1. Introduction.
Hydraulic transport of solids in pipelines is used in many industries and economies (e.g. mining, energy, mineral resources industry, food industry, chemistry, environmental protection) [1].
Without going into details, it can be said that most often (and in large masses) solids with dusty granulation (diameter of the so-called medium grain δs50 < 0 mm) and fine-grained (δs075 < 50 mm) are transported in the water stream. Thicker solids (several - several dozen mm) are transported less frequently and this usually applies to hydroexcavation and subsequent hydraulic transport of mineral aggregates, and sometimes agricultural produce.
Solids have very different shapes, regardless of size. Mixtures of dusty particles with water (called suspensions) are treated as homogeneous liquids; the velocities of liquids and solid particles during flow are virtually identical, and solid particles are distributed evenly in the flow cross-sections of pumps and pipelines. To put it simply, such suspensions can be treated as homogeneous liquids - but characterized by increased viscosity towards water, which causes a certain increase in the flow resistance of the suspensions compared to water. They are treated as non-sedimenting. Appropriate fluidity of the suspension is a condition for its ability to be pumped through pumps, transported in pipelines and spread on a flat surface. It depends on the density of solids, which should not exceed reasonable limits. Mixtures of fine-grained particles with water are two-phase heterogeneous liquids in which solid particles move slower compared to water, which causes energy losses during the flow of the mixture. Under the influence of gravity, solid particles in such mixtures fall in the pipelines (or move under the influence of centrifugal forces in the rotating channels), therefore their density in the flow sections is not uniform. A comparison of the distribution of dusty (P) and fine-grained (D) solid particles in the pipeline cross-section during the mixture flow is shown in Figure 1.
Solid particles in the mixture should remain suspended and at a certain distance (in the case of suspensions, even a very small one) from each other. This is different in the case of coarse-grained bodies, which are usually "dragged" along the bottom of the pipeline.

Fig. 1.
Since the pump efficiency and the liquid flow rate through the pipeline are measured in units of volume over time (e.g. m3 /s, m3 /h), so the parameter that most fully characterizes the composition and density of the mixture is volume concentration (volume fraction) cv solid phase in the mixture, defined by the formula where: Vs is the volume of the solid phase in the mixture, Vw is the volume of the liquid phase (water) in the mixture, and Vm is the volume of the mixture. Volume concentration cv Although it is an immeasurable quantity, its value has a significant impact on the fluidity (and therefore the "transportability") of mixtures and suspensions. It determines the degree of "occupation" of the space in which the mixture is located by solid particles.

Another parameter relating to the amount of mass contained in the mixture is mass concentration (mass fraction) cM solid phase in the mixture. The relationship between cM acv is as follows:

When mixtures with the same volume fraction cv solid phases contain solids that differ in density, their mass concentrations (mass fractions) cM solid phases are different. For example, it can be said that hydromixtures with the same volume concentration cv = 0,3, which includes crushed coal (ρs = 1400 kg / m3), fly ash (ρs = 2200 kg / m3) or fine sand (ρs = 2650 kg / m3) will be characterized by mass concentrations cM 0,375, 0,485 and 0,532, respectively, which are very significantly different.
Figure 2 shows an overview of the uniform distribution of identical grains of spherical solids in the flow cross-section, in mixtures with different volume fractions cv.. It is worth noting that already when cv = 0,3, the solid particles are close to each other.

Fig. 2.
The density of the mixture ρm depends on the volume concentration cv, determined by measurement or calculated from a simple formula, in which: ρs – is the apparent density of the solid phase (taking into account the presence of open and closed pores and caverns), and ρw – is the density of water. The apparent density of solid particles should be determined using the carrier liquid in which they will be transported (in practice, water).

