The largest Piston Diaphragm Pump in the world:

from drawing board to operational experience

Hein Krimpenfort, FELUWA PUMPS, Germany

Brad Ricks, Brass Engineering, Unites States

The largest Piston Diaphragm Pump in the world:
from drawing board to operational experience

Project introduction and pump description

By Hein Krimpenfort, Key Account Manager Feluwa Pumps

Boleo Key Project Data
- Location : Santa Rosalia, California Sur, Mexico
- Owner : Minera y Metalurgica del Boleo (MMB)
- Type of opeation : Copper /Cobalt mine and processing plant
- Capacity : 3.1 MTY
- EPCM contractor : Fluor ICA
- Pipeline engineer : Brass Engineering International, San Ramon, Ca, USA
- Start of construction : 2010
- Start of operation : 2014
- Proven reserve : 70 MT
- Estimated mine life : 22 years
Boleo Key Tailings Data
- Type of tailings : copper tailings mixed in sea water (corrosive)
- SG of solids : 2.6
- Concentration : 23 – 28% by weight
- SG of slurry : 1,16 – 1,21
- Pipeline length : 6.000 m
- Static head : 250 m
- Pipeline diameter : 500 mm
- Design capacity : 2.150 m³/hr
- Design pressure : 54 bar
- Size of pump : 750 m³/hr each
- Configuration : 3 operating + 1 standby
Boleo Pump Data
- Type of pump : Double hose piston diaphragm pump
- Pump configuration : 5 cylinder single acting
- Max. capacity : 1.000 m³/hr (@ 9.000 kPa)
- Max. pressure : 32.000 kPa (@ 200 m³/hr)
- Absorbed power : 3.000 kW (at max. duty)
- Pump manufacturer : Feluwa Pumps, Germany
- Start development : 2008
- First pump supplied : 2011
- In operation : 2014
Features of QGK design
- Pulsations
- 3 cylinder single acting : 23% peak to peak
- 2 cylinder double acting : 46% peak to peak
- 5 cylinder single acting : 5% peak to peak

- Diaphragm design
- Double hose : in case of diaphragm damage, pumping can continue

- Valves design
- Ball valves : only 3 wearing parts (ball, seat, guide)
- Smaller valves : reduce NPSHr, increased safety during maintenance
- Quick change : Swing out cassettes enable valve part replacement < 30 min.
The largest Piston Diaphragm Pump in the world:
from drawing board to operational experience

Pump selection sequence

By Brad Ricks, President Brass Engineering International

Pump selection sequence

• Specified Capacity Range

• Tailings Pipeline Route
• Tailings Slurry Properties

• Pumping Duty
• Availability
• Costs
 Pump selection sequence, pipeline and route
Specified Capacity Range
Nominal Transport Pipe: Profile & HGLs
Mass Rate, dry t/h
Tonnage = 488.3 dry t/h NPS 20 Boleo Tailings Pipeline Minimum Nominal Design
Cw = 26.00% by wt.
Flow = 1499.0 m3/h
DN 500 475.0 488.3 514.6
800.0

700.0

600.0 • ASME B31.11 Slurry Transportation Piping Systems

• API 5L Specification For Line Pipe
500.0 • ASME B16.5 Pipe Flanges and Flange Fittings
HGL Lines, masl

• ASTM D1248 Standard Specification for Polyethylene Plastics

400.0
Convential Tailings non-Newtonian Bingham Plastic

300.0

Static Lift
200.0
Newtonian

100.0

0.0
0.000 1.000 2.000 3.000 4.000 5.000 6.000
Kilometer Post

Ground Profile Allowable HGL Newtonian SlurryCAD Bingham P Static Lift

Slurry data
- Liquid
- Temperature : 36o C (97o F)
- Liquid SG : 1.06
- pH : 5 - 6 (corrosive)
- Viscosity : 0.00080 Pa-s

- Solids
- Solids SG : 2,6 operating data
: 2,06 initial data (light)

