive end
Low Profile
65
Performance test 550 MCR

3/26/08 5:28 PM Results at Test Speed
Time Stamp Test RPM Flow (GPM) Head (feet) BHP Efficiency (%) NPSHA (ft)
17:03:14 1 303 901 133.6 268.2 11.3 51.7
17:04:39 2 302 3369 135.1 327.8 35.1 50.3
17:06:24 3 302 6356 134.9 404.4 53.5 50.4
17:08:19 4 302 9353 133.2 483.8 65.0 50.1
17:10:14 5 302 12337 131.0 554.2 73.7 49.6
17:11:59 6 302 15130 127.4 610.6 79.7 49.2
17:13:34 7 302 18234 123.4 679.1 83.6 48.4
17:25:19 8 303 20534 120.1 731.0 85.2 48.0
17:24:10 9 303 22817 116.3 777.0 86.3 47.4
17:27:57 10 303 25417 112.3 828.0 87.0 46.0
17:19:54 11 302 28198 107.2 880.5 86.7 44.8
17:21:24 12 303 29944 104.2 914.2 86.2 43.9
Enter RPM Results stepped to 300 RPM
300 Test RPM Flow (GPM) Head (feet) BHP Efficiency (%)
1 300 894 131.4 261.5 11.3
3/26/08 5:28 PM 2 300 3342 132.9 319.8 35.1
3 300 6304 132.7 394.6 53.5
4 300 9277 131.0 472.0 65.0
5 300 12236 128.9 540.7 73.7
6 300 15006 125.3 595.7 79.7
7 300 18086 121.4 662.7 83.6
8 300 20361 118.0 712.7 85.2
9 300 22620 114.3 757.1 86.3
10 300 25202 110.4 807.2 87.0
11 300 27965 105.4 858.8 86.7
12 300 29695 102.5 891.6 86.2
550MCR- UMC55145EL1 - 300RPM - 3/26/2008
180 90
160 80
140 70
120 60
Head (ft)
Efficiency %
100 50
80 HD 40
60 HD DP 30
40 EFF 20
20 EFF DP 10
0 0
0 5000 10000 15000 20000 25000 30000 35000
Flow (GPM)
Performance Test
66
 650 MCR initial validation test

 Used to confirm actual pump operating
condition
 Customer witness tests
 Offsite Online viewing
Pump Maintenance
67
 3D very detailed pump maintenance and operating manuals

 Cast in Lugs for ductile iron non wear components
 Provide lifting beams for individual wear components
Pump Maintenance
68
 Lifting Beam for 4 & 5 vane Impellers

 Beams can safely lift both new and worn parts
 Bottom hook (blue piece) is unbolted and rotated as needed
Pump Maintenance
69
 With the correct tools / beams the

large 750 MCR pumps can be safely
maintained
Pump Maintenance
70
 Some customers with large crane

capacity will move complete pumps or
large sub assemblies
 Assign dedicated rebuild locations with all
required tools, spare pump
71
Quick Change Out
 New Wet End Installation

 Assembly of complete 550 MCR
72
Quick Change Out
 Install the frame plate liner and FPLI into frame plate
 Strap impeller and lower hub into FPLI bore
 Depending on discharge orientation slide the
impeller hub towards the 6 o’clock position
until it contacts the bore of the FPLI
SHAFT SLEEVE O-RINGS
Arrow direction shown for

discharge position A
73
Quick Change Out
 Install cover plate liner into cover plate

 Lower cover plate assembly
onto frame plate
 Install cover plate bolts
with anti-rotation nuts
74
Quick Change Out
 Install throatbush onto suction cover

 Lower suction cover
assembly into cover
plate and fasten
 Install throatbush
pusher bolts
75
Quick Change Out

 650 MCR wet end – 6 hours
 Fly in the complete wet
76
Quick Change Out
Start
Improving Performance – Over many Years 77
 Revising cutwater clearances and tongue geometries
 Modify impeller hydraulics
 Optimizing Impeller shroud thickness

Perpetual Process
 Correcting Impeller expelling vane height and length
 Increasing Elastomer liner or Volute thickness

MC Pump – The Range Development 78
760
79
Revisiting - Mineral Processing – Mill Circuit Area

Materials
80 Capital

70
60
50
40
30
20
10
0
0 5000 10000 15000 20000 25000
Useful Life (Hrs)