Figure 3 shows the dependence of the density of the mixture ρm on the volume fraction of the solid phase cv, for solids with densities ρs = 1400, 2200 and 2650 kg/m3. This range includes the densities of the vast majority of solids transported hydraulically in large masses (e.g. fly ash, energy slags, post-flotation waste in copper ore mining, sand and gravel, limestone, dolomite, a significant part of waste from the process of enriching hard coal, crushed coal). The density of the mixture increases linearly as c increasesv and in practice it often exceeds 1500 kg/m3.

Fig. 3.
2. Efficiency of the hydrotransport system.
Volumetric yield (mixture) Qm the hydrotransport system is expressed by a simple relationship,

where d – is the internal diameter of the transport pipeline, and vm – is the design flow rate of the mixture.
It should be remembered that the flow rates of hydromixtures in pipelines are usually significantly higher than the water flow rates, as solids should not be allowed to settle at the bottom of the pipeline. Therefore, the volumetric efficiencies of the hydrotransport system are usually relatively significant.
Mass efficiency of the M hydrotransport systemm is given by the formula:

or in a more extensive form – a model,

which shows that the mass efficiency of the hydrotransport system increases rapidly as the pipeline diameter increases, especially since the mixture flow rates increase (to avoid the deposition of solid particles).
3. Pumps in hydraulic transport systems.
Since the flow of hydromixtures in the pipeline (and their possible lifting to a higher level) requires specific work, it must be forced by the pump. In a hydraulic transport system, the pump is an active element in which energy supplied from the outside (from the driving engine) is transferred to the mixture stream.
If the mixture flows with density ρm and volumetric intensity Qm , the effective power P is transmitted in the pumpu , is the unit of weight of the mixture (1 N) will obtain an increase in energy H (expressed in J/N, and after formal simplification of dimensions in "m") resulting from the formula:

and called the useful head of the pump. This name refers to the interpretation of this concept, according to which it defines the geometric height to which the pumped liquid (and therefore also the hydromixture) can be raised, but without any losses associated with it.
Effective power of the pump Pu expresses a familiar pattern

Transferring energy to the hydromixture is accompanied by various types of energy losses in the pump, so the power P (supplied to the pump) is greater than the useful power Pu . The pump efficiency η, defined by the formula, characterizes the efficiency of energy transfer to the pumped medium.

4. Selection of pumps for the hydrotransport system.
When selecting a pump for a specific hydraulic system for transporting solids, the following factors should be taken into account:
– required pump operating parameters achieved under the conditions of pumping the hydromixture,
– pump design solution appropriate for a specific hydromixture,
– expected durability of the pump's internal components.
4.1. Determining the pump operating parameters.
The necessary operating parameters of the pump at the expected operating point in the hydrotransport system should be determined as precisely as possible. With the expected volumetric efficiency of the Q systemm (identical to the pump efficiency), the energy transferred to the unit weight of the mixture in the pump must balance the geometric height Hz (to which the mixture will be lifted) and the amount of hydraulic losses ΣΔhm in the transport pipeline (also related to the unit weight of the mixture), which arise during the flow of the hydromixture. The sum is the lifting height of the hydromixture transport system (Hi), the simplest diagram of which is shown in Figure 4, and the characteristics of the hydrotransport system Hi = f(Q) is shown in Figure 5.


Fig. 4.

Fig. 5. (Marked: M- mixture, W- water).
Solids in the hydromixture leaving the impeller have a certain kinetic energy. In the case of dusty particles, this energy is transferred to the liquid almost completely, in the case of fine-grained particles - to some extent, and in the case of "coarser" particles it is completely dissipated.

