Slurry Systems Handbook

Publisher's Products purchased from Third Party sellers are not guaranteed by the publisher for quality, authenticity, or access to any online entitlements included with the product. The most comprehensive resource on slurries and slurry systems, covering everything from fluid mechanics to soil classification, pump design to selection criteria Slurries are mixtures of liquids and solid particles of all types. For instance, liquid is used as a way of transporting what you get out of the mine, which might be better than shoveling it into freight cars and carrying it out by train. Slurry systems are fundamental to dredging, many mineral processes, bridge and tunnel construction, and to the manufacturer of synthetic petroleum products from oil sands. Front Matter......Page 2 About the Author......Page 5 Preface......Page 6 Table of Contents......Page 8 1.0 Introduction......Page 18 1.1 Properties of Soils for Slurry Mixtures......Page 19 1.1.1 Classifications of Soils for Slurry Mixtures......Page 20 1.1.2 Testing of Soils......Page 23 1.1.4 Plasticity of Soils......Page 28 1.2 Slurry Flows......Page 30 1.2.4 Flows of Emulsions......Page 31 1.3.2 Critical Velocity of Flows......Page 32 1.4 Density of a Slurry Mixture......Page 34 1.5.2 Absolute (or Dynamic) Viscosity of Mixtures with Solids with Volume Concentration Smaller Than 20%......Page 36 1.7 Thermal Conductivity and Heat Transfer......Page 37 1.8.1 Crushing......Page 39 1.8.2 Milling and Primary Grinding......Page 40 1.8.4 Concentration and Separation Circuits......Page 41 1.8.6 Disposal of the Tailings......Page 45 1.9 Closed and Open Channel Flows, Pipelines Versus Launders......Page 46 1.10 Historical Development of Slurry Pipelines......Page 47 1.11 Sedimentation of DamsThe role of the Slurry Engineer......Page 48 1.13 Nomenclature......Page 52 1.14 References......Page 53 2.1 Shear Stress of Liquid Flows......Page 55 2.2 Reynolds Number and Flow Regimes......Page 57 2.3 Friction Factors......Page 58 2.3.1 Laminar Friction Factors......Page 60 2.3.2 Transition Flow Friction Factor......Page 62 2.3.3 Friction Factor in Turbulent Flow......Page 63 2.3.4 HazenWilliams Formula......Page 72 2.4 The Hydraulic Friction Gradient of Water in Rubber-Lined Steel Pipes......Page 73 2.5.1 Entrance Length......Page 87 2.5.2 Friction Velocity......Page 89 2.6 Pressure Losses Due to Conduits and Fittings......Page 98 2.7 Orifice Plates, Nozzles, and Valves Head Losses......Page 103 2.8 Pressure Losses Through Fittings at Low Reynolds Numbers......Page 108 2.11 Fundamental Heat Transfer in Pipes......Page 112 2.11.3 The R Value......Page 114 2.11.7 Heat Transfer......Page 115 2.13 Nomenclature......Page 116 2.14 References......Page 118 3.1.3.1 Terminal Velocity of a Sphere Falling in a Vertical Tube......Page 119 3.1.3.3 Intermediate Spheres......Page 121 3.1.4 Effects of Cylindrical Walls on Terminal Velocity......Page 126 3.1.5 Effects of the Volumetric Concentration on the Terminal Velocity......Page 128 3.2 Generalized Drag Coefficient-The Concept of Shape Factor......Page 130 3.3 Non-Newtonian Slurries......Page 135 3.4.1 Bingham Plastics......Page 136 3.4.2.1 Homogeneous Pseudoplastics......Page 142 3.4.2.2 Pseudohomogeneous Pseudoplastics......Page 145 3.4.4 Yield Pseudoplastic Slurries......Page 146 3.5.1 Thixotropic Mixtures......Page 148 3.7 Measurement of Rheology......Page 