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A slurry pump is a general-purpose fluid machine specifically designed for conveying abrasive and corrosive slurries containing solid particles. It is mainly used in industries such as mining, power plants, dredging, metallurgy, chemicals, building materials, and petroleum to solve the problem of conveying solid-liquid mixed media during production processes. In principle, a slurry pump is a type of centrifugal pump, but its design, materials, and structure are specifically optimized for the abrasive and corrosive properties of slurries, resulting in higher reliability and a longer service life.
In industrial production, slurry pumps play a crucial role. For example, in the mining industry, they are responsible for conveying slurry and tailings; in thermal power plants, they are used for hydraulic ash removal; in coal washing plants, they handle the conveying of coal slurry and heavy media; and in the environmental protection field, they are used for river dredging and sludge treatment. Statistics show that approximately 80% of slurry pump applications are concentrated in mineral processing plants within the mining industry.
The working process of a slurry pump is based on the principle of centrifugal force, essentially a process of energy transfer and conversion. Its core working components are the impeller and the volute casing.
When the motor drives the impeller on the pump shaft to rotate at high speed, the blades in the impeller force the slurry to rotate accordingly. Under the action of inertial centrifugal force, the slurry is thrown from the center of the impeller to the edge, during which the pressure potential energy and kinetic energy of the slurry increase. The high-velocity slurry leaves the impeller and enters the volute casing (discharge chamber). Due to the gradual expansion of the flow channel in the casing, the slurry velocity gradually decreases, and some of the kinetic energy is converted into static pressure energy. Finally, the slurry is delivered to the desired location along the discharge pipe at a higher pressure.
Simultaneously, a certain vacuum low-pressure zone is formed in the central region of the impeller due to the slurry being thrown out. Under the action of atmospheric pressure or other pressures at the suction end (such as the liquid surface in the storage tank), new slurry continuously enters the impeller through the suction chamber to replenish the discharged slurry. Thus, with the continuous rotation of the impeller, the slurry is constantly drawn in and discharged, forming a continuous working flow.
Simply put, the slurry pump transfers the mechanical energy of the high-speed rotation of the electric motor through the impeller and converts it into the pressure and kinetic energy of the slurry being transported.
Based on different installation and usage methods, slurry pumps can be mainly divided into two categories: vertical submersible slurry pumps and horizontal slurry pumps.
The vertical submersible slurry pump is a vertical, single-stage, single-suction, cantilevered centrifugal pump. Its main characteristics include: Submersible operation: The submersible insertion length of the pump can be between 800mm and 1900mm, and a suction pipe can be added as needed, making it suitable for pumping slurry from pits and tanks.
Seal-free design: The pump shaft in the submersible section has sufficient rigidity. There are no bearings or shaft seals between the impeller and the pump body, simplifying the structure and reducing maintenance requirements.
Special Impeller: The impeller often adopts a semi-open design, with stirring blades at the inlet extension of the impeller blades. This helps prevent solid particle deposition and enhances media handling capacity.
Installation Precautions: During installation, it is essential to ensure that the slurry level is always higher than the pump body. Otherwise, the pump should be stopped immediately to prevent pump shaft oscillation and damage to the bearings.
Horizontal slurry pumps are widely used in the industry and are typically horizontal, single-stage, single-suction, cantilever, or centrifugal slurry pumps. Their significant characteristics include:
High Wear Resistance: Flow components (such as impellers, pump casings, and front and rear guard plates) are usually made of high-chromium wear-resistant alloys (such as Cr27), offering superior wear resistance and excellent particle conveying capacity.
Double Casing Structure: Many heavy-duty horizontal slurry pumps employ a double-casing design. The outer casing is a heavy-duty structure (often vertically split), while the inner lining is a replaceable high-chromium alloy wear-resistant liner. This design allows for replacement of only the liner after wear, rather than the entire pump casing, significantly reducing maintenance costs.
High-efficiency sealing system: Various shaft seal types are available, with a common combination being an auxiliary impeller and packing seal. The pressure head generated by the auxiliary impeller resists leakage of liquid from the impeller outlet, reducing pressure at the stuffing box and minimizing leakage and wear. In some applications, a shaft seal water system is also used to achieve leak-free operation.
Heavy-duty bracket: The bracket is typically a horizontal split type, internally equipped with heavy-duty double-row tapered roller bearings capable of withstanding axial and radial loads generated during pump operation, ensuring operational stability.
Slurry pumps have a wide range of applications, primarily for conveying abrasive slurries containing solid particles.
