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Since the 1980s, economic trends have been developing in the pulp and paper industry that have had major impacts on how mills must operate to survive in the 21st century. The industry now operates in a global market with foreign competition, so it must evolve with changing environmental regulations, remain competitive and supply products to users who demand higher quality products, all while cutting its cost per ton.
The pulp and paper industry has been a crucial part of society for generations, providing materials essential for communication, packaging, currency, etc. The industry has evolved, embracing new technologies to improve efficiency and productivity. The manufacturing processes involved in papermaking require the handling of various types of slurries, such as lime slurry, caustic, black liquor and white liquor.
In the pulp and paper industry, the main type of pump used to handle these slurries is American National Standards Institute (ANSI) centrifugal. This is the same type of pump used to handle clear water and pulp fiber slurry in the mill. The only difference in these units is the materials used in the construction of the impeller, casing, stuffing box and suction wear plates. The units handling slurries typically use a duplex stainless steel (SS) known as CD4MCu on these parts, while the units handling water and pulp fiber are typically 316 SS and ductile iron. The CD4MCu material has a 240 Brinell hardness and does offer extended wear versus 316 SS and ductile iron, but it is also expensive.
Slurry pumps have a long history and are commonly used in the power and sand and mining and gravel industries due to the need for handling both abrasive and corrosive slurries. Over the years, the advancement of materials and design efficiency in slurry pump technology has become crucial for maintaining efficient operations that help lower mining and power companies’ production costs.
For many years, slurry pumps were offered in chrome iron and natural rubber and were only used to pump neutral dirt or ore in the wet separation process in the mining industry. However, developments in materials have broadened the market for slurry pumps.
Various types of chrome materials are now used to handle materials with a potential of hydrogen (pH) of two and a variety type of acids. They are also available in elastomer products such as ethylene propylene diene monomer (EPDM), neoprene and butyl that can handle elevated temperatures and
corrosive liquids.
A slurry pump manufacturer recently visited a pulp and paper mill to discuss the use of slurry pumps versus ANSI process pumps. Slurry pumps are more robust and are designed to handle heavy abrasive and corrosive slurries that can dramatically increase the wear life and reliability of the pump installation. This can lead to cost savings by reducing the need for pump maintenance, spare parts and downtime.
How and why? First, a true centrifugal slurry pump is more robust than an ANSI centrifugal pump based on mass. For instance, a CD4MCu 6x4-13 ANSI unit weighs approximately 450 pounds (lbs). A chrome 6x4-13 slurry pump weighs 1,000 lbs. To break this down even further, the ANSI 13.0-inch impeller weighs approximately 20 lbs. A chrome slurry
13.0-inch impeller weighs 150 lbs. Therefore, the chrome slurry impeller will provide a longer wear life.
Second, technological advancements have allowed for the development of specialized slurry pumps, enabling paper mills to handle a broader range of slurries efficiently. Today, slurry pumps are available with numerous impeller styles, such as high-efficiency, large particle and open style for handling fibrous material and high-head applications.
Slurry pumps can play a pivotal role in various aspects of the papermaking process. They are extensively used for transporting different types of slurries within the mill, ensuring the continuous flow of materials between the different stages of paper production. Some of the key roles of slurry pumps in pulp and paper mills include:
Pumping lime slurry: Lime slurry plays a critical role in the papermaking process. It helps adjust the pH levels of pulp, thereby enhancing the bleaching process. Slurry pumps designed for handling lime slurries are equipped with abrasion-resistant materials, as lime slurries can be highly abrasive. These pumps efficiently transport the lime slurry to designated points, ensuring proper pH control and contributing to the production of high-quality paper.
Pumping caustic: Caustic solutions are vital for the pulping process, as they aid in breaking down lignin from wood fibers, making them suitable for papermaking. Slurry pumps used for handling caustic solutions are constructed with materials that are resistant to chemical corrosion. These pumps ensure the safe and efficient transfer of caustic solutions within the paper mill, optimizing the pulping process.
