Failure analysis and guidelines for further exploitation of centrifugal slurry pumps used for copper flotation waste transport: A case study

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis Pub Date : 2025-03-03 DOI:10.1016/j.engfailanal.2025.109479

Jakub Wróbel , Damian Pietrusiak , Radosław Rozmus , Robert Roicki , Bartłomiej Zarzycki , Paweł Stefanek

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Abstract

High power slurry pumps are the core element of copper flotation waste transport. Pump failure can lead to shutdowns of the flotation process and high financial losses. This paper is a case study of three high power, split case, rubber lined, closed impeller, tangential discharge slurry pump failures, where all failed pumps were located at the first stage of three different pumping sections. Analysis of the material strength of each pump housing showed a strong reduction in the ultimate tensile strength to 25 %, 39 % and 46 % of the specified min value of 241 MPa for ASTM A48 Class 35 Gray Iron Castings. Microstructure analysis showed numerous micro cracks formed along with casting defects such as cementite, phosphorus eutectic and porosities. Vibration analysis identified interference between pump stages that led to low frequency beat phenomena that consequently could cause cyclic load on the castings. Detailed FEM modeling of the pump housing assembly, including main bolted connections, indicated that tightening the pump housing bolts with the correct torque or operation at a nominal pressure of 0.69 MPa could cause the pump housing to fail due to strongly reduced material properties. Further investigation showed that the ASTM A48 Class 35 Gray Iron and cast stainless steel bodies A743 CA6NM did not show overload both when the housings are properly bolted together and when a 30 % overload is introduced on one of the fasteners, given the proper material properties.

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来源期刊

Engineering Failure Analysis 工程技术-材料科学：表征与测试

CiteScore

7.70

自引率

20.00%

发文量

956

审稿时长

47 days

期刊介绍： Engineering Failure Analysis publishes research papers describing the analysis of engineering failures and related studies. Papers relating to the structure, properties and behaviour of engineering materials are encouraged, particularly those which also involve the detailed application of materials parameters to problems in engineering structures, components and design. In addition to the area of materials engineering, the interacting fields of mechanical, manufacturing, aeronautical, civil, chemical, corrosion and design engineering are considered relevant. Activity should be directed at analysing engineering failures and carrying out research to help reduce the incidences of failures and to extend the operating horizons of engineering materials. Emphasis is placed on the mechanical properties of materials and their behaviour when influenced by structure, process and environment. Metallic, polymeric, ceramic and natural materials are all included and the application of these materials to real engineering situations should be emphasised. The use of a case-study based approach is also encouraged. Engineering Failure Analysis provides essential reference material and critical feedback into the design process thereby contributing to the prevention of engineering failures in the future. All submissions will be subject to peer review from leading experts in the field.