Slurry Conveyance Solids Control for Critical Velocity
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Solution Overview
Problem
Current industry practices in conveying slurries through conveyance pipes are inefficient due to the inability to actively control the mixture's solids concentration, leading to costly clogs, operational shutdowns, and increased equipment needs, particularly when dealing with heterogeneous solids that change over time.
Innovation Solution
A system and method that proactively adjusts the percent of solids in the slurry within a mixing tub based on target pump rates and distance to maintain critical velocity, using valves and a control system to optimize flow rates and reduce horsepower demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current industry practices adjust horsepower and speed of hydraulic pumps to compensate for changing critical velocities, then the conveyance can maintain transport, but the pump operates outside its efficient envelope causing cavitation, slippage, and breakdown
Solution Approach 1:
The system proactively adjusts the percent of solids in the slurry before pumping to maintain optimal flow characteristics. By controlling solids concentration in advance based on predicted pump performance and critical velocity requirements, the system prevents the pump from operating outside its efficient envelope, thereby avoiding cavitation, slippage, and breakdown while maintaining high efficiency
Solution Approach 2:
The control system continuously monitors pump performance parameters and slurry characteristics, adjusting the percent of solids in real-time to maintain optimal operating conditions. This feedback mechanism ensures the pump operates within its efficient envelope by dynamically matching slurry properties to pump capabilities, preventing inefficiencies and mechanical failures
2Adaptability or versatility
If multiple pump relay stations are used for long distance conveyance to handle varying solids concentrations, then the conveyance can adapt to different solids types, but the system requires more manpower, fuel, footprint, and equipment
Solution Approach 1:
The control system enables a single pump station to perform multiple functions by dynamically adjusting slurry solids concentration to match different pump performance characteristics and conveyance requirements. This eliminates the need for separate pump relay stations for different solids types, as one station can adapt to handle various conditions through controlled solids percentage adjustment
Solution Approach 2:
The system changes the percent of solids parameter in the slurry to adapt to different conveyance conditions and pump requirements. By dynamically adjusting this key parameter, the system achieves versatility in handling different solids types and conveyance distances without requiring additional pump relay stations, thereby reducing system complexity
3Device complexity
If the slurry solids concentration is increased to reduce the number of pump relay stations, then equipment costs are reduced, but the critical velocity must be maintained to prevent solids settling and clogs
Solution Approach 1:
The control system dynamically adjusts the percent of solids parameter to optimize the balance between conveyance efficiency and critical velocity requirements. By precisely controlling solids concentration, the system achieves higher concentrations that reduce equipment needs while maintaining sufficient flow velocity to prevent solids settling and clogging
Solution Approach 2:
The system replaces mechanical adjustments (multiple pump relay stations) with a control-based approach that uses sensors and automated solid percentage adjustment. This substitution allows the system to maintain critical velocity through intelligent control rather than mechanical redundancy, achieving both reduced equipment complexity and maintained flow performance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for higher solids concentrations in the slurry conveyance, reducing the need for multiple pump relay stations and minimizing mechanical failures, thus enhancing operational efficiency and profitability.
Implementation Method 1
a pump operable to pump the slurry through the conveyance line a distance to the placement site
Implementation Method 2
a mixing tub configured to mix the solid and the liquid to form the slurry
Data Source
AI summary
The present disclosure relates to methods and system for conveying a slurry which include a mixing tub configured to mix a solid and a liquid to form the slurry, a pump operable to pump the slurry through the conveyance line a distance to the placement site, and a control system operable to adjust a percent of solids of the slurry within the mixing tub based on at least one of a target pump rate or the distance to the placement site.