Fly Ash Environmental Problems
1.05 billion tons of coal is burned in the United States each year leaving harmful waste (fly ash) in dumping sites. These harmful fly ash dump sites contain harmful heavy metals such as mercury, arsenic, beryllium, cadmium, chromium, nickel, and selenium.
Fly ash has a fine powdery consistency that is easily carried by the wind and can affect nearby neighborhoods and people. Breathing in fly ash overtime can irritate the respiratory system and people with existing lung diseases such as emphysema, bronchitis, and chronic obstructive pulmonary disease should avoid breathing coal fly ash dust.
Fly Ash or Coal Ash is a difficult material to pump due to its abrasive nature. Centrifugal pumps quickly get worn down and lose their tolerances and suction capabilities. This results in significant downtime and costly spare parts.
The fly ash accumulates in many stages of the power generation process and proves to be very costly and time-consuming to remove. The most troublesome stages are dealing with the lined and unlined tailings ponds, rivers, sumps, and concrete basins.
Tailings ponds and rivers continuously need to be cleaned out to increase capacity. Finding the right pump and dredging equipment can often be a complicated process. Centrifugal pumps will only pump 10-20% solids by weight. This means that most of the discharge is water and very little fly ash is coming out of the pipeline. In contrast, the EDDY Pump design can pump 50-60% solids by weight. Pump less water, more solids.
Furthermore, the abrasive nature of the fly ash destroys the impeller of the pump and causes pump failures, costly repairs and spare parts. Our pump has a high tolerance ultra-recessed rotor that withstands the destructive nature of fly ash.
Tailings ponds are often lined with plastic to minimizes the seepage of contaminants. This makes it more difficult for conventional equipment to dredge or mechanically remove the fly ash sediment without damaging the liner. We have a liner-safe wheel option for the excavator attachment.
Sumps are often the most difficult areas in a power generation plant to handle. Fly ash, coal chunks, rocks and other debris are washed into sumps and continuously need to be pumped out. Centrifugal pumps get clogged and constantly wear out because of the tolerances between the impeller and the volute.
Paper and Pulp Pump Applications:
- Transporting Wood Chips for Pulp Making
- Pulp Digester Tanks
- Pulp Bleaching Process
- Pulp Slurry Transfer
Paper & Pulp Pumping Problems
Wood chips and paper pulp are difficult materials to pump due to their viscous and abrasive nature. Centrifugal pumps quickly get worn down and lose their tolerances and suction capabilities. This results in significant downtime and costly spare parts.
The papermaking process utilizes several steps that will benefit from the advantages of the EDDY Pump. During the debarking and chipping process, trees are brought in, debarked and broken down into wood chips. The largest supply of wood chips for the papermaking process comes from the recycled cuttings from sawmills. From there, wood chips are fed by conveyor to a large digester tank where they are cooked in an acidic solution to dissolve the lingin and help separate the plant fibers. This process creates what is called wood-free pulp because the lingin has been dissolved. Finally, additives and dyes are added to the pulp solution, depending on the type of paper being manufactured. All of these steps include abrasive and corrosive slurries that need to be pumped from one location to another.
Transporting Wood Chips and Tree Bark is the first step of the papermaking process. Trees are stripped of their bark, and fed to woodchippers to break them down into small pieces that can be more easily turned to pulp.
Additionally, the abrasive nature of woodchips and bark will quickly destroy the impeller of centrifugal pumps and causes pump failures, costly repairs, and spare parts. Our pump has a high tolerance ultra-recessed rotor that withstands the destructive nature of abrasive pulp slurry.
Pulp Digester Tanks are used to break down the woodchips by removing lingin and separating fibers. This process incorporates abrasive slurries in addition to strong acids that are highly corrosive. These materials are difficult to pump and will quickly wear down pumps with critical tolerances.
The EDDY Pump does not require critical tolerances between the rotor and the volute, making the EDDY Pump the perfect solution for abrasive and corrosive paper and pulp applications. Moreover, the EDDY Pump will run continuously with significantly less spare parts needed and saving papermaking and production plants millions in total ownership cost over the life of the pumps.
