Rising to the salt extraction challenge

A salt extraction operation needed to transfer shortly from an onshore to an offshore website equipped by 5 km of pipework. The firm turned to flow control associate 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 at the Frisia Zout BV site.
A new salt extraction plant off the north coast of Holland has been brought online ahead of schedule, stopping a possible halt in manufacturing when the prevailing onshore well 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 loose to a 40,000-tonne storage facility for delivery in bulk to business. The remainder is packed in smaller quantities to be used in meals manufacturing or made into cubes for water purification.
The salt is extracted under licence from the Dutch government. The present borehole licence
allowed K+S to extract salt from underground on the mainland. Due to regulatory adjustments, the new licence would solely allow extraction from subsea sources off the coast. Consequently, a new borehole and related plant was required at the Frisia Zout BV web site.
New challenges
K+S began planning for a model new pump building in 2017, and development began in April 2020 with the purpose of bringing it onstream before the prevailing extraction licence expired at the finish of 2021. However, pressure gauge น้ำ arose with the existing onshore properly, which meant that production would cease ahead of anticipated. To bridge the gap, Frisia Zout BV started bringing in salt water by tanker, but this was an costly alternative. As a result, it grew to become crucial to convey the new offshore well onstream as soon as attainable.
Time pressures were not 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 changed course twice before reaching the salt deposits. In fact, the new plant is fed by one of the deepest wells in the world and has 5 km of pipework past the water injection pumps. As a outcome, the process water needs to be pumped in at excessive pressure (250 barg) and at a high flow price (450 m3/h) to extract the amount of salt required, making the choice of pumps important to success.
Total resolution
Frisia Zout BV has a protracted and established relationship with Celeros FT via the ClydeUnion Pumps model, primarily based not solely on the high quality of ITS OEM pumps but in addition on its capability to reply quickly to any operational issues. The company turned to its trusted flow management partner as soon as once more for assist in meeting the unique circumstances encountered at the new salt well.
Celeros FT brand ClydeUnion Pumps assessed the move necessities for the water injection process at the new plant and verified that CUP-BB3 pumps could probably be made to fulfill necessities. The pumps had been specified with Duplex stainless-steel casings as a end result of they might be working in a salt-laden setting. Celeros FT manufactured, provided, installed and commissioned the mission-critical pumps for injecting water into the new offshore salt cavern, assembly uncommon necessities for high strain 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 ensure it met the new responsibility necessities.
Jouk Riemer, challenge manager for Frisia Zout BV, defined: “We have used CUP-BB3 pumps up to now and found that their multistage centrifugal design offers better efficiency, compared to plunger pumps, for this application. We wished to use them once more for the new project. The Celeros FT staff responded to the challenges magnificently, utilizing their engineering experience to establish one of the best resolution to meet the pressure and move charges we required, delivering the pump skids to fulfill the new building schedule and serving to us hold the challenge on track.”
Future assured
The new salt extraction plant got here on-line in December 2020. Its CUP-BB3 pumps meet the excessive strain and circulate charges required for the appliance and can run in parallel, which has improved productivity. The availability of a spare pump provides further confidence that production downtime shall be minimal. The company’s ability to fulfill the accelerated challenge deadline is especially spectacular when you consider that the Covid-19 pandemic was already affecting provides of supplies and components. The Celeros FT group worked hard to guarantee that this didn’t have any impact on their buyer.
Celeros FT also offered specialist engineering experience throughout the installation and commissioning phase and will continue to make sure the pumps function satisfactorily throughout the plant’s 15-year lifespan, though the pump constructing may be required to serve more than one well in future as demand for K+S excessive purity salt continues to develop. Easy replacement of wear components and ongoing service assist from Celeros FT will be certain that the BB3 pumps continue to satisfy operational parameters throughout the extraction plant’s lifetime.
Riemer mentioned: “The mixture of top quality OEM gear and practical engineering abilities supplied by Celeros Flow Technology was instrumental in delivering this challenge ahead of time. I’m convinced it might have taken so much longer to get what we required from one other pump manufacturer. The company’s responsiveness was essential in meeting our revised deadline, lowering prices and preserving extraction at this web site viable.” Riemer concluded: “This is the first offshore extraction well we have developed however it has been a largely constructive experience due to Celeros Flow Technology. They introduced invaluable engineering expertise and specialist pump information to this challenge and are a elementary a part of its success.”
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