Froth Pump Power Estimation According Weir [1]

Qp = 454 m/h Mineral froth corrections

H = 18.3 m From Weir diagram
S
P
= 1.15 -
PAV = 20%
H
stat
= 9.14 m
FVF = 1 / ( 1 - PAV)
PAV = 20%
FVF = 1.25 -
Volume flow rate with froth
Qf = FVF * Qd
FVF = 1.25 -
Qd = 454 m/h
Qf = 568 m/h
for the Froth Volume Factor
Specifiv gravity with froth FVF = 1.25
S
F
= S
P
/FVF Find the Mineral froth height and
S
P
= 1.15 efficiency corrections
FVF = 1.25 HRf = 0.95
S
F
= 0.92 - ERf = 0.95
Constant of system curve "C" Required water head
H = H
stat
+ C*Q^2 Hw = Hf/HRf
C = (H - Hstat ) / Q^2 Hf = 23.43
H = 18.3 m HRf = 0.95
H
stat
= 9.14 m Hw = 24.7
Q = 454 m/h
C = 4.43E-05 Efficiency on water
From the selected pump curve, for
Froht heigth Qf = 568
Height for q = Qf Hw = 24.7
Hf = H
stat
+ C*Qf^2 find the efficiency on water
H
stat
= 9.14 m Let the efficiency on water be
C = 4.43E-05 Ew = 0.68
Qf = 568 m/h
Hf = 23.43 m.p.c.
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Pump efficiency on froth
The pump efficiency on froth is
Ef = ERf * Ew
ERf = 0.95
Ew = 0.68
Ef = 0.646
Pump power
P = Qf * Sf* Hf / (367 * Ef)
Qf = 567.81 m
3
/h
Sf = 0.920 -
Hf = 23.4 m.p.c.
Ef = 0.646 -
P = 51.6 kW
P =
69.15 hp
- Security factor on power
Find the Mineral froth height and SFP = 1.2
considering fluctuations in duty due to
variations in air content.
Thus, the power requirement will be
HP
req
= SFP * HP
SFP = 1.2
HP = 69.1
HP
req
= 83.0 hp
m.w.c.
The next comercial size [3]
HP = 100 hp
From the selected pump curve, for
m/h
m.w.c.
Let the efficiency on water be
Staic head Hstat = 9.14 m
= 30 ft
Pulp head Hp = 18.3 m
= 60 ft
(without froth
Pulp head Hf = 23.43 m
= 75 ft
(with froth)
Required water head
Hw = 23.7 m
= 79 ft
Staic head Hstat = 9.14 m
= 30 ft
Pulp head Hp = 18.3 m

Pulp head Hf = 23.43 m


Hw = 23.7 m

Efficiency on water
Ew = 0.68
and pump speed
Froth pump selection (SI) [1]
Calculation of aereated flow "Qf"
Slurry design flow Qd = 454 m/h
Slurry design head (Note 1) H = 18.3 m
Specific gravity of slurry S
P
= 1.15 -
Percentage of air volume PAV = 20%
Static height Hstat = 9.14 m
Flow volume factor
FVF = 1 / ( 1 - PAV)
PAV = 20%
FVF = 1.25 -
Uncompressed (aereated) flow
Froth flow Qf = FVF * Qd
FVF = 1.25 -
Qd = 454 m/h
Qf = 568 m/h
Froth pump selection
Pump selection
Select froth pump such that:
Froth duty point is to the left of BEP line
and NPSHr < 3.7 m
Go to the next size pump if in doubt.
Add the froth system curve to the
selected pump curve.
Keep discharge pipe diameters large,
pipe velocities less than 2 to 2.5 m/s
and static head low to mantain total
head below 30 m.
The design slurry duty point corresponds to
Qd = 454 m/h
Hd = 18.3 m
The BEP line for the selected pump is the line for q = 74.5 %
Note 1. Calculate de design head of the slurry by the
method defined in the Proyect Design Criteria.
0.22712471
Plot system curve with static head
Hstat = 9.14 m 30 ft
and design flow and head
Qd = 454 m/h 2000 gpm
Hd = 18.3 m 60 ft

