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Slurry Transport Using Centrifugal Pumps

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Based on the industry leading short course “Transportation of Solids using Centrifugal Pumps,” founded by Dr. Kenneth Wilson and Graeme Addie, and hosted by the GIW Industries Hydraulic Laboratory, this expanded fourth edition has been extensively updated by the international team of engineers and authors who inherited this legacy and continue its development to the present day.  Focusing on the hydraulic design of slurry pipelines, the pumps that power them, and the interactions between pumps and systems, it retains the classroom tested balance of theoretical development and practical engineering which have made it a slurry transport classic. The topics covered are important to slurry system engineers for the optimization of new designs, as well as the operators of existing systems, who may need to calculate and plan for changing conditions from day to day. 

Updates to the fourth edition include:

·         Careful formulation of the theoretical concepts, providing greater clarity of slurry flow dynamics, including a new chapter on the principles and characterization of slurry flows. 

·         Expansion of the 4-Component Models for settling slurry pipeline flow and pump solids effect, based on an extensive series of full-sized tests.

·         An expanded treatment of complex slurries, including a broader discussion of non-Newtonian fluids and their interaction with coarse particles. 

·         A new chapter on test methods, presenting an overview of slurry system instrumentation, modern techniques for characterizing slurry rheology, and practical advice for planning and executing a slurry test.

·         An overview of advances in the computational modeling of slurries, including an in-depth parametric study of slurry pump wear and operating cost. 

The authors highlight methods for achieving energy efficiency, which are crucial to the effective use of scarce resources, given the foundational role of slurry transport systems in the energy intensive industries of mining and dredging. Key concepts are supported with case studies and worked examples.

Slurry Transport Using Centrifugal Pumps, fourth edition,is both methodical and in-depth. It is ideal as a teaching tool for classroom or self-directed learning domains, and valuable as a design guide for engineer practitioners at all experience levels.

Author(s): Robert Visintainer, Václav Matoušek, Lionel Pullum, Anders Sellgren
Edition: 4
Publisher: Springer
Year: 2023

