800-624-7069

Tag: slurry pump

What Makes or Breaks a Slurry Pump

Posted on by Vulcan Pumps

With how crucial slurry pumps are for certain industries, the stakes for a good one are great. Applications that aren’t well-served by a quality slurry pump experience disruption, breakdown, and increased maintenance and/or replacement costs. This being said, there are a handful of key aspects that inform a slurry pump’s performance—in layman’s terms what “makes or breaks it.” Here’s a helpful primer on these aspects, as well as what makes them so important to the success of a slurry pump. 

#1: Design

Intuitively, design is among the most critical aspects of a slurry pump. It has to be in order for the slurry not to wear down or downright destroy the impeller and other key components. 

Slurry is often highly abrasive and/or corrosive and, for this reason, slurry pump design has to be top-notch. Slurry also has a high possibility for the presence of unexpected solids, which has a chance to clog up or bottleneck pumps—potentially affecting the volume and causing loss of suction. The right slurry pump design is critical to keeping volute integrity (over time) in the most abrasive settings. 

#2: Construction

Design’s close counterpart, construction, is also top of list for slurry pumps. Abrasive-resistant metallurgies must be utilized if applications are heavily harsh and/or caustic. 

Typically, a high chrome is the preferred construction material for highly abrasive settings. In these cases, Vulcan Pumps builds our submersible slurry pumps with metallurgy 28% chrome iron, ASTMA532. 

Additionally, we manufacture duplex stainless steel construction pumps for slurry that exhibits both an abrasive nature and low pH. Good examples of where this construction is necessary are places with a high presence of chemical or chloride concerns. 

#3: Seal

Pump seal loss of function can have a devastating effect; oftentimes, motor manufacturers offer a generic seal, which can prove ill-suited for specific applications. Per application needs, the ideal seal is absolutely necessary. Often seals need to incorporate hard set, tungsten or silicon carbide faces in order to avoid cracking. 

At Vulcan Pumps, we partner with U.S.-based John Crane Co. for the most robust, application-made seals and seal designs. This ensures top quality from the get-go. 

#4: Size & Power

Slurry pump power and size is also a critical element that can inform the success of the pump for the application. With the abrasiveness of slurries, a pump must be of adequate size to operate slow enough to extend pump life. Ideally, a pump will be set to run between 900 and 1200 RPM; more than this can wear out the pump at its wear points through abrasive blasting. 

#5: Method of Use

The deployment or use method for the pump is the final key aspect to ensuring slurry pump success. Submersible pumps, the kind Vulcan Pumps specializes in, are pumps completely submerged in a liquid. This avoids the requirement for priming, as the pump is immersed in the liquid being pumped. Other pumping setups may involve priming (or be self-primed) or have additional needs prior to pumping. Knowing which pumping method the intended application calls for helps the pump be most effective and last longer. 

Find Your Ideal Submersible Slurry Pump

Vulcan Pumps offers top-of-the-line, U.S.-made submersible slurry pumps—with parts inventoried locally in the Southeast. Contact us to see how our pumps can best meet your application needs. 

How Do I Know My Slurry Pump Is Up to the Task?

Posted on by Vulcan Pumps

A slurry pump is a non-negotiable when having to pump slurry, which often comprises a mix of difficult-to-move solids and fluids. This is because of the abrasive nature of slurry—and the operational toll it often takes. For this reason, standard water pumps can’t stand up to the harsh wear and tear. Plus, in the grand scheme, slurry pumping costs carve out a significant portion of industrial operational pumping costs (even at a smaller overall pump distribution): some estimates being up to 80%. With everything that depends on quality slurry pumps, how do you know that a pump can handle the pressure?

How the Slurry Pump Is Made Matters

It stands to reason that pump make matters—and that holds true, if not more so, for slurry pumps. 

The materials slurry pumps move, coupled by the space they occupy (sump, discharge point, pipeline, etc.), increases the chance for higher wear rates. Typically, this results in larger, thicker, and heavier pumps (when compared to water pumps) in order to handle the materials present. Some may also incorporate heavy-duty internal liners and/or weightier components for the same (or similar) reason. 

But slurry pumping is anything but a one-size-fits-all model. The diverse application and pump-performance requirements among industries and sites necessitate an equally diverse arsenal of pump size, types, and mounts. This is all the more reason why custom submersible and slurry pumps are a must—not a maybe. 

Similarly, overall quality is of the utmost importance. If quality is sacrificed for cost-efficiency or another consideration, the over-time effects can be more than felt: They can be paralyzing. Maintenance may need to be called in year-round (increasing costs) or there may even be an all-out pump breakdown (decreasing production). 

Other Considerations

Slurry pumps don’t exist in a vacuum. What this means is this: Things external to (and involved with) the slurry pump need to also be regularly assessed. For instance, pump systems rely heavily on adequate motor power availability. With so many mills functioning on variable speed drives, taking an involved and real-time look at pump pressure and flow in regards to time has to happen. This information helps work out considerations like adequate and optimal pump size for the mill, plant, or site. 

