The importance of data can easily be overlooked especially with a pump that is already installed and has been running on its calculated duty point for some time. As sites develop, it is normal for duty points to change as manufacturing fluctuates to the market demand. An increase in flow may not be considered a major factor on some equipment, but when it comes to a pump it can push its operation from the most efficient point toward a critical range. There are other factors that can have detrimental impacts such as changes in the feed material and installation alterations to pipework like lengths, dimensions, and others. This can result in an increase in friction losses in the system.
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The reason pumps like to work at its most efficient point is because this reduces the amount of wear seen, ultimately extending the service life. It is well known in the industry that slurry pumps will not be able to run forever due to the nature of its work. But every mine aims to extend this life as much as possible, which happens by being as close to BEP as possible.
Small adjustments in flow or head can move the duty point on the curve considerably has and have implications on wear life. Moving further to the left of BEP, usually due to a reduction of flow or head, creating recirculation in the pump meaning the material travels around the casing excessively before it is moved down the line. This creates additional wear due to the extra circulation of particles.
Alternatively, the duty point can be pushed to the right of BEP by increasing the flow. This can cause issues with inlet velocity meaning the flow into the pump is greater than the installed size that the pump can manage. And resulting in increased wear rate around the discharge area of the casing and on the eye of the impeller, which is the first obstruction the flow finds when entering the pump.
In some of these cases a pump can be adjusted on speed to help deal with the changes of duty, but in other cases it would be recommended to change the pump size to best fit the altered application. Without taking these changes into consideration, a previously well performing pump can turn into a maintenance headache.
Another factor to keep in mind is that as a pump wears and moves away from its optimum point it has a reflective effect on the power consumption. An increase in power consumption turns into an increase in costs and carbon footprint.
Here are some key considerations to guide your selection process when choosing the best slurry pump for a specific application:
Application Requirements: Understand the specific requirements of your slurry pumping application. Consider factors such as the type and characteristics of the slurry (e.g., particle size, density, viscosity), required flow rate, total head, and the distance over which the slurry needs to be pumped.
Pump Type: Different types of slurry pumps are available, including centrifugal pumps, submersible pumps, and positive displacement pumps. Each type has its advantages and limitations. Centrifugal pumps are commonly used in slurry applications due to their efficiency and ability to handle high flow rates. Submersible pumps are suitable for pumping slurries from submerged locations. Positive displacement pumps can handle high-viscosity slurries or those containing large solids.
Construction Materials: Slurry pumps need to be constructed with materials that can withstand the abrasive and corrosive nature of the slurry being pumped. Consider the compatibility of the pump's wetted parts (impeller, volute, casing) with the slurry composition. Materials such as high-chrome alloys, rubber, or polyurethane may be used for wear resistance
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Solids Handling Capability: Evaluate the pump's ability to handle solids present in the slurry. Look for features such as large passages, agitators, or special designs that prevent clogging or excessive wear.
Efficiency and Operating Costs: Consider the pump's efficiency to ensure optimal energy usage and lower operating costs. Look for pumps with high hydraulic efficiencies and consider the power requirements for your application.
Manufacturer and Reputation: Choose a reputable manufacturer with a track record of producing reliable and high-quality slurry pumps. Consider factors such as after-sales support, warranty, and availability of spare parts.
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Maintenance and Serviceability: Assess the ease of maintenance and serviceability of the pump. Look for features such as easy access to components, replaceable wear parts, and availability of maintenance guidelines.
Budget Considerations: Consider the upfront cost of the pump as well as the long-term operating and maintenance costs. Balance the initial investment with the expected performance and durability of the pump.
Pump Size and Capacity: Consider the physical size and capacity of the pump. Ensure that the pump's size and flow capacity match the requirements of your application. Oversized or undersized pumps may lead to inefficiencies or operational issues.
Pump Head and Pressure: Evaluate the pump's head and pressure capabilities. The pump should be able to provide sufficient pressure to overcome the resistance in the pipeline system and deliver the slurry to the desired location.
Sealing and Leakage Prevention: Slurry pumps operate in demanding conditions, and proper sealing is crucial to prevent leakage. Look for pumps with effective sealing mechanisms such as mechanical seals or gland packing to minimize the risk of leakage.
Pump Reliability and Durability: Choose a pump that is known for its reliability and durability. Consider factors such as the pump's design features, robust construction, and the quality of materials used. A reliable pump will minimize downtime and maintenance costs.
Operational Flexibility: Assess whether the pump offers operational flexibility to adapt to varying slurry conditions, flow rates, or operational requirements. Some pumps may have adjustable impellers or speed controls to optimize performance.
Energy Efficiency: Energy consumption can be a significant operating cost when using slurry pumps. Look for pumps that are designed for energy efficiency, with features such as optimized impeller designs or variable speed drives that can help reduce power consumption.
System Integration: Consider the compatibility and ease of integration with your existing system or equipment. Ensure that the pump can be seamlessly integrated into your slurry handling system without significant modifications or disruptions.
Expert Advice and Support: If you are unsure about the selection process, seek advice from pump manufacturers, distributors, or industry experts. They can provide guidance based on their experience and knowledge to help you choose the best slurry pump for your specific application.
Remember that selecting the best slurry pump involves considering the unique requirements of your application and balancing factors such as performance, durability, cost, and support.
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