Language: English
Pages: 493
City: Cham

Foreword by Robert Cooke
Foreword by Cees van Rhee
Preface
Topics Covered in This Book
Updates in the Fourth Edition
Acknowledgments
Contents
Symbols and Abbreviations
Symbols
Abbreviations
About the Authors
Chapter 1: Introduction
1.1 Applications of Slurry Transport
1.1.1 Metals and Minerals
1.1.2 Dredging
1.1.3 Specialty Applications
1.2 The Blind Men and the Elephant
Reference
Chapter 2: Review of Fluid and Particle Mechanics
2.1 Introduction
2.2 Classification of Fluids
2.2.1 Rheological Properties
2.2.2 Common Simple Non-Newtonian Fluids
2.3 Classification of Solids
2.3.1 Solids Density
2.3.2 Particle Diameter
2.3.3 Particle Shape
2.4 Basic Relations for Fluid Flow in Pipelines
2.4.1 Conservation of Continuity and Momentum
2.4.2 Bernoulli´s Equation: Head and Hydraulic Gradients
2.5 Pipeline Friction of Newtonian Fluids
2.5.1 Example 2.1: Flow of Water in a Pipe-Pump System
2.6 Settling of Solids in Newtonian Fluids
2.6.1 Example 2.2: Calculation of Terminal and Hindered Settling Velocities
2.7 Settling of Solids in Non-Newtonian Fluids
References
Chapter 3: Principles and Classification of Slurry Flow
3.1 Introduction
3.2 Properties of Slurry and Slurry Flow
3.2.1 A Note About Concentration
3.2.2 Solids Concentration and Slurry Density
3.2.3 Pressure Gradient and Hydraulic Gradient for Slurry Flow
3.3 Classification of Slurry Mixtures and Flows
3.3.1 Categories of Slurry
3.3.1.1 Settling Slurry
3.3.1.2 Non-settling Slurry
3.3.2 Regimes of Slurry Flow
3.4 Physical Mechanisms of Particle Support and Friction
3.4.1 Contact Friction and Support
3.4.2 Turbulent Suspension
3.4.3 Off-the-Wall Repulsion
3.5 Friction Loss and Pipe Characteristic Curve
3.6 Characteristic Velocities of Slurry Flow
3.7 Specific Energy Consumption
3.7.1 Effect of High Concentration of Solids
3.8 Case Studies
3.8.1 Case Study 3.1: Flow of Pseudo-homogeneous Slurry in a Pipe-Pump System
References
Chapter 4: Stratification of Slurry Flow and Deposition of Solids in Pipes
4.1 Introduction
4.2 Flow Stratification and Development of Stationary Deposit
4.2.1 Layered Structure of Stratified Flow
4.2.2 Formation of Stationary Deposit
4.3 Modeling of Stratified Flows
4.3.1 Two-Layer Models: Concepts and Force Balance Between Layers
4.3.2 Conditions at the Interface Between Layers
4.3.3 Other Aspects of the Two-Layer Model
4.3.4 Survey of Layered Models for Stratified Flow with Newtonian Carrier
4.3.4.1 Early Two-Layer Model by Wilson
4.3.4.2 SRC Two-Layer Model
4.3.4.3 Unified Layered Model
4.3.4.4 Three-Layer Models
4.3.5 Two-Layer Models for Complex Slurry Flows
4.3.5.1 Turbulent Flow
4.3.5.2 Laminar Flow
4.4 Prediction of Velocity at the Limit of Stationary Deposition
4.4.1 Historical Perspective
4.4.2 Deposition Limit Velocity in Stratified and Heterogeneous Flows
4.4.2.1 Modeling
4.4.2.2 Experiment
4.4.3 Deposition Limit Velocity in Pseudo-homogeneous Flow
4.4.4 Effect of Solids Concentration on Deposition Limit Velocity
4.4.5 Deposition Limit Velocity in Complex Flow with Non-Newtonian Carrier
4.5 Case Studies
4.5.1 Case Study 4.1: Solids Deposition in a Tailings Pipeline
4.5.2 Case Study 4.2: Preliminary Pipe Sizing for Total System Design
References
Chapter 5: Settling Slurry Flow
5.1 Introduction
5.2 Pseudo-homogeneous Flow
5.3 Fully Stratified Flow with Sliding Bed
5.3.1 Simplified Evaluation Based on the Principles of Two-Layer Models
5.3.2 Scale-Up Technique
5.4 Heterogeneous Flow
5.4.1 Reference Velocity and Stratification Ratio
5.4.2 Scale-Up Technique
5.5 Broadly Graded Settling Slurry Flow
5.5.1 The 4-Component Model
5.5.2 Bimodal (Coarse and Fine) Slurries
5.6 Flow Over a Stationary Bed
5.6.1 Steady Solids Flow
5.6.2 Unsteady Solids Flow: Density Waves in Pipelines
5.7 Review of CFD Modeling
5.8 Particle Attrition
5.9 Case Studies
5.9.1 Case Study 5.1: Heterogeneous Flow: Pipe Characteristics for Total System Design
5.9.2 Case Study 5.2: Pipeline Characteristics: Flow of Broadly Graded Settling Slurry
5.9.3 Case Study 5.3: Transport of a Coarse-Stratified Settling Slurry
References
Chapter 6: Non-Newtonian Slurries and Suspensions
6.1 Introduction
6.1.1 Material Considerations
6.1.2 Slurry Types
6.2 Homogeneous Non-Newtonian Slurries
6.2.1 Laminar Flow
6.2.2 Turbulent Flow
6.2.3 Transitional Flow
6.3 Heterogeneous Non-Newtonian Slurries
6.3.1 Laminar Flow
6.3.2 Turbulent Flow
6.3.3 Paste and Thickened Tailings
6.4 Conversion and Scale-Up
6.4.1 Conversion
6.4.2 Scale-Up of Laminar Flow
6.4.3 Scale-Up of Turbulent Flow
6.5 Review of CFD Modeling
6.6 Case Studies