Materials
120 Capital
100
80
Parity of Production on 60
Power Consumption 40
20
0
0 5000 10000 15000 20000 25000
Useful Life (Hrs)
80
Mill Circuit Pumps – Power is the issue …
(Spares)
25 - 30
%
Capital Cost
(Energy)
55-60 %
(Capital Cost)
5-10 %
Five Year Operating Costs
81
Mill Circuit Pump Evaluation Criteria:
•
•Initial Capital Cost
•Pump Component Life / Mill Availability
•Parts Costs
•Energy Costs
•Seal Water Consumption
•Maintenance Costs Associated with Repair
•Inventory
82
•
• Factors which affect initial capital cost.
• Pump size & design
• Efficiency
• Materials of construction
• Drive arrangement
• Floor layout / footprint
Mill Circuit Pump Evaluation Criteria: 83
• Example on pump size & efficiency: 14,000 GPM @ 100’ Head
•
Horizontal Pump 400 MCR Horizontal Pump 450 MCR
CURVE SHOWS APPROXIMATE PERFORMANCE FOR CLEAR WATER (ANSI/HI 1.6-2000 Centifugal Pump Test Standard unless otherwise specified). For media other than water, CURVE SHOWS APPROXIMATE PERFORMANCE FOR CLEAR WATER (ANSI/HI 1.6-2000 Centifugal Pump Test Standard unless otherwise specified). For media other than water,
corrections must be made for density, viscosity and/or other effects of solids. WEIR MINERALS reserves the right to change pump performance and/or delete impellers without notice. Frame corrections must be made for density, viscosity and/or other effects of solids. WEIR MINERALS reserves the right to change pump performance and/or delete impellers without notice. Frame
suitability must be checked for each duty and drive arrangement. Not all frame alternatives are necessarily available from each manufacturing centre. suitability must be checked for each duty and drive arrangement. Not all frame alternatives are necessarily available from each manufacturing centre.
200 Pump 225 Pump
Discharge 16'' Discharge 18''
190 50% 60% Suction 18'' Suction 20''
450 rpm 70%
Impeller 50% 60% Impeller
180 75% 70%
Vanes 5 200 400 rpm 75% Vanes 5
78%
Vane ø 48.25'' 78% Vane ø 56.3''
170 80%
Type Closed 80% Type Closed
160 81% Part No Material Part No Material
TUMC40147 Metal 175 83% TUMC45147 Metal
81%
150
400 rpm 80% Frame (Rating - HP) Frame (Rating - HP)
83%
78% M150 1609 M150 1609
140
TU 1609 80% TU 1609
r
350 rpm
SH
NPSHr
150
Y
NP
130 Seal Seal
IE NC
C Y
IEN
Gland Sealed Pump
E FFIC
120 Hydroseal ® Sealed Pump
IC
350 rpm
EFF
Head, H (ft)
Head, H (ft)
110 125
Liner (Norm Max r/min) Liner (Norm Max r/min)
30ft
100 Elastomer 450 Elastomer 400
300 rpm
Min Passage Size Min Passage Size
25ft
30ft
90 100
5.25'' 6.5''
300 rpm
80 Curve Curve
25ft
Revision 0 Revision 1
20ft
70 Revision Notes B 75 250 rpm Revision Notes
Reference Min. Passage Size revised
60 250 rpm
20ft
Madison test 050903 & Artarmon Issued Jul 09
15ft
test 2561 A,B,C A4P-3686 A,B,C
50
Issued Sep 05
50 200 rpm
15ft
40 200 rpm
10ft
8ft
10ft
30
25
20
10
© 1/2011 Weir Minerals North America © 1/2011 Weir Minerals North America
All Rights Reserved All Rights Reserved
4000 8000 12000 16000 20000 24000 4000 8000 12000 16000 20000 24000 28000 32000
TYPICAL PUMP PERFORMANCE CURVE TYPICAL PUMP PERFORMANCE CURVE
Flow Rate, Q (usgpm) T-4701 Flow Rate, Q (usgpm) T-4801/1
Both fit duty conditions!

