Slurry Transport Using Centrifugal Pumps

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