Pulp pumping efficiency I – A critical review on loss and its estimation
Source abstract
Abstract
Abstract With growing demand of paper products, the electric consumption in pulp and paper industry is increasing globally where a share of 30 % is attributed to the pulp pumping system. The efficient designing and running of pumping system are critical for energy efficiency. The incomplete information on pulp flows and the oversized designs are the major causes of low efficiency. In the first part of this research, the fiber level models and rheological properties covering a series of unit applications are examined. A loss model of pulp pump is set up by considering different factors influencing pumping performance. The efficiency improvement opportunities in pulp pumping are systematically investigated. The drag-reducing feature at low consistency pulp pumping is highlighted which will be further applied in energy optimized sizing and dimensioning of a pulp pump in the second part of this research.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Advanced Cellulose Research Studies · Rheology and Fluid Dynamics Studies · Material Properties and Processing
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
National Research Center of Pumps , 12676 Jiangsu University , Zhenjiang , People’s Republic of China
Funding
National Natural Science Foundation of China · Natural Science Foundation of Jiangsu Province · Six Talent Peaks Project in Jiangsu Province
References (100+)
Show source-provided references
1. AbuYousef, I.A., Olson, J.A., Martinez, D.M., Green, S. (2010) Pumping performance increase through the addition of turbulent drag-reducing polymers to pulp fibre suspensions. In: Proceedings of the ASME 2010 International Mechanical Engineering Congress and Exposition, Vancouver, British, Canada, Columbia.10.1115/IMECE2010-37697 ↗
2. Amin, N.K., Abdel-Aziz, M.H., Ashtoukhy, E.S.Z. (2014) Effect of pulp fiber suspensions on the rate of mass transfer controlled corrosion in pipelines under turbulent flow conditions. Chem. Eng. Res. Des. 92(11):2333–2338.10.1016/j.cherd.2014.01.023 ↗
3. Anderson, H.H. Centrifugal Pumps and Allied Machinery. Elsevier, Amsterdam, 1994, ISBN 1856172317.10.1016/B978-1-85617-231-8.50018-9 ↗
4. Ayad, A.F., Abdalla, H.M., Aly, A.A.E.A. (2015) Effect of semi-open impeller side clearance on the centrifugal pump performance using CFD. Aerosp. Sci. Technol. 47:247–255.10.1016/j.ast.2015.09.033 ↗
5. Batchelor, G.K. (1970) Slender-body theory for particles of arbitrary cross-section in stokes flow. J. Fluid Mech. 44(3):419–440.10.1017/S002211207000191X ↗
6. Baun, D.O., Flack, R.D. (2003) Effects of volute design and number of impeller blades on lateral impeller forces and hydraulic performance. Int. J. Rotating Mach. 9:145–152.10.1155/S1023621X03000137 ↗
7. Baykal, B.A., Singh, P.M. (2015) Flow induced corrosion of steels exposed to pulping liquors. In: Corrosion 2015: Collaborate. Educate. Innovate, Dallas, Texas, USA.
8. Baykal, B.A., Singh, P.M. (2017) Erosion-corrosion behavior of steels in a particulate-containing pulping liquor environment at elevated temperature. In: Corrosion Conference and Expo 2017, New Orleans, Louisiana, USA.
