Positive Displacement Diaphragm Piston Pumps engineered and made by FELUWA in Germany

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
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CCoossttss ffoorr SSppaarreess
Operating Exp. MMaaiinntteennaannccee
Copyright 23 FELUWA Pumpen GmbH
VVaallvvee SSyysstteemm
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Control
DDoowwnnttiimmeess
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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