84
Wear trend chart – volute casing

VARIATION OF RELATIVE WEAR RATE AROUND THE CASING FOR VARIOUS FLOW RATES
2.50
A
Medium Specific Speed Design H T B
G C PERCENT
B.E.P.
2.00 D
F FLOWRATE
E
30%
BIASED TOWARDS CUTWATER 40%
RELATIVE WEAR RATE
50%
1.50 60%
70%
80%
90%
100%
1.00 110%
BEST CHANCE OF EVEN WEAR 120%
130%
0.50
BIASED TOWARDS DESIGN SECTION
0.00
H T A B C D E F G H
CASING WALL SECTIONS PUMP TYPE: ns = 28 (app Ns = 1450)
85
•
• Example on pump size:
Horizontal Pump 400 MCR
400 MCR Pump:
CURVE SHOWS APPROXIMATE PERFORMANCE FOR CLEAR WATER (ANSI/HI 1.6-2000 Centifugal Pump Test Standard unless otherwise specified). For media other than water,
corrections must be made for density, viscosity and/or other effects of solids. WEIR MINERALS reserves the right to change pump performance and/or delete impellers without notice. Frame
suitability must be checked for each duty and drive arrangement. Not all frame alternatives are necessarily available from each manufacturing centre.
• 100% of BEP Flow
200
190
450 rpm
50% 60%
70%
Pump
Discharge
Suction
16''
18''
• Pump RPM 361
• NPSHr = 23’
75% Impeller
180
78% Vanes 5
170 80% Vane ø 48.25''
Type Closed
160
150
400 rpm
81%
81%
80%
Part No
TUMC40147
Frame (Rating - HP)
Material
Metal • Efficiency 81%
78% M150 1609
140
TU 1609
r
SH
NP
130 Seal
Benefits:
C Y
IEN
120 Hydroseal ® Sealed Pump

IC
350 rpm
EFF
Head, H (ft)
110
• Lower Capital Cost

Liner (Norm Max r/min)
100 Elastomer 450
Min Passage Size
30ft
90
80
300 rpm
Curve
5.25''
• Efficiency 81%
25ft
Revision 0
• Smaller Footprint
70 Revision Notes B
Reference
60 250 rpm
20ft
Madison test 050903 & Artarmon

test 2561 A,B,C A4P-3686 A,B,C
• Lower pump and parts costs

50
Issued Sep 05
15ft
40 200 rpm
8ft
• Lower pump and parts weight

10ft
30
20
10
© 1/2011 Weir Minerals North America
All Rights Reserved
4000 8000 12000 16000 20000 24000
TYPICAL PUMP PERFORMANCE CURVE
Flow Rate, Q (usgpm) T-4701

Detractors:
• Limited on increase in flow
• High NPSHr requirements
• Higher impeller RPM
86
•
• Example on pump size:
450 MCR Pump:
• 76% of BEP Flow
Horizontal Pump 450 MCR
CURVE SHOWS APPROXIMATE PERFORMANCE FOR CLEAR WATER (ANSI/HI 1.6-2000 Centifugal Pump Test Standard unless otherwise specified). For media other than water,
corrections must be made for density, viscosity and/or other effects of solids. WEIR MINERALS reserves the right to change pump performance and/or delete impellers without notice. Frame
• Pump RPM 294
• NPSHr = 12’
suitability must be checked for each duty and drive arrangement. Not all frame alternatives are necessarily available from each manufacturing centre.
225 Pump
Discharge 18''
Suction 20''
200 400 rpm

50% 60%
70%
75%
78%
Impeller
Vanes
Vane ø
5
56.3''
• Efficiency 79%
80% Type Closed
Part No Material
175 83% TUMC45147 Metal
150 350 rpm

83%
80%
Frame (Rating - HP)
M150
TU
1609
1609
Benefits:
NPSHr
• Lower impeller RPM

Y
Seal
IE NC
Gland Sealed Pump

E FFIC
• Higher flow capability

Head, H (ft)
125
Liner (Norm Max r/min)
30ft
Elastomer 400
300 rpm
Min Passage Size
• Low NPSHr requirements

25ft
100
6.5''
Curve
Revision 1
20ft
75 250 rpm Revision Notes

Min. Passage Size revised
Issued Jul 09
15ft
50 200 rpm Detractors:

10ft
25 • Higher initial capital cost

4000 8000 12000 16000 20000 24000 28000 32000
© 1/2011 Weir Minerals North America
All Rights Reserved
• Larger footprint
• Heavier pump & parts weight
TYPICAL PUMP PERFORMANCE CURVE
Flow Rate, Q (usgpm) T-4801/1
• Higher parts costs

• Lower efficiency
87
•
Energy cost comparison:
Pump Absorbed $ / KWHr $ / Year Savings

Model kw (7 cents / kw-hr) Based on 8000
US $ / Yr
hrs/yr
400 MCR 488 kw $ 34.16 $273,280 $6,720
450 MCR 500 kw $35.00 $280,000 --------
* Power based on 14,000 GPM flow @ 100 feet Head @ a Slurry SG = 1.50
88

