Coal slurry pumps problems caused by wet parts wear

Slurry pumps are widely used in Coal production, such as slime water, recycled water, coal slurry and heavy medium suspensions slurry delivery. It is also working in grade (concentrate) cyclone, heavy medium (aqueous medium) separation cyclone and filter press feed.

Centrifugal slurry pump is one kind of centrifugal pumps, also used centrifugal force produced by the rotation of impeller to increase energy. Slurry pump designed to pump water with solid particles so a bit different compare with common water pumps. So there is a important problem you have to deal with: wet parts wear problem

Slurry pump wet parts wear
The wear is material destruction caused by cumulative damage between the solid particle impacts( friction or abrasive ) the wet parts of the slurry pump. Type of slurry pump wear is generally divided into chipping abrasion (caused by high-intensity impact, sometimes tear off debris), grinding abrasive (wear when the fine powder solids crushed between two surfaces,) and erosion wear (the high-speed or low-speed free movement abrasive, sometimes particles paralleled compact the grinding surface or collision the grinding).

Problems caused by slurry pump wear
1, Lower efficiency. Since the gap between impeller and liner mutual wear, causing the pump volumetric efficiency decreases. This will leading wet parts surface with uneven wear phenomenon. It will seriously affect the work efficiency of centrifugal slurry pump.
2, Maintenance problems. Since the degree of wear slurry growing, overhaul can not guarantee the normal operation of slurry pump, making maintenance work significantly increased and will gradually lengthen.
3, Reducing operational quality. Surface of centrifugal slurry pump wet parts are uneven after wear. It may promote turbulence and cavitation. Asymmetric wear impeller will cause mechanical imbalance. These reasons will make vibration intensified, shorten bearing and mechanical seal life and reduce the quality of operation.

How to increase slurry pump impeller and liner working life

AH slurry pumps

Slurry pump impeller and volute liner are most frequently changed parts of slurry pumps, why? The following analysis could help you know more of the problem:

1) The mutual chemical liquid slurry transport response, the electrical potential difference caused by chemical corrosion, slurry pump impeller and volute liner are direct contact with the slurry liquid

2) Since transport liquid containing solid impurities, which will cause wear and tear tempered, too hard and too sharp particles also can damage impeller and liner very quickly;

3)There is a deviation between slurry pump design point and operation, causing rapid corrosion of the components.Engineer should chosen suitable slurry pumps for different conditions, in order to avoid this problem.

4) The slurry liquid may contain large amounts anaerobes, which will cause corrosion damage to slurry pump impeller and liner. So, it will be much better to apply some lubricant one these parts to isolation air.

5) Cavitation damage by bad working condition, even just bolt loose problem. So do pump checking work very carefully.

6) The slurry liquid may contain too much chloride ions cause pitting and intergranular corrosion. Change the impeller and liner to suitable material if this happened.
7) Slurry pump impeller and liner are fatigue due to vibration lead to damage problem.

8) The operating temperature is too high when slurry pump working.

9) Slurry pump liner is over pressure when running the pump

10)There are mistakes when assembly the slurry pump.

The above10 points can fully explain why the slurry pump impeller and slurry pump liner maybe the shortest working life parts, as long as all the solutions for these reasons, we believe that you can greatly increase the life of them . For more information, welcome to contact us

AH slurry pump impeller

AH slurry pump liner

Warman AH Slurry pumps flow adjust ways

Warman AH slurry pumps are centrifugal horizontal water pumps, which are widely used in world. When you change your working condition where the pumps worked, you face one problem, change the pump working performance, like flow rate. Here bellow we will talk some methods you can use to adjust the Warman AH slurry pumps working data, flow rate(capacity)

(1) Valve regulating
This is the most common and popular way to change the flow rate. Adjust the control valve in the slurry pump pipeline to change the flow rate. Its easy and reliable, but its also loss large power with low efficiency, not good for low flow system.

(2) Speed control
Changing slurry pump flow rate by speed. By this way, there is a little power loss and its most economical method. But it needs to add transmission mechanism and variable speed motors, he initial investment is costly. Also can adjust motor frequency to change the speed, or by using couplings

(3) Bypass regulator
Use bypass flow shunt regulator, to resolve WARMAN AH slurry pump flow continuous operation in low flow condition, but result in a diversion flow underutilized and increase additional losses, while the process pipeline increasing
.
(4) Cutting impeller diameter
By cutting slurry pump impeller diameter to adjust the pump flow rate, the power loss is little, but you can not recover impeller size which means you can only adjust to a small flow direction. And there is also a limitation of cutting impeller, flow regulating range is limited. It applies to long-term work at a smaller flow rate and flow rate change is not the occasion.

