MSSP-1000 - Derrickinternational Equipment Company

MSSP-1000 

(MODULAR SLURRY SEPARATION PLANT) 

Derrick Civil Office: 

Derrick Equipment Company 

15630 Export Plaza Drive 

Houston, Texas 77032 – USA 

Telephone: (281) 590-3003 

Facsimile: (281) 590-6187 

Email: derrick@derrickequipment.com 

www.DerrickInternational.com 

Derrick Headquarters: 

Derrick Corporation 

590 Duke Road 

Buffalo, New York 14225 – USA 

Telephone: (716) 683-9010 

Facsimile: (716) 683-4991 

Email: info@derrickcorp.com 

MSSP-1000 Revision 9/09/2008

TABLE OF CONTENTS 


Overview Page 2 

Process Flow Page 3 

System Advantages 

Visual Monitoring Page 4.1 

System Control Page 4.1 

Self-Cleaning Sumps Page 4.1 

Plant Flexibility Page 4.1 

Large Capacity Page 4.1 

Screen Deck Angle Adjustment Page 4.2 

Elevated Centrifuge Page 4.2 

Automatic Operation Page 5 

Options Page 6 

Specification Page 7.1 - 7.4 

Photo Gallery Page 8 - 12 

Plant Modeling View Page 13 - 15 

Derrick Equipment Company – Modular Slurry Separation Plant 

1

OVERVIEW 


The Derrick Slurry Treatment Plant can process more than 1000 M3/Hr of fluid containing bentonite and 

solids excavated from tunnel boring machine (TBM) operations. The plant utilizes multiple processing steps, 

each designed to remove successively smaller solids. Critical steps within the process provide solids removal 

capacities equal to the maximum tunneling rate of the TBM. During ring-building operations, the re-circulating 

capability of the plant permits it to respond to challenging and constantly changing soil formations. 


2

PROCESS FLOW 


Flow from the TBM passes through a flowmeter and then to a Derrick C-56 low-speed, high-amplitude 

screening machine. The machine’s weir-style feeder distributes the slurry evenly on its urethane screen panels. 

Oversized material that does not pass through the screen bed is directed to a conveyor and stacker for 

deposit in a holding area. Solids and fluid that pass through the screen are directed by gravity to Sump 1 of 

the base tank, which is located directly below the screening machine. 

One abrasion-resistant pump draws slurry from the bottom of Sump 1 to feed 4 12” sand separator-type 

hydrocyclones. Each hydrocyclone discharges oversized material onto the urethane screening panels of 

a Derrick FLC-2000 screening machine. Undersize material and overflow fluid passing out the top of the 

hydrocyclones is discharged into Sump 2. Oversized material from each of the FLC-2000s is discharged 

to the belt conveyor. Fluid and solids that pass through the screens flow by gravity to Sump 2 for further 

processing. 

Two additional abrasion-resistant pumps have the capacity of drawing slurry from either the bottom of Sump 

1 to feed 8 additional 12” hydrocyclones or from Sump 2 to feed 80 4” hydrocyclones. Oversized material 

discharged from either the 12” sand separators or 4” hydrocyclones is further dried on 4 FLC-2000 screening 

machines. Overflow from the top of the hydrocyclones is fed by gravity to the appropriate sump. 

The three sumps in the base tank are separated by weirs for safe, gravity-flow operation. When the TBM is 

operating at 100 percent capacity, fluid passes through the processing equipment and then to the base tank 

sumps in sequential order. When the level in Sump 3 rises to the weir outlet, cleaned fluid flows by gravity to 

the TBM working tank. If the TBM pump is delivering less than 100 percent of design flow, part of the slurry 

in Sump 2 flows over the weir into Sump 1 instead of flowing out to the TBM tank. In addition, part of the 

slurry in Sump 3 returns to Sump 2 instead of flowing out to the TBM tank. This feature maintains sufficient 

fluid supply to the hydrocyclone feed pumps at all times. 

The plant includes two Derrick DE-7200 decanter-type centrifuges, which receive slurry from either the active 

working system or waste mud tank. Oversized material from the centrifuges is directed to the conveyor, while 

cleaned fluid flows by gravity to the TBM tank or to a site discharge point. When a nearly clear effluent 

discharge is desired, a completely automated dry polymer metering and mixing system can supply flocculent 

to both DE-7200 centrifuges simultaneously. 


3

SYSTEM ADVANTAGES 


Visual Monitoring 

Several movable and stationary cameras allow visual monitoring of all critical operations from the control 

room. Vision system control from a dedicated PC allows remote pan-tilt-zoom operation for the movable 

cameras and zoom operation for the stationary cameras. 

