WO2010078627A1 - Système de pompe amélioré - Google Patents

Système de pompe amélioré Download PDF

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Publication number
WO2010078627A1
WO2010078627A1 PCT/AU2010/000016 AU2010000016W WO2010078627A1 WO 2010078627 A1 WO2010078627 A1 WO 2010078627A1 AU 2010000016 W AU2010000016 W AU 2010000016W WO 2010078627 A1 WO2010078627 A1 WO 2010078627A1
Authority
WO
WIPO (PCT)
Prior art keywords
fluid
gas
pump
pumping
conduit
Prior art date
Application number
PCT/AU2010/000016
Other languages
English (en)
Inventor
John Joseph Garland
Original Assignee
John Joseph Garland
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2009900053A external-priority patent/AU2009900053A0/en
Application filed by John Joseph Garland filed Critical John Joseph Garland
Publication of WO2010078627A1 publication Critical patent/WO2010078627A1/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B19/00—Machines or pumps having pertinent characteristics not provided for in, or of interest apart from, groups F04B1/00 - F04B17/00
    • F04B19/04—Pumps for special use
    • F04B19/06—Pumps for delivery of both liquid and elastic fluids at the same time
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D13/00—Pumping installations or systems
    • F04D13/12—Combinations of two or more pumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04D—NON-POSITIVE-DISPLACEMENT PUMPS
    • F04D7/00—Pumps adapted for handling specific fluids, e.g. by selection of specific materials for pumps or pump parts
    • F04D7/02—Pumps adapted for handling specific fluids, e.g. by selection of specific materials for pumps or pump parts of centrifugal type
    • F04D7/04—Pumps adapted for handling specific fluids, e.g. by selection of specific materials for pumps or pump parts of centrifugal type the fluids being viscous or non-homogenous