Material costs outweigh initial capital and energy savings:
•
A smaller pump with smaller impeller may provide higher
efficiency, but wear is higher when compared to a larger
pump.
Wear is roughly proportional to the pump rpm (n) cubed.
Ratio of 400 vs 450 MCR pump speed is as follows:

2.85
Relative wear increase = (361/294)
Relative impeller wear life drop = 1.79
450MCR impeller life will be ~ 1.79 longer then the 400MCR

89

Metric 400 MCR 450 MCR
• Impeller Cost
Volute Liner Cost
Impeller Life Cycle 1,955 Hrs 3,500 Hrs
(1.79:1, 400 vs 450)
Impeller Cost / Yr
(8000 Hr / year)
Volute Liner Costs

(8000 Hr / year)
Downtime costs $795,500 $444,300

($32,400/hr) 6 Hrs per pump
size impeller changes only
Total Energy Cost $273,280 $280,000

Total Ownership $1,068,780 $724,300
Cost
Savings / Year $344,480
Downtime costs based on 12,000 TPD gold mill @ 0.12oz/ton head grade @ 90% recovery, $1,400 / oz gold. $800/ oz operating cost
90
•
 Energy is saved but at what cost?
 More frequent parts usage rates

 Increased maintenance
 Lower reliability
Unit malfunctions
 Unscheduled plant outages
 Exorbitant operational costs
 Saving energy at the expense of TOTAL OWNERSHIP

COST is not a good economy
Mill Circuit Pump 91

Tailings Pumps
Slurry Pumps for Tailings and Hydrotransport Service 93
 Multi-staged Pumping
 High Pressure Service
 Pump Train Arrangement
 Pump Train Speed Control

Two basic centrifugal pump arrangements may be used for

pipeline transportation duties:
Higher-pressure rated pumps multiple-staged at only one or a few stations.
Lower-pressure rated pumps spaced evenly along the pipeline.

 Multi-staged Pumping – High Pressure Service

The following features ensure safe, reliable and economic operation of the Weir
Minerals pumps.
 Encased liner design: This is an important safety feature when handling abrasive
and corrosive slurries.
 Ability to interchange pump liners: This is a major benefit when selecting the
most suitable material to resist abrasion.
 Heavy duty pump bearings: These are required as the axial thrust in the last
stages of a multi-staged scheme will be of high value, due to the combined
discharge pressures of the previous pumps acting over the shaft area (taken at
the stuffing box).
Caution: Be mindful of the axial thrust reversal at an intermediate stage.
 Ability to accept either packed gland or mechanical seal.
 Multi-staged Pumping – Pump Train Arrangement

Two basic layouts exist for
arranging a number of pumps ‘in
series’:
a. Parallel shafts (consecutive
pumps side by side)
b. Right angle shafts
(consecutive pumps at 90
degrees)
There are a number of

advantages and disadvantages
for each layout.
Generally pump station size and

configuration determines which
arrangement is used.
The “Parallel” layout allows access from the rear of the pump units. The
arrangement is compact and all pumps can generally be left unsupported
to take up small deflections in pump casings. Wear in the inter-stage piping may be
a problem with abrasive slurries.
The “Right Angle” layout has straight inter-stage piping, which normally provides
good wear life. Straight inter-stage piping can also be designed to be telescoping
which is an advantage for maintenance.
Alternate pump units need to be raised, and discharges vary from top horizontal to
bottom horizontal.
 Multi-staged Pumping Examples

Weir 500 HTP Heavy Duty Slurry Pump

500HTP Pump specifications
 Hydrotransport/tailings duty
 Design flow: 3000 - 7000 m3/hr
(15,000 - 30,000 gpm)
 Head: 50 m (164 ft)
 Specific Speed: 1500 Ns
 Impeller diameter: 1422 mm
(56 inches)
 Solid size: 200 mm sphere
(8 inch)

Pump specifications
 Pump
Performance

600HTP Pump specifications
 Hydrotransport/tailings duty
 Design flow: 4,000 - 9,000 m3/hr
(20,000 – 40,000 gpm)
 Head: 50 m (164 ft)
 Specific Speed: 1700 Ns
 Impeller diameter: 1575 mm
(62 inches)
 Solid size: 241 mm sphere (9.5”),
127 x 127 x 305 mm (5” x 5” x 12”)