9. Benson, S., Pacello, J. (1997) Solving the problems of pumping medium-to-high density paper stock. World Pumps 368:68–71.10.1016/S0262-1762(99)80115-1 ↗
10. Bhole, M.R., Bennington, C.P.J. (2010) Performance of four axial flow impellers for agitation of pulp suspensions in a laboratory-scale cylindrical stock chest. Ind. Eng. Chem. Res. 49(9):4444–4451.10.1021/ie901854d ↗
11. Bhole, M.R., Hui, L.K., Gomez, C., Bennington, C.P.J., Dumont, G.A. (2011) The effect of off-wall clearance of a side-entering impeller on the mixing of pulp suspensions in a cylindrical stock chest. Can. J. Chem. Eng. 89:985–995.10.1002/cjce.20503 ↗
12. Boitel, G., Fedala, D., Myon, N. (2016) Tip clearance effects on loads and performances of semi-open impeller centrifugal pumps at different specific speeds. 2016 IOP Conf. Ser.: Earth Environ. Sci. 49:032013-1-10.10.1088/1755-1315/49/3/032013 ↗
13. Bonifácio, A., Coelho, P., Fonseca, I., Lopes, F. (2012) Energy reductions in the pulp-and-paper industry by upgrading conventional pumping systems through the installation of VFDs – a case study. In: International Conference on Renewable Energies and Power Quality, Santiago de Compostela, Spain.10.24084/repqj10.600 ↗
14. Bousfield, D.W. (2008) Rheological issues in the paper industry. In: Rheology Reviews, 6. pp. 47–70.
15. Cao, S., Risaburo, O. (1998) Performance study of medium consistency centrifugal stock pumps. J. Tsinghua Univ. (Sci. Technol.) 38(1):5–9 (Chinese).
16. Carlsson, A., Söderberg, L.D., Lundell, F. (2010) Fibre orientation near a wall of a headbox. Nord. Pulp Pap. Res. J. 25:133–147.10.3183/npprj-2010-25-02-p204-212 ↗
17. Chen, K., Chen, S. (1991) The determination of the critical shear stress for fluidization of medium consistency suspensions of straw pulps. Nord. Pulp Pap. Res. J. 93:549–554.
18. Chen, X., Zhang, W., Huang, Z. (2002) Design method of the outlet width of centrifugal pump when handling viscous medium. J. Shanghai Jiaotong Univ. 36(11):1670–1693. (Chinese).
19. Cotas, C.I.P. (2015) Modelling of fiber suspensions flow in pipes. Ph.D. Thesis, University of Coimbra.
20. Cronin, R.J., House, D.A., Miller, A.C. (2004) Design considerations for nonclog pumps. In: Proceedings of the Twenty-First International Pump Users Symposium, Texas, USA.
21. Cui, H., Grace, J.R. (2007) Flow of pulp fibre suspension and slurries: a review. Int. J. Multiph. Flow 33:921–934.10.1016/j.ijmultiphaseflow.2007.03.004 ↗
22. Daily, J.W., Bugliarello, G. (1961) Basic data for dilute fibre suspensions in uniform flow with shear. Tappi J. 44:497–512.
23. Derakhshandeh, B. (2011) Rheology of low to medium consistency pulp fibre suspensions. Ph.D. Thesis, The University of British Columbia, Vancouver.
24. Derakhshandeh, B., Kerekes, R.J., Hatzikiriakos, S.G., Bennington, C.P.J. (2011) Rheology of pulp fiber suspensions: a critical review. Chem. Eng. Sci. 66(15):3460–3470.10.1016/j.ces.2011.04.017 ↗
25. Ducker Worldwide (2000) Energy Efficiency within the Pulp and Paper, Water and Wastewater and Irrigation Markets in the Pacific Northwest. Northwest Energy Efficiency Alliance, Portland, USA.
26. Duffy, G.G. (1978) Pipe Friction Pressure Loss of Pulp Suspensions: Literature Review and Evaluation of Data and Design Methods. Tappi press, TIS 0410-12.
27. Duffy, G.G. (2006) Measurements, mechanisms and models: some important insights into the mechanisms of flow of fibre suspensions. Annu. Trans. Nord. Rheol. Soc. 14:19–31.
28. Duffy, G.G., Abdullah, L. (2003) Fibre suspension flow in small diameter pipes. Appita J. 56(4):290–295.
29. Francis, D.W., Towers, M.T., Browne, T.C. Energy cost reduction in the pulp and paper industry – an energy benchmarking perspective. Pulp and Paper Research Institute of Canada, Montreal, 2002, ISBN 0-662-66163-X.