- Equilibrium moisture : 0% Tyler Mesh Particle Diam (mm) Percent Passing

65 0.210 100.0
Solid size distribution 100 0.150 99.5

150 0.110 96.9

200 0.070 91.5

270 0.050 85.2

325 0.040 81.0

400 0.040 71.0

500 0.030 67.0

Solids SG Comparison with other Tailings

Tailings Solid's Specific Gravities

3.5

3.0 90% Confidence

Average

90% Confidence
Solid's SG

2.5

Boleo
2.0

1.5

1.0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Project
Particle Size Distribution, Comparison with other Tailings
Slurry Data
- Slurry
- Cw : 22 – 28%
- Slurry SG : 1,219 – 1,271
- Viscosity : 0,0047 – 0,0092 Pa-sec
- Yield stress : 7,02 -42,1 Pa
Viscosity, Comparison with other Tailings
Reduced Viscosity In-house data
100.00
Average
90.00

80.00
Boleo
Reduced Viscosity In-house data
70.00 40.00

35.00

60.00 30.00

Boleo

Reduced Viscosity
25.00

Reduced Viscosity
20.00

50.00 15.00
Average
10.00

40.00 5.00

0.00
0% 5% 10% 15% 20% 25% 30%
Cw, %

30.00
AVERAGE Project 2 Project 8 Project 11 Project 12 Project 15
Project 16 Project 43 Project 47 Project 48 Project 49 Project 50
Project 51 Project 56 Project 57 Project 58 Project 59 Project 60

20.00 Project 61
Project 139
Project 65
Project 141
Project 66
Project 142
Project 67
Project 143
Project 68
Project 144
Project 77
Project 145
Project 146 Project 147 Project 148 Project 149 Project 150 Project 151
Project 152 Project 164 Project 165 Project 167 Project 171 Project 172
Project 176 Project 177 Project 178 Project 179 Project 180 Project 181
Project 182 Project 183 Project 184 Project 185 Project 186 Project 187

10.00 Project 188

Project 194
Project 189
Project 195
Project 190
Project 200
Project 191
Project 201
Project 192
Project 202
Project 193
Project 203
Project 222 Project 237 Project 239 Project 240 Project 261 Project 289
Project 290 Project 291 Project 292 Project 313 Project 314 Project 315
Project 322 Project 323 Project 335 Project 336 Project 1034 Boleo
Project 1036 Project 1037 Project 1049 Project 1050 Project 1055 Project 1056
0.00 Project 1100 Project 1101 Project 1102 Project 1103 Project 1104 Project 1105
Project 1106 Project 1108 Project 1110

0% 10% 20% 30% 40% 50% 60% 70% 80%

Cw,
Cw,%%

AVERAGE Project 2 Project 8 Project 11 Project 12 Project 15

Yield Stress, Comparison with other Tailings

3000.00
Yield Stress vs Cw - In-house Data

2500.00 Boleo

1000.00
Yield Stress vs Cw - In-house Data

900.00

2000.00 800.00
Boleo

Yield Stress, dyne/cm^2

700.00

Yield Stress, dyne/cm^2

600.00

500.00

1500.00
400.00 Average
300.00 Average
200.00

100.00

0.00

1000.00 0% 5% 10% 15%

Cw, %
20% 25% 30%

AVERAGE Project 2 Project 8 Project 11 Project 12

Project 15 Project 16 Project 43 Project 47 Project 48
Project 49 Project 50 Project 51 Project 56 Project 57
Project 58 Project 59 Project 60 Project 61 Project 65
Project 66 Project 67 Project 68 Project 77 Project 139
Project 141 Project 142 Project 143 Project 144 Project 145
Project 146 Project 147 Project 148 Project 149 Project 150
500.00 Project 151 Project 152 Project 164 Project 165 Project 167
Project 171 Project 172 Project 176 Project 177 Project 178
Project 179 Project 180 Project 181 Project 182 Project 183
Project 184 Project 185 Project 186 Project 187 Project 188
Project 189 Project 190 Project 191 Project 192 Project 193
Project 194 Project 195 Project 200 Project 201 Project 202
Project 203 Project 222 Project 237 Project 239 Project 240
Project 261 Project 289 Project 290 Project 291 Project 292
Project 313 Project 314 Project 315 Project 322 Project 323
0.00 Project 335 Project 336 Project 1034 Boleo Project 1036
Project 1037 Project 1049 Project 1050 Project 1055 Project 1056
0%
Project 1100 Project 1101 10%
Project 1102 20%
Project 1103 Project 1104 30% 40% 50% 60% 70% 80%
Project 1105 Project 1106 Project 1108 Project 1110

