Hydro Transportation. Djakarta Mining Club Copyright FELUWA Pumpen GmbH

Transcription

1 Hydro Transportation Djakarta Mining Club 2017

2 Market Segments Power & Energy Oil & Gas Food & Pharmacy Chemical Industry Minerals & Mining 2

3 Mineral Hydro-Transport 3

4 Mineral Hydro-Transport Minerals Coal to gas (CTG) PROCESS Coal to liquid (CTL) Coal to fuel (CTF) Mineral Hydro-Transport Pipeline Storage Pipeline FELUWA MULTISAFE Pump FELUWA MULTISAFE Pump J-24 4

5 Mineral Transport - General - General transport systems are: Trucking - Hauling Shipping - Barges Conveyors - Conveying Train - Rail Hydro-Transportation Pumping Slurries in Pipelines 5

6 Mineral Transport - Distances - Hauling (intermitted) Short distance: < 20km Long distance: < 75km Barging (intermitted) Post and Barge size, loading unloading capacities Conveying (continuous) Up to around 20km (pipe) < 50km (flat) Trains (intermitteed) Unlimited distances Hydro-Transportation (continuous) up to 250km (per one pumping station) No. E Heinz M. Nägel

7 Mineral Transport - Limitations - Hauling Environmental impact, roads and maintenance costs, Barging: Waterways required, loading and unloading, weather condition, Conveying Environmental impact, Radius limitations, max 8-10% grade Trains Rail, -equipment, -maintenance, un-, loading, rail crossing, max.2% grade Hydro-Transportation: Viable over long distances, rheology (it need to be pumpable) OPEX, process flow, environment, no losses (eg. Gold) No. E Heinz M. Nägel

8 Mineral Hydro-Transport - Advantages - Economical very viable Short- to long-range (5km-250km per each Pumpstation) Direct after use paste like transport possible Understand rheology rheological design Very low OPEX, Continuous Process Flow, Transport losses zero Maintenance by flushing (if required) No road maintenance (just secondary service road) Any Terrain possible (sea, over- and underground Degradation of solids during transportation - zero No weather influence due to climatic condition No environment impact during operation (spill, noise, odour, dust) No. E Heinz M. Nägel

9 Mineral Hydro-Transport - Example - PROJECT EXAMPLE: COAL PIPELINE QUANTITY of transported coal: DISTANCE of transportation: 140Tto, 250Tto, 400Tto ~ 10km GUARANTEED continuous operation: > 8.000hrs (availabilty) DURATION (Life time): > 25years Data source: public knowledge and project managment by NatPower AG No. E Heinz M. Nägel

10 Mineral Hydro-Transport - Example - Cost items considered: CAPEX: OPEX: Conveyor: Strucure Energy Covering Belt Belt Girlands Hauling: Truck Energy Grader Infrastructure Loader Hydro-Transport: Pump Energy Pipeline Spare and Wear No. E Heinz M. Nägel

11 Mineral Hydro-Transport Transportation operation hours p.a Convayor belt Hauling Hydrotransport to to to No. E Heinz M. Nägel

12 Mineral Hydro-Transport 7,000 6,000 5,000 Total Cost per ton of coal transported (25years) 5,976 Convayor belt Hauling Hydrotransport 4,000 3,000 3,140 2,771 Barge E.Kalim. Barge S.Sumatra Rail 2,000 1,000 0,000 1,819 0,996 0,558 0, to to to 1,250 0,410 Rail Cost 0,330 Barge Cost No. E Heinz M. Nägel

13 Mineral Hydro-Transport 3,500 CAPEX per ton of coal transported (25years) 3,000 2,500 2,286 2,869 2,000 1,973 1,500 1,000 0,500 0,000 1,148 1,350 0,717 0,182 0,127 0, to to to Convayor belt Hauling Hydrotransport No. E Heinz M. Nägel

14 Mineral Hydrotransport 3,500 3,000 OPEX per ton of coal transported (25years) 3,108 2,500 2,000 1,500 1,000 0,500 0,000 1,423 0,813 0,797 1,002 0,854 0,469 0,287 0, to to to Convayor belt Hauling Hydrotransport Linear (Hauling) Linear (Hydrotransport) No. E Heinz M. Nägel

