feluwa applied bionics in pumps for hydrotranport & process

Copyright FELUWA Pumpen GmbH

Applied Bionics in Pumps for Hydrotransport

Rudolf Gänsl – Managing Director

Copyright FELUWA Pumpen GmbH2

Basics for Hydrotransport


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 -

Pre

ssu

re[b

ar]

Capacity [m³/h]

He

ad

[b

ar]

Capacity [m³/h]

Centrifugal Pump-Train Positive Displacement Pump

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


Evolution and Characteristics of Hose-Diaphragm Pumps

Bionics in Pumps

or the


Piston

Evolution of Hose-Diaphragm Pumps- Piston Pump -

Inlet

Outlet

Check valve

(One-way valve)


Evolution of Hose-Diaphragm Pumps - Piston Pump -

Piston

Inlet

Outlet

Suction stroke

Piston

Inlet

Outlet

Discharge stroke


Piston Pump and Hose-Diaphragm Pump

Piston

Inlet

Outlet

Piston

Inlet

Outlet

Flexible hose

Hydraulic liquid


Evolution of Pumps- Hose-Diaphragm Pump -

Piston

Inlet

Outlet

Piston

Inlet

Outlet

Piston in rear position

=

End of suction stroke

Piston in front position

=

End of discharge stroke



Piston

Inlet

Outlet DiaphragmHousing

Pumped medium

Hydraulic liquid


MULTISAFE Pumps- Double Hose-Diaphragm Pump -

End of suction stroke End of discharge stroke

Second

diaphragm



• 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 Pumpthe unique MULTISAFE Double-Hose-Diaphragm Pump since 2000

FELUWA 1960 traditional design

FELUWA from 1970hose 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 -

Copyright FELUWA Pumpen GmbH


• 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%

Double Hose-Diaphragm Pumps - Advantages -


FELUWA Standard Range


FELUWA MULTISAFE QuintuplexDouble Hose-Diaphragm Pump

MULTISAFE Quintuplexpumps provide

lowest pulsations

5 Heads

Up to 1000m³/h – 4400gpm

Up to 320bar – 4640psi


Cost Efficiency

Energy

Efficiency Availibility

Investment

Maintenance

SparesLifetime


Cost Efficiency of MULTISAFE Pumps

EnergyEnergyEfficiencyEfficiency

AvailibilityAvailibility

InvestmentInvestmentand

Operating Exp. MaintenanceMaintenance

Costs for SparesCosts for Spares

LifetimeLifetime

Changing TimeChanging Time

Valve SystemValve System

Ball ValvesBall Valves

Quick ChangeQuick Change

DiagnosticDiagnostic

Multiple PumpMultiple PumpControl

DowntimesDowntimes

DownflowDownflow

MULTISAFE

Double Hose-Diaphragm Pump


Double Hose-Diaphragm Pumps- 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.


Double Hose-Diaphragm Pumps- Flat vs. Hose-Diaphragm -

Flat diaphragm Double hose-diaphragm

Pumped medium is in contact with

diaphragm housing


diaphragm housing

Pump head volume about 40% smaller

3 times higher filling ratio

volume mediummax

volumepumped ratio filling =


diaphragm, only


diaphragm, only

About 5%

higher efficiency


Unique MULTISAFE design - Comparison of Fluid Wetted Items -

26

Example: ZGL 300/250 – 2K 180 – 4 SM 460 HD

Weight of wetted parts: 6,400 kgExample: 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 -

Heinz M. NägelNo. E 2201103-2

Open position Closed position


Valve Types- Ball Valve Assembly -

Foliennr.

steel sealingrevearsing

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 byValve Wear Detection

Flo

w R

ate

Time

Po

wer

Start of valve wear

Energyloss


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


0

1

2

3

0 100 200 300 400 500 600 700

Vo

lum

e f

low

[a.u

.]

Crankshaft angle [°]

3 triplex pumpswithout phase shift

Sum of 3 triplex pumps

3 triplex pumpswith optimized phase shift

Multiple Pump Control- Phaseshift Control of 3 Triplex Pumps -

2,2%

23,2%

23,2%


Sedimentation

inside the

diaphragm chamber

Pumping of Heterogeneous Mixtures

Flow direction


Transport of Solid Particles

Lowsinking

rate

Homogeneous HeterogeneousMIXTURE

Highsinking

rate

Length of discharge

stroke

Sinkingrate


Special Configurations- Downflow Transport -

Downflow Technology in everyday life!

PD Ketchup Pump

(hand-operated)

Flow


Pumping of Heterogeneous Mixtures

Downflow Configuration is the counteragent against

sedimentation inside the pump

Downflow Configuration=

Flow from the top to the bottom of the pump

Downflow Configuration for the handling of particulary heavy

solids and heterogeneous mixtures


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 up to 750

QGK 500 3.500 50 to 250 up to 1000

(e.g. Boleo) 1.100 45 750


Process Pumps / Feeding


FELUWAHigh Pressure and Low Pressure Pumps

Heinz M. NägelNo. E 2201052

Copyright FELUWA Pumpen GmbH50No. E 2201051

FELUWA Quadruplex High Pressure Hose Diaphragm Piston Pumps for Four-Burner Type Gasifiers

Heinz M. Nägel


Quadruplex ConfigurationDouble-Acting Two-Cylinder Pump

Heinz M. NägelNr. D 2109499-21

FELUWA Hose Diaphragm Piston Pump

Copyright FELUWA Pumpen GmbH52No. E 2201085-1 Heinz M. Nägel

FELUWA Hose Diaphragm Piston Pump

Quadruplex ConfigurationDouble-Acting Two-Cylinder Pump


FELUWA Areal View

Thanking for your kind attention