Pump calculation according "Warman Slurry Pumping Handbook"

Slurry parameters [2]

Slurry density Carbon steel pipe selected

100 dn = 6 in
ρP = [2] (1-4) sch = STD
Cw 100 − Cw
+ di = Pipe_Imp_CS_Dint_dn_sch
ρs ρL
di = 154.08 mm
ρP = 100 / (Cw/ρs +(100-Cw)/ρL ) di = 0.15408 m
 Cw = 30 %
ρs = 2.65 t/m3 Pipe area
3 (pi()/4) * di^2
ρL = 1 t/m A=
3 di =
ρP = 1.23 t/m 0.15408 m
A= 0.0186 m²
Slurry mass flow rate
ms = mP ⋅ C w mP =
ms Slurry velocity
Cw vP = VP / A
mP = m s / Cw VP = 0.049 m³/s
ms = 65 t/h A= 0.0186 m²
Cw = 0.3 - vP = 2.6 m/s
mP = 216.7 t/h
Limiting settlig velocity
Slurry volume flow rate d50 = 211 µm
VP = mP / ρP Cv = 13.9 %
mP = 216.7 t/h d= 6 in
3 SS =
ρP = 1.23 t/m 2.65 -
VP = 176.2 m³/h d50 >= 200 µm
VP = 48.9 l/s 5% <= Cv <= 40%
cualquier diámetro
Volumetric concentration VL=Slurry_Limit_Deposition_Velocity_JRI_Imp_d50_Cv_dn_Ss

VL = 2.32 m/s
Cw
Cv = OK. v > vL
S s ⋅ (1 − C w ) + C w
Cv = 100 * Cw / (Ss* (1-Cw) +Cw )
Cw = 0.30 %
Ss= 2.65 t/m3
ρL = 1 t/m3
Cv = 13.9 %

Friction head Hf for the pipeline Slurry density

ρ= 1230 kg/m³
Pipe equivalent length
Pipe lenght Kinematic viscosity
L= 100 m ν= µ/ρ
Number of long rad. 90 elb. µ= 2.0E-03 Pa s
N= 5 ρ= 1229.7 kg/m³
Elbow equivalent lenght ν= 1.7E-06 m/s²
Lelbow = 3.35 m
N-Elbows equivalent lenght Reynolds
LN-lbow = N *Lelbow Re = v*d/ν
N= 5 v= 2.62 m/s
Lelbow = 3.35 m d= 0.15408 m
LN-elbows = 16.75 m ν= 1.7E-06 m/s²
Total eqivalent length Re = 244,021
Leq = L + LN-elbows
L= 100 Relative rugosity
 LN-elbows = 16.75 m Rabs = 0.1 mm
Leq = 116.75 m di = 154.08 mm
Rrel = 0.0006 -
Slurry properties
t= 10 °C Friction factor
P= 3 bar f= f(Rrel, Re)
Rrel = 0.0006 -
Water absolute viscosity Re = 244,021 -
µw = SaturatedWaterAbsoluteViscosity_t f= Pipe_Friction_Factor_Rrel_Re

µw = 1.3E-03 Pa s f= 0.0192 -

Pulp viscosity Kinematic pressure

Ratio of viscosities (Thomas) hv = (ρ/2) * v^2
µp / µf = (1+2.5*Cv 10.05*Cv^2+0.00273*Exp(16.6*Cv)) ρ= 1229.70 kg/m³
Cv = 0.1392 v= 2.62 m/s
µp / µf = 1.57 hv = 4236.3 Pa
µp = µp / µw * µw
µp / µf = 1.57
µw = 1.3E-03 Pa s
µp = 2E-03 Pa s