System curve calculation
H = Hstat + C * Q
C = (Hd-Hstat)/Qd
Hd = 18 m
Hstat = 9.14 m
Qd = 454 m/h
C = 0.000044
Froth height calculated from system
curve, for froth flow rate Qf
Hf = Hstat + C*Qf^2
Hstat = 9.14 m
C = 0.000044
Qf = 568 m/h
Hf = 23.4 m.p.c. 77 ft
(This is the calculated value)
System duty point at froth flow
Qf = 568 m/h 2500 gpm
The estimated value from graphic is
Hf = 22.86 m 75 ft
This estimated value will be adopted in
the further calculation to mantain the
Warman values.
Hf: froth height calculated from system
curve, for froth flow rate Qf (page 2)
Hf = 23.4 m.p.c.
(this is not the estimated Warman value)
Mineral froth head and eficiency corrections
Froth head correccin "HRf"
HRf = Hf / Hw
with
Hd : Head on froth
Hw : Head on water
Froth efficiency correccin "ERf"
ERf = Ef / Ew
with
Ed : Efficiency on froth
Ew : Efficiency on water
Note
Only QU1 flow inducer impellers
are used now
From figures, determine the correction factors
For
FVF = 1.25
one obtains
HRF = 0.95
ERF = 0.95
Required water head
From
HRf = Hf / Hw
The weater head is
Hw = Hf / HRf
with
Hf = 22.86 m
HRf = 0.95
Hw = 24 m
The operation point in the pump diagram
is defined by
Qf = 568 m/h
Hw = 24 m
or
Qf = 2500 gpm
Hw = 79 ft
The required speed and efficiency on water
at this condition is read from the diagram
N = 640 rpm
Ew = 68.0%
Froth height
Hf = 75 ft.p.c.
Hf = 22.9 m.p.c.
Height on water
Hw = 79 ft.w.c.
Hw = 24.1 m.w.c.
Selected pump
Qf = 568 m/h
Hw = 24.1 m.w.c.
N = 640 rpm
Ew = 68 %
Slurry efficiency Power
From
ERf = Ef / Ew
The slurry efficiency is
Ef = ERf * Ew
with
ERf = 0.95 Q: Flow rate without froth
Ew = 68.0% S
P
: Specifuc gravity of pulp without froth
Ef = 64.6% Hf = TDH : Total dynamid head of pulp with froth
q
f
= Ef : Pump efficiency on pulp with froth
Ef = ERf * Ew
Erf : Correction factor from figure
Ew : Water equivalent efficiency
from pump diagram, for
Q = 454 m/h
Hf = 22.9 msc
Qp: slurry flow rate witout froth
Sp: specific gracity witout froth
Hf: froth height calculated from system P = Qp * Sp* Hf / (367 * Ef)
curve, for froth flow rate Qf (page 2) Qp = 454.25 m
3
/h (without froth)
Hf = 22.9 m.p.c. Sp = 1.150 - (without froth)
Ef: efficiency on slurry with froth Hf = 22.9 m.p.c. (syst. c.@Qf)
Ef = ERf * Ew Ef = 0.646 - (with froth)
ERf: froth correction factor P = 50.3 kW
Ew: efficiency on water, from P = 67.46 hp
pump diagram, @ Qf and Hw
(page 4)
Hw = Hf / HRf
HRf: froth correction factor
Pump power [1]
Pump power P = Qp * Sp* Hf / (367 * Ef)
Pulp flow rate without froth Qp = 454.25 m
3
/h
Pulp specific gravity without froth Sp = 1.150 -
Heigth from system curve, for the Hf = 22.9 m.p.c.
pulp flow rate with froth (Qf)
Efficiency oh froth Ef = Ew*ERf Ef = 0.646 -
P = 50.3 kW
P =
67.46 hp
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Froth pump selection, according Weir 5.- Froth height calculated from system
curve, for froth flow rate Qf
In this example, Hf = Hstat + C*Qf^2
Qp = 454 m/h Hstat = 9.14 m
Hp = 18.3 m.p.c. C = 0.000044
Hstat = 9.14 m Qf = 568 m/h
FVF = 1.25 - Hf = 23.4 m.p.c.
Sp = 1.150 - (Se note 1)
1.- Calculate de pulp system pressure 6.- Froth correction factors from
loss "Hp" for maximum flow "Qp". Weir figure
For the froht pump selection, this flow
and the heigt are input data.
Qp = 454 m/h
Hp = 18.3 m.p.c.
2.- Known points of system curve
2a.- Zero flow point
Q = 0 m/h
Hstat = 9.14 m
For a froth volume factor
2b.- Duty point without froth FVF = 1.25