Definitions

  • the invention relates to systems for pumping fluids, and more particularly to systems for pumping liquids vertically by supplying or injecting a gas.
  • Pumps are used to move fluids, such as water, over a distance.
  • a limitation of pumps is that the pump output can only overcome a limited amount of resistance. This is particularly noticeable when pumping a fluid vertically against gravity, such as in a mine.
  • Mining operations are often subject to large volume inflows of water, and the removal of ore can not usually start if a shaft or area contains water. Typically the mining is delayed until the removal of water is complete as access to the ore bearing surfaces is impossible when pits and/or shafts fill with water which occurs during wet weather.
  • boost pump In the case where a booster pump is used, a more complex control system is typically needed to balance the pressures and flow rates at each pump so that both operate around their best efficiency point (BEP). Additionally, having a boost pump results in a system that is usually less reliable and more costly to manufacture and maintain.
  • a system for pumping a fluid over an at least partially vertical distance comprising: a pump for pumping a fluid through a conduit having a substantially vertical component; and a gas supply for supplying a gas to a diffuser that diffuses the gas into the fluid, wherein the diffuser is located at or near the bottom of the substantially vertical component of the conduit.
  • a method of pumping a fluid over an at least partially vertical distance through a conduit having a substantially vertical component comprising the steps of: pumping a fluid through the substantially vertical component of the conduit; and supplying a gas to the conduit through a diffuser that diffuses the gas into the fluid at or near the bottom of the substantially vertical component of the conduit.
  • the injection of air into an inlet of the pump can also be used to decrease cavitation, particularly in high capacity pumps.
  • the pump may be used with the conduit on either the inlet or the discharge side of the pump. This will typically be determined by the pump's location. For example, when the pump is located at or near the top of the vertical portion (e.g. on the surface in the case of a mining operation), normally the conduit will be on the inlet or suction side of the pump. When used in this configuration, it is preferred that suction cavitation is minimised or avoided entirely.
  • Suction cavitation occurs when the pump suction is under a low-pressure/high- vacuum condition where the liquid turns into a vapor at the eye of the pump impeller. This vapor is carried over to the discharge side of the pump, where it no longer experiences vacuum and is compressed back into a liquid by the discharge pressure. This imploding action occurs violently and attacks the face of the impeller.
  • An impeller that has been operating under a suction cavitation condition can have large chunks of material removed from its face or very small bits of material removed, causing the impeller to look spongelike. Both cases will cause premature failure of the pump, often due to bearing failure. Suction cavitation is often identified by a sound like gravel or marbles in the pump casing.
  • Discharge cavitation occurs when the pump discharge pressure is extremely high, normally occurring in a pump that is running at less than 10% of its best efficiency point.
  • the high discharge pressure causes the majority of the fluid to circulate inside the pump instead of being allowed to flow out the discharge.
  • a pump that has been operating under these conditions shows premature wear of the impeller vane tips and the pump housing.
  • premature failure of the pump's mechanical seal and bearings can be expected. Under extreme conditions, this can break the impeller shaft.
  • the conduit may have both vertical and horizontal components or portions, but preferably, the majority of the conduit is substantially vertical.
  • the conduit may be a pipe, bore, delivery line, or any other suitable conduit for pumping fluid.
  • the conduit may be partially below ground and may extend to the surface where the fluid can be utilised or expelled.
  • the conduit may have a check valve or foot valve that opens when the pump operates to allow fluid to enter the conduit but closes when the pump shuts off to prevent fluid from flowing out.
  • the gas used according to the present invention will be less dense than the fluid to be pumped.
  • the gas is supplied in a compressed form, and a compressor may be provided to compress the gas prior to supplying the gas to the diffuser.
  • the fluid to be pumped is preferably denser than the gas, and even more preferably the fluid is a liquid.
  • the fluid will be water and the gas will be air.
  • the air may therefore be compressed by an air compressor which may be located either at or near the diffuser, or fed to the diffuser from another location.
