Tag Archive for: abrasive

FGD Washdown Sumps

Flue Gas Desulfurization (FGD) systems scrub sulfur dioxide from exhaust gases in coal-fired plants. Washdown sumps collect slurry containing lime, gypsum, and residual solids from these systems. Efficient sump pumping is essential to maintain clean, safe, and compliant operations.

Challenges:
FGD slurries are chemically aggressive and highly abrasive, causing corrosion and erosion in conventional pump materials. pH fluctuations and dense solids often lead to clogging and seal damage. Downtime for cleaning or repair directly impacts environmental compliance and plant uptime.

Solution:
Hevvy/Toyo pumps designed for FGD service use corrosion- and abrasion-resistant alloys and elastomers. Their recessed impellers minimize contact with solids, and agitators keep materials in suspension for complete sump cleaning. The result is reliable, chemical-resistant performance that maintains sump integrity and minimizes manual intervention.

Coal Pile Runoffs

Coal pile runoff systems manage water that drains from coal storage areas during rainfall or washdown operations. This runoff often contains coal fines, sediments, and hydrocarbons, which must be collected and treated to prevent contamination of surrounding waterways.

Challenges:
Runoff water is highly abrasive and varies in solids concentration depending on rainfall or operational activity. Pumps must handle fluctuating flows and dirty water containing fine coal particles without clogging or premature wear. Maintaining reliability in outdoor, exposed environments adds further complexity.

Solution:
Hevvy/Toyo’s submersible slurry pumps are built to handle variable, abrasive coal runoff streams. Their recessed impellers pass solids easily, while agitators prevent sediment buildup in sumps or collection pits. Corrosion-resistant materials and mechanical seal protection ensure reliable, low-maintenance operation even in the harshest outdoor environments.

Fly Ash and Bottom Ash

Fly ash and bottom ash are the by-products of coal combustion in thermal power plants. Fly ash consists of fine particles carried by flue gases, while bottom ash settles at the furnace base. Both need to be collected, transported, or disposed of safely to comply with environmental regulations and maintain plant efficiency.

Challenges:
These ashes are abrasive, dense, and often mixed with water to form a heavy slurry that wears out pump components quickly. Variable solids concentration and temperature fluctuations make consistent flow difficult. Traditional pumps experience rapid erosion, clogging, and seal failures in ash-handling systems.

Solution:
Hevvy/Toyo’s submersible and horizontal slurry pumps feature hardened materials and open or recessed impellers designed for abrasive service. Their high-chrome wet ends, heavy-duty bearings, and optional agitators handle high-solid ash slurries with ease. The result is longer service life, reduced maintenance, and dependable ash management in demanding power plant conditions.

Subsea Drilling

Subsea drilling involves extracting oil and gas from beneath the ocean floor, often at great depths. Pumping systems are vital for managing drilling fluids, cuttings, and seawater mixtures under high pressure and variable flow conditions.

Challenges:
Subsea environments expose equipment to immense pressure, corrosion from saltwater, and abrasive drilling muds. Pumps must operate reliably in remote, difficult-to-access locations where failures are costly and repairs require specialized intervention.

Solution:
Hevvy/Toyo offers rugged, corrosion-resistant submersible pumps engineered for deepwater and offshore use. Constructed from marine-grade alloys and sealed for subsea conditions, they handle abrasive muds and solids with ease. Their proven hydraulic efficiency and long-life components reduce intervention frequency, ensuring dependable operation in mission-critical drilling systems.

Sand Separation

Sand separation is a critical step in oil and gas production to remove sand and other particulates from produced fluids. Whether upstream in separators or downstream in treatment systems, effective sand removal protects equipment, reduces erosion, and maintains flow assurance.

Challenges:
Separated sand tends to settle and compact in sumps and tanks, forming abrasive layers that are difficult to remove. High solids loading quickly wears out conventional pumps, while intermittent flow can lead to blockages or inefficient operation.

Solution:
Hevvy/Toyo pumps with recessed impeller designs and agitators are ideal for handling abrasive, sand-laden fluids. They maintain solids in suspension, preventing settling and ensuring consistent transfer. With options for hard-metal wet ends and explosion-proof motors, these pumps deliver safe, durable performance in demanding sand-handling environments.

Bottom Pumps

Bottom pumps are used to remove heavy residues or slurries that settle at the bottom of storage tanks, separators, or process vessels. These materials often include sediment, sand, or sludge that must be cleared to maintain system efficiency and prevent buildup.

Challenges:
The main challenge lies in the high density and abrasiveness of settled materials. Conventional pumps often fail to pick up settled solids, leading to accumulation and manual cleaning. Limited access inside tanks also makes maintenance and replacement difficult.

Solution:
Hevvy/Toyo’s submersible bottom pumps with integrated agitators can lift and transport settled solids directly from the tank floor. Their rugged construction and wear-resistant impellers handle heavy slurries effortlessly. The compact, portable design allows quick deployment for cleaning or continuous service — reducing downtime and extending tank life.

Desalting Sludges

Desalting sludges are dense mixtures of oil, water, and solids generated during the crude-oil desalting process. The desalting unit removes salts and other contaminants before refining, but this separation leaves behind thick, abrasive, and often corrosive sludges that must be safely removed and transferred.

Challenges:
These sludges are highly viscous and contain sticky hydrocarbons, solids, and sometimes corrosive chlorides, making them difficult to pump. Standard centrifugal pumps struggle with suction loss, overheating, or clogging, while maintenance can be hazardous due to the sludge’s chemical nature and high temperature.

Solution:
Hevvy/Toyo submersible agitator pumps excel in handling heavy, viscous, and abrasive sludge. Their agitator technology keeps solids suspended, while robust high-chrome or stainless-steel materials resist corrosion and wear. This ensures continuous operation with minimal manual intervention — reducing downtime, cleanup, and maintenance costs.