Design pulp flow rate (Qp = Qd) HRf = 0.95
Qp = 454 m/h ERf = 0.95
Design pulp height (Hp = Hd)
Hp = 18.3 m.p.c. 7.- Required water head Hw
3.- Constant of system curve Hw = Hf / HRF
Hp = Hstat + C * Q Head on froth
C = (Hp-Hstat)/Qd Hf = 23.4 m.p.c.
Hp = 18 m Head correction for height
Hstat = 9.14 m HRf = 0.95
Qp = 454 m/h Water head
C = 0.000044 Hw = 24.7 m.w.c.
4.- Froth flow 8.- Efficiency on water
Qf = FVF * Qp From selected pump curve, find the
FVF = 1.25 - eficiency on water @
Qp = 454 m/h
Qf = 568 m/h Note 1. This is thecalculated value. The
Weir estimated value from system curve
is Hf = 22.86 m.p.c.
Rev. cjc. 28.06.2013
1
2
3
4
5
Security factor on power
SFP = 1.2
considering fluctuations in duty due to
variations in air content.
REf. 2
Thus, the power requirement will be
HP
req
= SFP * HP Warman horizontal froth pump selection procedure
SFP = 1.2
HP = 67.5 1.- Determine type of froth
HP
req
= 81.0 hp Brittle
Tenaciuos
The next comercial size [3] Medium
HP = 100 hp
2.- Qs = De-aereated slurry flow (L/s)
Use maximum reated design flow
Check for maximum duty slurry flow
8.- Slurry density Sf = Sm / FVF
3.- Qf = Aereated froth flow
9.- Calculate froth power Qf =
Pf (kW) = Qf * Hf * Sf * 0.98 / EF
4.- Calculated froth system head Hf (m)
Froth flow at aereated flow (Qf) for concentration of
Qf = FVF * Qs (L/s) solids in slurry, disregarding froth.
Slurry density Keep dischatge pipe dismeters large
Sf = Sp / FVF
5.- Hw =
Qf * Sf = FVF * Qs * Sp / FVF
Qf * Sf = Qs * Sp 6.- Select froth pump with duty point is
to the left of BEP. Q >= 25% QBEP
Pf (kW) = Qs * Hf * Sp* 0.98 / EF NPSHreq >= 3.5 m
7.- At the duty point, select the pump
Pump power [2] speed Nf /rpm) and the water efficiency
P = Qp * Sp* Hf / (367 * Ef) Ew (%).
P = Qf/FVF * Sf*FVF* Hf / (367 * Ef)
P = Qf * Sf* Hf / (367 * Ef) 8.- Slurry density Sf = Sp / FVF
Qf = 567.81 m
3
/h Sp =
Sf = 0.920 - FVF =
Hf = 22.9 m.p.c. Sf =
Ef = 0.646 -
P = 50.3 kW 9.- Calculate froth power
P =
67.46 hp Pf (kW) =
10.- Check power
11.- Select motor size with 20% margin
Qf = 568 m/h
Hw = 24.7 m.w.c.
For the selected pump
Ew = 0.68
9.- Efficiency on froth
Ef = ERf * Ew
ERf = 0.95
Ew = 0.68
Ef = 0.646
10.- Pump velocity
From selected pump curve, find the
pump velocity @
Qf = 568 m/h
Hw = 24.7 m.w.c.
For the selected pump
N = 640 rpm
11. Power [1]
P = Qp * Sp* Hf / (367 * Ef)
Qp = 454.25 m
3
/h
Sp = 1.150 -
Hf = 23.4 m.p.c. (Note 1)
Ef = 0.646 -
P = 51.6 kW
P = 69.15 hp
12.- Motor
Margin for the motor selection
marg = 0.2
Motor power with margin
Pmarg = P * (1 + marg)
P = 69.15 hp
marg = 0.2
Pmarg = 83.0 hp
13.- Selected motor
From sheet Ref. 3 Motors table
Pmotor = 100 hp
Warman horizontal froth pump selection procedure
1.- Determine type of froth
1.1 <0 FVF <= 1.25
1.5 <0 FVF <= 1.8
1.25 <0 FVF <= 1.5
2.- Qs = De-aereated slurry flow (L/s)
Use maximum reated design flow
Check for maximum duty slurry flow
3.- Qf = Aereated froth flow
FVF * Qs (L/s)
4.- Calculated froth system head Hf (m)
at aereated flow (Qf) for concentration of
solids in slurry, disregarding froth.
Keep dischatge pipe dismeters large
Hf/HRf
6.- Select froth pump with duty point is
to the left of BEP. Q >= 25% QBEP
NPSHreq >= 3.5 m
7.- At the duty point, select the pump
speed Nf /rpm) and the water efficiency
Ef = Ew * ERf
8.- Slurry density Sf = Sp / FVF
1.15
1.25
0.92
9.- Calculate froth power
Qf * Hf * Sf * 0.98 / EF
10.- Check power
11.- Select motor size with 20% margin

