Slurries are specialized compounds found in various processing industries, including sanitary sectors like mining, aggregates, mineral processing, dredging, tunneling, and water treatment, as well as other industries that involve slurry or sewage. Because slurries combine the properties of liquids and solids, special consideration must be given when determining the type and size of the slurry pump to use with them. Kingda Pump features several companies that specialize in slurry pumps capable of handling a wide range of loads, from light to heavy.
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Slurries are solid-liquid mixtures, with the liquid acting as a transport mechanism for the solid. The size of particles in slurries can range from a micron to thousands of millimeters. The ability of a pump to move a slurry through a process line is greatly influenced by particle size.
Aslurry pump is a centrifugal pump used to transport abrasive and frequently corrosive solid particles inside a carrier fluid. To minimize substantial particle velocity and thus wear rates, the slurry pump should have a low specific speed design that allows for slower operating speeds than ordinary water pumps. Depending on the application, wear-resistant metallic or elastomeric materials are used in slurry pump components that come into contact with the pumped medium.
Slurries are further classified into four classes by industry based on their aggressiveness, with Class 1 being the least aggressive and Class 4 being the most aggressive. Pumping slurries can wear out pumps and pipeline components in the following ways:
Several types of pumps are suitable for pumping slurries, as described below. However, we must address a couple of critical issues before deciding which technology to use.
The pump’s speed and shear the pump can cause damage to solids or slurry, which is a concern for centrifugal pumps. Twin screw pumps, generally, because of the minor slurry’s solids.
Because slurries weigh a lot and are hard to push, the pumps explicitly made for slurries will have heavier and more potent than pumps designed for liquids with less viscosity.
Slurry pumps tend to be larger than conventional pumps, have more horsepower, and are constructed with more robust bearings and shafts. The centrifugal pump can be described as the most popular kind of pump for slurry. These pumps employ an impeller rotating like water-like liquids flow through a centrifugal pump.
Pumps designed explicitly for slurry pumps will usually feature the following features compared to conventional centrifugal pumps. Centrifugal force can push it outward if something is spinning fast around a central point.
These pumps may also be made of specialized high-wear alloys for pumping abrasive slurries. Hardening stainless steel is another popular option for abrasive slurries.
Helpful displacement pumps may be better than centrifugal pumps for certain slurry pumping conditions.
Follow these four simple steps to determine what type of slurry pump is the best for your particular need or application.
Think about the following:
Are the design and material used to construct the impeller of a centrifugal pump suitable for pumping slurries?
It is also critical to consider the slurry’s chemical compatibility with any elastomers in the pump. Once the nature of the slurry and the components of various types of pumps have been addressed, we can choose a potential candidate slurry pump for the application.
The most crucial part of this equation is determining the required pump horsepower to supply a certain quantity of liquid at the needed differential pressure. Think about the following:
Most centrifugal slurry pumps operate at low speeds to reduce component wear — typically less than rpm. Find the ideal spot where the pump can run at a minimum speed without allowing solids to settle into the slurry and clog the lines.
Then, to reduce wear even further, reduce the pump’s discharge pressure to the lowest setting possible. Also, use proper piping layout and design principles to ensure consistent and uniform slurry delivery to the pump.
Thanks to features such as the large diameter of the impeller, shafts, bearings, and internal passageways, and their heavy-duty construction, Slurry pumps can withstand massive wear. Slurry pumps have more upfront operating costs than water pumps in the industrial industry. But, only slurry pumps are efficient in hydro-transporting solid materials. The longer-term advantages outweigh the initial cost.
The production of centrifugal force that causes the material to move outwards from the center of the pump is crucial for the efficiency of slurry pumps. However, the power of centripetal force pulls the material toward the center. Since the energies that impart the speed of the slurry increase, the process of transport of Slurry pumps works on the principle of centrifugal force. A centrifugal pump, however, is ineffective since the solids in the slurry would build up rather than flow freely.
Knowing the exact conditions required for each pump is crucial for anyone planning to set up a slurry pump.
Wet – the drive and slurry pump are entirely submerged in this setup. Certain types of slurry pumping, like underwater operations, will require this.