  • the compressed air may be provided in the form of tanks or high capacity canisters of compressed air. If the compressed air is fed to the diffuser from another location, the air may be fed along a second conduit which may be internal, integral with, adjacent to, or external to the first mentioned conduit.
  • the diffuser is preferably located at least partially inside the conduit, such that it spreads the gas across the flow area of the fluid. Even more preferably, the gas is introduced into the fluid flow as small bubbles substantially evenly across a cross section of the conduit.
  • the diffuser may also be a simple valve, opening/aperture, or nozzle through which the gas is added or injected into the fluid, and no limitation is meant thereby.
  • the diffuser may be a diffusion plate with a plurality of outlets for the gas. Normally the diffusion plate will be oriented substantially perpendicularly to the longitudinal axis of the conduit. Normally the diffusion plate will have a number of flow openings therethrough to allow fluid to flow past or through the plate with minimal friction and/or disturbance.
  • the diffuser is preferably located at or near the bottom of the conduit or, at least, at or near the bottom of the substantially vertical portion of the conduit.
  • the phrase "near the bottom of the conduit” in this context includes any location or position in the lower half of the conduit (or lower half of the vertical portion of the conduit).
  • the diffuser will be located in the lower quarter of the conduit (or lower quarter of the vertical portion of the conduit).
  • the rate of gas supplied to the conduit by the diffuser may be altered or controlled to achieve the desired level of gas introduced into the liquid. For example, when the load on the pump is light, little or no air may be supplied, but when the load on the pump is high (e.g. during wet conditions), a suitable amount of air may be supplied.
  • the rate of gas supplied may be such to avoid annular flow patterns within the conduit, as with annular flow the velocity of the air is faster than the fluid.
  • the gas volume to fluid ratio is preferably less than 0.75, and even more preferably below 0.52.
  • the rate of gas supplied may be controlled by the gas supply, or the diffuser, or any other suitable means.
  • the rate of gas flow is preferably controlled by controlling the speed of the compressor.
  • An open loop control system, closed loop control system, or manual control may be implemented, and no limitation is meant thereby.
  • the pump may be located at any suitable point in the flow cycle, but in a first embodiment it is preferably at or near the upper end of the conduit. In the event that the conduit is underground, the pump is preferably at least partially aboveground. Where an air compressor is utilised, the pump and air compressor are preferably both situated above ground within close proximity to each other.
  • the pump may be located underground near the source or body of fluid/water to be pumped.
  • the pump may even be submerged within the source or body of fluid/water.
  • the suction pipe head cannot exceed a particular predetermined value such as, for example, 10 metres.
  • the pump is a high head single stage centrifugal pump.
  • the pump may be a Sykes XHl 50 which is designed for high head requirements often seen in the mining industry, particularly for dewatering operations.
  • FIG. 1 illustrates a pump system according to an embodiment of the invention with a magnified portion labelled 'A'.
  • Figure 2 illustrates a schematic view of a pump system according to an embodiment of the invention.
  • Figure 3 illustrates different flow patterns in a vertical conduit.
  • Figure 4 illustrates different flow patterns in a horizontal conduit.
  • Figure 5 is a plot of the relationship between vertical lift and horizontal transfer distance to achieve a constant total dynamic head of 165m.
  • Figure 6 is a plot comparing total dynamic head with air injection and without air injection over vertical pipe height.
  • Figure 7 is a plot comparing water flow rate with air injection and without air injection over vertical pipe height.
  • Figure 8 is a plot comparing total power usage with air injection and without air injection over vertical pipe height.
  • Figure 9 is a plot showing percentage increases in flow rate and total power usage (a measure of efficiency) with air injection over vertical pipe height.
  • Figure 10 is a plot comparing total dynamic head with air injection and without air injection over horizontal transfer distance.
  • Figure 11 is a plot comparing water flow rate with air injection and without air injection over horizontal transfer distance.
  • Figure 12 is a plot comparing total power usage with air injection and without air injection over horizontal transfer distance.
  • Figure 13 is a plot comparing showing percentage increases in flow rate and total power usage (a measure of efficiency) with air injection over horizontal transfer distance.
  • Figure 14 is a plot showing air volume fraction (as a %) at the top of a vertical section of pipe over horizontal transfer distance.
  • FIG. 1 illustrates a pump system according to an embodiment of the invention.