30. Fällman, M.C. (2009) Turbulence measurements in fiber suspension flows: experimental methods and results. Technical Report, Royal Institute of Technology KTH, Stockholm, Sweden.
31. Garman, M.A. (2015) Local particle velocity measurement in slurry flow in pipes and centrifugal pumps using ultrasound technique. Ph.D. Thesis, Case Western Reserve University, Cleveland, USA.
32. Graham, L.J.W., Pullum, L., Slatter, P., Sery, G., Rduman, M. (2010) Centrifugal pump performance calculation for homogeneous suspensions. Can. J. Chem. Eng. 87(4):526–533.10.1002/cjce.20192 ↗
33. Gullichsen, J., Härkönen, E. (1981a) Medium consistency technology. I. fundamental data. Tappi J. 64:69–72.
34. Gullichsen, J., Härkönen, E. (1981b) Medium Consistency Technology. II. Storage Dischargers and Centrifugal Pumps. Tappi J. 64:113–116.
35. Guo, C. (2020) Overview of world paper industry in 2018. China Pulp Pap. 39(3):78–82.
36. Gülich, J.F. Centrifugal Pumps. Springer-Verlag, Berlin, 2008, ISBN 978-3-642-12823-3.
37. Harit, H., Gupta, P., Gupta, S.C. (2013) Energy and cost analysis in pulp and paper industry by auditing techniques: a case study. Int. J. Eng. Res. Technol. 6(3):619–624.
38. Hemström, G., Möller, K., Norman, B. (1976) Boundary layer studies in pulp suspension flow. Tappi J. 59:115–118.
39. Higgins, B.G., Wahren, D. (1982) Optimum consistency for pumping pulp. Tappi J. 65:131–133.
40. Holik, H. Handbook of Paper and Board. 2nd ed. Wiley-VCH Verlag GmbH & Co. KGaA, 2013, ISBN 978-3-527-33184-0.
41. Holmberg, K., Kivikytö-Reponen, P., Härkisaari, P., Valtonen, K., Erdemir, A. (2017) Global energy consumption due to friction and wear in the mining industry. Tribol. Int. 115:116–139.10.1016/j.triboint.2017.05.010 ↗
42. Huhtanen, J.-P. (1998) Non-Newtonian flows in paper making. Ph.D. Thesis, Tampere University of Technology, Hervanta, Finland.
43. Huhtanen, J.-P., Karvinen, R.J. (2006) Characterization of Non-Newtonian fluid models for wood fiber suspensions in laminar and turbulent flows. Annu. Trans. Nord. Rheol. Soc. 14:51–60.
44. Hyensjö, M., Krochak, P., Olson, J.A., Hämäläinen, J., Dahlkild, A. (2004) Modelling a turbulent dilute fibre suspension in a planar contraction: effect of vane types, vane position and wall boundary layer on fibre orientation distribution. In: 5th International Conference on Multiphase Flow, ICMF’04, Yokohama, Japan.
45. Isono, M., Nohmi, M., Uchida, H., Kawai, M., Kudo, H., Kawahara, T., Miyagawa, K., Saito, S. (2014) An experimental study on pump clogging. 2014 IOP Conf. Ser.: Earth Environ. Sci. 22:012009-1-11.10.1088/1755-1315/22/1/012009 ↗
46. Jalayer, M. (2011) Energy reduction in pumping low consistency pulp fiber suspensions. Master Thesis, The University of British Columbia, Vancouver, Canada.
47. Jensen, A.L., Rosendah, L., Sørensen, H., Lykholt-Ustrup, F. (2015) Towards simulation of clogging effects in wastewater pumps: a review of the state-of-the-art in cloth modelling and challenges in the simulation of clogging effects. In: Proceedings of the ASME-JSME-KSME 2015 Joint Fluids Engineering Conference, Seoul, South Korea.10.1115/AJKFluids2015-33214 ↗
48. Jensen, A.L., Sørensen, H., Rosendah, L. (2016) Towards simulation of clogging effects in wastewater pumps: modelling of fluid forces on a fiber of bonded particles using a coupled CFD-DEM approach. In: International Symposium on Transport Phenomena and Dynamics of Rotating Machinery, Hawaii, Honolulu.