6.6.1 Case Study 6.1 Estimation of Transition Velocity for Slurries Other Than Bingham Plastics
6.6.2 Case Study 6.2 Scale-Up from Laboratory Tests
6.6.3 Case Study 6.3 Optimization Procedure for Homogeneous Suspensions
References
Chapter 7: Vertical and Inclined Slurry Flow
7.1 Introduction
7.2 Pressure Drop
7.3 Internal Structure of Flow
7.4 Vertical Flow Applications
7.4.1 Pressure and Velocity Requirement
7.4.2 Density Measurement Using an Inverted U-Tube
7.5 Inclined Flow Applications
7.5.1 Effect of Inclination on Deposition Limit Velocity
7.5.2 Effect of Pipe Inclination on Pressure Gradient
7.6 Case Studies
7.6.1 Case Study 7.1: Vertical Hoisting
7.6.2 Case Study 7.2: Inclined Settling Slurry Flow in Suction Pipe of Cutter Suction Dredge
References
Chapter 8: Centrifugal Slurry Pumps
8.1 Introduction
8.1.1 Basic Relations
8.1.2 Performance Scaling
8.2 Hydraulic Design and Specific Speed
8.2.1 Hydraulic Components
8.2.2 Theoretical Head Characteristic
8.2.3 Pump-Specific Speed
8.2.4 Practical Hydraulic Design
8.3 Cavitation and Net Positive Suction Head
8.4 Mechanical Design
8.5 Case Studies
8.5.1 Case Study 8.1 Scaling a Pump Performance Test to Another Speed
8.5.2 Case Study 8.2 Interpreting and Scaling NPSHR Tests
8.5.3 Case Study 8.3 Calculating an Impeller Trim Diameter
References
Chapter 9: Effect of Solids on Pump Performance
9.1 Introduction and Definitions
9.1.1 Example 9.1: The Head Derating Procedure
9.2 Settling Slurries with Newtonian Liquids
9.2.1 Effects of Solids Concentration
9.2.1.1 Standard Metal Pumps
9.2.1.2 Pumps with Thick Hydraulic Sections
9.2.2 Effects of Solids Density
9.2.3 Effects of Pump Size
9.2.4 Effects of Particle Size
9.2.5 Modeling
9.2.5.1 Mono-size Particle (d50) Modeling for RH
9.2.5.2 The 4-Component Pump Solids Effect Model
9.2.5.3 Carrier Fluid Contribution
9.2.5.4 Pseudo-Homogeneous Contribution
9.2.5.5 Heterogeneous Contribution
9.2.5.6 Fully Stratified Contribution
9.2.6 Example 9.2: A 4-Component Method Derate Calculation
9.3 Non-Newtonian Slurries
9.3.1 Thickened Tailings Loop Test Results
9.3.2 Modeling
9.3.2.1 Walker and Goulas
9.3.2.2 Graham and Pullum
9.4 Suction Performance
9.5 Case Studies
9.5.1 Case Study 9.1: Heterogeneous Flow Pump Selection for Total System Design
References
Chapter 10: System Stability and Operability
10.1 Introduction
10.2 The Equivalent Liquid Case
10.3 Effect of Solids Concentration in Settling Slurries
10.4 Effect of Particle Size
10.5 Non-Newtonian Slurries
10.6 Specific Energy Consumption in System Design
Chapter 11: Practical Experience with Slurry Systems
11.1 Introduction
11.2 Pumps in Series
11.2.1 Pump Spacing and Hydraulic Grade Line
11.2.2 Downhill Flow
11.2.3 Suction Conditions and NPSHR
11.2.4 ``Pumping Through´´ Pumps
11.2.5 Piping Arrangements and Loads
11.3 Pumps in Parallel
11.4 Start-up, Shutdown, and Transient Conditions
11.5 Operation with a Stationary Bed
11.6 Water Hammer
11.7 Reverse Flow
11.8 Pump Explosion
11.9 Sumps and Suction Piping
11.9.1 Sumps
11.9.2 Agitated Sumps
11.9.3 Suction Piping
11.9.4 Open Pit Sump and Dredge Applications
11.10 Pumping Frothy Mixtures
11.11 Slurry Pump Drive Trains
References
Chapter 12: Testing and Instrumentation
12.1 Introduction
12.2 Pipeline Testing
12.2.1 Test Plan Development
12.2.2 Testing Equipment and Procedures
12.3 Pump Performance Testing
12.4 Rheology and Viscometry
12.4.1 Rheometers and Viscometers
12.4.2 Testing and Rheograms
12.5 Instrumentation
12.5.1 Flow Rate
12.5.2 Pressure
12.5.3 Slurry Density and Solids Concentration
12.5.4 Deposition Limit Velocity
12.5.5 Pump Input Power
12.5.6 Velocity Distribution
12.5.7 Tomographic Techniques
References
Chapter 13: Erosive Wear
13.1 Introduction
13.2 Mechanisms of Erosive Wear
13.3 Wear-Resistant Materials
13.4 Combined Erosion and Corrosion
13.5 Cavitation Wear
13.6 Experimental Testing Methods
13.7 Wear Coefficients
13.8 Numerical Modeling of Flow and Wear
13.9 Parametric Study of Slurry Pump Wear
13.9.1 Suction Liner Wear
13.9.2 Casing Wear
13.9.3 Impeller Wear
13.9.4 Trends in Wear Rate
13.10 Practical Considerations and Field Experience
References
Chapter 14: Pump Selection and Cost of Ownership
14.1 Basic Principles of Centrifugal Slurry Pump Selection
14.1.1 Procedures Common to All Centrifugal Pumps
14.1.2 Special Considerations for Slurry Pumps
14.1.3 Multi-pump Systems
14.2 Wear Considerations
14.2.1 Slurry Service Class
14.2.2 Recommended Operating Limits
14.3 Economic Considerations
14.3.1 Pump Operating Cost Analysis
14.3.2 Total Operating Cost
14.3.3 Downtime Costs
References
Appendix: VSCALC Function
MATLAB Script for Vscalc Function (4th Edition)
Index