  • the pump system has a pump 10 above a ground level 11 in connection with a vertical conduit or delivery line 12 located below ground level 11. Adjacent the pump 10 is an air compressor 13 that supplies air along second conduit 14 to a diffuser 15.
  • the diffuser 15 is located near the bottom of the conduit 12 above a foot valve 16.
  • the foot valve allows fluid to enter the conduit when the pump is operating, but prevents fluid from flowing out when the pump is stopped.
  • the diffuser 15 is in communication with the second conduit 14 and diffuses air 17 (or other gas) into water 18
  • the second conduit 14 is illustrated as being a distance from the delivery line 12, it is envisaged that it could also be inside or adjacent the delivery line 12.
  • the diffuser 15 is located relatively central to the axis of the conduit 12, allowing for a substantially even distribution of air bubbles 17 in the water 18. However, it is also possible that in this arrangement the diffuser 15 could limit or restrict the flow of water
  • the diffuser 15 may also be arranged in the side of a conduit 12, or in any other suitable arrangement that allows the gas to be diffused into the fluid 18 in the conduit 12.
  • the diffused air 17 in the lower part of the delivery line 12 enables the pump 10 to operate more efficiently, and allow it to lift water 18 greater distances.
  • this provides a quicker, and usually easier, process to pump fluids a certain distance.
  • pumps can be smaller than otherwise would have been needed.
  • the increased efficiency of the pumping systems means operations, particularly mining operations, can begin earlier and have reduced downtime, providing further cost savings as well as increased productivity.
  • FIG. 2 illustrates a pump system having a pump 20 located below a vertical portion of a conduit of delivery line 22.
  • a compressor 21 is provided to supply or inject air via a second conduit 24 to a diffuser 25 near the bottom of the vertical portion of the delivery line 22.
  • air is supplied downstream of the pump 20 to reduce, or minimise, cavitation.
  • the system is utilised to pump fluid, such as water 26, over a highwall 29.
  • the highwall may be any height up to several hundred metres, and is typically at least 50 metres in height.
  • a single stage centrifugal pump is typically used as it is reliable, portable, and relatively easy to operate.
  • pump systems are typically utilised including the use of multistage pumps and/or pumping stations with booster pumps.
  • a single stage pump is run above a best efficiency point (BEP) and at a severe duty point.
  • BEP best efficiency point
  • the present invention draws the water 26 to be removed in to the pump through a suction line 27, then pumped up the conduit 22, with air being supplied therein by the diffuser 25, and then along a horizontal portion of the conduit 12 to an outlet location 28.
  • the supply of air to the water being pumped decreases the total dynamic head of the pump system by reducing the static head, providing significant efficiency gains in certain circumstances.
  • Two factors are considered to be particularly important when considering the gas supplied to the fluid within the conduit, namely, pipe wall friction experienced in two phase flow, and the relative velocity of the gas compared to the fluid.
  • the transition of bubble flow 31 to annular flow 34 occurs when the gas volume ratio/fraction is between approximately 0.2 and 0.6, more particularly between 0.25 and 0.52.
  • gas volume ratio/fraction is below 0.5, or at least below a predetermined value determined by analysis for a particular gas/fluid system.
  • Wall friction between the fluid/gas and the conduit can be calculated using models based on theories and empirical results.
  • a homogenous model may be used where it is assumed that the gas/fluid mixture is a homogenous mixture with no 'slip' occurring between the gas and fluid, i.e. it is assumed that the bubbles do not rise faster than the fluid.
  • the density of this homogenous mixture is calculated by:
  • Mi, oc G ⁇ a + a L ⁇ L
  • OCG volume fraction of gas phase
  • PG density of gas phase
  • ⁇ o dynamic viscosity of gas phase
  • (XL volume fraction of liquid phase
  • PL density of liquid phase
  • ⁇ L dynamic viscosity of liquid phase.
  • the performance of a pump under normal operation can be determined by its pump curve.
  • the flow rate is inversely related to total dynamic head (TDH) or pressure. Therefore, reducing the TDH will increase the flow rate and vice versa.
  • TDH may be calculated by the following formula:
  • TDH SuctionLift + StaticHead + FrictionLoss
  • the supply/injection of a gas into the flow reduces the density of the mixture and, therefore, reduces the static head term in the above equation. Furthermore, the volume fraction of gas in the fluid flow at any point will be dependent on the pressure at that point. As the pressure in the conduit changes, gas injected at or near the bottom of the conduit will gradually expand in volume as it traverses the substantially vertical portion of the conduit.
