Feluwa applied bionics in pumps for hydrotranport & process

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1. Applied Bionics in Pumps for Hydrotransport Rudolf Gänsl – Managing Director Copyright FELUWA Pumpen GmbH 2. Basics for Hydrotransport Copyright 2 FELUWA Pumpen…
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  • 1. Applied Bionics in Pumps for Hydrotransport Rudolf Gänsl – Managing Director Copyright FELUWA Pumpen GmbH
  • 2. Basics for Hydrotransport Copyright 2 FELUWA Pumpen GmbH
  • 3. Basics for Hydrotransport • Our customers handle and transport through pipes heterogeneous, abrasive and corrosive media with a defined viscosity • The Competing Systems are: Copyright 3 FELUWA Pumpen GmbH • train • truck • belt • and comes to pipelines – centrifugal pumps
  • 4. 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 4 FELUWA Pumpen GmbH
  • 5. Pump Characteristic - Centrifugal versus PD Pump - Centrifugal Pump-Train Positive Displacement Pump Pressure [bar] Copyright 5 FELUWA Pumpen GmbH Capacity [m³/h] Head [bar] Capacity [m³/h] Speed
  • 6. 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 Copyright 6 FELUWA Pumpen GmbH
  • 7. Project Dimensions Slurry capacity pressure distance Pumps/P.Station (m³/h) (bar) (km) (Nos.) • Bauxit 2000 90 240 1 • Cu/Zn 2500 140 300 4 • Bauxit 500 250 150 1 • Cu/Ni/Co 2250 50 10 1 • Minerals 1500 130 700 6 Copyright 7 FELUWA Pumpen GmbH
  • 8. Bionics in Pumps or the Evolution and Characteristics of Hose-Diaphragm Pumps Copyright 8 FELUWA Pumpen GmbH
  • 9. Evolution of Hose-Diaphragm Pumps - Piston Pump - Piston Outlet Inlet Copyright 9 FELUWA Pumpen GmbH Check valve (One-way valve)
  • 10. Evolution of Hose-Diaphragm Pumps - Piston Pump - Piston Outlet Copyright 10 FELUWA Pumpen GmbH Outlet Inlet Suction stroke Piston Inlet Discharge stroke
  • 11. Piston Pump and Hose-Diaphragm Pump Piston Outlet Copyright 11 FELUWA Pumpen GmbH Outlet Inlet Piston Inlet Flexible hose Hydraulic liquid
  • 12. Evolution of Pumps - Hose-Diaphragm Pump - Piston Outlet Copyright 12 FELUWA Pumpen GmbH Outlet Inlet Piston Inlet Piston in rear position = End of suction stroke Piston in front position = End of discharge stroke
  • 13. Evolution of Pumps - Hose-Diaphragm Pump - Outlet Housing Diaphragm Piston Copyright 13 FELUWA Pumpen GmbH Inlet Pumped medium Hydraulic liquid
  • 14. MULTISAFE Pumps - Double Hose-Diaphragm Pump - End of suction stroke End of discharge stroke Second diaphragm Copyright 14 FELUWA Pumpen GmbH
  • 15. Evolution of Pumps - Hose-Diaphragm Pump - • Hydrostatic Pressure by surrounding hydraulic liquid Copyright 15 FELUWA Pumpen GmbH • Pressure inside and outside the diaphragm is equal • Hose-diaphragm is not covering any pressure, except for static load • Medium in contact with diaphragm only
  • 16. Evolution of FELUWA MULTISAFE Pump the unique MULTISAFE Double-Hose-Diaphragm Pump since 2000 FELUWA 1960 traditional design FELUWA from 1970 hose diaphragm Copyright 16 FELUWA Pumpen GmbH FELUWA - MULTISAFE Double-Hose-Diaphragm
  • 17. MULTISAFE Pumps - Double Hose-Diaphragm - Copyright 17 FELUWA Pumpen GmbH Inner diaphragm Outer diaphragm Both hose-diaphragms are in direct contact Double safety Hose-diaphragms are never stretched!