(5) Replacement of slurry pump impeller
Different diameter impeller adjustment lead to low power loss, but need to prepare a variety of impeller diameter.

(6) Blocked impeller passage
Block slurry pump impeller passage (even) to reduce pump flow. Its equivalent of outlet valve but are actively adjust way which additional energy loss reduction is less than outlet valve.

(7) Adjust the angle of impeller vane
By changing the angle of impeller vane to achieve flow regulation is used for axial flow pump, centrifugal slurry pump is not very good.

(8) Cavitation adjustment
By changing Warman AH slurry pump inlet pressure (water level, inlet valve) may lead to cavitation. It will change the pump characteristic curve, and so the pump flow. It has proved that cavitation adjust if used appropriately, the damage to slurry pump wet parts is not serious; on the other hand, it can automatically adjust the flow and reduce the power consumption.

(9) Increase or decrease the quantity of slurry pumps
By increasing or decrease slurry pumps with supplemented suitable way to achieve the merger regulation of flow rate.

The above nine methods are most common methods of adjusting Warman AH slurry pumps flow. You can choose suitable way according to actual mining conditions.

How to solve Warman AH slurry pumps motor overheat problems

Warman AH slurry pumps are most common and maximum utilization of slurry pumps. AH slurry pump is designed by Australia Warman company, which with simple structure and durable working life. Hope what we talked bellow could help you solve motor overheat problems you may have in maintenance process of AHslurry pumps.

Why slurry pump overheating?
1, Slurry pump working under overflow condition, too larger than designed flow point.
2, Slurry pump speed is too high. The slurry pump speed too high will need more shaft power, increasing pump burden.
3, Slurry pump seal ring wear problem. Slurry pump seal ring wear too much will lead to adhesion to the shaft, causing overheat of shaft.
4, Slurry liquid density is too high. The density is too large, resulting in pump pressure increased, it will increase the burden on slurry pump itself.
5, Slurry pump rotating parts friction. The distance between the various components of the slurry pump is limited.
6, Bad quality motor. It may be aluminum motor or inside winding relatively is small.
7, Slurry pump packing is too tight. Too tight packing may lead to dry running of slurry pumps phenomenon, will seriously hamper the operation of slurry pump.
Solutions to overheating problems
1, Turn down outlet valve or other ways to decrease slurry pump flow.
2, Reduce the slurry pump speed.
3, Replace the seal ring and increase lubrication efforts.
4.Increase motor power.
5, Make sure all clearance of slurry pumps installed in accordance with specifications, eliminating friction.
6, Use better motor. Remember to use good motor all the time, do not use defective products.
7, Loose slurry packing filler to reduced pressure.

Things you should know before purchase slurry pumps

For slurry pumps selection, there are some thing you need to know before it. Hope what we talked bellow could help you on slurry pump selection.

Installation type

There are vertical slurry pumps, horizontal slurry pumps, submersible slurry pumps. Horizontal slurry pumps can be installed into CV, CR, DC and ZVz types, customers could choose according to their own working conditions.

slurry pump driven type

Good slurry pump parameters

Slurry parameters include: suction and discharge size, flow rate, head, power, NPSH, etc. These are the parameters must be confirmed first before slurry pump selection. Only confirm all these data well, you could choose the right pump then.

Slurry pump structure selection

There are light duty slurry pumps, heavy-duty slurry pump, low head slurry pumps, high head slurry pumps and etc. Warman AH slurry pump is one kind of heavy duty slurry pumps, HH type is high head slurry pumps, M series is medium slurry pump, AHR is rubber lined slurry pumps. There are many types of slurry pumps, so you must confirm the pump structure.
ah ah horizontal slurry pumps Horizontal slurry pumps

Material of slurry pump

After you done above steps, then you have to face another important problem, slurry pump material. You have to choose right material according to working conditions. There are some common slurry pump materials: A05 material (high-chromium alloy KmTBCr26), A49 (desulfurization pump special material), A33 (Naifushibeng special material) and others.

