Slurry Systems Handbook, Second Edition

by Baha Abulnaga

Overview

A complete guide to slurries and slurry systems―fully updated for the latest advances

This thoroughly revised guide contains start-to-finish coverage of slurry systems—from fundamentals and fluid mechanics to pump design and materials selection. Written by a recognized expert in the field, Slurry Systems Handbook, Second Edition clearly explains the components, dynamics, and design of slurry systems for many applications, including mineral processing, nuclear waste processing, extra heavy oil upgrade, mineral concentrate transport, tailings systems and metal melting. You will get real-world examples, solved problems, and current codes as well as guidelines for conducting feasibility studies and hands-on operating procedures.

Coverage includes:

• General concepts of slurry flows
• Multi-species and stratified heterogeneous flows
• Non-Newtonian slurry flows
• Open channel and cascade slurry flows
• Slurry Hammer and Transients in closed and open channels
• Centrifugal and positive displacement slurry pumps
• Long distance slurry pipelines by commodity such as coal, copper, phosphate or gold
• Oil sand extraction
• Slurry reactors, hydrocracking and heat transfer
• Hydrocarbon and hydrate-based slurry pipelines
• Semi-solid metals casting
• Tailings systems, paste backfilling
• Slurry flows for nuclear waste processing
• De-silting hydroelectric reservoirs

Product Details

ISBN-13:	9781260452808
Publisher:	McGraw Hill LLC
Publication date:	03/05/2021
Sold by:	Barnes & Noble
Format:	eBook
File size:	68 MB
Note:	This product may take a few minutes to download.

About the Author

Baha Abulnaga, P.E., obtained his Bachelor of Aeronautical Engineering degree in 1980 from the University of London and his Masters in Materials Engineering from the American University in Cairo, Egypt. Since 1990, he has been active in design of rotating equipment, pumps, and slurry pipelines and processing plants, slurry hydrocracking research. Through his career he worked for major engineering firms. He has received awards from the Department of Interior for innovation in reservoir sediment removals and from the National Science Foundation for innovation in metallurgy of iron. He is director at Mazdak International Inc (dba Splitvane Engineers). He holds many patents in different fields of slurry, liquid piston engine design, pump design and metallurgy.

