Manipulating the nature of slurry flowsto overcome production and maintenance challenges
DR STEVE ALGIE
CONSULTANT, FLOCEP PTY LTD
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What is PROmotion™ Technology?
PROmotion Technology is the basis for:
• a family of devices that
• solve problems arising from the inherent tendency for
• segregation of the solids within slurry flows
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Engineering models (usefully) simplify reality
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Newitt’s slurry flow classification classification (single particle size)
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Fully suspended
Suspended with moving bed
Suspended with saltation (particles ‘hop’ along pipe)
Blocked pipeLenticular
deposits
Stationary deposits with ripplesIn
creasin
gvelocity
Increasing solids concentration
FLOprep unit
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• Flow preparation upstream of hydrocyclone distributor
• Solids loading ~60%; high abrasion index (47)
• FLOprep installed 2012• Projected life 188 weeks
• Flow rate changes have not affected performance
• Accepted and performance validated by client Evolution Mining ‐ Edna May Operations
FLOdistributor
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Evolution Mining ‐ Edna May Operations
During installation in a scheduled 12‐hour shut‐down
In use
FLOdistributor
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Evolution Mining ‐ Edna MayOperations
• Gold recovery increased from ~90 to ~94%
• Stable performance: optimal process operations
• Maintenance costs reduced 95%• uniform wear on cyclones
• Underflow densities uniform to 1% solids (74‐75%)• Adjustment intervals increased from 3 days to 4 months• Cyclone life cycle increased from 3 weeks to 16 weeks• Rubber‐lined spools not replaced in more than three years’ operation (previous ceramic spools had 16 week life)
MAXbend®
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The situation:• Most severe location in the plant for bend wear
• Superheated caustic slurry entering first flash tank
• Flashing inside bend results in very high erosion
• Standard bend life 120 days
Alumina refinery in southwest WA
MAXbend®
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• MAXbend installed 2012• service life to date ~900 days
• Projected life of the MAXbend: 1800 days (15 times multiplier)
• Flow rate increased by ~20% with no effect on MAXbend performance
• Acceptance and validated performance by both clients• Rental option offered to clients and under consideration
Similarly spectacular results in SandfireResources’ DeGrussa copper‐gold operations
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MAXbend® Performance Timeline
StandardBend Life MAXbend Bend Life
Note : Expected life based on inspection results from 1 year’s service (April 2013) and 2 year’s service (June 2014)
A PROmotion™ Technology
Where might you use PROmotion™ Technology?PROmotion™ Technology pays off in places where the non‐homogeneous flow inside the pipe might get you into trouble:• Measurement, or sampling• Addition of a chemical• Splitting a slurry flow• Where there’s a bend in the pipe
Consider how much easier these operations would be if the slurry were actually homogeneous at these points!
Then …
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