49. Kaya, D., Yagmur, E.A., Yigit, K.S., Kilic, F.C., Eren, A.S., Celik, C. (2008) Energy efficiency in pumps. Energy Convers. Manag. 49(6):1662–1673.10.1016/j.enconman.2007.11.010 ↗
50. Kerekes, R.J. (2006) Rheology of fibre suspensions in papermaking: an overview of recent research. Nord. Pulp Pap. Res. J. 21(5):100–114.10.3183/npprj-2006-21-05-p598-612 ↗
51. Kerekes, R.J. (2015) Perspectives on high and low consistency refining in mechanical pulping. BioResources 10(4):8795–8811.10.15376/biores.10.4.8795-8811 ↗
52. Kerekes, R.J., Schell, C.J. (1992) Characterization of fibre flocculation by a crowding factor. J. Pulp Pap. Sci. 18(1):32–38.
53. Kerekes, R.J., Soszynski, R.M., Doo, P.A.T. (1985) The flocculation of pulp fibres. In: Proceedings of the 8th Fundamental Research Symposium, Oxford, England.
54. Kida, K., Kitayama, K. (1961) Experimental studies on pumping up of high consistency paper stock. Japan Tappi J. 15:733–738. (Japanese).10.2524/jtappij.15.733 ↗
55. Klugman, S. (2008) Energy systems analysis of Swedish pulp and paper industries from a regional cooperation perspective – case study modeling and optimization. Master Thesis, Division of Energy Systems, Department of Management and Engineering, Linköping University, Sweden.
56. Kramer, K.J., Masanet, E., Xu, T., Worrell, E. Energy Efficiency Improvement and Cost Saving Opportunities for the Pulp and Paper Industry. Ernest Orlando Lawrence Berkeley National Laboratory, University of California, USA, 2009.
57. Krüger, S., Martin, N., Dupont, P. (2010) Assessment of wear erosion in pump impellers. In: Proceedings of the Twenty-Sixth International Pump Users Symposium, Texas, USA.
58. Kudo, H., Kawahara, T., Kanai, H., Miyagawa, K., Saito, S., Isono, M., Nohmi, M., Uchida, H., Kawai, M. (2014) Study on clogging mechanism of fibrous materials in a pump by experimental and computational approaches. 2014 IOP Conf. Ser.: Earth Environ. Sci. 22:012011-1-11.10.1088/1755-1315/22/1/012011 ↗
59. Kurian, T., Krishna, H.C.R. (1974) An experimental investigation on the clearance effects of semi open radial flow impellers. In: Fifth Australian Conference on Hydraulics and Fluid Mechanics, Christchurch, New Zealand.
60. Lee, P.F.W., Duffy, G.G. (1976) An analysis of the drag reducing regime of the pulp suspension flow. Tappi J. 59:119–122.
61. Li, H., Geng, W., Fan, J., Zhang, W. (2008) Experiments on a medium consistency centrifugal pump. China Pulp Pap. 27:71–72 (Chinese).
62. Li, H., Yuan, S.Q., Yuan, J.P., Liu, W.W. (2007) Stock pump design based on numerical simulation of pulp fiber suspension in pump. J. Jiangsu Univ. (Nat. Sci. Ed.) 28(1):51–55. (Chinese).
63. Li, H., Zhuang, H., Geng, W. (2012) Design of a turbulence generator of medium consistency pulp pumps. Int. J. Rotating Mach. 2012:413674-1-7.10.1155/2012/413674 ↗
64. Li, W.G. (2011) Effect of exit blade angle, viscosity and roughness in centrifugal pumps. TASK Quarterly 15(1):21–41.