Table of Contents

	Preface	xvii
Part 1	Hydraulics of Slurry Flows
1	General Concepts of Slurry Flows	3
1-0	Introduction	4
1-1	Properties of Soils for Slurry Mixtures	5
1-2	Slurry Flows	15
1-3	Sinking Velocity of Particles, and Critical Velocity of Flow	17
1-4	Density of a Slurry Mixture	19
1-5	Dynamic Viscosity of a Newtonian Slurry Mixture	21
1-6	Specific Heat	22
1-7	Thermal Conductivity and Heat Transfer	22
1-8	Slurry Circuits in Extractive Metallurgy	24
1-9	Closed and Open Channel Flows, Pipelines Versus Launders	31
1-10	Historical Development of Slurry Pipelines	32
1-11	Sedimentation of Dams--A role for the Slurry Engineer	33
1-12	Conclusion	37
1-13	Nomenclature	37
1-14	References	38
2	Fundamentals of Water Flows in Pipes	1
2-0	Introduction	1
2-1	Shear Stress of Liquid Flows	1
2-2	Reynolds Number and Flow Regimes	3
2-3	Friction Factors	4
2-4	The Hydraulic Friction Gradient of Water in Rubber-Lined Steel Pipes	19
2-5	Dynamics of the Boundary Layer	33
2-6	Pressure Losses Due to Conduits and Fittings	44
2-7	Orifice Plates, Nozzles and Valves Head Losses	49
2-8	Pressure Losses Through Fittings at Low Reynolds Number	54
2-9	The Bernoulli Equation	58
2-10	Energy and Hydraulic Grade Lines with Friction	58
2-11	Fundamental Heat Transfer in Pipes	58
2-12	Conclusion	62
2-13	Nomenclature	62
2-14	References	64
3	Mechanics of Suspension of Solids in Liquids	1
3-0	Introduction	1
3-1	Drag Coefficient and Terminal Velocity of Suspended Spheres in a Fluid	1
3-2	Generalized Drag Coefficient--The Concept of Shape Factor	12
3-3	Non-Newtonian Slurries	17
3-4	Time-Independent Non-Newtonian Mixtures	18
3-5	Time-Dependent Non-Newtonian Mixtures	30
3-6	Drag Coefficient of Solids Suspended in Non-Newtonian Flows	32
3-7	Measurement of Rheology	32
3-8	Conclusion	38
3-9	Nomenclature	38
3-10	References	41
4	Heterogeneous Flows of Settling Slurries	1
4-0	Introduction	1
4-1	Regimes of Flow of a Heterogeneous Mixture in Horizontal Pipe	2
4-2	Hold Up	5
4-3	Transitional Velocities	5
4-4	Hydraulic Friction Gradient of Horizontal Heterogeneous Flows	19
4-5	Distribution of Particle Concentration in Compound Systems	30
4-6	Friction Losses for Compound Mixtures in Horizontal Heterogeneous Flows	33
4-7	Saltation and Blockage	43
4-8	Pseudohomogeneous or Symmetric Flows	47
4-9	Stratified Flows	48
4-10	Two-Layer Models	50
4-11	Vertical Flow of Coarse Particles	57
4-12	Inclined Heterogeneous Flows	58
4-13	Conclusion	62
4-14	Nomenclature	63
4-15	References	66
5	Homogeneous Flows of Nonsettling Slurries	1
5-0	Introduction	1
5-1	Friction Losses for Bingham Plastics	2
5-2	Friction Losses for Pseudoplastics	11
5-3	Friction Losses for Yield Pseudoplastics	17
5-4	Generalized Methods	19
5-5	Time-Dependent Non-Newtonian Slurries	28
5-6	Emulsions	29
5-7	Roughness Effects on Friction Coefficients	29
5-8	Wall Slippage	33
5-9	Pressure Loss through Pipe Fittings	34
5-10	Scaling up From Small to Large Pipes	35
5-11	Practical Cases of Non-Newtonian Slurries	35
5-12	Drag Reduction	39
5-13	Pulp and Paper	40
5-14	Conclusion	41
5-15	Nomenclature	42
5-16	References	44
6	Slurry Flow In Open Channels and Drop Boxes	1
6-0	Introduction	1
6-1	Friction for Single-Phase Flows in Open Channels	2
6-2	Transportation of Sediments in an Open Channel	9
6-3	Critical Velocity and Critical Shear Stress	23
6-4	Deposition Velocity	27
6-5	Flow Resistance and Friction Factor for Heterogeneous Slurry Flows	29
6-6	Friction Losses and Slope for Homogeneous Slurry Flows	39
6-7	Flocculation Launders	44
6-8	Froude Number and Stability of Slurry Flows	45
6-9	Methodology of Design	45
6-10	Slurry Flow in Cascades	54
6-11	Hydraulics of the Drop Box and the Plunge Pool	56
6-12	Plunge Pools and Drops Followed by Weirs	67
6-13	Conclusion	71
6-14	Nomenclature	71
6-15	References	74
Part 2	Equipment And Pipelines
7	Components of Slurry Plants	3
7-0	Introduction	3
7-1	Rock Crushing	3
7-2	Secondary and Tertiary Crushers	9
7-3	Grinding Circuits	11
7-4	Horizontal Tumbling Mills	23
7-5	Agitated Grinding	27
7-6	Screening Devices	31
7-7	Slurry Classifiers	32
7-8	Flotation Circuits	38
7-9	Mixers and Agitators	40
7-10	Sedimentation	59
7-11	Conclusion	64
7-12	Nomenclature	64
7-13	References	66
8	The Design of Centrifugal Slurry Pumps	1
8-0	Introduction	1
8-1	The Centrifugal Slurry Pump	2
8-2	Elementary Hydraulics of the Slurry Pump	6
8-3	The Pump Casing	25
8-4	The Impeller, the Expeller and the Dynamic Seal	34
8-5	Design of the Drive End	42
8-6	Adjustment of the Wet End	53
8-7	Vertical Slurry Pumps	53
8-8	Gravel and Dredge Pumps	59
8-9	Affinity Laws	60
8-10	Performance Corrections for Slurry Pumps	61
8-11	Conclusion	72
8-12	Nomenclature	72
8-13	References	75
9	Positive Displacement Pumps	1
9-0	Introduction	1
9-1	Solid Piston Pumps	1
9-2	Plunger Pumps	6
9-3	Diaphragm Piston Pumps	8
9-4	Accessories for Piston and Plunger Pumps	13
9-5	Peristaltic Pumps	13
9-6	Rotary Lobe Slurry Pumps	14
9-7	The Lockhopper Pump	15
9-8	Conclusion	16
9-9	References	17
10	Materials Science for Slurry Systems	1
10-0	Introduction	1
10-1	The Stress- Strain Relationship of Metals	1
10-2	Iron and Its Alloys for the Slurry Industry	3
10-3	White Iron	4
10-4	Natural Rubbers	11
10-5	Synthetic Rubbers	13
10-6	Wear Due to Slurries	18
10-7	Conclusion	21
10-8	References	22
11	Slurry Pipelines	1
11-0	Introduction	1
11-1	Bauxite Pumping	1
11-2	Gold Tailings	2
11-3	Coal Slurries	2
11-4	Limestone Pipelines	10
11-5	Iron Ore Slurry Pipelines	12
11-6	Phosphate and Phosphoric Acid Slurries	16
11-7	Copper Slurry and Concentrate Pipelines	21
11-8	Clay and Drilling Muds	22
11-9	Oil Sands	23
11-10	Backfill Pipelines	24
11-11	Uranium Tailings	27
11-12	Codes and Standards for Slurry Pipelines	27
11-13	Conclusion	30
11-14	References	31
12	Feasibility Study for A Slurry Pipeline and Tailings Disposal System	1
12-0	Introduction	1
12-1	Project Definition	2
12-2	Rheology, Thickeners Performance, Pipeline Sizing	5
12-3	Reclaim Water Pipeline	8
12-4	Emergency Pond	9
12-5	Tailings Dams	11
12-6	Submerged Disposal	15
12-7	Tailings Dam Design	17
12-8	Seepage Analysis of Tailings Dams	18
12-9	Stability Analysis for Tailings Dams	18
12-10	Erosion and Corrosion	19
12-11	Hydraulics	19
12-12	Pump Station Design	19
12-13	Electric Power System	20
12-14	Telecommunications	21
12-15	Tailings Dam Monitoring	21
12-16	Choke Stations and Impactors	22
12-17	Establishing an Approach for Start-up and Shutdown	22
12-18	Closure and Reclamation Plan	23
12-19	Access and Service Roads	24
12-20	Cost Estimates	24
12-21	Project Implementation Plan	27
12-22	Conclusion	27
12-23	References	28
Appendix A	Specific Gravity and Hardness of Minerals	1
Appendix B	Units of Measurement	1
	Index	1