Cw, %
AVERAGE Project 2 Project 8 Project 11 Project 12
Project 15 Project 16 Project 43 Project 47 Project 48
Project 49 Project 50 Project 51 Project 56 Project 57
Project 58 Project 59 Project 60 Project 61 Project 65
Project 66 Project 67 Project 68 Project 77 Project 139
Project 141 Project 142 Project 143 Project 144 Project 145
 Pump Duty
- Nominal Capacity: 488 dry t/h, solids, SG=2,6, Cw=26%, Flow= 1500 m³/h
Operating Conditions
Diameter 20.000 NPS Cw 26.00% % Capacity 488.33 dry /th Sfac 1.100
10.000
User: blr
Date: 2017-02-04

Operating Conditions
Dry solid throughput t/d 11720
Availability % 100.0% He = 0
Throughput/pipeline t/h 488.3 1.000
Weight Concentration % 26.00% 26.0%
Solid/liquid Volume Ratio 0.143 0.143
Volume Concentration % 12.5% 12.5%
Slurry Specific Gravity 1.253 1.253
Flowrate Per Pipeline m³/h 1499.0 1499.0 Rec
Flowrate Per Pipeline gpm 6600.2 6600.2 0.100
Plastic Viscosity cP 7.2 7.2
Yield Stress dyn/cm² 240.7 240.7
f
Centrigugal Pump Overall Efficiency 76.6% 2474 kW
PD Pump Overall Efficiency 91.2% 2078 kW
0.010
Fluid Type = 3
Fluid Type = Bingham Plastic

0.001
10 100 1000
Re 10000 100000 1000000 10000000
 Pump Selection Sequence
Pipeline and Route Specified Capacity Range
Profile & HGLs Mass Rate, dry t/h
Boleo Tailings Pipeline Minimum Nominal Design
Nominal Transport Pipe: 475.0 488.3 514.6
800.0
Tonnage = 488.3 dry t/h
NPS 20
Cw = 26.00% by wt.
700.0
DN 500
Flow = 1499.0 m3/h
600.0
• ASME B31.11 Slurry Transportation Piping Systems
500.0 • API 5L Specification For Line Pipe
HGL Lines, masl

• ASME B16.5 Pipe Flanges and Flange Fittings

400.0 • ASTM D1248 Standard Specification for Polyethylene Plastics
Convential Tailings non-Newtonian Bingham Plastic

300.0

Static Lift
200.0
Newtonian

100.0

0.0
0.000 1.000 2.000 3.000 4.000 5.000 6.000
Kilometer Post

Ground Profile Allowable HGL Newtonian SlurryCAD Bingham P Static Lift

 Pump Duty
- Design Capacity: 514 dry t/h: solids, SG=2,6, Cw=22%, Flow= 1920 m³/h (low Cw, high flow)
Operating Conditions
Diameter 20.000 NPS Cw 22.00% % Capacity 514.58 dry /th Sfac 1.100
10.000
User: blr
Date: 2017-02-04

Operating Conditions
Dry solid throughput t/d 12350
Availability % 100.0% He = 0
Throughput/pipeline t/h 514.6 1.000
Weight Concentration % 22.00% 22.0%
Solid/liquid Volume Ratio 0.115 0.115
Volume Concentration % 10.3% 10.3%
Slurry Specific Gravity 1.219 1.219
Flowrate Per Pipeline m³/h 1919.1 1919.1 Rec
Flowrate Per Pipeline gpm 8449.7 8449.7 0.100
Plastic Viscosity cP 4.7 4.7

f
Yield Stress dyn/cm² 70.2 70.2

Centrigugal Pump Overall Efficiency 80.9% 2705 kW

PD Pump Overall Efficiency 91.2% 2398 kW
0.010
Fluid Type = 3
Fluid Type = Bingham Plastic

