Engineering & Mining Journal

JUL 2019

Engineering and Mining Journal - Whether the market is copper, gold, nickel, iron ore, lead/zinc, PGM, diamonds or other commodities, E&MJ takes the lead in projecting trends, following development and reporting on the most efficient operating pr

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Page 31 of 67

PUMPS, PIPING AND VALVES 30 E&MJ • JULY 2019 Science fiction writers commonly assign human characteristics to computers, ro- bots or mechanical systems as a literary tool to stoke reader interest. Let's give it a try: Picture a mining operation as a living organism. Logically, the operation's pumps, valves and pipes would corre- spond to the human vascular system, metering and transferring valuable fluids where they're needed most and deliver- ing depleted or unwanted constituents to disposal mechanisms, similar to how the human heart, arteries and veins function. Taking the analogy a step or two fur- ther, human health depends heavily on the vascular system's basic design and inherent efficiency, but almost as impor- tantly on care and attention. Likewise for a mining operation's piping, pumps and valving, good basic design, proper selec- tion of components and regular upkeep are essential for best performance. Programs for Pumps and Piping Optimal performance begins with solid system design. Among the tools available for pump selection, pipeline design and system simulation are programs available both from vendors and third parties. Met- so, for example, offers PumpDim for sizing and selecting the right models from its pump product line. According to the com- pany, Microsoft Windows-based PumpDim can size a pump for a specified duty point or a pipe system, pumping clear water, vis- cous liquids or a suspension of solids in a liquid. When it comes to sizing pumps for slurry applications, Metso said results from PumpDim are representative for set- tling slurries with "normal" particle size and distribution such as those found in mineral processing industries, with con- centrations lower than 40% by volume. The program considers and/or calcu- lates the following: • Critical flow velocity to avoid settling of particles in pipes. • The complete pipe head loss system curve when static head, pipes, fittings and other components are specified. • Pumping of froth when a froth factor is specified. • Effect of solids on the generated pump head and pump efficiency. • Recommends material for the pump wet end considering particle size and distribution. • Selects pump size for the specified duty and calculates required pump speed. • Calculates shaft deflection and bearing life at the duty point. • Recommends motor size and drive. • Calculates slurry density based on parti- cle and liquid density and concentration and/or tonnage. • Calculates actual flow through an ex- isting installation based on pipe sys- tem, slurry properties and pump speed. FluidFlow from Flite Software can be used to determine pressure losses and de- sign flow distribution systems transporting settling slurries. Flite said the software helps engineers eliminate the pitfalls of spreadsheet solutions by enabling a whole-system evaluation. The tools within the program help users select optimum pipe sizes and pump capacities, eliminat- ing the risk of incorrect line sizing which can lead to poor system performance, en- ergy wastage and line blockages. FluidFlow software has been used to model slurry flow systems by Worley Parsons, Jacobs, Hatch, Emirates Global Aluminum, Rusal, BHP Billiton and others, according to the developer. Its major features include: • A database of fluids, pumps and equip- ment, to which users can also add their own data. • Solids derating. • Pump power usage. • Simulation of variable speed pumps. • Evaluation of impeller trimming. • Determination of solids delivered in set- tling slurry systems. Datamine announced that the latest version (3.0) of Pumpsim, a 3D flow simu- lation software package developed for pipe networks, is now available. The software allows users to design, simulate and opti- mize pump and liquid reticulation (piping) systems. According to Datamine, it was designed to tackle the common problem of poor water reticulation design within the mining and other industrial environments, which often leads to unreliable water sup- ply systems. This may result in insufficient water supply or pressure, pipe breakage, poor pump performance and productions delays. These problems, said Datamine, can be solved by the software as it ensures pumps and pipes are correctly sized and rated, and that pipe and pump design is optimal for all required activities. The new release brings several im- provements claimed to make the simu - lation easier and more efficient. These include: • 3D Containers – Any 3D shape can now be converted to model bodies of water, including open pits and flooded tunnels. • Stages – Simulate the different stages of the project in one file. • Dynamic Simulation – Enter a sequence of time on and off for dynamic simulation. Finessing the Flow Pumps can be too big or too small for the job, pipes can wear out quicker than expected, and valves might not stand up to tough applications. Take advantage of the tools, products and technologies that can help avoid most of these problems. By Russell A. Carter, Contributing Editor Modern sizing procedures for slurry pumps are computerized and much easier to conduct with software tools such as Metso's PumpDim for Windows.

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