Pump specifications
 Pump
Performance
Weir 500 and 600 HTP Heavy Duty Slurry Pump

Pump specifications
 Dual casing
configuration for safe
operation
 4000 Kpa (580 psi)
working pressure
 6000 Kpa (870 psi)
hydrotest pressure
 Foot mounted casing

Pump specifications
 Ductile iron outer casing

 Separate suction cover
 Metal or elastomer throatbush
 650+ high chrome iron liners
 Adjustable stuffing box
 Standard/proven Warman
mechanical end

Casing
 Ductile iron construction

80-65
 Deep rib construction
for
high pressure capability
 Robust foot mount
increases allowable
piping loads
 Reduced stuffing box
to shaft sleeve
deflection

Casing
 Anti-rotation cavity
retains fasteners

Casing/Volute
 Consistent
location of
flanges for pipe
fit-up during
wear part
replacement
 Piping loads
supported by
ductile iron
casing, not high
chrome iron
volute

Casing/Volute
 Inherent double wall

safety
 Volute supported by
massive ribbed
ductile iron casing
 Allows for greater
utilization of wear part
thickness

Separate Suction Cover/Throatbush

allows access to throat
bush, impeller and shaft
sleeve without disturbing
discharge piping


bush, impeller and shaft
sleeve without disturbing
discharge piping


bush, impeller and
shaft sleeve without
disturbing discharge
piping

Throat bush
 Metal or elastomer (rubber)


Throatbush
 Metal or elastomer
(rubber)
100 mm
 Easily replaceable
 Thick cross section
 Metal: 125 mm
 Elastomer: 100 mm
 Elastomer: longer
wear life than high
chrome iron
*500 HTP: 130 mm (metal) and 90 mm
(elastomer)

Impeller
 Specific speed selected for

optimum wear life and
efficiency

Impeller
 Aggressive deep expeller

vanes front and back
 Improve throatbush wear life
 Lower stuffing box pressure
 Lower axial force
 Improve bearing life

Impeller
 Robust thick cross

sections
 4 vane configuration
 Able to pass:
 500 HTP: 8 inch (200 mm)
sphere
 600 HTP: 9.5 inch (240 mm)
sphere

Stuffing box arrangement
 Adjustable stuffing box assures concentricity to shaft sleeve
Assures concentricity of
Stuffing box to shaft sleeve
Close tolerance lantern
restrictor
Minimum gland water
consumption
Longer sleeve life
Forgiving design allows
adjustment to compensate
for piping loads

Ease of assembly/maintenance
 Part specific
lifting tools
 HTP suction
cover with
mounted suction
liner & lifting tool
 HTP volute liner
& lifting tool
 HTP impeller &
lifting tool
 Reduced
downtime
 Safety
 Multi-staged Pumping Control Options
 The best arrangement in multi-staged pumping application is to have all pumps controlled
by the same VFD settings so that each pump speed ramps up and down as needed.
Variations in flow rate and pressure over time of two six stage pump
trains working sequentially through the same pipe line.
 Having some pumps on VFD and some not, may present operational and wear
challenges, although is quite common. Below is an example tailings application utilizing
two high pressure pumps, one being VFD controlled, the other - fixed speed.
The dramatic difference in operating envelopes and resulting wear life between
the pumps is evident.
 If the control strategy is to have only one pump controlled by VFD, the preference will be
to have it on first stage with certain low speed limit.
In this case, in order to avoid slowing the first pump down too much and create
suction problems downstream, one of the fixed speed pumps, say third or fourth
stage, can be taken off line and left freewheeling.
 A different school of thought calls for having the last stage pump controlled by VFD.
A lot depends on users prior experience and corresponding comfort level.
Flotation Area
Slurry Pumps for Froth Service 125
 Air Entrainment
 System Improvements
 Pump Sizing for Froth Applications
 Warman Froth Pump Selection
 New Developments
126
Background
 Air can be entrained in slurry due to:

 local vortices on free surface of hopper
 tank levels too low (“snoring”)
 incoming streams free falling into tanks
 purposefully adding air via flotation process
 Aeration can:
 affect pump performance reducing developed head and flow
 increase wear on pump parts
 Air bubbles may be:
 finely dispersed throughout the slurry as part of a froth
 large “slugs” or bubbles which can be easily separated from liquid
 or somewhere in between
127
Flotation
 Means to separate wettable particles

 cyclone overflow is fed to flotation cells
 agitator provides vigorous mixing
 air is supplied from a separate compressor
 chemical reagents are added to create froth
 Nonwettable minerals float on top of the froth
 pumped away by froth pumps, or
 scraped off by mechanical devices
 Wettable particles, such as gangue, sink to the bottom
 pumped to secondary grinding for further processing, or
 pumped by tailings pumps to final tailings box
 Flotation process is commonly done in steps
128
System Improvements
 Traditional system modifications to improve performance include:

 Launders
 Baffles
 Feed wells and submerged inlets
 Spray nozzles and misting
 Vent pipes
 Casing rotation
 Tangential inlet
 All of the above are designed to minimize the entrainment of air in the slurry, and to
maximize venting of air in the sump, suction piping and pump.
129
System Improvements
 Baffles:
 a shield for the downward flow
of slurry from the pump
suction
 more horizontal dispersion
and larger surface area of the
slurry to maximize release of
air
 a “dead zone” under the baffle
to allow for additional air
release
 Vent pipes:
 vent pipes assist with removal
of air from the suction and
impeller eye
130
System Improvements
 Submerged Inlets:
 to prevent additional
entrainment of air from
the downward
cascading flow of slurry
 Feed Wells:
 a shield between the
downward flow of slurry
and the pump suction
 lower developed  normal developed
 to allow time for venting
head head
of entrained air and  higher speed
prevent direct ingestion  reduced speed
 higher wear
of air into the pump inlet  expect better wear
131
System Improvements
 Spray nozzles and misting:

 assist in breaking down the froth
and releasing air bubbles from
the slurry in the launders and
sump
Mist spray on active side of baffle
Lack of mist spray on inactive side of baffle

132
System Improvements
 Vented Suction Pipe:

 may consist of an
inverted tee with
vented stand
pipe, or
 oversized inlet
with eccentric
venting back to
suction tank/sump
133
System Improvements
 Tangential feed:
 to minimize air
entrainment
 Oversized conical suction
(eccentric):
 to reduce velocity
and allow venting
back to the sump
134
System Improvements
 Rotated pump casing:

 Top 45 degree
discharge
 Top horizontal
discharge
 To assist with
venting of the air
out of the casing
(past the
cutwater)
135
System Improvements
 All of the above are designed to minimize the entrainment of air in the
slurry, and to maximize venting of air in the sump, suction and pump.
 The degree of improvement brought about is dependent upon the quality of

their implementation and the tenacity of the froth.
136
Pump Sizing Past Practices
 Utilize empirical froth factor

(FF) values
 Select a pump to handle

factored design flow
 Select a pump drive to handle

increased flow
Generally no consideration given to

air phase compressibility
137
Pump Types
 Traditional Horizontal Slurry

Pumps:
 typically use large froth
factors (multiples of
design flow rate)
 oversized to handle large
air volume
 operate well to the left of
the best efficiency point
 often utilize open or
recessed impellers
 corresponding low
efficiency
138
Pump Types
 Vertical Froth Pumps:

 tangential inlet
 self venting
 limited tank volume
 head limited by critical
speed of overhung shaft
 higher cost than horizontal
pump*
*disregarding the fact that
horizontal pump requires a
suction tank/sump
139
Pump Types
 Warman AHF, LF, and MF Flow Inducer Froth Pumps:
 very large inlet

configuration
 unique flow inducer

impeller design
 inlet sized for aerated

volume flow, discharge
sized for design flow
140
Pump Types
 Warman AHF, LF, and MF Flow Inducer Froth Pumps
 based on proven Warman

AH, L, and M series
heavy duty slurry pumps
 easily convertible to or from

enclosed impeller pump design
141
Warman Pump Selection
 Key Parameters:
 Froth Type:
 Mineral Froth
 Bitumen Froth
 Percent Air Volume
 System Curve
142
 Froth Type:
 Mineral Froth:
 a product of flotation
 contains fine particles, tiny air bubbles, water and
chemicals
 air content varies dependent on type of mineral and
stage in the process
 Bitumen Froth:
 a product of bitumen (tar) extraction from sand
 contains air bubbles, bitumen, water and fine silica
 bitumen and air content varies between primary and
secondary processes
143
 Froth Type:
 Mineral Froth:
 tenacious or brittle
 charted corrections for head and efficiency
 typically turbulent flow - exponential system curve
 Bitumen Froth:
 specific head and efficiency ratios
 dependent upon bitumen content
 dependent on temperature
 laminar or turbulent flow depending upon above
144
 Calculation of Froth Volume Factor

