Rising to the salt extraction challenge

A salt extraction operation had to transfer quickly from an onshore to an offshore site equipped by 5 km of pipework. The company turned to flow control partner Celeros to assist meet the distinctive circumstances encountered at the new salt nicely.
Overview of the two new water injection pumps for single and parallel operation, following set up and commissioning on the Frisia Zout BV website.
A new salt extraction plant off the north coast of Holland has been introduced online ahead of schedule, preventing a possible halt in production when the existing onshore nicely developed issues. Frisia Zout BV, a half of K+S Minerals and Agriculture GmbH, was able to overcome the time and technical challenges of accelerating the project by working in partnership with Celeros Flow Technology (Celeros FT).
The bulk of the salt produced by Frisia Zout BV goes unfastened to a 40,000-tonne storage facility for supply in bulk to industry. The the rest is packed in smaller quantities for use in food manufacturing or made into cubes for water purification.
The salt is extracted beneath licence from the Dutch government. The current borehole licence
allowed K+S to extract salt from underground on the mainland. Due to regulatory changes, the model new licence would solely permit extraction from subsea sources off the coast. Consequently, a model new borehole and associated plant was required at the Frisia Zout BV web site.
New challenges
K+S started planning for a new pump constructing in 2017, and development started in April 2020 with the purpose of bringing it onstream before the existing extraction licence expired at the finish of 2021. However, Secret arose with the present onshore well, which meant that manufacturing would stop ahead of anticipated. To bridge the gap, Frisia Zout BV started bringing in salt water by tanker, however this was an costly various. As a result, it became imperative to deliver the model new offshore well onstream as quickly as potential.
Time pressures were not the one challenges the company faced. Due to the pure geology, the extraction path to the new offshore useful resource was not a straight bore: it changed direction twice before reaching the salt deposits. In truth, the new plant is fed by one of the deepest wells on the earth and has 5 km of pipework past the water injection pumps. As a outcome, the process water has to be pumped in at high stress (250 barg) and at a excessive move price (450 m3/h) to extract the quantity of salt required, making the selection of pumps important to success.
Total solution
Frisia Zout BV has an extended and established relationship with Celeros FT by way of the ClydeUnion Pumps brand, based not solely on the top quality of ITS OEM pumps but in addition on its capability to respond shortly to any operational issues. The firm turned to its trusted circulate control associate as quickly as again for assist in meeting the unique circumstances encountered on the new salt well.
Celeros FT model ClydeUnion Pumps assessed the circulate necessities for the water injection course of on the new plant and verified that CUP-BB3 pumps might be made to fulfill requirements. The pumps were specified with Duplex stainless-steel casings because they would be working in a salt-laden environment. Celeros FT manufactured, equipped, put in and commissioned the mission-critical pumps for injecting water into the model new offshore salt cavern, meeting unusual requirements for prime stress and high circulate charges. In addition, they supported Frisia Zout BV in bringing an older pump back into service as a spare: assessing it and upgrading the casing to make sure it met the model new duty requirements.
Jouk Riemer, challenge supervisor for Frisia Zout BV, defined: “We have used CUP-BB3 pumps up to now and located that their multistage centrifugal design provides better efficiency, in comparison with plunger pumps, for this utility. We wished to use them once more for the model new venture. The Celeros FT staff responded to the challenges magnificently, using their engineering expertise to determine the best solution to meet the stress and flow rates we required, delivering the pump skids to meet the new construction schedule and serving to us hold the challenge on monitor.”
Future assured
The new salt extraction plant came online in December 2020. Its CUP-BB3 pumps meet the high strain and move rates required for the application and can run in parallel, which has improved productivity. The availability of a spare pump gives extra confidence that manufacturing downtime shall be minimal. The company’s capability to satisfy the accelerated venture deadline is particularly impressive when you think about that the Covid-19 pandemic was already affecting supplies of materials and components. The Celeros FT team worked hard to make certain that this didn’t have any influence on their buyer.
Celeros FT additionally offered specialist engineering expertise all through the installation and commissioning part and will continue to make sure the pumps operate satisfactorily throughout the plant’s 15-year lifespan, though the pump building may be required to serve multiple nicely in future as demand for K+S excessive purity salt continues to grow. Easy replacement of wear and tear parts and ongoing service support from Celeros FT will be certain that the BB3 pumps continue to fulfill operational parameters throughout the extraction plant’s lifetime.
Riemer mentioned: “The mixture of excessive quality OEM equipment and practical engineering skills supplied by Celeros Flow Technology was instrumental in delivering this project ahead of time. I’m satisfied it would have taken a lot longer to get what we required from another pump producer. The company’s responsiveness was essential in meeting our revised deadline, decreasing prices and keeping extraction at this site viable.” Riemer concluded: “This is the first offshore extraction well we now have developed nevertheless it has been a largely optimistic experience thanks to Celeros Flow Technology. They brought invaluable engineering experience and specialist pump information to this venture and are a basic part of its success.”
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