Dry — the setup protects the bearings and the pump’s drive free of the slurry. The wet part is freestanding and free of any liquid that surrounds it, comprised of the impeller, shell and suction liner, hub and shaft sleeve, and the stuffing box. The slurry pump technician puts most horizontal pumps in place using this method.
Semi-dry — this particular arrangement is used in horizontal pump dredging. The wet side and the bearings are flooded; however, the drive is dry. In this situation, bearings require a sealing arrangement.
This guide gives a brief overview of slurry pump types and their installation; however, there is more to be learned. Kingda will be there to help those looking to comprehend slurry pumps and applications or require help deciding what type of pump and installation is best for their needs.
When it comes to pumping slurry, many can agree it isn’t an easy task. Above all else, you need to make sure you have the right pump for the right slurry.
There is no easy way to select the perfect slurry pump design for your application without proper knowledge and application specifics. With this in mind, Global Pumps’ experts have provided a helpful guide to selecting the best slurry pump for you.
What is slurry?
Slurry is a semi-liquid mixture comprised of fine particles; examples being manure, cement and starch. Due to these added particles, and the fluid’s thicker consistency, it is crucial a special pump is selected.
Selecting the Right Pump
To ensure your pump is suitable, consider the following attributes:
Impeller: the impeller should have large enough passageways so that the solid particles, no matter their size, can pass through without clogging.
Casing: The casing of the pump, which handles the pressure, should have larger gaps between the impeller and the cut water tongue, to reduce wear and prevent large solid particles from getting stuck.
These two elements, when combined with the other components, have crucial roles in the operational success of the pump moving the slurry. If these parts are not appropriate you may be spending money on maintenance and causing longer downtime.
Materials of Construction
The materials of construction are possibly the most important characteristics of your slurry pump:
Metal and/or rubber pump liners that are used will combat the erosion from the solid particles.
Metal casing will resist erosion caused by the increased pressure and circulation. In some circumstances, the casing will be manufactured from wear-resistant steel, so that the pump can be welded if in need of repair.
Depending on the application, variations in these materials may occur. For example, if you work in the cement industry, and mainly handle fine particles at low pressure, the casing of your slurry pump may be constructed from a lighter material. Whilst in rock pumping, the pump casing and impeller must resist the hard knocks.
If you’re looking to buy a slurry pump or would like to learn more about what pump will suit your application, contact our Global Pumps team.
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Pumps designed for pumping slurries will be heavier duty than those designed for less viscous liquids since slurries are heavy and difficult to pump.
slurry pumps are typically larger in size than standard pumps, with more horsepower, and built with more rugged bearings and shafts. The most common type of slurry pump is the centrifugal pump. These pumps use a rotating impeller to move the slurry, similar to how a water-like liquid would move through a standard centrifugal pump.
Centrifugal pumps optimized for slurry pumping will generally feature the following in comparison to standard centrifugal pumps:
Larger impellers made with more material. This is to compensate for wear caused by abrasive slurries.
Fewer, thicker vanes on the impeller. This allows the passage of solids more readily — typically 2-5 vanes, compared to 5-9 vanes on a standard centrifugal pump.
For pumping abrasive slurries, these types of pumps may also be made from specialized high wear alloys such as AL-6XN® or Hastelloy® C-22®. Hardening stainless steel is also a common option for abrasive slurries, with Expanite and Armoly being two hardening processes.
For certain types of slurry pumping conditions, positive displacement pumps may be a more appropriate choice than a centrifugal-style pump.
These conditions include:
A low slurry flow rate
A high head (i.e., the height to which the pump can move liquid)
A desire for greater efficiency than that afforded by centrifugal pumps
Improved flow control
Common types of positive displacement pumps used in slurry pumping applications include:
Rotary Lobe pumps
These pumps use two meshing lobes rotating within a pump's housing to move fluids from the pump's inlet to its outlet.
Twin-screw pumps
These pumps employ rotating screws to move liquids and solids from one end of the pump to another. The screws' turning action creates a spinning motion that pumps material.
Diaphragm pumps
These pumps use a flexible membrane that expands the volume of the pumping chamber, bringing in fluid from an inlet valve and then discharging it through an outlet valve.