  • Friction losses for a given pipe system are depending on various factors including fluid velocity and the density of the fluid.
  • V average velocity of mixture
  • D diameter of the conduit
  • the pump may be a Sykes XHl 50 which is a high head, single stage pump having a maximum head of 185 metres, and a maximum capacity of 150L/sec. Despite the maximum head of 185 metres, to operate around the pump's best efficiency point (BEP), the pump should be operated with a head of less than 155 metres. Furthermore, when heads are greater than 173 metres, the pump is operating out of its recommended operating range. In such circumstances it is envisaged that the system of the present invention would be particular beneficial. For example, it is envisaged that a pump such as the Sykes XHl operating with 175 metres head could be used outside of the recommended operating range to deliver approximately 60 litres per second. With air injection according to the present invention, the head may be reduced by 5 metres bringing the flow rate to 76 litres per second which is not only a 25% increase in flow rate, but would also bring the pump within its recommended operating range.
  • the horizontal transfer distance of a conduit typically has a detrimental effect as the vertical lift has to be reduced to maintain a TDH of 165 metres (as illustrated).
  • the system and method of the present invention are considered particularly advantageous with: • static head requirements between 100 and 200 metres, and even more preferably between 150 and 185 metres;
  • the TDH that can be expected for different vertical lift heights without air injection is higher than with air injection.
  • the TDH reduction is up to 7 metres which, although may not seem large, as illustrated in figure 7 the increase in flow rates can consequently be quite significant, up to 20 litres per second.
  • Figure 8 shows that there is also an increase in power usage, primarily associated with the increase in flow rate (i.e. from the pump) and with an air compressor to supply the gas/air.
  • the increase in power usage is around 4OkW, 3OkW of which is due to the power usage attributed to the air compressor.
  • Figure 9 shows the percentage increase in flow and the percentage increase in total power usage.
  • the intersection between the two curves represents the point at which efficiency is at parity (i.e. there is a 17% increase in flow, and a 17% increase in power usage).
  • the values to the right of the intersection point have an increased efficiency, and those on the left of the intersection point have a decreased efficiency.
  • the decreased efficiency case may benefit from the system and method of the present invention as the flow rate is increased which is often an important factor for mine dewatering applications.
  • Figure 10 shows how TDH reduction due to the injection of air is eliminated as the horizontal transfer distance increases. As illustrated in figure 11, the flow rate benefit also drops off as the horizontal transfer distance is increased.
  • Figure 12 shows the implications horizontal transfer distance has on power usage, and in figure 13, on efficiency. In figure 13, the intersection between the two curves represents the point at which efficiency is at parity. The values to the right of the intersection point have an increased efficiency, and those on the left of the intersection point have a decreased efficiency. In general as the horizontal transfer distance increases the benefits of air injection decline. For this reason, it is preferred that horizontal transfer distances (if any) are kept to a minimum.
  • Figure 14 shows the air volume fraction/ratio at the top of the vertical portion of the conduit/pipe.
  • the head reduction due to air injection occurs primarily because the gas/fluid mixture in the vertical section is less dense than the fluid on its own, and although having a less dense mixture in a horizontal section gives no benefit, because of the frictional losses in the horizontal portion of the conduit the pressure at the top of the vertical portion of the conduit can be quite high which compresses the gas bubbles (resulting in a reduced air volume fraction).
  • the air volume fraction at the top of the vertical portion is just 20%, or half of the 40% air volume fraction with no horizontal transfer.
  • the system and method of the present invention reduces the total dynamic head of pump.
  • the pump is preferably a single stage centrifugal pump, at least partially because they are considered to be reliable and simple to operate, and are often favoured in mining operations.
  • the present invention is considered to be particularly useful at reducing the head and, therefore efficiency and/or flow rate.
  • the improvements are most notable where the pipe/conduit has a relatively short horizontal transfer distance after the vertical portion of the conduit, and also where larger diameter pipes are utilised which result in lower friction due to lower velocities of the fluid and/or gas for the same flow rate.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)