The Pulp Bleaching Process involves moving the freshly separated pulp to large tanks for the injection of bleach, fillers, dyes and other materials required for the type of paper being produced. This process also removes any residual traces of lingin from the pulp. From here, the pulp is dried for use in the next step of the papermaking process.
Some industries, such as sugar production, produce large quantities of by-products, in this case, bagasse. Bagasse is the term for the leftover, crushed sugar cane material that is left behind after the sugar juice extraction process. This bagasse is used in some countries as pulp for papermaking.
Pulp Slurry Transfer is a constant process in the papermaking industry. At several stages of papermaking, pulp slurry is needed to be transported from one location to another. This slurry is often extremely viscous, heavy and abrasive which requires a pump built to withstand clogs, high solids content and corrosive materials.
EDDY Pump’s open rotor design promotes the passage of large solids such as woodchips, rocks, pulp and other fibrous material that easily clog centrifugal pumps.
Equipment Options For Job:
- Transporting Wood Chips: Submersible, EDDY Slurry Pump, Self-Priming Pump
- Pulp Digester Tanks: Submersible, EDDY Slurry Pump, Flooded Suction, Self-Priming Pump
- Pulp Bleaching Process: Submersible, EDDY Slurry Pump, Flooded Suction, Self-Priming Pump
- Pulp Slurry Transfer: Submersible, EDDY Slurry Pump, Self-Priming Pump
EDDY Pump Equipment for Paper & Pulp Production
The EDDY Pump can be deployed in various configurations to optimize the paper & pulp process. Some of the ideal deployments for paper and pulp pumping are Submersible, EDDY Slurry Pump, Flooded Suction, Self-Priming Pump
EDDY Slurry Pump
Most EDDY Pumps are submersible, with a self-priming unit, the pump and power unit are not submerged. The suction house goes into the slurry and the unit acts like a super-sized wet vacuum. This type of pump can remove air on its own and continue operation without assistance, making it perfect for mounting on a trailer that can be wheeled from location to location. Becuase the pump is not submerged, both the operation and maintenance of self-priming slurry pumps are economical and relatively easy.
Paper & Pulp Pumping Scenario
Applications: Debarking and Wood Chipping, Pulp Lingin Separation, Pulp Washing, Pulp Bleaching Process, Pulp Slurry Transfer
The purpose of this page is to identify your application and learn more about an equipment solution to meet your needs. These are the most common paper and pulp pump applications that we work with. We are the OEM for the tools shown.
Application: Pulp Slurry Transfer
Material: Wood pulp, in slurry form
Common Pulp Pumping Scenario:
The EDDY Slurry Pump is ideal for pumping large amounts of pulp slurry and aids with several stages of the papermaking process.
By mounting the submersible EDDY Pump to a chemical sump or pulp digester tank, you can handle the most difficult pump applications. The EDDY Pump allows you to pump slurry at distances over 2-miles at production rates of up to 600 tons of mud per hour or 5000 GPM.
Below are commonly distances we see, along with a pump curve to match the details. Contact us with your exact numbers.
Distance: 400 ft
Vertical Rise: 40 ft
Production: 1500 GPM
Equipment Used: EDDY Pump 6 Inch Submersible Sump Pump.
Power Options: EDDY Pump equipment can be powered by electric or hydraulic motor setups. The ideal option is based on your project requirements.
See How EDDY Pumps Are Better
Paper & Pulp Pumping Video
If you have questions about your application, contact us.
Why EDDY Pumps Are Better – Highlights
This video shows how EDDY Pump beats out traditional centrifugal pumps when it comes to tough slurry and abrasive materials. EDDY Pump is the at the heart of all of our featured dredge pump equipment including the Remote Operated Subdredge, Diver Operated Pump and a Excavator Attachment Dredge Pump.
Call For Sales or Support
If you need help with Pump selection, Sales or Engineering Support, Call 619-258-7020.