  • 18. Double Hose-Diaphragm Pumps - Working Principle - Copyright 18 FELUWA Pumpen GmbH
  • 19. 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% Copyright 19 FELUWA Pumpen GmbH
  • 20. FELUWA Standard Range Copyright 20 FELUWA Pumpen GmbH
  • 21. FELUWA MULTISAFE Quintuplex Double Hose-Diaphragm Pump MULTISAFE Quintuplex pumps provide lowest pulsations Up to 1000m³/h – 4400gpm Up to 320bar – 4640psi 5 Heads Copyright 21 FELUWA Pumpen GmbH
  • 22. Cost Efficiency Lifetime Spares Energy Efficiency Availibility Copyright 22 FELUWA Pumpen GmbH Investment Maintenance
  • 23. Cost Efficiency of MULTISAFE Pumps EEffffiicciieennccyy EEnneerrggyy AAvvaaiilliibbiilliittyy IInnvveessttmmeenntt and LLiiffeettiimmee CChhaannggiinngg TTiimmee CCoossttss ffoorr SSppaarreess Operating Exp. MMaaiinntteennaannccee Copyright 23 FELUWA Pumpen GmbH VVaallvvee SSyysstteemm BBaallll VVaallvveess QQuuiicckk CChhaannggee DDiiaaggnnoossttiicc MMuullttiippllee PPuummpp Control DDoowwnnttiimmeess DDoowwnnffllooww MULTISAFE Double Hose-Diaphragm Pump
  • 24. Double Hose-Diaphragm Pumps - Pressure sensor - Copyright 24 FELUWA Pumpen GmbH Foliennr. • 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.
  • 25. Double Hose-Diaphragm Pumps - Flat vs. Hose-Diaphragm - Flat diaphragm Double hose-diaphragm Pumped medium is in contact with diaphragm housing Pump head volume about 40% smaller 3 times higher filling ratio pumped volume max medium volume filling ratio = Copyright 25 FELUWA Pumpen GmbH Pumped medium is in contact with diaphragm, only About 5% higher efficiency
  • 26. Unique MULTISAFE design - Comparison of Fluid Wetted Items - Example: ZGL 300/250 – 2K 180 – 4 SM 460 HD Weight of wetted parts: 6,400 kg Copyright 26 FELUWA Pumpen GmbH 26 Example: TGK 300/250 – K 180 – DS 100 HD Weight of wetted parts: 150 kg -97,7%
  • 27. Valve Types - Corner vs. Linear Valves - Copyright 27 FELUWA Pumpen GmbH
  • 28. MULTISAFE Check Valves - Ball Valve - Open position Closed position No. E 2201103-2 Heinz M. Nägel Copyright 28 FELUWA Pumpen GmbH
  • 29. Valve Types - Ball Valve Assembly - Copyright 29 FELUWA Pumpen GmbH Foliennr. steel sealing revearsing seal ring
  • 30. MULTISAFE Check Valves - Quick Change System - Copyright 30 FELUWA Pumpen GmbH Foliennr.
  • 31. Special Configurations - Double Valves - Copyright 31 FELUWA Pumpen GmbH Double Valves • Double valves are used for critical processes, which do not allow an interrupted flow. • Double valves provide double-safety against smallest leakages. • Double valves reduce the wear of the valves and increase maintenance intervals.