0.001
10 100 1000
Re 10000 100000 1000000 10000000
Pump Duty
- Design Capacity: 514 dry t/h: solids, SG=2,6, Cw=22%, Flow= 1920 m³/h (low Cw, high flow)
Design Transport
Specified Capacity Range
Tonnage = 514.6 dry t/h Profile & HGLs Mass Rate, dry t/h
Cw = 22.00% by wt.
Boleo Tailings Pipeline Minimum Nominal Design
Flow = 1919.1 m3/h 475.0 488.3 514.6
900.0

800.0

700.0

600.0
HGL Lines, masl

500.0

Convential Tailings non-Newtonian Bingham Plastic

400.0

300.0
Static Lift

200.0 Newtonian

100.0

0.0
0.000 1.000 2.000 3.000 4.000 5.000 6.000
Kilometer Post

Ground Profile Allowable HGL Newtonian SlurryCAD Bingham P Static Lift

 Pump Duty
- Design Capacity: 514 dry t/h: solids, SG=2,6, Cw=28%, Flow= 1450 m³/h (low Cw, high flow)
Operating Conditions
Diameter 20.000 NPS Cw 28.00% % Capacity 514.58 dry /th Sfac 1.100
10.000
User: blr
Date: 2017-02-04

Operating Conditions
Dry solid throughput t/d 12350
Availability % 100.0% He = 0
Throughput/pipeline t/h 514.6 1.000
Weight Concentration % 28.00% 28.0%
Solid/liquid Volume Ratio 0.159 0.159
Volume Concentration % 13.7% 13.7%
Slurry Specific Gravity 1.271 1.271
Flowrate Per Pipeline m³/h 1446.2 1446.2 Rec
Flowrate Per Pipeline gpm 6367.8 6367.8 0.100
Plastic Viscosity cP 9.2 9.2

f
Yield Stress dyn/cm² 420.6 420.6

Centrigugal Pump Overall Efficiency 76.2% 2865 kW

PD Pump Overall Efficiency 91.2% 2392 kW
0.010
Fluid Type = 3
Fluid Type = Bingham Plastic

0.001
10 100 1000
Re 10000 100000 1000000 10000000
Pump Duty
- Design Capacity: 514 dry t/h: solids, SG=2,6, Cw=28%, Flow= 1450 m³/h (low Cw, high flow)
Design Transport Specified Capacity Range
Profile & HGLs
Tonnage = 514.6 dry t/h Boleo Tailings Pipeline Mass Rate, dry t/h
Cw = 28.00% by wt. Minimum Nominal Design
800.0 Flow = 1446.2 m3/h 475.0 488.3 514.6
700.0

600.0

500.0
HGL Lines, masl

400.0
Convential Tailings non-Newtonian Bingham Plastic

300.0

Static Lift
200.0
Newtonian

100.0

0.0
0.000 1.000 2.000 3.000 4.000 5.000 6.000
Kilometer Post

Ground Profile Allowable HGL Newtonian SlurryCAD Bingham P Static Lift

Pump Duty and Description
- Common to both centrifgal and PD pumps
- Cw : 22 – 28%
- Flow : 1560 -1950 m³/h
- TDH : 330 – 440 m
- Casing pressure : 3,85 – 5,25 MPa
- Casing pressure : 560 – 760 psig (ANSI Class 400)

- Centrifugal pumps
- Duty : medium – heavy
- Tip speed : 33 – 38 m/sec
- Corrosion resistant lining (High Chrome (28%) and impeller (High Chrome)

- Positive displacement pumps

- Corrosion resistant wetted fluid parts (super duplex steel)
Availability Centrifugal Pumps Centrifugal Pump Station Availability

Pumping Unit Availability

Prime Mover 0.970
Seal Water 0.995
PP07..PP08 Pumping Unit 0.96515
PP01..PP06 0.970
Pump Train Avaiability
0.970 Pumping Unit 0.96515
Train 01 Units in series 8
Pump Train 0.752937
0.995