65. Li, W.G., Su, F.Z., Xiao, C. (2002) Influence of the number of impeller blades on the performance of centrifugal oil pumps. World Pumps 427:32–35.10.1016/S0262-1762(02)80126-2 ↗
66. Li, W.G., Xue, D.S. (1995) The fifty years study of centrifugal pump when handling high viscous oil (continued). Fluids Mach. 23(4):30–34. (Chinese).
67. Li, Z., Li, J., Xu, J., Mo, L., Feng, Y., Chen, K. (2016) The fluidization properties of bagasse pulp suspensions in a rotary device. BioResources 11(1):2629–2639.10.15376/biores.11.1.2629-2639 ↗
68. Lin, J.Z., Zhang, Q.H. (2014) Three-dimensional fiber orientation of fiber suspensions flowing through a rotating curved expansion duct. Fiber Polym. 15(2):364–372.10.1007/s12221-014-0364-z ↗
69. Lindsay, J.D., Gullichsen, J. (1996) Pulp pumping and hydraulics. In: Pulp Bleaching – Principles and Practice, Eds. Dence, C.W., Reeve, D.W. Tappi Press.
70. Lobanoff, V.S., Ross, R.R. Centrifugal Pumps: Design and Application. Gulf. Publishing Co., Huston, 1992, ISBN 978-0-08-050085-0.
71. Luthi, O. (1987) Pulp rheology applied to medium consistency pulp flow. In: Tappi Engineering Conference, Atlanta, USA.
72. Ma, X.D., Li, Z.F., Yu, H., Wu, D.Z., Wang, L.Q. (2013) Experimental study on a medium consistency pump. J. Fluids Eng. 135(10):104503-1-5.10.1115/1.4024865 ↗
73. Mackaplow, M.B., Shaqfeh, E.S.G. (1996) A numerical study of the rheological properties of suspensions of rigid, non-Brownian fibres. J. Fluid Mech. 329:155–186.10.1017/S0022112096008889 ↗
74. Mackay, R. The Practical Pumping Handbook. Elsevier, Oxford, 2004, ISBN 978-1-85617-410-7.10.1016/B978-185617410-7/50002-3 ↗
75. Mason, S.G. (1948) The flocculation of cellulose fibre suspensions. Pulp Pap. Mag. Can. 99–104.
76. Moller, K., Duffy, G.G. (1978) A design equation for predicting pipe friction loss in the transition regime for pulp suspension. Tappi J. 61:63–66.
77. Nesbitt, B. Handbook of Pumps and Pumping. Elsevier, Cambridge, 2006, ISBN 978-1-85617-476-3.
78. Nesbitt, B. Handbook of Valves and Actuators: Valves Manual International. Butterworth-Heinemann, Oxford, 2007, ISBN 978-1-85617-494-7.
79. Nishi, Y., Matsuo, N., Fukutomi, J. (2009) A study on internal flow in a new type of sewage pump. J. Fluid Sci. Technol. 4(3):648–660.10.1299/jfst.4.648 ↗
80. Nourbakhsh, A., Jaumotte, A., Hirsch, C., Parizi, H.B. Turbopumps and Pumping Systems. Springer, Heidelberg, 2008, ISBN 978-3-540-25129-3.
81. Ogawa, K., Yoshikawa, S., Suguro, A., Ikeda, J., Ogawa, H. (1990) Flow characteristics and circular pipe flow of pulp-suspension. J. Chem. Eng. Jpn. 23(1):1–6.10.1252/jcej.23.1 ↗
82. Olson, J.A., Delfel, S., Ollivier-Gooch, C., Gooding, R.W. (2009) Computational Fluid Dynamics in the pulp and paper industry – the design of a high performance pulp screen rotor. In: Seventh International Conference on CFD in the Minerals and Process Industries, Melbourne, Australia.