Slurry pump shaft seal

There are three main kinds of seal types, Gland packing seal, expeller seal and mechanical seal. Depending on the working conditions, the sealing material could be different, such as mechanical seal can be divided into stainless steel 316L and 3cr13. Customers can choose according to their own work conditions.

Hope the above information cloud help you in some way, if you want know more, please contact us.

Where and how to find good warman slurry pump parts

Warman® centrifugal slurry pumps are the world’s most comprehensive range of centrifugal slurry pumps for use in mining, chemical and industrial applications. The horizontal and vertical slurry pumps are designed for ultra heavy duty applications such as mill discharge, process plant and tailings, pipelines as well as specialty applications. The Warman® range also includes axial flow pumps for applications in the salt industry.

There is always a problem of maintenance work, wear parts replacement. If buy from Warman, it will be costly, but its quality you do not need to worry. But if you want to cut down the running cost, you have to think try others parts, which could 100% interchangeable with Warman. In this way, you have to consider the quality at first place.
All around the world, there are so many companies selling these parts, how you can find a good one from them?
1. Talk with them for some times
2. Try to get drawing from suppliers
3. Check their products by yourself if you can go to visit them
4. Ask someone you know in the local to help to visit them
5. Buy from sample order before you make bulk ones
There are many other ways you can choose to get answers, so try to ask more questions.

From Libra, you could get full time service and 100% assurance for the parts quality and size interchangeable with original ones. Welcome to contact us for more details.

Slurry pumps for lime slurry

From construction to cosmetics, Limestone Slurry is a versatile, cost effective product widely used in industry for a number of diverse applications.

Durability and reliability are just some of the benefits of the range of pumps we offer for Limestone Slurry application. You can purchase from a hand-picked collection that offers you expertly engineered, long-lasting technology and value for money.
Common uses for Limestone Slurry
It’s most common use is to clean coal burning power plants, where it is used to remove sulphur dioxide deposits left over from burnt coal.
Gypsum – a by-product of the Lime Slurry process – is then pumped around the power plant, for intended use in the production of drywall boarding for building construction.
Detoxification of environmentally hazardous by-products from manufacturing is also one if it’s key applications.
Reduce downtime and maintenance
You can rely on us to supply pumps of the highest quality for use in the Lime Slurry process. By providing a product you can rely on, we can help reduce your maintenance costs. What’s more, we pride ourselves on providing the fastest response time, reducing your downtime so your business can keep moving.

Recommended pumps

Heavy Duty Slurry Pumps
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Light Duty Slurry Pumps
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Vertical Slurry Pumps
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Ash&Ore Slurry Pumps
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High Head Slurry Pumps
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Submersible Slurry Pumps
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Single Casing Slurry Pumps
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Slurry pumps are built to handle thick, abrasive, or solids-filled slurries. The pumps are typically made with durable material so that they can handle abrasive fluids over long periods of time without excessive wear.

Slurry pumps are available in several different types. Slurry centrifugal pumps are usually single stage, end suction configuration. The pumps are often made with durable high nickel iron to minimize the abrasive wear on the pump’s parts. As an alternative to hardened high nickel iron, slurry pumps may be lined with rubber to protect against wear. This distinction is dependent on the velocity, size and shape of the abrasive particles in the slurry. Centrifugal slurry pumps use replaceable liners on both sides of the casing. In some cases, these liners can be adjusted while the pump is running. This allows operations that run 24-hours a day – such as minerals processing plants — to change the pump’s impeller clearance without shutting down, ensuring high productivity and maximum pump efficiency.

Positive displacement slurry pumps are often a type of diaphragm pump that uses a reciprocating diaphragm to expand or contract the pumping chamber — either mechanically or by pressurized air. As the diaphragm expands, it draws slurry or sludge into the chamber through a valve designed to prevent backflow. When the diaphragm contracts, fluid is pushed through the out take side of the chamber.

Slurry pumps are best used to process fluids that contain abrasive solids. These applications include large mining, mine slurry transport and minerals processing plants. They are also used in sand and gravel dredging, as well as plants that produce fertilizers, cement, steel and salt. Slurry pumps are sometimes found in agricultural processing facilities and wastewater treatment plants.

