A review of industrial pumps for viscous and non-Newtonian slurry transport

This paper presents a concise review of industrial pumps for viscous and non-Newtonian slurry transport. It combines both the computational fluid dynamics (CFD) and experimental analysis to investigate the performance and limitations of various rotodynamic and positive displacement (PD) pumps for various slurry transport applications. The factors influencing head, efficiency and reliability in rotodynamic and PD pumps were evaluated for viscous and non-Newtonian fluids applications. Available literature showed that centrifugal pumps experience head losses of ≥ 8 m and efficiency reduction of 20 % when viscosity approaches 800–1000 cP, whereas the blade and volute optimisation could improve the overall efficiency. The performance of the multiphase pump showed a sharp decline when handling non-Newtonian fluids, primarily due to the formation of complex vortex structures and tip‑leakages. This study also highlighted key geometric parameters for optimisation to improve overall performance and enable the integration of multiphase pumps as a prime mover in a jet pump system, for a robust handling of highly viscous and solid‑laden fluids. While the special‑effect jet pumps had lower peak efficiencies compared to other rotodynamic pumps, robustness and passability for abrasive and multiphase flows were demonstrated, achieving up to 40 % efficiency in sand slurry applications. PD pumps, such as the reciprocating plunger and diaphragm designs, exhibited the highest viscosity tolerance, however, their performance was limited by valve response and mechanical complexity. This review particularly focused on the capabilities of Tesla disc pump for handling highly viscous and abrasive fluids. Literature on Tesla disc pumps emphasised that geometric optimisation of the disc impeller, combined with the use of a dedicated volute, could significantly enhance its efficiency and position it as a complementary solution to both centrifugal and PD pumps. The analysis of life cycle cost (LCC) showed that the Tesla disc pump maintained moderate costs for harsh applications, indicating a sustainable operational life cycle.