System Control 

System operating mode is selectable from the operator control room. Operating features in manual and 

automatic mode are as follows: 

• Manual Mode - Allows the operator to start and stop each pump and screening machine 

individually 

• Automatic Mode - Monitors the flow meter and tank level sensor feedback signals to open/ 

close valves and successively start screening machines and pumps when flow is detected 

In manual or automatic mode, the operator can initiate recirculation where fluid from the TBM working tank is 

pumped back to Sump 2 for re-processing through the 12” or 4” hydrocyclones. This process eliminates the 

need to run TBM pumps for extended periods of time in bypass mode during ring-building operations, while 

allowing continued uninterrupted solids removal from the active working system. 

Self-Cleaning Sumps 

Sumps 1, 2 and 3 are self-cleaning during operation, eliminating the need for agitators. Each of the sumps 

is connected to a common pump to facilitate clean-out or draining prior to extended shutdown periods. The 

pump discharge can be directed to the TBM working tank or a collection tank for future processing. 

Plant Flexibility 

In soil formations consisting primarily of sand-sized particles, the 12” hydrocyclones with built-in excess 

processing capacity, provide exceptional solids removal. However, in soil formations containing silt-sized 

particles, 4 banks of 4” hydrocyclones can be employed both in drilling mode and re-circulating mode to 

reduce fine-sized solids accumulation in the active working system. 

Large Capacity 

Generous TBM and waste mud tank storage capacities are provided to permit operational flexibility and 

eliminate the need for additional off-site processing. 


(continues next page) 

4.1


SYSTEM ADVANTAGES (continued) 

Screen Deck Angle Adjustment 

The C-56 and all FLC-2000s have deck angle adjustment capability. Raising the deck angle increases the 

dryness of discharged solids but increases conveyance time. Lowering the deck angle reduces conveyance 

time but increases wetness. 

Elevated Centrifuge 

Remote monitoring and control permits the centrifuge to be located on the uppermost level, thereby eliminating 

the need for additional mechanical pumping. With the centrifuge elevated, centrifuge effluent returns by 

gravity to the TBM working tank or collection point for offsite discharge. 


4.2

AUTOMATIC OPERATION 


Fresh bentonite slurry can be mixed manually or automatically. Two operator inputs are required for automatic 

bentonite mixing: 

• Volume of new slurry to be mixed 

• Ratio of dry bentonite to fresh water 

With these inputs supplied, the control system opens the necessary valves, starts the mixing hopper pump, 

determines speed, and sends a start command to the bentonite silo auger to discharge the appropriate 

quantity of dry bentonite for the requested mix ratio. 

Transfer of new bentonite slurry to the active working system as well as transfer of slurry from the TBM tank to 

waste mud tank, can be accomplished with automatic operation. The operator is required to only define the 

volume of fluid to be transferred, origin tank, and destination tank. The control system opens and closes the 

required valves, starts the appropriate pump and monitors the destination tank level sensor when the specified 

volume has been transferred the pump is stopped and valves returned to their normal position. 


5

OPTIONS 


• Fresh water storage tank, pressure tank, pump, valves and level sensor for locations where 

local supply pressure or volume are insufficient. 

• Main power switch-panel providing electrical disconnect and protection for power supplied 

from sub-station to slurry plant. 

• DE-7200 high speed decanting centrifuge, feed pump, chute and associated valves 

and piping. 


6

SPECIFICATION 


Equipment Description: 1000 M 3 /Hr Separation Plant 

Application: Modular Slurry Treatment Plant for Large Diameter Tunneling 

System Capacity: 1000 M 3 /Hr (4,400 GPM) Fluid Volume and 

250 TPH Solids Removal 

Plant Type: Modular 20’ and 40’ Containers Stacked Three High by Two Deep. 

Incorporates Primary Screening, Sand Separators, Hydrocyclones, 

Drying Screens, Sumps, Pumps, Centrifuges, Polymer Mixing and 

Dispensing unit, Stairs, Walkways, Electrical Motor Control Centers, 

Slurry Test Lab and Control Room. 

Primary Screens: One C-56 Low Speed High Amplitude Screens 

• Capacity: 1300 M 3 /Hr (5,700 GPM) 

• Screen Size: 700um to 10.0mm (25 mesh to 3/8’’) 

• Screen Type: Derrick Patented High Open Area, 

Long Life Polyurethane 

• Dimensions: Nominal 5 feet (1.5m) wide by 14 feet (4.2m) long 

Sand Separators: Twelve 12” Hydrocyclones with Integrated Underflow Regulator 


• D50 Cut Point: 35 – 55 Micron (Water-Solid Slurry with 1.3 S.G.) 

Hydrocyclones: Eighty 4” Urethane Construction with Ceramic Lining 


• D50 Cut Point: 15 - 40 Micron (Water-Solid Slurry with 1.3 S.G.) 