Coal ash slurry pumps

If clean water is important to you and your family, you need to know about a silent danger to our waterways and public health.
Coal ash, the waste left over after coal is burned to generate power, contains concentrated amounts of heavy metals, such as lead, mercury, arsenic, chromium, and selenium, which are hazardous to human health, and to wildlife.

Thermal power plants generate more than half of the world’s electric power by burning millions of tonnes of coal and simultaneously produce large quantity of coal ash. Slurry pipelines are commonly used across the world for the transportation of coal ash (fly ash and bottom ash) from the plant to the ash ponds in thermal power plants. These systems are very energy intensive and also lead to excessive wear of pipeline and wastage of water.
Further, the present enhanced consciousness towards the imbalance in the eco-system and related stringent government policies are forcing the thermal power plants to adopt environment friendly transportation systems. Thus, high concentration slurry disposal (HCSD) system has emerged as preferred option to transport coal ash in thermal power plants as it is economical and environmentally friendly.
Concentration of 50% by weight was the limit of safe pumping of coal ash using a centrifugal pump and positive displacement pumps may become necessary to pump coal ash slurries above this concentration.
Here bellow we list some slurry pumps could do the work well

heavy duty slurry pump

H series heavy duty slurry pumps
H series heavy duty slurry pumps are end-suction, split-case, centrifugal slurry pumps provide excellent wear life while maintaining efficiency during the wear cycle providing the best total operating cost.

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Ash and ore slurry pumps

Ash&Ore Handling Slurry Pumps
Z series centrifugal slurry pumps suitable for handling abrasive and corrosive solids-bearing slurry with maximum concentrations of wt45%(ash) and wt 60%(ore). They are widely used in mining ,metallurgy, power, coal，petroleum,chemical and building material sectors.

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high head slurry pumps

G series High Head Slurry Pumps
G series high head slurry pumps are horizontal, single-stage, single-suction, cantilever, double-casing, centrifugal slurry pumps. The pumps are designed for heavy duty slurry transport with high head application,especially for multi-stages work.

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Slurry pump

D series Single casing Slurry Pumps
D Slurry Pumps are innovative in hydraulic designs, structural designs and materials of castings after integrating congeneric products throughout the world. They have many features: high efficiency, reasonable design, reliable operation, long in service time, easy maintenance, and low running costs and so on.

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Slurry Pump Impeller Tip Speed

It’s no easy task to size and select a slurry pump. Along with considering pump hydraulic and mechanical characteristics (which we won’t cover in this post, but would be happy to help you with), it has become vital to consider the impeller tip (or peripheral) speed, the impellers revolutions per minute (RPM) and how these elements have an effect on the wear of your slurry pump.  We offer a few suggestions here on how to gauge a pump’s wear rate, based on tip speed, RPM and impeller size.

Slurry Pump Impeller Tip Speed and Pump Wear

One criterion that is commonly used to indicate you’ve selected the correct slurry pump is if the impeller tip (or peripheral) speed is below the maximum allowable tip speed, which is based on the class of slurry being pumped, and the impeller material.

It is definitely important to note that a pump’s wear rate is associated with the impeller tip speed, but that it’s more accurately connected with the impeller revolutions per minute (rpm).

Here’s a basic formula to help remember the relationship between a pumps wear rate and the impeller rpm:  Pump Wear Rate ≈ rpm3

Case Study: Different Sized Impellers with Identical Tip Speeds with Different Resistance to Wear

To illustrate this a little further, we might look at two different sized impellers: one is Ø12” and the other is Ø24”. Let’s say they have identical tip speeds, but as you will discover drastically different resistance to wear when pumping abrasive slurry.

Here’s how it works (again using a simple formula):

Slurry Class: 3 Impeller Material: Metal
D (Impeller Ø)	Max Impeller Tip Speed	N (Impeller RPM)
12” (305mm)	108 ft/s (33 m/s)	2063
24” (610mm)	108 ft/s (33 m/s)	1032

Looking at this example, you can hopefully see that–according to the Pump Wear Rate formula I included above–the Ø24” impeller that’s operating at 1032rpm will last about eight times as long as the Ø12 impeller operating at 2063rpm, even though the two impellers have identical tip speeds.

Clearly, from this example, the second (Ø24”) impeller is one to go with. You can play around with the formula–it’s reliable. But if you have any questions at all, we’re always here to help.