Pump Station Availability

0.995
Pump Trains 0.752937
PP07..PP08 Trains in Parallel 2
Availability of at leat 1 train 0.93896
PP01..PP06 0.970

0.970 At Least 1 of 2
Train 02 Uptime 8225 hours per year
DownTime 535 hours per year
0.995 DownTime 22.3 days per year

0.995
Pump Station Availability
Pump Trains 0.752937
Tarins in Parallel 3
Availability of at least 1 train 0.984919

At Least 1 of 3
Uptime 8628 hours per year
DownTime 132 hours per year
DownTime 5.5 days per year
Availability Piston Diaphragm Pumps
PD Pump Station Availability
PP-P01
Charge Pump Unit Availability
Charge Pump 0.970
Seal Water 0.995
0.970 Charge Pump Unit 0.96515

Charge Pumps Availability

Charge Pump Unit 0.96515
PP-P02
Charge Pumps in Parallel 2
PP-C01 Availability of at least 1 unit 0.998785
0.970
Prime Movers Availability
0.970
Prime Mover 0.970
Prime Movers in Parallel 4
Availability of at least 3 unit 0.994814
0.995

Pump Station Availability: 3 of 4 Pumps)

PP-P03 Charge Pumps 0.998785
PP-C02 Prime Movers 0.994814
Pump Station Availability 0.993605
0.970
0.970
At Least 3 of 4
Uptime 8704 hours per year
DownTime 56 hours per year
0.995 PP-P04 DownTime 2.3 days per year

Pump Station Availability: 2 of 3 Pumps)

Charge Pumps 0.994814 N
0.970
Prime Movers 0.997354 O
Pump Station Availability 0.992181
M
At Least 2 of 3 I
Uptime 8692 hours per year N
DownTime 68 hours per year
DownTime 2.9 days per year
A
L
Costs
Note: quotes from three different PD Pump manufacturers were received. The FELUWA
MULTISAFE Double Hose-Diaphragm Pumps were selected based upon limited amount of
fluid end parts exposed to the corrosive slurry (valves and seats).

Other pumps also utilized corrosion resistant metals, but the quantity of these metals were
more than required by the Feluwa pumps and consequently more expensive
 Initial Cost Comparison
- Piston diaphragm versus centrifugal pumps

PRIME MOVERS VF Drives Gland Seal Water Pumps Charge Pumps

Description Number Pumps Unit Cost Total Cost Units Unit Cost Total VFDs Units Unit Cost Tot SW Pumps Units Unit Cost Tot C Pumps

Centrifugal 16 (8 + 8) $152,000 $2,432,000 6 $251,000 $1,506,000 16 $20,000 $320,000 0 $160,000 $0

Centrifugal 24 (8 +16) $152,000 $3,648,000 9 $251,000 $2,259,000 24 $20,000 $480,000 0 $160,000 $0

Feluwa (650 m3/h) 4 (3 + 1) $1,760,000 $7,040,000 4 $251,000 $1,004,000 2 $5,000 $10,000 2 $160,000 $320,000
3
Feluwa (780 m /h) 3 $2,190,000 $6,570,000 3 $251,000 $753,000 2 $5,000 $10,000 2 $160,000 $320,000

PRIME MOVERS Backup PD Pump D Installed Electrical Gear

Total Costs
Description Number Pumps Unit Cost Total Cost Units Unit Cost Tot PD Pumps D kW Unit Cost Total

Centrifugal 16 (8 + 8) $152,000 $2,432,000 1 $715,000 $715,000 200 $1,400 $280,000 $5,253,000

Centrifugal 24 (8 +16) $152,000 $3,648,000 1 $715,000 $715,000 300 $1,400 $420,000 $7,522,000

Feluwa (650 m3/h) 4 (3 + 1) $1,760,000 $7,040,000 0 n/a n/a base base $0 $8,374,000
3
Feluwa (780 m /h) 3 $2,190,000 $6,570,000 0 n/a n/a base base $0 $7,653,000
 Operating Cost Comparison
- Piston diaphragm versus centrifugal pumps
- Efficiency : overall efficiency (motor, gear, volumetric)
- Power costs : 0,088/kwh

Prime Mover Operating Cost Comparison (Nomial Capacity, Cw=26%)

