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.
Process Pump Applications:
- Process Pumps
- Foundry Waste / Mill Scale
- Sump Cleanouts
Process Pumping Problems
Process pumps are found in a wide variety of industries and are typically built and utilized for a specific purpose. Process pumps can also be found at many different stages throughout the entire industrial process, often employed to pump difficult materials which can routinely cause problems for the pump which, in turn, affects the entire operation.
Factories, processing plants, and manufacturing centers all have the need for reliable, specialized pumps. These specialized pumps are called process pumps and are available in many different types. The selection of a process pump is heavily dependent on the type of process and the type of material that will be handled by the pump. For highly abrasive and viscous material, a centrifugal pump would have frequent maintenance problems including clogs and impeller wear. As a result, the best type of pump for this highly abrasive and viscous material would be a heavy-duty EDDY Pump.
Mill Scale Pumps
Foundries also have their own share of waste they must deal with, mostly in the form of mill scale. Mill scale is an oxidation byproduct from forging various metals. Mill scale is formed on the outer surfaces of metallic plates or sheets when they are being produced by rolling red-hot iron or steel billets in rolling mills.
Furthermore, the abrasive nature of mud, manure, and other abrasive sediments will 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 mud, sand, and rocks.
Submersible pumps are often used to remove a liquid from a particular area at no great depth. This could include emptying sumps from manufacturing operations or pumping waste material from a collection or holding tank. These types of pumps can be mounted vertically or horizontally depending on the setup of the sump or tank.
The EDDY Pump is the ideal solution for these sumps and can be deployed electrically, hydraulically or as a self-priming unit. Furthermore, the abrasive nature of manufacturing waste such as mill scale will quickly wear down the impeller of centrifugal pumps and cause pump failures which will lead to costly repairs, and spare parts. Our pump has no critical tolerances along with an ultra-recessed rotor that withstands the damaging nature of abrasive solids.
Equipment Options For Job:
- Process Pumps: Submersible, EDDY Slurry Pump, Self-Priming Pump
- Mill Scale Pumps: Submersible, EDDY Slurry Pump, Self-Priming Pump
- Fly Ash Mixing and Remediation: Electric or Diesel Driven Submersible EDDY Slurry Pumps
EDDY Pump Equipment
The EDDY Pump can be deployed in various dredge configurations to optimize cleanup of sediment and manure transfer. Some of the ideal deployments for agricultural pumping are Excavator Pump Attachments, Self-Priming Pumps, Submersible Pumps, Liner-Safe Dredges, Cable-Deployed Pumps, Autonomous Dredges, Spud-Dredges, and the Subdredge.
The adjustable size, ultra recessed rotor can pass the largest material in the industry.
In harsh conditions with sand, sludge, rocks, slurry, normal dredge pumps clog, wear and fail more often. This leads to downtime for maintenance, hurting your bottom line. Not the case with EDDY Pumps, since we have the tolerance to pump objects up to 9 inches!
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. Because the pump is not submerged, both the operation and maintenance of self-priming pumps are economical and relatively easy.
Process Pumping Scenario
Typical Process Pump Applications:
- Process Pumps
- Foundry Waste / Mill Scale
- Sump Cleanouts
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 process and manufacturing pump applications that we work with. We are the OEM for the tools shown.
Application: Sump waste cleanout. Removing waste collected in sumps from manufacturing and processing.
Material: Sludge. Suspended solids and abrasive, in slurry form.
Common Process Pump Scenario:
The Submersible EDDY Slurry Pump is excellent for pumping thick, sludgy material that collects at the bottom of sumps, holding tanks, or other types of vesicles. The pump can be mounted vertically or horizontally depending on the particular setup or project needs.
By mounting the submersible EDDY Pump to a processing sump or waste holding tank, you can handle the most difficult pump applications. The EDDY Pump allows you to pump highly abrasive slurry at distances over 2-miles at production rates of up to 600 tons of slurry per hour or 5000 GPM.
Optional upgrades such as a jetting ring or cutterhead will ensure even agitation of highly viscous material, allowing easy feeding into the pump.
Below are commonly distances we see, along with a pump curve to match the details. Contact us with your exact numbers.
Distance: 2500 ft
Vertical Rise: 30 ft
Production: 1414 GPM
Equipment Used: 6 Inch EDDY Pump
Optional HPU: EDDY Pump equipment can be powered by electric or hydraulic motor setups. The ideal option is based on your project requirements.
See The EDDY Pump in Action
Process Pump Demo Video
Call For Sales or Support
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.