(FVF)
 Example: 20% air volume

(PA)
 FVF = 1/(1-
0.20)
 FVF = 1.25
145
 Froth Volume Factor (FVF)
 Provides for more

consistent test-based
Finer particles
approach compared to
empirical FF
 FVF is linked to air
volumetric content in Coarser particles
Froth (PA)
 FF versus FVF can vary
depending on froth
146
 Flow Terminology:
 Qs = Slurry Flow Rate = Design Flow = Compressed Flow = De-aerated

Flow
 Qf = Froth Flow Rate = Uncompressed Flow = Aerated Flow
 Qf = FVF x Qs
147
 Calculation of Uncompressed (Aerated) Flow:
 Example: Design flow: 120 l/s

 Design head: 20 m
 Specific gravity: 1.15
 % Air volume: 20%
 FVF (previous calc.): 1.25
 Uncompressed (aerated) flow = 1.25 x 120 l/s

= 150 l/s
148
 Froth Pump Selection:
 Select pump with

Qf to left of BEP
 Select Pump with

NPSHr @ Qf
less than 3.7 m
 Design circuit with

minimal friction,
minimal static head,
& minimal total head,
to keep speed low
149
 Plot system curve with static

head
This example: 10 m static head
 Determine system head

at Qf, uncompressed (aerated) flow
This example: 23 m system head

@ 150 l/s
150
 Mineral Froth Head and Efficiency Corrections:

 HRf =

 ERf =

Note: Only QU1 Flow Inducer Impellers

are used in Warman Froth Pumps now
151
 Mineral Froth Head and Efficiency Corrections:
 Our example:
20% air volume,

1.25 FVF:
 HRf = 0.95
 ERf = 0.95
Note: Only QU1 Flow Inducer Impellers

are used in Warman Froth
Pumps now
152
 Apply Head Ratio:

Corresponding water head
@
=

 Our example:
Corresponding water head

= = 24.2 m
.
 Required water speed @ uncompressed

flow and water head (150 l/s @ 24.2 m):
= 640 rpm
153
 Calculate Slurry Efficiency:
 Water efficiency at 150 l/s @ 24.2 m: 68 %
 ERf, efficiency ratio: 0.95
 Slurry efficiency = water efficiency x efficiency ratio

= 68 % x 0.95
= 64.6 %
154
 Calculate Required Power:
( )
 P= x
( ) ( )
 For our example:
/ . . ( . )
P= x
( . ) ( . )
P = 51 kW
 Select a motor with at least 20% margin to allow for fluctuations in duty due to
variations in air content. That is, select a 75 kW motor for this application.
155
Bitumen Froth
 Saskatchewan Research Council Pipeline Technology Center:
 An offshoot of the
University of Saskatchewan
 Tests slurries and fluids for

Canadian industry
 Warman 8 inch Froth Pump

feeding Warman 10/8 AH
Slurry Pump in 20 inch loop
for Syncrude Bitumen Froth
Test
156
Pump Installations
12 TAHF at Aurora:

 bitumen flotation froth
recycle
 replaced horizontal
pump with open impeller
 replaced horizontal
pump with recessed
impeller and inducer
157
Pump Installations
350 FF LF at Suncor:
 bitumen flotation froth recycle
 replaced undersized Warman 8

MF horizontal froth pump
 very high air volume (25 to 40

percent)
158
Pump Installations
14 TUAHF:
 based on Warman 16/14 TUAH
 1125 mm impeller
 flows in 1000 to 3000 m3/hr
range
 heads to 40 m
 300 PSI design
159
Pump Installations
14 TUAHFP:
 based on Warman 16/14
TUAHP
 1125 mm impeller
 flows in 1000 to 3000 m3/hr
range
 heads to 40 m
 500 PSI design
160
Froth Pumps – New Development
 What technical solution can be offered for slurry with high FVF?
 FVF = 4.0 75% Air and 25% Slurry
 Current design of Centrifugal Froth Pump cannot handle it
 Solution: Continuous Air Removal System - CARS

161
 CARS design
 1 – Impeller with
venting holes
 2 – Flow inducer

 3 – Expeller chamber

 4 – Venting pipe
162
 CARS design principle

 Froth Separation and Air Removal is performed in two stages
 1st stage
Flow inducer blade of the froth impeller promotes movement of the froth slurry into impeller eye and imposes
pre-rotation for initial separation of froth (air laden mixture) in the centre of the inlet towards venting holes
located in the impeller back shroud
 2nd stage
Flow inducer (propeller) located behind the main froth impeller promotes further separation and axial movement of
towards the chamber vent which is connected with venting pipe ending at the top of suction tank
163
 New name for Froth Pump with CARS : AHFC
Retrofit of existing AHF to AHFC requires 4 new castings
Impeller with venting holes
FPLI with large bore
Flow inducer (propeller)
Expeller chamber with vent