Choosing the right pump for your slurry application can be a complex task due to the balance of many factors including flow, pressure, viscosity, abrasiveness, particle size, and particle type. An applications engineer, who knows how to take all of these factors into account, can be a great help in navigating the many pump options available.
~ Matthew Sato, Applied Products Sales Manager, Ampco Pumps
In determining which type of slurry pump is best suited for your particular application, follow these four simple steps.
by Steven Rose
As a quarry manager, one of the most important components of your washplant is the slurry pump system.
“Many standard pumps are fine for moving rain/clear flood water but for slurry pumps, life isn't so smooth.”
So, what to be aware of when choosing a pump for slurry handling? There are many factors that good slurry pump manufacturers need to bear in mind in the design and specification. Being aware of these will enable you to choose the correct pump for your quarry sludge transfer pumping.
Sludge from quarrying or post-washplant carries solids such as sand or other minerals, often of a wide range of unpredictable particle size and type. Some of these are very abrasive and can quickly wear down vital parts resulting in a shortened pump life, reduced performance, or costly breakdown.
Longevity of Materials. Quality slurry pumps are built with abrasive resistant parts and internal linings such as specially formulated rubbers and high-chrome alloys.
Viscosity and Particle Size Range. Over time and season, your slurry composition is likely to vary so the pump needs to handle a sensible range. Impeller blades in slurry pumps are generally larger than general-purpose pumps to enable them to pass larger solids and must be designed to retain good pressure head results.
Ease of Maintenance. Wearing parts need to be quickly accessed for inspection and replacement when needed, with minimal downtime. A split-case pump design makes it quick and cost-effective to replace worn parts without replacing the whole pump.
Correct levels of lubrication must be maintained to ensure continued performance, safety, and efficiency of mechanical parts. Pumps with an auto-greasing system save time and ensure that this task is done consistently.
Size and Power of Pump. This is determined largely by the volume and transfer distance. Slurry pumps typically have a flatter head curve to aid the movement of thicker solution over the entire length of the discharge pipe.
Balancing energy usage with reliable capacity is becoming more critical. Over-spec can lead to significant profit revenue losses and unnecessary climate impact whilst going cheap risks having to buy again or repair too soon. Ask Atlantic Pumps for help calculating the power necessary for your particular flow and head requirements.
Parts and Service Availability. Always check the brand’s parts availability/servicing requirements and look out for pump units that can be opened up to access the areas taking the brunt of wear and tear. You need to keep production going at all times. Atlantic Pumps understand this importance so carry good stocks of spare parts, backed up by extensive UK-wide coverage of specialist quarry pump engineers.
The shaft entrance into the impeller chamber is where leakage is most likely to occur on any centrifugal pump. Whether this is of concern depends on the slurry being handled.
The most basic seal (and lowest cost from the manufacturer’s side) is a flexible and absorbent rope-like sealant, called a gland seal. The tighter the packing, the less leakage but also more resistance is created. To keep these opposing attributes balanced over time, regular re-packing of gland seals is necessary.
An improvement on this is an expeller seal which uses the spinning shaft to reduce the pressure at its entrance; this works well when the pump is in full operation albeit with a slight increase in resistance.
Slurry pumps typically have a flatter head curve compared to general-purpose pumps to the aid transfer of thick slurry over further distance.
One of the most common types of pump used for slurry is a centrifugal action one. The simple concept of a centrifugal pump gives pump manufacturers more scope to match the capacity and flow rate to the target need. Optimum efficiency and performance can be achieved through impellor design and size of inlet and outlet. By using larger impeller vanes, these pumps can be made to pass larger solids with ease whilst still achieving the required head.
Centrifugal pumps take up less floor space than an equivalent reciprocal pump, with obvious advantages for site operations and logistics.
Vertical pumps are good where they need to sit over a sump whereas horizontal pumps are best where the performance of flow and head are most important, making them the most common solution for quarries and other sites with bulk slurry handling needs.
Another type of pump that may suit particular slurry transfer needs is a peristaltic pump. As the pumped fluid does not come into direct contact with the pump’s mechanics, industrial peristaltic pumps are good for corrosive or difficult-to-clean slurry.
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