150 3.7.1 The Capillary-Tube Viscometer......Page 151 3.7.2 The Coaxial Cylinder Rotary Viscometer......Page 154 3.9 Nomenclature......Page 156 3.10 References......Page 159 4.0 Introduction......Page 162 4.1 Regimes of Flow of a Heterogeneous Mixture in Horizontal Pipe......Page 163 4.1.2 Flow with a Moving Bed......Page 164 4.1.4 Symmetric Flow at High Speed......Page 165 4.3 Transitional Velocities......Page 166 4.3.1 Transitional Velocities V1 and V2......Page 168 4.3.2 The Transitional Velocity V3 or Speed for Minimum Pressure Gradient......Page 169 4.3.3 V4: Transition Speed between Heterogeneous and Pseudohomogeneous Flow......Page 179 4.4 Hydraulic Friction Gradient of Horizontal Heterogeneous Flows......Page 180 4.4.1 Methods Based on the Drag Coefficient of Particles......Page 182 4.4.2 Effect of Lift Forces......Page 186 4.4.3 Russian Work on Coarse Coal......Page 187 4.4.5 Models Based on Terminal Velocity......Page 189 4.5 Distribution of Particle Concentration in Compound Systems......Page 191 4.6 Friction Losses for Compound Mixtures in Horizontal Heterogeneous Flows......Page 194 4.7.1 Pressure Drop Due to Saltation Flows......Page 204 4.7.2 Restarting Pipelines after Shut-Down or Blockage......Page 206 4.8 Pseudohomogeneous or Symmetric Flows......Page 208 4.9 Stratified Flows......Page 209 4.10 Two-Layer Models......Page 211 4.11 Vertical Flow of Coarse Particles......Page 218 4.12 Inclined Heterogeneous Flows......Page 219 4.12.1 Critical Slope of Inclined Pipes......Page 220 4.12.2 Two-Layer Model for Inclined Flows......Page 222 4.13 Conclusion......Page 223 4.14 Nomenclature......Page 224 4.15 References......Page 227 5.0 Introduction......Page 230 5.1.1 Start-Up Pressure......Page 231 5.1.2 Friction Factor in Laminar Regime......Page 234 5.1.3 Transition to Turbulent Flow Regime......Page 237 5.1.4 Friction Factor in the Turbulent Flow Regime......Page 238 5.2.1.2 The Metzner and Reed Approach......Page 240 5.2.1.3 The Tomita Method......Page 242 5.2.3 Turbulent Flow......Page 243 5.3.1 The Hanks and Ricks Method......Page 246 5.3.3 The Torrance Method......Page 247 5.4.2 The Chilton and Stainsby Method......Page 248 5.4.3 The Wilson-Thomas Method......Page 251 5.4.4 The Darby Method: Taking into Account Particle Distribution......Page 253 5.5 Time-Dependent Non-Newtonian Slurries......Page 257 5.7 Roughness Effects on Friction Coefficients......Page 258 5.8 Wall Slippage......Page 262 5.9 Pressure Loss through Pipe Fittings......Page 263 5.11.1 Bauxite Residue......Page 264 5.11.2 Kaolin Slurries......Page 267 5.12 Drag Reduction......Page 268 5.13 Pulp and Paper......Page 269 5.14 Conclusion......Page 270 5.15 Nomenclature......Page 271 5.16 References......Page 273 6.0 Introduction......Page 276 6.1 Friction for Single-Phase Flows in Open Channels......Page 277 6.2 Transportation of Sediments in an Open Channel......Page 284 6.2.1 Measurements of the Concentration of Sediments......Page 287 6.2.2 Mean Concentrations for Dilute Mixtures (Cv < 0.1)......Page 293 6.2.3 Magnitude of beta......Page 297 6.3 Critical Velocity and Critical Shear Stress......Page 298 6.4 Deposition Velocity......Page 302 6.5 Flow Resistance and Friction Factor for Heterogeneous Slurry Flows......Page 304 6.5.1 Flow Resistances in Terms of Friction Velocity......Page 305 6.5.2.2 Effect of Particle Concentration on Slurry Viscosity......Page 