15 Mineral Hydro-Transport - existing - Slurry capacity pressure distance No. of PS (m³/h) (bar) (km) Bauxit Cu/Zn Bauxit Cu/Ni/Co Minerals

16 Applications Abrasive, corrosive, viscose media in the form of Homogenious or heterogenous mixtures # Fly & Bottom Ash # Gasifier / Autoclave Feeding # Mine Dewatering # Digester Feeding # Spray Dryer Feeding # Tailingstransfer (coal, ore`s, etc...) Mineral Hydrotransport high concentrated slurries (HCS) 16

17 SCHERSPANNUNG (Pa) Mineral Hydrotransport - Application Range - Slurry / SCHLAMM Paste / PASTE Cake / KUCHEN Heterogen / HETEROGEN Disposal above Ground / ÜBERIRDISCHE ENTSORGUNG Homogen / HOMOGEN Backfilling / RÜCKVERFÜLL G (+ cement / +ZEMENT) CONVENTIONAL THICKENERS Overlap / ÜBERLAPPUNG HIGH DENSITY THICKENERS DEEP CONE THICKENERS FILTER TURBULENT LAMINAR Plug Flow / PFROPFENSTRÖM. Centrifugal / ZENTRIFUGAL Pumps / PUMPEN Displacement / VERDRÄNGER Pumps / PUMPEN MECHAN. FÖRDERER STRASSE/SCHIENE FÖRDERBAND Concentration of Weight / GEWICHTPROZENT (C/W) Overlap / ÜBERLAPPUNG Quelle: Paste and Thickened Tailings A Guide 17

18 Mineral Hydrotransport - Rheology - No. E Heinz M. Nägel

19 Mineral Hydrotransport - Rheology - Homogeneous MIXTURE Heterogeneous Length of discharge stroke Low sinking rate Sinking rate High sinking rate Foliennr. 19

20 Mineral Hydrotransport - Rheology - No. E Heinz M. Nägel

21 Evolution of FELUWA Pumps Diaphragm Piston Pump developed by FELUWA in 1960 No. E Heinz M. Nägel

22 Working Principle - Multisafe Outlet Outlet Flexible hose Piston Piston Hydraulic liquid Inlet Inlet 22

23 Hose Diaphragm Piston Pump Advantageous Design Features Double safety by hose and diaphragm B-14 23

24 Evolution of FELUWA MULTISAFE Pumps In 1970 FELUWA developed the Hose Diaphragm Piston Pump No. E Heinz M. Nägel

25 Working Principle - Multisafe Outlet Outlet Piston in rear position = End of suction stroke Piston in front position = End of discharge stroke Piston Piston Inlet Inlet 25

26 FELUWA s MULTISAFE Double Hose Diaphragm 26

27 Double Hose-Diaphragm Pumps - Double Hose-Diaphragm - Inner diaphragm Outer diaphragm Double Hose is Double Safety 27

28 Evolution of FELUWA MULTISAFE Pump Made in Germany Single diaphragm pump Hose-diaphragm pump Double hose-diaphram pump (1st generation /1960) (2nd generation /1970) (3rd generation /2000) B-4 28

29 Double Hose-Diaphragm Pumps MULTISAFE Double Hose-Diaphragm Pumps Advantages - Efficiency - 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% 29

30 Extract of References 30

31 FELUWA Multisafe Coal gasification, China 3 x bar Folio No. E

32 FELUWA Multisafe 32

33 FELUWA Multisafe Autoclave feed, Morenci, USA, copper concentrate 3 x bar 33

34 FELUWA Multisafe 34

35 FELUWA Multisafe Autoclave feed, Sepon Copper, Laos, copper concentrate 3 x bar 35

36 FELUWA Multisafe Folio No. E

37 FELUWA Multisafe Autoclave feed, Vale Sossego, Brazil, copper concentrate 2 x 3,3 16 bar 37

38 FELUWA Multisafe Folio No. E

39 FELUWA Multisafe Tailings 54 bar Foliennr. 39

40 FELUWA Multisafe Folio No. E

41 FELUWA Multisafe 24hour full load test 41

42 FELUWA Multisafe Triplex Single Acting Pumps (during assembly) 42

43 FELUWA Multisafe 300 m³/h, 100 bar 43

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