Transverse Pressure Exchange Pumping System for Slurry Hoisting
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Solution Overview
Problem
Current hydraulic ore hoisting systems face challenges in transporting large particle sizes due to limitations in pumping equipment, including high wear rates, contamination of driving fluids, and reduced reliability, especially when handling abrasive slurries with particles larger than 1 mm.
Innovation Solution
A pumping system utilizing a transverse elongate pipe pressure exchange chamber with a positive displacement pump, where the driving fluid is in direct contact with the medium, allowing for high velocities and suspension of particles without a mechanical separator, and using a controller to manage valve operations for efficient filling and discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If large passage slurry centrifugal pumps are used to handle particles up to 100 mm, then particle size handling capacity is improved, but head rise is limited to less than 50 m requiring extensive pumps in series
Solution Approach 1:
The system segments the pumping function into two distinct stages: a slurry pump handles particle intake and initial suspension, while a separate clean water pump provides high-pressure driving fluid. This segmentation allows each pump to be optimized for its specific function, with the clean water pump generating the high pressure needed for deep hoisting without being constrained by particle size limitations.
Solution Approach 2:
Clean water acts as an intermediary driving fluid that transfers energy to the slurry mixture. The clean water pump generates high-pressure driving fluid that forces the slurry through the riser pipe, eliminating the need for the slurry pump to directly generate high pressure while still handling large particles effectively.
2Stress or pressure
If multiple centrifugal pumps are placed in series to overcome pressure requirements, then head rise is improved, but system complexity increases and reliability decreases
Solution Approach 1:
The pumping system is segmented into two independent pumping circuits: a slurry handling circuit with a single slurry pump, and a driving fluid circuit with a clean water pump. This segmentation eliminates the need for multiple slurry pumps in series, reducing system complexity while maintaining the required head rise through the clean water pump's high-pressure output.
3Volume of moving object
If large passage slurry centrifugal pumps are used, then particle size handling capacity is improved, but energetic efficiency is limited compared to multi-stage clean liquid centrifugal pumps
Solution Approach 1:
The system segments the energy transfer function, with the clean water pump serving as the primary energy source operating at high efficiency with clean fluid, while the slurry pump operates at lower efficiency but handles the particle-laden mixture. The overall system efficiency is improved because the high-efficiency clean water pump provides the majority of the energy required for hoisting.
4Stress or pressure
If positive displacement pumps are used for high pressure, then head rise is improved, but wear rates increase and driving fluid contamination occurs when handling abrasive slurries
Solution Approach 1:
Clean water serves as an intermediary driving fluid that is in direct contact with the positive displacement pump, while the abrasive slurry remains in a separate handling circuit. The clean water pump (which can be a positive displacement type for high pressure) experiences no wear from particles, and the slurry pump handles particles but operates under lower pressure conditions, thus reducing wear rates and preventing contamination of the high-pressure driving fluid.
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 system enhances the reliability and efficiency of transporting large particle slurries by maintaining stable flow rates and reducing wear on valves, enabling continuous operation with minimal contamination and increased solids concentration handling capacity.
Implementation Method 1
a positive displacement pump operable to pump a driving fluid in direct contact with the medium so that the medium is displaced from the pressure exchange chamber to the pressurised discharge by the driving fluid
Implementation Method 2
allowing for high velocities and suspension of particles
Implementation Method 3
allowing for high velocities and suspension of particles
Data Source
AI summary
A pumping system for pumping a medium is described. The system comprises: at least one transverse pressure exchange chamber, but preferably multiple pressure exchange chambers. Each pressure exchange chamber has a valve arrangement at each end. The system also includes a pressurised discharge at a delivery end of the system and a filling mechanism operable to fill the pressure exchange chamber with the medium. A positive displacement pump is operable to pump a driving fluid in direct contact with the medium so that the medium is pumped from the pressure exchange chamber to the pressurised discharge. A method of pumping a medium is also described.