Required water head Hw
Hw =
[1]
P =
Qf =
Hf =
Sf =
Ef =
P =
P =
The used Hf-value is from the Weir
example, not the calculated value
Required water head Hw
Hw =
[1]
P =
Qf =
Hf =
Sf =
Ef =
P =
P =
The used Hf-value is from the Weir
example, not the calculated value
f
p
f f
E
FVF
SG
H Q
HP

|
|
.
|

\
|

=
3960
f
f f f
p
f
E
SG H Q
HP
FVF
SG
SG

=
=
3960
Required water head Hw
Hf / HRF
HP = ( Qf * Hf * Sf ) / (3960 * Ef)
Sf = Sp/FVF
Sp = 1.15
FVF = 1.25
Sf = 0.92
Qf = 2500 gpm
Hf = 75 ft
Sf = 0.92 -
Ef = 0.646 -
HP = 67.43 BHP
P = Qf * Hf *Sf* / (367 * Ef)
Qf = 568 m/h
Hf = 22.9 m.p.c.
Sf = 0.920 -
Ef = 0.646 -
P = 50.3 kW
P =
67.46 hp
The used Hf-value is from the Weir
example, not the calculated value
Weir technical bulletin N 28. Ver. 3
http://www.weirminerals.com/pdf/Technical%20Bulletin%2028v.2%20-%20082109.pdf
Kevin Burges
Warman Pump Thechnology Centre
Artarmon
Australia
2.- HRf & ERf also include effects of fine solids
REf. 2
Warman horizontal froth pump selection procedure
1.- Determine type of froth
Brittle
Tenaciuos
Medium
2.- Qs = De-aereated slurry flow (L/s)
Use maximum reated design flow
Check for maximum duty slurry flow
Qf =
4.- Calculated froth system head Hf (m)
at aereated flow (Qf) for concentration of
solids in slurry, disregarding froth.
Keep dischatge pipe dismeters large
5.- Hw =
6.- Select froth pump with duty point is
to the left of BEP. Q >= 25% QBEP
NPSHreq >= 3.5 m
7.- At the duty point, select the pump
speed Nf /rpm) and the water efficiency
Ew (%).
8.- Slurry density Sf = Sm / FVF
9.- Calculate froth power
Pf (kW) =
10.- Check power
11.- Select motor size with 20% margin
Vertical pump type
Use mainly for brittle type frothd eg copper
Use
Select a duty flowrate 30% to 85% of maximum
flow shown on vertical froth pump curve
Use HR = ER = 0.9
Select head and spedd as for horizontal froth pump
Ensure a good vortex in the hopper
Warman Pump Thechnology Centre
2.- HRf & ERf also include effects of fine solids (Wath about heterogeneous flows?)
REf. 2
Warman horizontal froth pump selection procedure
1.- Determine type of froth
Brittle 1.1 <0 FVF <= 1.25
Tenaciuos 1.5 <0 FVF <= 1.8
Medium 1.25 <0 FVF <= 1.5
2.- Qs = De-aereated slurry flow (L/s)
Use maximum reated design flow
Check for maximum duty slurry flow
3.- Qf = Aereated froth flow
Qf = FVF * Qs (L/s)
4.- Calculated froth system head Hf (m)
at aereated flow (Qf) for concentration of
solids in slurry, disregarding froth.
Keep dischatge pipe dismeters large
5.- Hw = Hf/HRf
6.- Select froth pump with duty point is
to the left of BEP. Q >= 25% QBEP
NPSHreq >= 3.5 m
7.- At the duty point, select the pump
speed Nf /rpm) and the water efficiency
Ew (%). Ef = Ew * ERf
8.- Slurry density Sf = Sm / FVF
9.- Calculate froth power
Pf (kW) = Qf * Hf * Sf * 0.98 / EF
10.- Check power
11.- Select motor size with 20% margin
Vertical pump type
Use mainly for brittle type frothd eg copper
Use 2.0 <= FVF <= 2.5
Select a duty flowrate 30% to 85% of maximum
flow shown on vertical froth pump curve
Use HR = ER = 0.9 (Conical hooper)
Select head and spedd as for horizontal froth pump
Ensure a good vortex in the hopper
http://www.calgarypumpsymposium.ca/archives/Presentations/2007/Froth-Presentation.pdf
[1] http://www.calgarypumpsymposium.ca/Froth-Presentation.pdf
[2] Warman Technical Bulletin No 28, version 2
http://www.weirminerals.com/pdf/Technical%20Bulletin%2028v.2%20-%20082109.pdf

[3] Standard motors
http://oee.nrcan.gc.ca/regulations/products/14297