Rising to the salt extraction challenge

A salt extraction operation had to move shortly from an onshore to an offshore site provided by 5 km of pipework. The company turned to move management partner Celeros to help meet the distinctive circumstances encountered at the new salt properly.
Overview of the 2 new water injection pumps for single and parallel operation, following installation and commissioning on the Frisia Zout BV web site.
A new salt extraction plant off the north coast of Holland has been introduced online forward of schedule, preventing a possible halt in production when the present onshore nicely developed points. Frisia Zout BV, part of K+S Minerals and Agriculture GmbH, was in a place 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 trade. The the rest is packed in smaller quantities to be used in food production or made into cubes for water purification.
The salt is extracted under licence from the Dutch authorities. Underground existing borehole licence
allowed K+S to extract salt from underground on the mainland. Due to regulatory adjustments, the new licence would only permit extraction from subsea sources off the coast. Consequently, a new borehole and related plant was required on the Frisia Zout BV website.
New challenges
K+S began planning for a model 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, unexpected difficulties arose with the present onshore well, which meant that production would stop ahead of anticipated. To bridge the hole, Frisia Zout BV started bringing in salt water by tanker, but this was an costly different. As a outcome, it grew to become crucial to convey the new offshore properly onstream as soon as possible.
Time pressures weren’t the one challenges the corporate confronted. Anonymous to the pure geology, the extraction route to the new offshore useful resource was not a straight bore: it changed course twice before reaching the salt deposits. In reality, the new plant is fed by one of the deepest wells in the world and has 5 km of pipework beyond the water injection pumps. As a outcome, the process water needs to be pumped in at high pressure (250 barg) and at a high move price (450 m3/h) to extract the quantity of salt required, making the choice of pumps crucial to success.
Total solution
Frisia Zout BV has a long and established relationship with Celeros FT through the ClydeUnion Pumps brand, based mostly not only on the prime quality of ITS OEM pumps but also on its capability to reply shortly to any operational issues. The company turned to its trusted flow control associate once once more for assist in assembly the unique circumstances encountered on the new salt properly.
Celeros FT model ClydeUnion Pumps assessed the flow necessities for the water injection course of on the new plant and verified that CUP-BB3 pumps could be made to fulfill necessities. The pumps have been specified with Duplex stainless-steel casings because they might be operating in a salt-laden setting. Celeros FT manufactured, provided, installed and commissioned the mission-critical pumps for injecting water into the model new offshore salt cavern, meeting uncommon necessities for high pressure and excessive circulate 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 ensure it met the new obligation requirements.
Jouk Riemer, challenge manager for Frisia Zout BV, explained: “We have used CUP-BB3 pumps up to now and found that their multistage centrifugal design offers higher efficiency, compared to plunger pumps, for this software. We needed to make use of them once more for the new venture. The Celeros FT team responded to the challenges magnificently, using their engineering experience to identify the best resolution to satisfy the stress and flow rates we required, delivering the pump skids to fulfill the new construction schedule and helping us keep the venture on track.”
Future assured
The new salt extraction plant came on-line in December 2020. Its CUP-BB3 pumps meet the excessive strain and circulate charges required for the appliance and may run in parallel, which has improved productivity. The availability of a spare pump gives extra confidence that production downtime will be minimal. The company’s capability to fulfill the accelerated challenge deadline is especially impressive when you think about that the Covid-19 pandemic was already affecting provides of materials and elements. The Celeros FT group labored exhausting to guarantee that this didn’t have any impact on their buyer.
Celeros FT additionally offered specialist engineering experience throughout the set up and commissioning section and can proceed to make sure the pumps operate satisfactorily all through the plant’s 15-year lifespan, though the pump constructing may be required to serve a couple of properly in future as demand for K+S excessive purity salt continues to grow. Easy alternative of wear elements and ongoing service help from Celeros FT will be sure that the BB3 pumps proceed to meet operational parameters all through the extraction plant’s lifetime.
Riemer said: “The mixture of top of the range OEM gear and practical engineering skills offered by Celeros Flow Technology was instrumental in delivering this project forward of time. I’m convinced it would have taken so much longer to get what we required from another pump manufacturer. The company’s responsiveness was essential in meeting our revised deadline, lowering costs and maintaining extraction at this web site viable.” Riemer concluded: “This is the first offshore extraction properly we now have developed nevertheless it has been a largely constructive expertise thanks to Celeros Flow Technology. They introduced invaluable engineering expertise and specialist pump data to this venture and are a elementary part of its success.”
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