Page 8 - Technical Support & Resources

Slurry pumping is a critical component in the mining industry, where the movement of heavy and abrasive slurries is necessary for the extraction of minerals. However, the high energy demands and wear and tear associated with slurry pumping can make it a costly and inefficient process. As such, it is essential for mining companies to take steps to improve the efficiency of their slurry pumping systems. In this article, we will explore strategies for optimizing slurry pumping performance, including...

As a result of conservative engineering practices, pumps are often substantially larger than they need to be for an industrial plant’s process requirements. Centrifugal pumps can often be oversized because of  “rounding up,” trying to accommodate gradual increases in pipe surface roughness and flow resistance over time, or anticipating future plant capacity expansions. In addition, the plant’s pumping requirements might not have been clearly defined during the design phase.

Because of this conservative...

A pump’s efficiency can degrade as much as 10% to 25% before it is replaced, according to a study of industrial facilities commissioned by the U.S. Department of Energy (DOE), and efficiencies of 50% to 60% or lower are quite common. However, because these inefficiencies are not readily apparent, opportunities to save energy by repairing or replacing components and optimizing systems are often overlooked.

Define Pumping System Efficiency

System efficiency incorporates the efficiencies of the pump,...

Overview 

Centrifugal pumps handle high flow rates, provide smooth, non pulsating delivery, and regulate the flow rate over a wide range without damaging the pump. Centrifugal pumps have few moving parts, and the wear caused by normal operation is minimal. They are also compact and easily disassembled for maintenance. The design of an efficient pumping system depends on relationships between fluid flow rate, piping layout, control methodology, and pump selection. Before a centrifugal pump is selected,...

Every industrial facility has a piping network that carries water or other fluids. According to the U.S. Department of Energy (DOE), 16% of a typical facility’s electricity costs are for its pumping systems. 

The power consumed to overcome the static head in a pumping system varies linearly with flow, and very little can be done to reduce the static component of the system requirement. However, there are several energy- and money-saving opportunities to reduce the power required to overcome the...

Understanding Your Pumping System Requirements 

Pumps transfer liquids from one point to another by converting mechanical energy from a rotating impeller into pressure energy (head). The pressure applied to the liquid forces the fluid to flow at the required rate and to overcome friction (or head) losses in piping, valves, fittings, and process equipment. The pumping system designer must consider fluid properties, determine end use requirements, and understand environmental conditions. Pumping applications...

When multiple pumps operate continuously as part of a parallel pumping system, there can be opportunities for significant energy savings. For example, lead and spare (or lag) pumps are frequently operated together when a single pump could meet process flow rate requirements. This can result from a common misconception—that operating two identical pumps in parallel doubles the flow rate. Although parallel operation does increase the flow rate, it also causes greater fluid friction losses, results in a...

An industrial facility can reduce the energy costs associated with its pumping systems, and save both energy and money, in many ways. They include reducing the pumping system flow rate, lowering the operating pressure, operating the system for a shorter period of time each day, and, perhaps most important, improving the system’s overall efficiency.

Often, a pumping system runs inefficiently because its requirements differ from the original design conditions. The original design might have been too...

Effective pump maintenance allows industrial plants to keep pumps operating well, to detect problems in time to schedule repairs, and to avoid early pump failures. Regular maintenance also reveals deteriorations in efficiency and capacity, which can occur long before a pump fails. Wear ring and rotor erosions, for example, can be costly problems that reduce wire-to-water efficiency by 10% or more. 

The amount of attention given to maintenance depends on how important a system is to a plant’s operations...

Pumping system control valve inefficiencies in plant processes offer opportunities for energy savings and reduced maintenance costs. Valves that consume a large fraction of the total pressure drop for the system or are excessively throttled can be opportunities for energy savings. Pressure drops or head losses in liquid pumping systems increase the energy requirements of these systems. Pressure drops are caused by resistance or friction in piping and in bends, elbows, or joints, as well as by throttling...