164
CARS Features and Benefits
 No air-locking at the impeller eye
 Excellent performance on abrasive mineral froth slurry with Froth Volume Factor up to 4.0
 Stable performance proven in extreme froth conditions on site tests
 No need for additional Froth Volume Factor reduction
 No product loss due to sump overflow and CARS venting back to suction tank
165
CARS Features and Benefits
 Froth Volume factor variations in flotation process are balanced by CARS venting
 No more restrictions to flotation process upgrade requiring increased Froth Volume Factor
 Superior pump efficiency than the competition allowing smaller motor size
 CARS upgrade available on popular horizontal froth pumps AHF, LF, MF

166
Recommendations
 To maximize system performance when pumping froth:
 Minimize pump speed by designing system with low required head

 Minimize entrainment of air in sump by use of launders and tangential
inlets
 Maximize release of air by use of baffles, spray mists, vent pipes,
enlarged eccentric suctions, proper casing orientation
 Select appropriate pump for the duty
 Preferably select pump with NPSHr less than 12 to 14 ft at aerated flow
rate
 Avoid parallel pumping
 Don’t over speed pumps: utilize VFD’s to optimize control of system
Questions ? 167

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Date: August 1, 2013

Weir Minerals Division

Centrifugal Slurry Pumps

Prepared by: Aleks Roudnev, Manager of R&D, WMNA

 Pumps for Mill Circuits

 Pumps for Hydrotransport and Tailings

 Pumps for Frothy Mixtures

Mill Circuit Pump

Slurry Pumps for Mill Circuits 5

 Design Criteria and Specifications

 Assembly and Maintenance

Weir Minerals - FULL HOUSE Solution

Rubber lined tanks

Hoses & Spools

Mill Circuit Pumps

Mineral Processing – Mill Circuit Area

%TOC vs Useful Life 2c/kWhr Energy

% Total Ownership Cost

%TOC vs Useful Life 15c/kWhr Energy

MCR / MCM Mill Circuit Pumps

 Pumps can be classified by “Standard” slurry application (Severe,

 Life of pump in any application depends on

ANSI/HI 12.1–12.6 - 2011 Service class/Materials

WMD – Mill Circuit Pumps are for Severe Duty

WMD – Mill Circuit Pumps are for Severe Duty

 Severe Duty Pump Range is called MC (Mill Circuit)

Mill Circuit Pump – Design Criteria

 Maximum Wear Life while Maintaining Pump Efficiency

 Predictable Wear Life - Exclude Catastrophic Failures

 Equal/Multiple Wear Life of Wet End Components

 Ability to Handle Coarse Solids and Mill Tramp

 Ability to Operate Over Range of Mill Duty Flow Rates

 Ability To Handle High Slurry Concentrations of 45-65 %

MC Pump – The Range 14

Severe duty - Pump Plan Summary 15

 Severe duty – MC range

 To meet the mill circuit severe duty

Weir Minerals 650 MCR Severe Duty Slurry Pump

Weir Minerals 650 MCU Severe Duty Slurry Pump

MC Pump – Mill Circuit Design

 Actual wear performance studies conducted in the field. Unique

 Modifying impeller hydraulics by optimising vane angles, profiling vane

 Volute design method based on a “constant vortex” principle.

MC – Mechanical Design Features

 Interchangeable elastomer & metal bolt-in design provide ease of

Slurry Pump Impeller Hydraulic Design

Mill circuit pumps use large

Vane number is low to provide

Despite these compromises

Pump Impeller – Flow Modelling

Vane Inlet Flow Modelling Vane Inlet Edge Velocity Profile

Typical Standard (5 vane) Impeller Wear

EL style (4 vane) Impeller Wear

Copper/Gold Mine, Australia

 100 mm (4 in) thickness

MC Pump - Adjustable Suction Side Liner 31

Suction side liner

MC Pump – Unique features 32

 Maintain the impeller front seal face clearance

 Allows customer to maintain drive side clearance,

MC Pump – Unique features 33

 Throatbush and Frame Plate Liner Insert are

 EMLTM patented technology eliminates hard iron