Fig. 6. (A – fine particles, B – coarser particles).
The presence of solids in the pumped mixture therefore affects the operating parameters of the pumps, in particular the useful lifting height, efficiency and shaft power, which change in relation to the parameters achieved when pumping water.
Changes in pump parameters are characterized by the following dimensionless coefficients:
– lifting height change factor KH

– efficiency change coefficient Kη

K coefficient valuesH and Kη depend on the type of solids (density ρs and medium grain size δs50) and their volume fraction cv. It is also influenced by the size of the pump. K-type algebraic graphs and relationshipsH = f(Q) and Kη = f (Q) published in the literature enable approximate prediction of the impact of the presence of solids on the characteristics H = f(Q) and η = f(Q) of the pump pumping the water-solids mixture. However, they should not be treated uncritically, as they usually refer to a specific pump and specific solids. An example of such relationships quoted from [2] is shown in Figure 7. They refer to a pump with a four-blade impeller, but of unspecified size and unknown operating parameters.

Fig. 7. (Marked: a – fine sand 0,8-0,35 mm, coarse sand 0,3-2 mm, fine gravel 0,9-5 mm).
Figure 8 shows an overview of the characteristics of the lifting height H - Q and efficiency η - Q of a centrifugal pump pumping mixtures with the same volume concentration, but containing solids of different grain sizes - against the background of the characteristics related to water.

Fig. 8.
When selecting a pump in a specific situation, you should first determine the lifting height of the pump installation Him under the conditions of pumping the mixture (at the required system capacity Qm), which at the expected operating point of the system must be identically equal to the useful lifting height achieved by the pump pumping the mixture (Him = HM). Required effective pump head Hm (in the conditions of pumping the mixture) cannot be directly used to select a specific pump, because pump manufacturers provide pump characteristics determined when pumping water. Therefore (after adopting reliable values of the K coefficientsH and Kor), the useful lifting height H must be determinedw, which the analyzed pump would achieve by pumping water (because always Hw ≥ HM).

and calculate power on the pump pumping the mixture (Pm) from the relationship:

To more precisely adjust the pump parameters to the required ones, it may be necessary to reduce the outer diameter of the impeller or change the rotational speed (e.g. by selecting appropriate pulleys).
Note that the K ratioH / Kη is usually close to 1 and only in the case of coarse-grained mixtures and more dense fine-grained mixtures it is lower, so the power on the pump shaft under the conditions of pumping the hydromixture increases approximately in proportion to the density ratio ρm /ρw . The increase in power demand must be taken into account when selecting the engine (and possible belt transmissions) to drive the pump.
Selecting a pump for a specific mixture hydrotransport system is often (due to the complexity of the problem) a difficult matter and it makes sense to use the support of specialists. Reputable manufacturers of hydrotransport pumps usually have experience and knowledge in this field, and relying on the suggestions of bidders without experience is risky.
4.2. Selection of the pump design solution.
Centrifugal pumps for hydrotransport are generally single-stage, although there were multi-stage versions for special needs. Examples of design solutions for hydrotransport pumps are presented in the following figures 9 and 10 [4] and 11. The common features of these pumps are large impeller widths (which allows for the "passage" of larger solids), large collecting channels - with a constant cross-section or in the form of "incomplete" spiral, the possibility of adjusting the radial gap at the impeller inlet - which allows to reduce internal leakage at the impeller inlet, the use of elements directly in contact with the pumped mixture as relatively easily replaceable, solid bearings of the rotating unit due to the usually much higher axial and radial forces, and closure water stuffing boxes. The pump shown in Figure 10 is also equipped with a specific impeller that relieves the stuffing box, which significantly increases its durability in the case of uninterrupted water supply. This solution is intended for difficult working conditions.
![Fig. 9. PH pump (Powen-Wafapomp SA Group), [4].](http://kronikatechnikipompowej.pl/wp-content/uploads/2015/05/rys9.jpg)
Fig. 9. PH pump (Powen-Wafapomp SA Group), [4].
![Fig. 10. HC type pump (Powen-Wafapomp SA Group), [4].](http://kronikatechnikipompowej.pl/wp-content/uploads/2015/05/rys10.jpg)
Fig. 10. HC type pump (Powen-Wafapomp SA Group), [4].
Pumps whose internal elements are made of hard metal materials (e.g. Fig. 9 and 10) can be used to pump hydromixtures containing grains of any size. A hard material resists "cutting" - by coarser particles - especially "angular" ones - and "grinding" by fine particles. However, pumps (Fig. 11) whose internal elements are made of elastomers (rubbers, polyurethanes) are generally intended for pumping mixtures containing fine particles. An elastomer with appropriate abrasion resistance absorbs the energy of striking particles and, to some extent, causes them to bounce off the attacked surface.