Mining: This is the largest application area for slurry pumps. They are mainly used for tailings transportation, slurry circulation, and metallurgical slag discharge. For example, at the Erdenet copper mine in Mongolia, NEP Mining Machinery’s large 750NZJ slurry pumps are used for tailings transportation, with a flow rate as high as 15,000 cubic meters per hour. In recent years, with the rise of the new energy industry, the mining and beneficiation of emerging minerals such as lithium has become inseparable from slurry pumps. For example, Jizhong Equipment Stone Pump Company successfully won a bid for a lithium mine project in Nigeria, providing it with ZJ series slurry pumps.
Power Industry: In thermal power plants, slurry pumps are responsible for ash and slag handling, mainly used in hydraulic ash removal systems and ash slurry transportation.
Metallurgy and Coal Processing: In metallurgical plants, they are used to transport high-concentration slag; in coal washing plants, they handle coal slurry and heavy media separation media.
Environmental Protection and Municipal Engineering: Used in river dredging, sewage sludge transfer, industrial wastewater treatment, and the suction of flowing sludge. In these applications, slurry pumps are sometimes also called sand pumps, dredging pumps, or silt removal pumps.
Other Industries: In the chemical, pharmaceutical, paper, cement, and food industries, they are used to pump fluids containing mud, sand, and slag, and even some corrosive liquids.
Correct selection is crucial for ensuring the efficient and long-term operation of a slurry pump. The following factors should be considered during selection:
Slurry Characteristics: This includes the particle size, shape, hardness, and concentration of solid particles, as well as the pH and temperature of the slurry. For example, a certain type of horizontal slurry pump is specifically designed for highly abrasive slurries with a particle size ≤25mm and a mass concentration ≤60%.
Operating Parameters: These mainly include flow rate (m³/h) and head (m). Calculations should be performed based on process requirements to select a model that operates within the pump’s high-efficiency range.
Material Selection: The appropriate material for the flow-through components should be selected based on the abrasiveness and corrosiveness of the slurry. For highly abrasive slurries, high-chromium alloys are a common choice; for conditions involving both abrasion and corrosion, rubber linings or other corrosion-resistant alloys may need to be considered.
Installation: The dimensions, location, and elevation of the foundation should meet the design requirements, and the anchor bolts must be secure. The pump leveling and alignment should comply with technical specifications.
Pre-start Inspection: Inspect the pump according to routine inspection requirements, ensuring the pipeline is unobstructed. For pumps using mechanical seals, a water supply to the shaft seal must be guaranteed; operation without water is strictly prohibited, otherwise the mechanical seal will burn out rapidly.
Regular Maintenance: Regularly check the lubrication condition of the bearings and add or replace grease as needed. Monitor for shaft seal leakage and adjust or replace the packing as necessary. Pay attention to the wear of flow-through components (impeller, wear plate, pump casing, etc.) and replace worn parts promptly.
Common Faults:
Insufficient Flow: May be caused by impeller or pipeline blockage, severe impeller wear, excessively low speed, or air intake.
Vibration or Noise: May be caused by cavitation, bearing damage, pump shaft bending, or insecure base installation.
Bearing overheating: This may be caused by poor lubrication, unclean lubricating oil, improper bearing clearance adjustment, or insufficient cooling.
Case 1: Successful Operation of Naipu Mining Machinery’s Large Slurry Pump in a Mongolian Copper Mine
The large 750NZJ slurry pump, developed and designed by Jiangxi Naipu Mining Machinery Co., Ltd., has been successfully put into operation at the Erdenet Copper Mine in Mongolia and passed the user’s 100-hour acceptance test. With a flow rate of 15,000 cubic meters per hour, it was hailed as the world’s largest slurry pump at the time, used for tailings transportation at the copper mine. Its superior performance has been highly praised by the customer.
Case 2: Jizhong Equipment Stone Pump Company Wins Bid for Nigerian Lithium Mine Project
In 2023, Jizhong Equipment Group Stone Pump Company, leveraging its high-quality ZJ series slurry pump products, efficient project execution, and strong technical advantages, successfully won a bid for a Nigerian lithium mine project from a Shandong hydrocyclone company. The company detailed the structural features of its slurry pumps and the advantages of its independently developed wear-resistant materials during the bidding process, ultimately winning the order with a total contract value exceeding 2 million yuan. This demonstrates the competitiveness of Chinese slurry pump technology in the “Belt and Road” market.
From a technological development perspective, slurry pumps are evolving towards larger scale, higher efficiency, longer service life, and intelligent operation. The research and application of new materials (such as new high-chromium alloys and ceramic composite materials) have improved wear and corrosion resistance; advanced hydraulic design and manufacturing technologies (such as 3D printed molds) have enhanced pump efficiency and reliability; and the introduction of digital monitoring technology facilitates real-time understanding of pump performance and health, enabling predictive maintenance.
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