Additionally, pipe sizing, floor sump space, gland seal pressure, and gearbox cooling are other considerations to have in order to inform your decision-making—and ensure pump systems are operating optimally. The correct pipe sizing reduces friction and wear. Well-sized floor sumps are able to deal with site-specific volume. A proper gland seal size ensures a constant flow of gland water throughout operational conditions. The gearbox needs to be properly calibrated to avoid overheating, especially at increased altitudes and temperatures. 

Have Your Pump Perform

Again, as for the pump itself, durability is a stand-out feature. For pumping slurry, you want a well-rounded pump—one that continually performs, offers resistance to wear, provides needed power, is easy-to-maintain, and is applicable to the pumped material. Specific pumping conditions and requirements will often inform what pump will work where. For instance, pumps may differ depending on pump rate (steadfast vs. intermittent), as well as the amount of heavy mechanical wear present in conditions. 
Vulcan Pumps offers a completely U.S.-made pump and pump components that differ in metallurgies based on conditions at hand (including 28% chrome iron, ASTMA532 for abrasive). Reach out to learn more about what we can do for pump systems—from high-quality product to ongoing support.

A Closer Look at Our HDS Slurry Pump Accessories

Posted on by Vulcan Pumps

Our custom HDS submersible slurry pumps have the option for additional accessories—one quoted standard. The slurry pump accessories we offer include spray (sparge) ring, Vulcan Guard, and lifting bail. All these accessories offer ease-of-use and cost-over-time benefits. Read on for more about their application readiness and purposes. 

An Overview of Our Slurry Pump Accessories 

As mentioned, we offer three slurry pump accessories: the sparge or spray ring, the proprietary, standard-quoted Vulcan Guard, and lifting bail. Following is a helpful breakdown of each:

#1: Sparge or Spray Ring

The spray or sparge ring can be mounted to any submersible pump, and provides a cleaner sump overall. The spray ring works well for virtually all industries that handle high concentrations of solids, including power generation, mining, and steel. 

When regularly pumping abrasive solids, the sparge ring fluidizes or agitates into suspension the solids (e.g. ore, coal fines) that settle and coagulate in the pit. The spray ring improves suspension to pump solids, which leads to a cleaner sump. Over time, built-up solids that aren’t appropriately agitated require removal using a vacuum truck. The spray ring lessens build-up of solids  and increases pit cleanliness, resulting in less frequent visits from the vacuum truck.

#2: Vulcan Guard

Vulcan Guard is a proprietary slurry pump accessory quoted with every custom pump purchase. It boasts a dual feature innovation not found elsewhere: a one-box, two-feature safety sensor. Vulcan Guard places both a moisture sensor and thermal overload connections in one box for a single point of connection. 

The moisture sensor alerts you of a bottom seal failure, which helps protect the pump from further water intrusion. A red warning light will signal when the seal has failed, alerting operators to pull the pump, stop the motor, and replace the seal. Additionally, Vulcan Guard houses a built-in motor thermal overload function that stops the motor if overheated—as well as a corresponding control panel light that halts the motor until able to fully stop or reset. 

Vulcan Guard is unique in industry as it innovates past the prevailing two-box system. Our system offers single-point connection and safety features for improved risk reduction and increased operator peace of mind. 

#3: Lifting Bail

Our 304 stainless steel lifting bail does as its name implies: helps to hoist the pump when needed. The lifting bail is made for our HDS submersible slurry pump, connects to the top of the motor, and brings it to a single lifting point. The slurry pump’s motor houses two lifting lugs, which the lifting bail easily hooks up to. The lifting bail makes pump removal from sump much more streamlined. Included in the bail is 25 feet of lifting cable. 

Benefits to Our Accessories

Generally, our accessories:

  • Reduce maintenance;
  • Reduce pump repair cost;
  • And increase pump life. 

That’s not all though. More specifically, the spray ring affords over-time cost reduction to industries through less routine plant (and sump) upkeep, decreased maintenance and labor expenses, and diminished (if not eliminated) vacuum truck visits for site cleanup. Plus, sparge rings can be outfitted to anyone’s pump—and our 24-spray nozzle selection comes standard in 304 stainless steel. When margins are thin, this accessory could be the difference. 

Additionally, the client-requested Vulcan Guard, of course, provides an innovative and intuitive interface for improved safety and risk reduction. The two-feature, one-box system enables more control, less risk, and on-the-spot detection. 

Finally, our 304 stainless steel lifting bail is outfitted for easy attachment and single-point lifting, which is a favorite feature for those in power generation and similar industries. Contact us to learn more about our HDS submersible slurry pump as well as the accessories offered for enhanced ease of use and improved functioning. 