Fig. 11.
Recently, there has been a tendency to use cast steel impellers in pumps with a collecting channel and liners made of elastomer. This allows for a noticeable increase in pump efficiency.
The choice of a specific pump should be aimed primarily at achieving the longest possible operating periods between the inevitable replacements of impellers and other elements (housings, side linings), which is conditioned by the high durability of the internal elements of the pump, and this criterion is even more important than achieving slightly higher efficiency by the pump. .
It is advantageous when hydrotransport pumps have low speed (750 - 1200 (1500) rpm), because it is found that impeller wear (understood as the loss of element mass) increases approximately in proportion to the square of the rotational speed. Also, the rate of increase in the width of the radial gap sealing the rotor inlet and the wear of the stuffing box seals decreases as the rotational speed decreases.
4.3. Durability of pump components.
The impeller of the hydrotransport pump is the element subject to the fastest wear, and the places of the most intense wear are marked in Figure 12. In the case of the content of "coarse" particles in the mixture G the largest losses occur in the inlet area of the rotor (inlet edges of the blades and rear rotor disc), and in the case of pumping "fine" particles D although the losses in these places are smaller, significant losses are observed at the ends of the blades, on their active side, which - when they become large enough - adversely affect the velocity distribution of the outflowing mixture, which leads to a noticeable reduction in the pump lifting height. As a result, the blades and rear disc of the rotor are thickened, especially in places of the most intense wear. The number of blades is small, z = 3 – 4 (sometimes 5), in order to maintain sufficiently large clearances at the impeller inlet and not excessively impair the suction capacity of the pump.
The bodies of collecting channels are subject to accelerated local wear in the area where the channel enters the outlet connector. as a result of "impacts" of solid bodies on the edge acting as a residual "tongue".
Rotors and replaceable metal elements (collection duct bodies and side linings) are made of cast steel containing significant amounts of alloy additives and are heat treated to increase their hardness, which requires an appropriate technological level. Replacement elements used during replacements and renovations should be of appropriate quality (ensuring appropriate durability) and for this reason it is risky to use "replacements" of undocumented quality, as it may turn out to be unprofitable. Hydromixture pumps are, for obvious reasons, inferior to water pumps in terms of efficiency, so the expected durability of their components is a decisive factor in their selection. It should also be taken into account that faster wear of the pump components leads to an extension of the period during which it operates at low efficiency.

Fig. 12.
5. Some issues regarding the operation of pumps in hydrotransport systems.
The phenomena occurring during the flow of the hydromixture through the pump are much more complex than during the pumping of water. Therefore, you should pay attention to several circumstances that affect the proper operation of the pump, which determines the uninterrupted functioning of the hydrotransport system as a whole.
5.1. Consequences of increased factor density.
The relatively high density of the mixture increases the power consumption of the pump (and the need to use an engine with appropriate power) and increases the pressure in the pump discharge port, which is important in the event of a possible need to connect two pumps in series. Not every pump is designed to operate in conditions of significant pressure increases, so such uncertainty should be clearly explained. Care should also be taken to supply water with appropriately increased pressure to the water "lock" of the stuffing box of the second pump in the series.
5.2. Ensuring geometric inflow to the pump.
The mixture should flow to the pump from the tank (with the bottom inclined towards the inlet) to the shortest possible supply pipeline located above the pump axis (Fig. 4). Pressure in the pump inlet psm when pumping the mixture should be significantly higher compared to the situation when pumping water. At low volume concentrations of solids in mixtures (cv ≤ 0.1) the anti-cavitation surpluses are close to each other in both cases (NPSH3w ≈ NPSH3m) [5] , but even then the required ("safe") pressure in the pump inlet port when pumping a mixture must be higher due to the higher density of the mixture

