PUMPS
Engineered for mining
Moving on to another leading pump OEM , IM spoke to Mitchell Thompson , Applications Engineer II at FLSmidth
Q FLS just launched the Krebs hMAX pump – what are its attributes and what applications can it be used for in mining and why ? A The FLS KREBS hMAX is a robust , horizontal , recessed impeller pump with a concentric casing . The impeller and casing are engineered to provide a variety of benefits : minimise degradation , prevent shearing , reduce wear , and prevent air locking and clogging . Anything that can pass through the discharge can be pumped . Due to its unique design , the hMAX has proved successful in a variety of applications . These include froth , activated carbon transfer ( CIL / CIP / CIC / ADR ), pulp & paper , sewage , and digester recirculation . It has also been successful in processes with tramp material , degradation concerns , and entrained air .
Q Is the market for pumping of tailings growing in mining and how is the slurryMAX- XD well set up to serve this market ? A If the world continues mining , tailings management will remain a critical step in mineral processing . It is safe to assume there will be no shortage of mining anytime soon to meet the human demand for products anywhere from technology to buildings to medicine . With that being said , the FLS KREBS slurryMAX-XD product line is trusted to meet standard and complex tailings management requirements . slurryMAX-XD pumps are designed for fine solids applications in which metal lined pumps have poor wear life . This elastomer lined , splitcasing pump has extremely thick liners and a heavy-duty impeller to provide extended wear life . The high-pressure version of the slurryMAX-XD , the slurryMAX-HP , is ideal for multi-stage high pressure pumping systems often seen in tailings transfers . With the highpressure outer casing , and added rib reinforcement , the slurryMAX-HP uses all the same extreme wear parts as the XD , delivering long life and consistent performance . To meet the demands of longer and higher-pressure tailings systems , FLS also offers the slurryMAX- XHP , the highest-pressure pump in this product line . As with the HP , the XHP uses the same wear parts as the XD , but with an even more robust outer casing .
Q Are there any unique – patented or otherwise – design elements of Krebs pumps that you would identify that makes them stand out in the market ?
A FLS KREBS pumps are distinguished by the patented wear ring technology which effectively eliminates a common problem faced by centrifugal slurry pumps – suction side recirculation . In a pump , slurry naturally flows from regions of high pressure to low pressure zones . While one path that slurry takes is through the discharge pipe to its intended destination , another route is through the suction side gap between the impeller and the suction liner . Extensive studies and control room data have proven that a larger suction side gap leads to loss of flow from recirculation , rather than efficiently directing the slurry out of the discharge pipe . To combat this issue , the FLS KREBS wear ring is engineered to close the gap at the low-pressure zone of the impeller eye , while maintaining wider clearances around the suction liner . This design not only prevents recirculation , but also eliminates the mechanical grinding that commonly afflicts traditional slurry pumps that try to close the suction side gap by adjusting the entire suction liner ( throatbush ). The wear ring has a small surface area compared to the entire suction liner , making it easily adjustable by a single person with a standard wrench . From an economic and reliability standpoint , the advantages of the wear ring technology are numerous – substantial cost savings are achieved through a 1.5-2x increase in the wear life of all wet end parts . Enhanced energy efficiency is enhanced by reducing mechanical grinding and , in turn , reducing the overall power consumption by 5- 10 %. Valuable time and resources are saved as maintenance can be safely conducted while the pump is running . In conclusion , FLS KREBS pumps equipped with the wear ring technology offer unparalleled performance , extended wear life , improved energy efficiency , and streamlined maintenance processes .
Q Robustness of materials has always been to the fore in mining pumps – how do the materials used in Krebs pumps help them stand up to mining conditions ? A FLS KREBS pump materials are continuously evolving as we discover new and innovative ways to improve wear life . While our metal lined pumps are typically constructed of high chrome white iron , we do have stainless steel options for corrosive applications . Our range includes various proprietary high chrome alloys known as ‘ Kreballoys .’ Each Kreballoy is a carefully formulated alloy tailored to meet the demands of various applications . FLS KREBS product development and applications engineering teams analyse slurry rheology to select the most suitable metal , ensuring optimal performance in terms of abrasion and corrosion resistance . In addition to our metal lined pumps , FLS provides elastomer lined pumps with a wide range of material options . The main elastomer groups available are natural rubber , synthetic rubber , and urethane . Similar to our metal lined pumps , we carefully consider the slurry rheology when selecting the optimal material for tear strength , resilience , corrosion , abrasion and temperature resistance .
Q Sensor-based real time analysis is becoming more important in the pumps market especially in mining where pumps are located in remote areas , to avoid unplanned downtime – what is FLS ’ s capability and offering in this regard ? A At FLS , we recognise the importance of sensor-based condition monitoring and its role in ensuring equipment uptime , even in remote or hard to access areas . Our digital monitoring offerings , under the Insights suite , specifically address this need , providing comprehensive solutions to enhance operational efficiency and minimise unplanned downtime . With our Insights – Connect package , we empower users with real-time access to pump equipment operation , health , and performance data through our FLS mobile insights app . This secured application , using existing plant sensors , allows stakeholders at various levels , from executives to engineers in the field , to monitor pump performance and respond promptly to any issues , no matter where they are located . Features such as advanced key performance indicators , real-time and historical trend visualisation , and personalised thresholds with alerts ensure that users are always informed and empowered to make data-driven decisions . Furthermore , our Insights – Monitor package takes monitoring and analysis to the next level by providing expert support from our FLSmidth Digital Services Reliability team . Through this package , customers not only retain all the features of Insights – Connect but also benefit from weekly condition monitoring reports and quarterly in-depth performance reports . These reports , combined with expert insights and recommendations , enable proactive maintenance and optimisation of critical pumps , thus minimising the risk of unplanned downtime . In essence , FLS ’ digital monitoring offerings , powered by expert analysis , provide a comprehensive solution to meet the evolving needs of the pumps market , particularly in remote mining environments . By leveraging real-time data and expert insights , our customers can optimise asset management , improve operational visibility , and mitigate the risk of costly downtime .
40 International Mining | JUNE 2024