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Pumping white and black liquors: White and black liquors are essential byproducts of the pulping process. White liquor is used for cooking wood chips, while black liquor contains valuable chemicals that can be recovered and recycled. Efficient pumping of these liquors ensures minimal waste and optimal resource utilization within the paper mill.
Slurry pumps have played a crucial role in pulp and paper mills, facilitating the transport of various slurries essential for the papermaking process. From handling lime slurry and caustic to pumping white and black liquor, slurry pumps are indispensable in ensuring smooth operations and high productivity. The future of slurry pumps in pulp and paper is promising, with advancements in materials and energy efficiency on the horizon. As technology continues to evolve, slurry pumps will remain a vital component in the ongoing success of the papermaking industry, helping mills lower their cost per ton and remain profitable.
Applications of the slurry pumps
Slurry pumps are widely used in metallurgy, mining, coal, electric power, petrochemical, food, urban construction, environmental protection and river port dredging, reclamation and other sectors of the national economy.
Development History
The pipeline hydraulic transportation technology of solid materials has a long history, and the long-distance pipeline transportation technology developed rapidly in the 1950s.
Due to the advantages of high efficiency, less land occupation, low cost and no pollution, this conveying method has been paid more and more attention by people. The United States, Brazil, Japan, the former Soviet Union, South Africa, Canada and other countries have successively built a number of hydraulic pipelines for solid materials.
According to the literature, from the 1950s to the early 1980s, there were 28 slurry transportation pipelines that were put into operation, with a maximum length of 440km. According to reports, the Wyoming-Arkansas coal pipeline planned to be put into operation in the United States in 1979 is 1,670km long, with an annual coal transportation capacity of 25 million tons.
It is also reported that the coal transportation pipeline of ETST Energy Systems in the United States is 2,500km long, with an annual coal transportation capacity of 3.7 million t. It was originally planned to be completed in 1985.
In 1980, the Soviet Union conducted a feasibility analysis on the Kuzbass coal pipeline. The pipeline was 2,500km long and the annual coal volume was 25 million tons. The slurry delivery concentration has developed from Cw=40%~60% in the 1950s to Cm=60%~70% in the early 1980s.
Due to the development of pipeline transportation technology, the demand for various types of solid-liquid pumps, which are essential for the hydraulic transportation of solid materials in pipelines, is increasing.
Companies engaged in the production of solid-liquid pumps outside of China
According to incomplete statistics, there are more than 300 foreign companies specializing in the production of solid-liquid pumps.
Many of them include Warman International Equipment Company in Australia, Goulds Pump Company in the United States, Worthington Pump Company in the United States, Holthuis Company in the Netherlands, Wirth Company in Germany All kinds of solid-liquid pump products produced by KSB and other manufacturers have advanced design, reasonable structure, high efficiency and long service life. They are widely used in conveying projects of various materials and enjoy a high reputation in the world.
Four types of solid-liquid pumps are mainly used in various industries
At present, various industries and other departments mainly use four types of solid-liquid pump products - centrifugal pump, reciprocating pump, diaphragm pump and screw pump.
Among these four types of solid-liquid pump products, centrifugal pumps account for the vast majority (about 80% of the total pump usage). The total investment cost and manufacturing cost of the centrifugal pump are low, the disassembly and assembly are convenient, and there is a tendency to be applied to long-distance pipelines.
In recent years, reciprocating pumps such as plunger mud pumps, Mars pumps, piston diaphragm pumps, oil or water isolated mud pumps, etc. have been developed and attracted people's attention. The total investment cost of this type of pump is 2 to 5 times that of a centrifugal pump, but the maintenance and operation costs are low, and it is suitable for long-distance pipeline transportation of high-concentration abrasive slurries such as concentrates and tailings.
Development direction of solid-liquid pump
With the development of the national economy, the demand for solid-liquid pumps is increasing, and the requirements for the performance range of varieties and specifications are also increasing. At the same time, great progress and great development have been made in the theoretical research of slurry pump, product development, manufacturing and product quality level.
As far as the centrifugal slurry pump product itself is concerned, it is developing towards high lift, large flow, high efficiency, long life, many varieties, wide performance, high degree of sanitation and rational use.
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