306 6.5.2.3 Effects of Particle Sizes on the Chezy Coefficient......Page 307 6.5.3 The Graf-Acaroglu Relation......Page 308 6.5.4 Slip of Coarse Materials......Page 310 6.5.5 Comparison between Different Models......Page 311 6.6 Friction Losses and Slope for Homogeneous Slurry Flows......Page 314 6.6.1 Bingham Plastics......Page 315 6.7 Flocculation Launders......Page 319 6.9 Methodology of Design......Page 320 6.10 Slurry Flow in Cascades......Page 329 6.11 Hydraulics of the Drop Box and the Plunge Pool......Page 331 6.12 Plunge Pools and Drops Followed by Weirs......Page 342 6.14 Nomenclature......Page 346 6.15 References......Page 349 7.1 Rock Crushing......Page 354 7.1.1 Primary Crushers......Page 355 7.1.1.1 Jaw Crushers......Page 356 7.1.1.2 Gyratory Crushers......Page 358 7.1.1.3 Impact Crushers......Page 359 7.2.1 Cone Crushers......Page 360 7.3 Grinding Circuits......Page 362 7.3.1 Single-Stage Circuits......Page 372 7.4 Horizontal Tumbling Mills......Page 374 7.4.3 Autogeneous and Semiautogeneous Mills......Page 377 7.5 Agitated Grinding......Page 378 7.5.4 Vibrating Ball Mills......Page 379 7.6 Screening Devices......Page 382 7.7.1 Hydraulic Classifiers......Page 383 7.7.3 Hydrocyclones......Page 384 7.8 Flotation Circuits......Page 389 7.9 Mixers and Agitators......Page 391 7.10 Sedimentation......Page 410 7.10.1 Gravity Sedimentation......Page 411 7.10.2 Centrifuges......Page 413 7.12 Nomenclature......Page 415 7.13 References......Page 417 8.0 Introduction......Page 418 8.1 The Centrifugal Slurry Pump......Page 419 8.2 Elementary Hydraulics of the Slurry Pump......Page 423 8.2.1 Vortex Flow......Page 424 8.2.2 The Ideal Euler Head......Page 425 8.2.3 Slip of Flow Through Impeller Channels......Page 428 8.2.4 Specific Speed......Page 431 8.2.5 Net Positive Suction Head and Cavitation......Page 435 8.3 The Pump Casing......Page 442 8.4 The Impeller, Expeller and Dynamic Seal......Page 451 8.5 Design of the Drive End......Page 459 8.5.2 Axial Thrust Due to Pressure......Page 460 8.5.3 Thread Pull Force......Page 465 8.5.5 Total Forces from the Wet End......Page 468 8.5.6 Flange Loads......Page 469 8.7 Vertical Slurry Pumps......Page 470 8.8 Gravel and Dredge Pumps......Page 476 8.9 Affinity Laws......Page 477 8.10.1 Corrections for Viscosity and Slip......Page 478 8.10.2 Concepts of Head Ratio and Efficiency Ratio When Pumping Solids......Page 481 8.10.3 Concepts of Head Ratio and Efficiency Ratio Due to Pumping Froth......Page 485 8.12 Nomenclature......Page 489 8.13 References......Page 492 9.1 Solid Piston Pumps......Page 494 9.2 Plunger Pumps......Page 499 9.3 Piston Diaphragm Pumps......Page 501 9.4 Accessories for Piston and Plunger Pumps......Page 506 9.6 Rotary Lobe Slurry Pumps......Page 507 9.7 The Lockhopper Pump......Page 508 9.8 Conclusion......Page 509 9.9 References......Page 510 10.1 The Stress-Strain Relationship of Metals......Page 511 10.2.1 Grey Iron......Page 513 10.3.1 Malleable Iron......Page 514 10.3.3 Ni-Hard......Page 515 10.3.4 High-Chrome-Molybdenum Alloys......Page 516 10.4 Natural Rubbers......Page 521 10.4.3 White Food-Grade Natural Rubber......Page 522 10.5.1 Polychlorene (Neoprene)......Page 523 10.5.5 Nitrile......Page 525 10.5.7 Hypalon......Page 527 10.6 Wear Due to Slurries......Page 528 10.7 Conclusion......Page 531 References......Page 532 11.1 Bauxite Pumping......Page 533 11.3.1 Size of