Rising to the salt extraction challenge

A salt extraction operation had to move shortly from an onshore to an offshore web site provided by 5 km of pipework. The firm turned to flow management companion Celeros to assist meet the unique circumstances encountered on the new salt well.
Overview of the 2 new water injection pumps for single and parallel operation, following set up and commissioning at the Frisia Zout BV web site.
A new salt extraction plant off the north coast of Holland has been brought online forward of schedule, stopping a potential halt in production when the existing onshore well developed points. Frisia Zout BV, part of K+S Minerals and Agriculture GmbH, was able to overcome the time and technical challenges of accelerating the venture 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 delivery in bulk to trade. The remainder is packed in smaller quantities to be used in meals manufacturing or made into cubes for water purification.
The salt is extracted beneath licence from the Dutch government. The existing borehole licence
allowed K+S to extract salt from underground on the mainland. Due to regulatory changes, the brand new licence would solely permit extraction from subsea sources off the coast. Consequently, a new borehole and related plant was required at the Frisia Zout BV site.
New challenges
K+S began planning for a model new pump constructing in 2017, and building started in April 2020 with the purpose of bringing it onstream before the present extraction licence expired on the finish of 2021. However, unforeseen difficulties arose with the existing onshore nicely, which meant that production would cease ahead of anticipated. To bridge Never again , Frisia Zout BV started bringing in salt water by tanker, however this was an expensive alternative. As a result, it grew to become crucial to bring the brand new offshore properly onstream as soon as possible.
Time pressures weren’t the one challenges the company faced. Due to the natural geology, the extraction path to the new offshore resource was not a straight bore: it modified course twice earlier than reaching the salt deposits. In reality, the new plant is fed by one of many deepest wells in the world and has 5 km of pipework past the water injection pumps. As a end result, the method water must be pumped in at excessive stress (250 barg) and at a high circulate price (450 m3/h) to extract the quantity of salt required, making the choice of pumps important to success.
Total answer
Frisia Zout BV has a protracted and established relationship with Celeros FT via the ClydeUnion Pumps brand, based not only on the top quality of ITS OEM pumps but in addition on its capacity to respond shortly to any operational points. The company turned to its trusted circulate management partner once once more for help in assembly the unique circumstances encountered on the new salt nicely.
Celeros FT model ClydeUnion Pumps assessed the circulate necessities for the water injection course of at the new plant and verified that CUP-BB3 pumps could be made to meet requirements. The pumps were specified with Duplex stainless-steel casings because they’d be operating in a salt-laden environment. Celeros FT manufactured, supplied, installed and commissioned the mission-critical pumps for injecting water into the brand new offshore salt cavern, assembly unusual necessities for high strain and high move rates. In addition, they supported Frisia Zout BV in bringing an older pump again into service as a spare: assessing it and upgrading the casing to make sure it met the new duty necessities.
Jouk Riemer, project supervisor for Frisia Zout BV, explained: “We have used CUP-BB3 pumps up to now and found that their multistage centrifugal design gives higher efficiency, in comparability with plunger pumps, for this utility. We needed to make use of them once more for the new challenge. The Celeros FT group responded to the challenges magnificently, using their engineering expertise to identify the best answer to fulfill the pressure and flow rates we required, delivering the pump skids to meet the new building schedule and serving to us keep the project on track.”
Future assured
The new salt extraction plant got here on-line in December 2020. Its CUP-BB3 pumps meet the high strain and circulate rates required for the appliance and may run in parallel, which has improved productivity. The availability of a spare pump offers further confidence that manufacturing downtime will be minimal. The company’s capability to meet the accelerated venture deadline is especially impressive when you consider that the Covid-19 pandemic was already affecting provides of supplies and elements. The Celeros FT group labored onerous to ensure that this didn’t have any influence on their buyer.
Celeros FT additionally offered specialist engineering experience all through the installation and commissioning part and will continue to ensure the pumps function satisfactorily all through the plant’s 15-year lifespan, although the pump building may be required to serve a couple of nicely in future as demand for K+S excessive purity salt continues to grow. Easy substitute of wear components and ongoing service help from Celeros FT will make sure that the BB3 pumps continue to meet operational parameters throughout the extraction plant’s lifetime.
Riemer stated: “The mixture of high quality OEM equipment and sensible engineering skills provided by Celeros Flow Technology was instrumental in delivering this project forward of time. I’m convinced it might have taken lots longer to get what we required from another pump producer. The company’s responsiveness was essential in meeting our revised deadline, decreasing costs and preserving extraction at this web site viable.” Riemer concluded: “This is the primary offshore extraction properly we have developed nevertheless it has been a largely optimistic expertise because of Celeros Flow Technology. They introduced invaluable engineering experience and specialist pump data to this venture and are a basic a half of its success.”
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