(with NPSH3m is the anti-cavitation surplus of the pump under the conditions of pumping the mixture).
When the volume fraction of solids in mixtures and suspensions cv > 0,1, then NPSH3m, and therefore the required pressure value in the pump inlet port, increase quickly because in the inlet area of the rotor solid bodies (especially those with larger granulation) are "pressed" by the force of inertia against the rear disc of the rotor (Fig. 13) [6], and their displacement causes much greater losses, and therefore a local pressure drop. However, in the case of suspensions of very fine particles, as their density increases, additional pressure losses occur due to the existence of non-Newtonian fluid characteristics in the suspension.
Therefore, ensuring an appropriate geometric inflow of the mixture to the pump is necessary.

Fig. 13.
5.3. Pump operation at close to optimal efficiency.
The pump should permanently operate at a capacity close to optimal, i.e. close to the point of highest efficiency. Then, the bearing loads caused by the radial force acting on the rotor are relatively small, the flow in the inter-blade channels of the rotor takes place with the smallest turbulence and is most even, and the rotor wear is the slowest. Of course, the pump operation is then the most economical.
Operating the pump at increased efficiency causes increasing losses in the inlet area of the impeller, and reducing efficiency during operation increases the risk of solids settling in the pipeline.
5.4. Other.
In addition to the issues mentioned above, the condition of the pump should, of course, be checked, especially the pressure in the pump discharge port, the water supply to the stuffing box, the temperature of the bearings, the vibrations of the rotating unit and the current electrical power consumption of the motor (or at least the intensity of the electrical current consumed). It is also worth remembering that the dominant influence on costs is the correct selection of the pump and its operation close to the point of maximum efficiency, and above all, avoiding pumping too dilute mixtures, because then a significant part of the energy is used to pump excessive amounts of water.
6. Ending.
Hydrotransport systems, although they contain similar elements (tanks, pumps, pipelines) and water pumping systems, operate in different conditions. Pumps must meet requirements in terms of solids throughput and durability. Tanks should be appropriately designed (slanted bottom and possibly equipped with a mixer), and pipelines and fittings should be selected appropriately. Operating parameters and values characterizing the system should be determined based on the identified characteristics of the mixture or suspension and a reliable calculation methodology, and the pump selection should be made carefully.
Pumps in hydrotransport installations must perform in usually difficult conditions - primarily in terms of durability and operational reliability, and their operation requires understanding of the problems and knowledge of the supervisory team, as well as increased involvement of the staff. As a result, however, it will limit unexpected disruptions in the functioning of the system and, to some extent, also the frequency of renovations, and in the medium term it will reduce costs.
Literatura:
The literature on the issues discussed is very extensive, so due to the nature of the publication, the publication is limited only to items directly related to the issues discussed.
1.Palarski J., Hydrotransport, WNT, Warsaw, 1982
2.. Surek J., Probleme der Flüssigkeits-Feststoffgemisch – Förderung mit Kreiselpumpen, Maschinenbautechnik, Heft 9, 1972.
3. Roco NC, Wear mechanism in centrifugal slurry pumps, Journal of Science and Engineering, Vol. 46, No. 5, 1990.
4. National Forum of Producers and Users of Pumps in Mining, Lubiatów, May 6-8, 1998, (collection of materials)
5. Źiwotowskij Ł.S., Smojłowskaja Ł.A., Techniczeskaja mechanica gidrosmiesiej i primerowyje nasosy, Izd. Mashinostroyeniye, Moscow, 1986.
6. Karielin W., Iznashiwanije łopasnych nasosov, Izd. Mashinostroyeniye, Moscow, 1973.
Dr. Eng. Jerzy Rokita
MSc. Zbigniew Krawczyk