Unit pressure los Kinematic pressure

J= f * (1/d) * hv hv = v^2 / (2*g)
f= 0.019 v= 2.62 m/s
d= 0.15408 g= 9.81 m/s²
hv = 4236.3 hv = 0.351 msc
J= 528.8 Pa/m
Pressure loss in expansion
Pressure loss ∆Pexp = K2_θ = 30 * hv
Hf = Leq * J K2_θ = 30 = 1.271
Leq = 116.75 m hv = 0.351 msc
J= 528.8 Pa /m ∆Pexp = 0.45 msc
Hf = 61,736 Pa
Hf = 6295 mmwc Loss at pipe discharge
Hf = 6.30 mwc
Exit loss factor
Pressure loss in msc Kexit = 1 -
Hf [msc] = Hf [mwc] / Ss
Hf = 6.30 mwc Kinematic pressure
Ss = 1.23 kg/m³ hv = 0.351 msc
Hf = 5.12 msc
Exit pressure loss
Loss in discharge pipe enlargement ∆Pexit = Kexit * hv
Pump discharge diameter Kexit = 1
dP = 100 mm hv = 0.351 msc
pipe diameter ∆Pexit = 0.35 msc
di = 154.08 mm
Gradual expansion (θ = 30°)
β= 0.65
Pipe_Expansion_Theta30gr_beta
K2_θ = 30 = 1.271

Loss at entrance to suction pipe HR factor

Validity
Entrance loss factor Ss : 1-6
Kentr = 0.5 - Cw : 1- 70%
Kinematic pressure d50 : 20 - 10000
hv = 0.351 msc
Exit pressure loss Ss = 2.7 -
∆Pentr = Kentr * hv Cw = 30 %
Kentr = 0.5 d50 = 211 µm
hv = 0.351 msc HR = Slurry_HR_factor_Ss_Cw_d50
∆Pentr = 0.18 msc HR = 0.891

Total dynamic head Equivalent water column

Zd = 20 Hw = Hm / HR
Zs = -1 Hm = 25.1
Hf = 5.12 msc HR = 0.891
∆Pexp = 0.45 msc Hw = 28.2 mwc equiv.
∆Pexit = 0.35 msc
∆Pentr = 0.18 msc Let
Hm = 25.09 msc Hw = 28.2 mwc

Correction factor HR to express the head Pump selection

in water column (pump selection) Select a pump with following results
VP = 48.9 l/s
Hw = 28.2 mwc
Ss = 2.65 -

In this case a Warman 6/4 D-AH heavy

duty ruber lined pump is selected with
a 5 vane closed rubber impeller at a
pump spedd of
N= 1130 rpm

See sheet "Pump

From figure 3.4, the efficiency on water
can be read as
 ηw = 66 %

l 
Q   ⋅ S P ⋅ TDH [msc] l 
Q   ⋅ S P ⋅ Hw[msc]
P=  
s
[kW ] P=  
s
[kW ]
1.02 ⋅η m [%] 1.02 ⋅η w [%]

with P= (1/1.02) * Q * Ss * Hw / ηw
TDH = Hm Q= 48.9 l/s
and SP = 1.23 -
η= ηm Hw = 28.2 mwc
Index "m": mixture (pulp) ηw = 66 -
P= 25.2 kW
l 
Q   ⋅ S P ⋅ Hm[msc]
P=  
s
[kW ] Also, the power can be expresses as
1.02 ⋅ηm [%]
l 
with Q   ⋅ S P ⋅ TDH [msc]
P=  
s
Hm = Hw * HR [kW ]
1.02 ⋅ ER ⋅η w [% ]
and
ηm = ηw * ER where ηw is the water equivalent
pump efficiency, read from performance
l  curve for (Q, and Hw)
Q   ⋅ S P ⋅ Hw ⋅ HR[msc]
P=  
s
[kW ]
1.02 ⋅η w⋅ ER[%]

as HR is assumed equal to HR

l 
Q   ⋅ S P ⋅ Hw ⋅ HR[msc]
P=  
s
[kW ]
1.02 ⋅η w⋅ H R[%]

l 
Q   ⋅ S P ⋅ Hw[msc]
P=  
s
[kW ]
1.02 ⋅η w [%]