83. Patel, D., Ein-Mozaffari, F., Mehrvar, M. (2011) Dynamic performance of continuous-flow mixing of pseudoplastic fluids exhibiting yield stress in stirred reactors. Ind. Eng. Chem. Res. 50(15):9377–9389.10.1021/ie102388y ↗
84. Paulapuro, H. Papermaking Part 1, Stock Preparation and Wet End. 1st ed. Finish Paper Engineers’ Association/Paperi ja Puu Oy, Finland, 2000, ISBN 9789525216080.
85. Pemberton, M. (2003) Strategies for optimizing pump efficiency and LCC performance. Pap. Age 23:28–32.
86. Petrich, M.P., Koch, D.L., Cohen, C. (2000) An experimental determination of the stress-microstructure relationship in semi-concentrated fiber suspensions. J. Non-Newton. Fluid Mech. 95(2-3):101–133.10.1016/S0377-0257(00)00172-5 ↗
87. Pfleiderer, C. Die Kreiselpumpen fuer Fluessigkeiten und Gase: Wasserpumpen, Ventilatoren, Turbogeblaese, Turbokompressoren. Springer, Berlin, 1961, ISBN 978-3-642-53120-0.
88. Pirouzpanah, S., Morrison, G. (2014) Predictive erosion modeling in an ESP pump. In: Proceedings of the ASME 2014 4th Joint US-European Fluids Engineering Division Summer Meeting, Chicago, Illinois, USA.
89. Pullum, L., Graham, L.J.W., Rduman, M. (2007) Centrifugal pump performance calculation for homogeneous and complex heterogeneous suspensions. J. S. Afr. Inst. Min. Metall. 107:373–379.
90. Rayner, R. Pump Users Handbook. Elsevier, Oxford, 1995, ISBN 978-1-85617-216-5.10.1016/B978-185617216-5/50002-3 ↗
91. Reese, D. (2009) Measuring paper machine energy performance. In: TAPPI PaperCon 2009, St. Louis, Missouri, USA.
92. Round, G.F. Incompressible Flow Turbomachines: Design, Selection, Applications, and Theory. Elsevier Butterworth Heinemann, Amsterdam, 2004, ISBN 978-0-7506-7603-8.
93. Selvakumar, J., Natarajan, K. (2015) Failure analysis of centrifugal pumps based on survey. J. Eng. Appl. Sci. 10(4):1960–1965.
94. Shaqfeh, E.S.G., Fredickson, G.H. (1990) The hydrodynamic stress in a suspension of rods. Phys. Fluids A 2(1):7–24.10.1063/1.857683 ↗
95. Shojaeefard, M.H., Tahani, M., Khalkhali, A., Ehghaghi, M.B., Fallah, H., Beglari, M. (2013) A parametric study for improving the centrifugal pump impeller. Heat Mass Transf. 49(2):197–206.10.1007/s00231-012-1074-y ↗
96. Shukla, S.N., Kshirsagar, J. (2007) Numerical simulation of tip clearance flow in semi-open impeller pump. In: ASME/JSME 2007 5th Joint Fluids Engineering Conference, San Diego, California, USA.10.1115/FEDSM2007-37355 ↗
97. Singh, P.M., Aydin, B.B. (2015) Flow induced accelerated corrosion in pulping liquors. In: TAPPI PEERS Conference 2015: Sustainable Solutions for Our Future, Atlanta, Georgia, USA.
98. Singh, P.M., Mahmood, J. (2009) Effect of flow on corrosion of pulp mill equipment. In: TAPPI Engineering, Pulping and Environmental Conference 2009 – Innovations in Energy, Fiber and Compliance, Memphis, Tennessee, USA.
99. Stoor, T. (2006) Air in pulp and papermaking processes. Ph.D. Thesis, University of Oulu, Oulu, Finland.
100. Sulzer Pumps Centrifugal Pump Handbook. 3rd ed. Elsevier Science Publishing Co., New York, 2010, ISBN 978-0-75-068612-9.