Slurry Pumps vs. Sludge: What Are the Differences?

Posted on by Vulcan Pumps

Different pumps are often required for different, or more specific, applications. For instance, slurry pumps are made for pumping slurry—while other specialized pumps are made to pump thermal oil or hot water. Two common pumps used in many industries are sludge and slurry pumps. But these aren’t one and the same. Here’s a helpful primer on the differences between the two. 

First, Defining Sludge and Slurry

It stands to reason that if sludge and slurry pumps aren’t the same thing then sludge and slurry aren’t either. And that’s correct. There is a difference between the two materials. 

Sludge is a general term for any solids apart from suspension in a liquid. This could be any near-solid or semi-solid material that’s left over from a variety of processes: water/wastewater treatment and industrial being two primary ones. 

Slurry, on the other hand, is defined as any flowing or flowable suspension of particles in liquid. Cement slurry from construction applications is a highly recognizable example. Other industries where slurry is a routine byproduct includes mining and agriculture or renewable natural gas (RNG). 

Some forms of mining produce liquid waste which possesses high levels of toxicity; this waste is then pooled into sizable dams or slurry tailing ponds. Slurry is also common in agriculture—often a blend of animal waste, other organic compounds, and water—which is routinely saved as fertilizer in a slurry pit. 

Sludge and slurry are highly different from one another—there’s a big difference in thickness, which is due to the discrepancy in both particle shape and size. 

Sludge vs. Slurry Pumps

For this reason, slurry can be pumped in large part by slurry pumps or centrifugal pumps. This is not the case for sludge. Sludge requires a different kind of pump to adequately meet the needs of the material makeup. 

Slurry is essentially small solids inside of a liquid. Sludge is nearby solids in liquid, which calls for sludge pumps, diapham pumps, lobes, or progressive cavity pumps to properly pump the material through. 

Additionally, slurry pumps have certain key characteristics:

·        Large shaft and bearing  to reduce shaft reflection;

·        Low velocity reduce wear;

·        Heavier cast parts made from abrasion resistant materials;

·        Mech seal designed for slurries. 

Our Slurry Pump

Vulcan Pumps offers a first-rate submersible slurry pump that is made custom to your application. It is U.S.-made with premium metallurgy. Plus, we perform enhanced quality control prior to assembly and as we manufacture. You can learn about its key features and our quality standpoint across the board. Connect with us to see how we can best meet your specific application needs!

Vulcan HDS Slurry Pump: Comprehensive Product Spotlight

Posted on by Vulcan Pumps

The Vulcan HDS slurry pump is our major product staple, and for good reason. It offers high-quality, custom design, U.S.-made components and make, and application-specific metallurgies to withstand typical and atypical abrasion. See how our HDS slurry pump meets your needs, and how Vulcan Pumps is poised to deliver quality on every front. 

A U.S.-Made HDS Slurry Pump

Vulcan Pumps offers a purely U.S.-made product. All patterns, casting, machine parts, and more for our HDS slurry pump are made in our cutting-edge facility based in the southeastern U.S. Plus, our pump seals are made in tandem with John Crane Co., and we have worked together to develop multiple seal designs that are application-ready. This is to our clients’ benefit as it ensures the best seal per application for complete peace of mind: You don’t have to rely on a motor manufacturer to give a generic seal selection. 

In addition, our pump parts are locally inventoried in Birmingham. This offers quick turnaround (typically a one-week lead-time) for components that are guaranteed quality and reasonably priced. 

We also offer an on-site (remove) rebuild program on an as-needed basis. We submerge test recording, moisture sensor, AMP draw, and thermal overloads (along with a flow and head test), and provide documents prior to delivery. We provide this as an additional service to coincide with required internal processes as applicable. We can also work closely with your quality control team, determining pump rate, head performance, and other measurements before installation. 

Metallurgies Used

We provide a range of metallurgies for project-specific needs: 316 Stainless Steel, Alloy 20, Hastelloy, 2205, 2507, CD4MCUN, and more. 

For atypical, abrasive applications, we offer 28% chrome iron, ASTMA532. For when chemicals, chlorides, or other highly corrosive conditions are present, we have several choices available: ASTM A890 duplex and super duplex stainless steels (CD4, 2205, and 2507) and ASTM A494 high nickel alloys C276 and A20. There’s also an opportunity for us to make motor shafts, pump components, and other hardware in these high-resistance materials. 

Quality Across the Board

Vulcan Pumps quality program ensures you receive a HDS slurry pump that is no exception to peak performance expected. We also perform comprehensive pump quality control for every part before assembly and during manufacturing. We extensively quality-test pump materials and appearance long before it reaches you. 
If you need a high-performance submersible pump that withstands the test of applications, the Vulcan HDS slurry pump is the pump for your processes. Contact us with questions or to learn more.