Operating Power Operating Spares Total
Description Number Pumps
Eff kW Annual Costs Annual costs Annual

Centrifugal 16 (8 + 8) 0.766 2,561 $1,974,586 $760,000 $2,734,586

Centrifugal 24 (8 +16) 0.766 2,561 $1,974,586 $760,000 $2,734,586

Feluwa (650 m3/h) 4 (3 + 1) 0.912 2,152 $1,658,635 $131,000 $1,789,635

Feluwa (780 m3/h) 3 0.912 2,152 $1,658,635 $131,000 $1,789,635

Eff = Overall Efficiency (Motor, Gear, Volumetric)

Power Costs = $0.088 per kWh
NPV Cost Comparison
- Piston diaphragm versus centrifugal pumps
- Nominal Capacity : 488 ndry t/h
- Cw : 26%
- Increment : 1 year
- Annual discount rate: 6%
Net Present Values Net Present Values
$40,000,000 $25,000,000

$35,000,000
$20,000,000
$30,000,000

$25,000,000 $15,000,000

NPV, USD
NPV, USD

$20,000,000
3.8 years
$10,000,000
$15,000,000

2.9 years
$10,000,000
$5,000,000

$5,000,000

$0 $0
0 2 4 6 8 10 12 14 16 18 20 0 1 2 3 4 5 6
Time, years Time, years

Centrifugal 16 (8 + 8) Centrifugal 24 (8 +16) Centrifugal 16 (8 + 8) Centrifugal 24 (8 +16) Feluwa (650 m3/h) 4 (3 + 1)

Feluwa (650 m3/h) 4 (3 + 1) Feluwa (780 m3/h) 3 Feluwa (780 m3/h) 3 Fel 3 + 1 Pay Back Fel 3 Pay Back
Pump Selection Sequence

Pump Selection Summary

FELUWA MULISAFE
Category Centrifugal Pump Double Hose
Diaphragm Pump
Slurry Dilution
Resartart w/ Plug requires PD pump
Corrosion Resistance
Efficiencies
Availability
Initial Costs
NPV Analysis
The largest Piston Diaphragm Pump in the world:
from drawing board to operational experience

Scope of Supply, Operational Experience and Conclusion

By Hein Krimpenfort, Key Account Manager Feluwa Pumps

Scope of Supply
- 4 pumps
- Down Flow Technology
- Capacity : 750 m³/h
- Pressure : 54 bar (design)
- Stroke rate : 42 per minute
- Weight : 150 ton
- 4 motors : ABB
- 4 VFD´s : ABB
- Electronic crankshaft connection
- Pulsorber pulsation dampeners with automitic charge pressure adjustment
- 2 year inspection contract
Operational experience
- Development and performance of pump components at Boleo

- Diaphragms
- Material : NBR
- Life time : > 16.000 operating hours

- Valves
- Balls material : Polyurethan
- Seat material : Super duplex stainless steel
- Life time : > 2.500 operating hours
Operational Experience
Utility consumption

Power consumption
- At pump shaft : 1030 kW
- Auxiliary power : 8 kW
- Charge pumps : 55 kW
- Cooling fan : 15 kW
Total power consumption : 1108 kW

Water consumption
- Only gland water for charge pump
- Flushing water in case of extended stops

Air consumption
- None
Impressions: FAT
Impressions: transportation
Impressions: erection
Impressions: operation
 The largest Piston Diaphragm Pump in the world:
from drawing board to operational experience

Conclusions :

- QGK500 is designed for capacities of up to 1.000 m³/hr @ pressures up to 9.000 kPa

- At Boleo QGK500 pumps are in operation since > 6 years

- Pipeline design company compared QGK500 pumps with multiple centrifugal pumps

- QGK500 pumps were favoured due to lower OPEX costs

- Payback time for QGK500 pumps is within 2,9 to 3,8 years

- QGK500 pumps operate very satisfactory at Boleo

The largest Piston Diaphragm Pump in the world:
from drawing board to operational experience

Contact :

Brad Ricks : [email protected]

Hein Krimpenfort : [email protected]

TECNIFLOW : [email protected]
Thank you!