Maintenance Technology August 2014 - (Page 36)
PUMP SOLUTIONS
cally friendly process called Warm Solution Mining (WSM), wherein a leaching
solution, in this case brine, is pumped
into the mineral deposit field where it
dissolves ore content, which is pumped
to the surface and processed. The extraction process is made possible in part
through a custom-designed, industrialgrade pumping station from Grundfos
that accommodates the aggressive and
continuously changing brine solution
chemistry, not to mention the extreme
temperatures that can reach 130 F.
"The company's mining processes are
subject to some of the harshest conditions, including extreme desert temperatures and caustic solutions. Therefore,
the pumping systems that support these
systems need to be highly reliable and
efficient," says Milt Bachman, President
of Delta Pump Systems, a Californiabased industrial distributor specializing
in pump design and specifications.
"Variable-speed pumping combinations
had failed the operating conditions in
the past, and Searles management was
looking for a more dependable, engineered solution."
The extraction process begins at
36 |
MAINTENANCE TECHNOLOGY
Searles Dry Lake, a 125-square-mile
mineral field with nearly 200 vertical
wells that are fueled by thousands of
submersible and vertical turbine pumps
that range from 3 to 50 HP and generate
nearly 14,000 gpm. The pumps carry
Compared with the
previous constant-speed
pumping arrangement,
current savings are
calculated at $3500
per month, with a
two-year payback.
thousands of gallons of brine solution from one reservoir or lake bed to
another, and the eventual transfer of the
mineral-rich brine into holding tanks.
The application's challenges-both in
terms of extreme operating conditions,
as well as the required variable pumping
volumes-led Searles' Operations Engi-
neer, David Hakim, to search for a more
efficient and cost-efficient solution.
An integrated approach
In spring 2012, Hakim asked Delta Pump
Systems' Bachman and the Grundfos
Engineered Systems (GES) group to
help him brainstorm a new, integrated
pumping process. The GES team works
with clients to develop one-of-a-kind,
custom-engineered pumping systems
that integrate engineering, intelligent
controls and the most efficient pump
types and technologies available for a
specific application.
In the case of SVM, Hakim deployed
the Grundfos CU 352 controller to
manage the energy-efficient PACO
horizontal split case pumps, intelligent
pump control logic, and Danfoss variable-frequency drives (VFD). This new
pumping station design allowed for the
ability to monitor real-time flows, pressures and temperatures in one location.
"The integrated GES systems
approach that SVM envisioned was critical in developing a pumping system that
helped increase production reliability,
boost mineral yield and reduce energy
AUGUST 2014
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