Abstract

L'invention porte sur un système et sur un procédé pour pomper un fluide sur une distance au moins partiellement verticale. Le fluide, tel que de l'eau, est pompé à travers une conduite ayant une partie sensiblement verticale et du gaz, tel que de l'air, est distribué au niveau ou à proximité d'une région inférieure de la partie verticale de la conduite. L'ajout de gaz au fluide peut diminuer avantageusement la hauteur manométrique totale de la pompe dans le système, lui permettant de fonctionner de façon plus efficace et/ou à de plus hauts débits.
PCT/AU2010/000016 2009-01-07 2010-01-07 Système de pompe amélioré WO2010078627A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
AU2009900053 2009-01-07
AU2009900053A AU2009900053A0 (en) 2009-01-07 An Improved Pump System
AU2009238321A AU2009238321A1 (en) 2009-01-07 2009-11-18 An Improved Pump System
AU2009238321 2009-11-18

Publications (1)

Publication Number Publication Date
WO2010078627A1 true WO2010078627A1 (fr) 2010-07-15

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Application Number Title Priority Date Filing Date
PCT/AU2010/000016 WO2010078627A1 (fr) 2009-01-07 2010-01-07 Système de pompe amélioré

Country Status (2)

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AU (1) AU2009238321A1 (fr)
WO (1) WO2010078627A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2587789C2 (ru) * 2010-09-14 2016-06-20 Арк'Терикс Эквипмент Инк Система защиты с воздушной подушкой безопасности
WO2017213511A1 (fr) * 2016-06-10 2017-12-14 Melbu Systems As Procédé et système de pompage de liquide contenant des particules ; de préférence un poisson dans l'eau
WO2022189529A1 (fr) 2021-03-10 2022-09-15 Mmc First Process As Pompes reliées en série
WO2024039247A1 (fr) * 2022-08-15 2024-02-22 Searas As Transfert de poissons d'un premier conteneur à un second conteneur

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5183391A (en) * 1990-05-11 1993-02-02 Isco, Inc. Valve pump
US5400858A (en) * 1993-09-13 1995-03-28 International Technology Corporation Groundwater recovery system
FR2809179A1 (fr) * 2000-05-18 2001-11-23 Ate Antipollution Tech Entpr Dispositif d'amorcage automatique de cannes de prelevement de fluides
JP2002206495A (ja) * 2001-01-10 2002-07-26 Mitsui Miike Mach Co Ltd 縦軸ポンプの空気吸入装置
US6497287B1 (en) * 1999-06-07 2002-12-24 The Board Of Regents, The University Of Texas System Production system and method for producing fluids from a well
JP2004052744A (ja) * 2002-07-19 2004-02-19 Akio Yokobayashi 気泡のエネルギーを遠心力に変えて吐出量と水圧を上昇させた遠心力気泡ポンプ。
US20070235197A1 (en) * 2006-03-31 2007-10-11 Becker Billy G Gas Lift Chamber Purge and Vent valve and Pump Systems

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5183391A (en) * 1990-05-11 1993-02-02 Isco, Inc. Valve pump
US5400858A (en) * 1993-09-13 1995-03-28 International Technology Corporation Groundwater recovery system
US6497287B1 (en) * 1999-06-07 2002-12-24 The Board Of Regents, The University Of Texas System Production system and method for producing fluids from a well
FR2809179A1 (fr) * 2000-05-18 2001-11-23 Ate Antipollution Tech Entpr Dispositif d'amorcage automatique de cannes de prelevement de fluides
JP2002206495A (ja) * 2001-01-10 2002-07-26 Mitsui Miike Mach Co Ltd 縦軸ポンプの空気吸入装置
JP2004052744A (ja) * 2002-07-19 2004-02-19 Akio Yokobayashi 気泡のエネルギーを遠心力に変えて吐出量と水圧を上昇させた遠心力気泡ポンプ。
US20070235197A1 (en) * 2006-03-31 2007-10-11 Becker Billy G Gas Lift Chamber Purge and Vent valve and Pump Systems

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Title
DATABASE WPI Derwent World Patents Index; Class D15, AN 2002-068552 *
DATABASE WPI Derwent World Patents Index; Class Q56, AN 2002-685590 *
DATABASE WPI Derwent World Patents Index; Class Q56, AN 2004-175202 *

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2587789C2 (ru) * 2010-09-14 2016-06-20 Арк'Терикс Эквипмент Инк Система защиты с воздушной подушкой безопасности
WO2017213511A1 (fr) * 2016-06-10 2017-12-14 Melbu Systems As Procédé et système de pompage de liquide contenant des particules ; de préférence un poisson dans l'eau
GB2565025A (en) * 2016-06-10 2019-01-30 Melbu Systems As Method and system for pumping a liquid containing particles; preferably fish in water
GB2565025B (en) * 2016-06-10 2021-10-06 Melbu Systems As Method and system for pumping a liquid containing particles; preferably fish in water
WO2022189529A1 (fr) 2021-03-10 2022-09-15 Mmc First Process As Pompes reliées en série
WO2024039247A1 (fr) * 2022-08-15 2024-02-22 Searas As Transfert de poissons d'un premier conteneur à un second conteneur

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