Coal Particles......Page 534 11.3.2 Degradation of Coal During Hydraulic Transport......Page 535 11.3.3 Coal-Magnetite Mixtures......Page 536 11.3.5 Coal-Oil Mixtures......Page 537 11.3.6 Dewatering Coal Slurry......Page 538 11.3.8 Combustion of Coal-Water Mixtures (CWM)......Page 540 11.4 Limestone Pipelines......Page 542 11.5 Iron Ore Slurry Pipelines......Page 544 11.6 Phosphate and Phosphoric Acid Slurries......Page 548 11.6.1 Rheology......Page 549 11.6.2 Materials Selection for Phosphate......Page 550 11.6.3 The Chevron Pipeline......Page 551 11.6.4 The Goiasfertil Phosphate Pipeline......Page 552 11.7 Copper Slurry and Concentrate Pipelines......Page 553 11.8 Clay and Drilling Muds......Page 554 11.9 Oil Sands......Page 555 11.10 Backfill Pipelines......Page 556 11.12 Codes and Standards for Slurry Pipelines......Page 559 11.13 Conclusion......Page 562 11.14 References......Page 563 12.0 Introduction......Page 567 12.1 Project Definition......Page 568 12.2 Rheology, Thickeners Performance, and Pipeline Sizing......Page 571 12.3 Reclaim Water Pipeline......Page 574 12.4 Emergency Pond......Page 575 12.5.1 Wall Building by Spigotting......Page 577 12.5.2 Deposition by Cycloning......Page 578 12.5.2.2 Mobile Cycloning by the Downstream Method......Page 580 12.6 Submerged Disposal......Page 581 12.7 Tailings Dam Design......Page 583 12.9 Stability Analysis for Tailings Dams......Page 584 12.12 Pump Station Design......Page 585 12.13 Electric Power System......Page 586 12.15 Tailings Dam Monitoring......Page 587 12.17 Establishing an Approach for Start-Up and Shutdown......Page 588 12.18 Closure and Reclamation Plan......Page 589 12.20.1 Capital Costs......Page 590 12.20.2 Operation Cost Estimates......Page 591 12.22 Conclusion......Page 593 12.23 References......Page 594 Appendix A: Specific Gravity and Hardness of Minerals......Page 595 Appendix B: Units of Measurement......Page 607 A......Page 611 B......Page 612 C......Page 613 D......Page 615 F......Page 616 G......Page 617 H......Page 618 K......Page 619 M......Page 620 P......Page 622 R......Page 624 S......Page 625 T......Page 627 V......Page 628 Z......Page 629 Here is expert, comprehensive coverage of slurries and slurry systems, covering everything from fluid mechanics and soil classification, to pipeline, plant and pump design and materials selection criteria for wear resistance. This unique handbook is logically divided into two sections: the first covers the hydraulics of slurry flows and includes information on the principles of classifying soils, mixing with water, design of pipelines from coarse to very fine slurries, as Newtonian and Non-Newtonian flows. In a very innovative approach, the mathematics of flow of slurry in open channels, drop boxes and cascades is presented. The reader is guided through those complex flows by numerous solved problems in SI and USCS units. The second section is devoted to the equipment used to make and pump slurries, and contains data on rock crushing, milling, and grinding, separation, classification, filtering, and thickening. The author also delves into the specific aspects of the design of slurry pumps, the selection of materials for wear resistance. The book progresses with practical examples of operating slurry pipelines, appropriate codes and guidelines to conduct feasibility studies for slurry concentrate or tailings disposal systems.