Feluwa applied bionics in pumps for hydrotranport & process

Applied Bionics in Pumps for Hydrotransport
Rudolf Gänsl – Managing Director
Copyright FELUWA Pumpen GmbH

Basics for Hydrotransport
Copyright 2 FELUWA Pumpen GmbH

Basics for Hydrotransport
• Our customers handle and transport through pipes
heterogeneous, abrasive and corrosive media with a defined viscosity
• The Competing Systems are:
• train
• truck
• belt
• and comes to pipelines – centrifugal pumps

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)

Pump Characteristic
- Centrifugal versus PD Pump -
Centrifugal Pump-Train Positive Displacement Pump
Pressure [bar]
Capacity [m³/h]
Head [bar]
Capacity [m³/h]
Speed

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

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

Bionics in Pumps
or the
Evolution and Characteristics
of Hose-Diaphragm Pumps

Evolution of Hose-Diaphragm Pumps
- Piston Pump -
Piston
Outlet
Inlet
Check valve
(One-way valve)

Evolution of Hose-Diaphragm Pumps
- Piston Pump -
Piston
Outlet
Outlet
Inlet
Suction stroke
Piston
Inlet
Discharge stroke

Piston Pump
and Hose-Diaphragm Pump
Piston
Outlet
Outlet
Inlet
Piston
Inlet
Flexible hose
Hydraulic liquid

Evolution of Pumps
- Hose-Diaphragm Pump -
Piston
Outlet
Outlet
Inlet
Piston
Inlet
Piston in rear position
=
End of suction stroke
Piston in front position
=
End of discharge stroke

Evolution of Pumps
Outlet Housing Diaphragm
Piston
Inlet
Pumped medium
Hydraulic liquid

MULTISAFE Pumps
- Double Hose-Diaphragm Pump -
End of suction stroke End of discharge stroke
Second
diaphragm

Evolution of Pumps
• Hydrostatic Pressure by
surrounding hydraulic liquid
• 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

Evolution of FELUWA MULTISAFE Pump
the unique MULTISAFE Double-Hose-Diaphragm Pump since 2000
FELUWA 1960
traditional design
FELUWA from 1970
hose diaphragm
FELUWA - MULTISAFE
Double-Hose-Diaphragm

MULTISAFE Pumps
- Double Hose-Diaphragm -
Inner
diaphragm
Outer
diaphragm
Both hose-diaphragms
are in direct contact
Double safety
Hose-diaphragms are
never stretched!

Double Hose-Diaphragm Pumps
- Working Principle -

- 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%

FELUWA Standard Range

FELUWA MULTISAFE Quintuplex
Double Hose-Diaphragm Pump
MULTISAFE Quintuplex
pumps provide
lowest pulsations
Up to 1000m³/h – 4400gpm
Up to 320bar – 4640psi
5 Heads

Cost Efficiency
Lifetime Spares
Energy
Efficiency Availibility
Investment
Maintenance

Cost Efficiency of MULTISAFE Pumps
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Operating Exp. MMaaiinntteennaannccee
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Control
DDoowwnnttiimmeess
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MULTISAFE
Double Hose-Diaphragm Pump

- Pressure sensor -
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.

- 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 =
Pumped medium is
in contact with
diaphragm, only
About 5%
higher efficiency

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
26
Example: TGK 300/250 – K 180 – DS 100 HD
Weight of wetted parts:
150 kg -97,7%

Valve Types
- Corner vs. Linear Valves -

MULTISAFE Check Valves
- Ball Valve -
Open position Closed position
No. E 2201103-2 Heinz M. Nägel

Valve Types
- Ball Valve Assembly -
Foliennr.
steel sealing
revearsing
seal ring

MULTISAFE Check Valves
- Quick Change System -
Foliennr.

Special Configurations
- Double Valves -
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.

FELUWA Check Valves in Quick Change Design
with Hydraulically Supported Fastening in Single
or Double Valve Design (as per Illustration)

Diagnosis Systems
- Energy Loss in Case of Leaking Check Valves -
Leakage in discharge and/or
suction valve
Suction stroke

Diagnosis Systems
- FELUWA Valve Performance System (FVPMS) -
Valve
sensor

Energy Savings by
Valve Wear Detection Flow Rate
Time
Power
Start of
valve wear
Energy
loss

FELUWA Pulsation Dampener
- combined air vessel + diaphragm -
Additional
air cushion
(air vessel)
Bladder
accumulator

Multiple Pumps
- Pressure Pulse Optimisation -
Pump 1 Pump 2 Pump 3
Wrong
phaseshift
Optimized
phaseshift
Resulting pulsation on common discharge pipe
or

Multiple Pump Control
- Pressure Pulse Optimisation -
• Optimized phaseshift,
when a pump is shut off
• Automatic speed
increase to avoid a
standby pump
Optimized
phaseshift
Pump 1
Pump 2
Pump 3
Resulting flow to pipeline

Multiple Pump Control
- Phaseshift Control of 3 Triplex Pumps -
Sum of 3 triplex pumps
3 triplex pumps
without phase shift
with optimized phase shift
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%

Pumping of Heterogeneous Mixtures
Sedimentation
inside the
diaphragm chamber
Flow direction

Transport of Solid Particles
Homogeneous Heterogeneous
Low
sinking
rate
MIXTURE
High
sinking
rate
Length of
discharge
stroke
Sinking
rate

Special Configurations
- Downflow Transport -
Downflow Technology
in everyday life!
PD Ketchup Pump
(hand-operated)
Flow

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

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

Hydrotransport

Hydro Transport
• QGK 500
750 m³/h – 54 bar

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

Process Pumps / Feeding

FELUWA
High Pressure and Low Pressure Pumps
No. E 2201052 49 Copyright FELUWA Pumpen GmbH
Heinz M. Nägel

FELUWA Quadruplex High Pressure Hose Diaphragm
Piston Pumps for Four-Burner Type Gasifiers
Copyright No. E 2201051 50 FELUWA Pumpen GmbH
Heinz M. Nägel

FELUWA Hose Diaphragm Piston Pump
Quadruplex Configuration
Double-Acting Two-Cylinder Pump
Nr. D 2109499-21 Heinz M. Nägel

FELUWA Hose Diaphragm Piston Pump
Quadruplex Configuration
Double-Acting Two-Cylinder Pump
Copyright No. E 2201085-1 52 FELUWA Pumpen GmbH Heinz M. Nägel

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Feluwa applied bionics in pumps for hydrotranport & process

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