Power  m3  l 
Q  ⋅ TDH [Pa ] Q  ⋅ S
 Q
m
 ⋅ TDH [Pa ] l 
Q  ⋅ S
 s 
P=  
s
P= [W ]
 m3  η P [−] 1.02
Q  ⋅ TDH [Pa]  m3 
 s  Q  ⋅ TDH [mmwc]
 s  Q
P= g ⋅100
η P [−] P= g⋅
η P [−] P=
3600
⋅

 m3   N   m3 
Q  ⋅ TDH [mwc] m
Q ⋅ TDH     s 
Q
 s   m 2  P = g ⋅ 1000 ⋅  P=
g
⋅  h
η P [−] 36
P=
η P [−]  m3   m3 
Q  S P ⋅ TDH [msc] Q  ⋅
m  s  h
P=  
Q ⋅ TDH  [N ] P = g ⋅ 1000 ⋅
η P [−]
[W ] 3.
P= s
 m3 
η P [−] Q  ⋅ S P ⋅ TDH [msc]
 s 
⋅ 
g ⋅1000
 Nm  P= [kW ]
Q ⋅ TDH  1000 η P [−]

P=  s   m3 
η P [−] Q  ⋅ S P ⋅ TDH [msc]
 s 
P= g⋅ [kW ]
J  η P [−]
Q ⋅ TDH  
 m3 
P= s Q  ⋅ S P ⋅ TDH [msc]
η P [−] P = g ⋅ 100 ⋅ 
s 
 [kW ]
η P [%]
Q ⋅ TDH
P= [W ] l 
η P [−] g ⋅100
Q   ⋅ S P ⋅ TDH [msc]
s
P= ⋅ [kW ]
________________ 1000 η P [%]
l 
Q   ⋅ S P ⋅ TDH [msc]
P=
g
⋅ s [kW ]
10 η P [%]
l 
Q   ⋅ S P ⋅ TDH [msc]
P=
g
⋅ s [kW ]
10 η P [%]
l 
Q   ⋅ S P ⋅ TDH [msc]
P=
1
⋅ s [kW ]
10 η P [%]
g
l 
Q   ⋅ S P ⋅ TDH [msc]
P=  
s
[kW ]
1.02 ⋅η P [%]
 Rev. cjc. 30.01.2014

Solids flow rate ms = 65 t/h

Specific gravity of solids Ss = 2.65 -
Average particle size d50 = 211 µm
Solids concentration Cw 30 %
Static discharge head Zd = 20 m
Suction head Zs = 1 m
Pipeline length L= 100 m
Number of long rad. 90 elb. N= 5
Kinematic pressure
hv = v^2 / (2*g)
v= 2.62 m/s
g= 9.81 m/s²
hv = 0.351 msc

Unit pressure los

J= f * (1/d) * hv
f= 0.019 -
d= 0.154 m
hv = 0.4 mwc
J= 0.044 mwc/ m

Pressure loss
Hf = Leq * J
Leq = 116.75 m
J= 0.044 msc/m
Hf = 5.12 msc
 Pump curves have TDH expressed in mwc.
S ⋅ TDH [msc]
S P ⋅ TDH [msc]
To be able to use the pump curve for the
[kW ]
02 ⋅η [%] calculated TDH "Hm [msc]", Weir presents
following relation
 m3  Hm
Q   ⋅ S P ⋅ TDH [msc] Hw =
 h  [kW ] HR
η [%]
m3  where HR is always less than 1.
⋅ S P ⋅ TDH [msc]
h  Thus, for the given flow rate, the equivalent water
[kW ]
η [%] TDH "Hw" is always larger than the calculated
value Hm [msc]
⋅ S P ⋅ TDH [msc] With the actual flow rate and with the equivalent
[kW ] water height the efficiency on water can be obtained
.67 ⋅η [%]
from pump curve