  • 32. FELUWA Check Valves in Quick Change Design with Hydraulically Supported Fastening in Single or Double Valve Design (as per Illustration) Copyright 32 FELUWA Pumpen GmbH
  • 33. Diagnosis Systems - Energy Loss in Case of Leaking Check Valves - Leakage in discharge and/or suction valve Suction stroke Copyright 33 FELUWA Pumpen GmbH
  • 34. Diagnosis Systems - FELUWA Valve Performance System (FVPMS) - Copyright 34 FELUWA Pumpen GmbH Valve sensor
  • 35. Energy Savings by Valve Wear Detection Flow Rate Time Copyright 35 FELUWA Pumpen GmbH Power Start of valve wear Energy loss
  • 36. FELUWA Pulsation Dampener - combined air vessel + diaphragm - Additional air cushion (air vessel) Copyright 36 FELUWA Pumpen GmbH Bladder accumulator
  • 37. Multiple Pumps - Pressure Pulse Optimisation - Pump 1 Pump 2 Pump 3 Copyright 37 FELUWA Pumpen GmbH Wrong phaseshift Optimized phaseshift Resulting pulsation on common discharge pipe or
  • 38. Multiple Pump Control - Pressure Pulse Optimisation - • Optimized phaseshift, when a pump is shut off • Automatic speed increase to avoid a standby pump Copyright 38 FELUWA Pumpen GmbH Optimized phaseshift Pump 1 Pump 2 Pump 3 Resulting flow to pipeline
  • 39. Multiple Pump Control - Phaseshift Control of 3 Triplex Pumps - Sum of 3 triplex pumps 3 triplex pumps without phase shift with optimized phase shift Copyright 39 FELUWA Pumpen GmbH 3 2 1 0 3 triplex pumps 0 100 200 300 400 500 600 700 Volume flow [a.u.] Crankshaft angle [°] 2,2% 23,2% 23,2%
  • 40. Pumping of Heterogeneous Mixtures Sedimentation inside the diaphragm chamber Flow direction Copyright 40 FELUWA Pumpen GmbH
  • 41. Transport of Solid Particles Homogeneous Heterogeneous Copyright 41 FELUWA Pumpen GmbH Low sinking rate MIXTURE High sinking rate Length of discharge stroke Sinking rate
  • 42. Special Configurations - Downflow Transport - Downflow Technology in everyday life! PD Ketchup Pump (hand-operated) Copyright 42 FELUWA Pumpen GmbH Flow
  • 43. 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 Copyright 43 FELUWA Pumpen GmbH
  • 44. 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 1000m³/h per pump • Linear ball valves with Top Entry, Quick Change wear detection • Optimized phase-shift control for multiple pumps • Downflow Technology Copyright 44 FELUWA Pumpen GmbH
  • 45. Hydrotransport Copyright 45 FELUWA Pumpen GmbH
  • 46. Hydro Transport • QGK 500 750 m³/h – 54 bar Copyright 46 FELUWA Pumpen GmbH
  • 47. Ready for the future Pump type Power [kW] Pressure [bar] Flow [m³/h] TGK 500 3.000 50 to 250 u p to 750 QGK 500 3.500 50 to 250 up to 1000 (e.g. Boleo) 1.100 45 750 Copyright 47 FELUWA Pumpen GmbH
  • 48. Process Pumps / Feeding Copyright 48 FELUWA Pumpen GmbH
  • 49. FELUWA High Pressure and Low Pressure Pumps No. E 2201052 49 Copyright FELUWA Pumpen GmbH Heinz M. Nägel
  • 50. FELUWA Quadruplex High Pressure Hose Diaphragm Piston Pumps for Four-Burner Type Gasifiers Copyright No. E 2201051 50 FELUWA Pumpen GmbH Heinz M. Nägel
  • 51. FELUWA Hose Diaphragm Piston Pump Quadruplex Configuration Double-Acting Two-Cylinder Pump Nr. D 2109499-21 Heinz M. Nägel Copyright 51 FELUWA Pumpen GmbH
  • 52. FELUWA Hose Diaphragm Piston Pump Quadruplex Configuration Double-Acting Two-Cylinder Pump Copyright No. E 2201085-1 52 FELUWA Pumpen GmbH Heinz M. Nägel
  • 53. FELUWA Areal View Thanking for your kind attention Copyright 53 FELUWA Pumpen GmbH
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