Cone Pumps: Three 8 X 6 X 14 Centrifugal Pump, Abrasion Resistant Wetted Parts 

with Mechanical Seal and VFD Control 



7.1

SPECIFICATION 


Drying Screens: Six FLC-2000 4-Panel High “G” Shakers with Adjustable Deck Angle 

•Capacity: Fluid - 1350 M 3 /Hr (6,000 GPM) 

Solid - 270 TPH (Short) 

• Screen Size: 500μm to 700μm (25-35 mesh) 

• Screen Type: Derrick Patented High Open Area, 

Long Life Polyurethane 

• Dimensions: Nominal 4 feet (1.2m) wide by 10 feet (3.0m) long 

Centrifuges: Two DE-7200 VFD Centrifuges with Local and Remote PLC Control 

• Capacity: 200 M 3 /Hr (900 GPM) 

• D50 Cut Point: 8-10 Micron 

• Conveyor Type: Helical/Radial 

• Bowl Diameter: 21.5’’ 

• Bowl Length: 72’’ 

• Gear Box Ratio: 49:1 

Feed Pumps: Two Progressing Cavity Centrifuge Feed Pumps 

• Type: Positive Displacement 

• Capacity: 0 - 250 M 3 /Hr (0 - 1,100 GPM) 

• Gear Box: Fixed Ratio 

• Motor: Inverter Duty 

Flocc Station: One Polymer Mixing and Dispensing System with 

Local and Remote PLC Control 

• Polymer Type: Dry Powder – Big Bag Package 

• Capacity: 460 – 4,600 l/hr (2 – 18 GPM) Metered to Two (2) 

Centrifuges Maximum Simultaneously via onboard 

Dosing Pumps 

Storage Tanks: Circular Large Capacity Tanks with Pipe Connection Flanges, Pipe 

Supports, External Caged Ladder and Observation Platform 

and Agitators 

• Type: Galvanized Steel Panel and Ring Bolted together on-site 

• Sizes: Two (2) 300 M 3 (80,000 Gal) TBM Active Working Tanks 

One (1) 900 M 3 (240,000 Gal) Waste Mud Storage Tank 

One (1) 200 M 3 (53,000 Gal) New Bentonite Storage Tank 



7.2

SPECIFICATION 


Bentonite Storage: One Dry Bentonite Storage Silo with Dust Control Filtering System, 

Level / Mass Sensing, External Caged Ladder and Observation Platform, 

Fill Pipe and Inclined Auger for Dispensing 

• Capacity: 700 BBL Dry Powder 

• Auger: 0 – 23 TPH VFD Controlled 

Bentonite Mixing: One Open Hopper with Attached Jet-Venturi Nozzle and Pump 

Transfer Pumps: Two 8 X 6 X 14 

Sump Cleanout Pumps: One 6 X 5 X 14 

• Capacity: Bentonite – 180 Kg per Min (400 LBS Per Minute) 

Fluid – 136 M3 Per Hr (600 GPM) 

Flow Meters: One 12” Full Flow Electromagnetic 

Level Sensors: Four Non-Contact Ultra-Sonic Type 

Conveyors: One 60 ft Horizontal Belt Conveyor with Edge Guides and Material 

Weighing System 

One 80 ft. Radial Inclined Belt Conveyor Stacker 

Motor Control Center: One Self Contained Climate Controlled Electrical Equipment Room 

containing Disconnects, Starters, Soft Starters and Variable Frequency 

Drives for respective Motors as well as PLC Controllers, I/O Modules, 

Power Supplies, Centrifuge Control Systems and Network 

Communication Hardware 

Operator Control Room: One Climate Controlled Room with Touch Screen Operator Interface 

Panels for Monitoring and Control of all Shakers, Centrifuges, 

Pumps, Agitators, Automatic Valves and Bentonite Mixing System. 



7.3

SPECIFICATION 


Slurry Test Lab: One Climate Controlled Room with Sink and Heavy Duty Floor / Wall 

Mount storage cabinets. Test Lab layout accommodates Bentonite 

Slurry testing, equipment storage and sample storage 

Vision System: One Plant wide Vision System consisting of multiple Pan-Tilt-Zoom 

cameras, multiple Zoom-Only cameras and Workstation for 

Monitoring and Control 

Valves: Three 4” Automatic Butterfly Valves 

Thirtythree 6” Automatic Knifegate Valves 

Nine 8” Manual Knifegate Valves 

Eight 8” Automatic Knifegate Valves 

Piping: All Pipes, Fittings and Connections within the Modular Structure for 

Pumps, Hydrocyclones and Centrifuges 

Elec. Cable: All Power, Control and Communication Cable within the Modular 

Structure necessary for Equipment Operation and Control 


7.4

PHOTO GALLERY 

Operator Control Room 

Motor Control Room 



8

PHOTO GALLERY 

C56 Dewatering Machine (Recovered Solids) 


Derrick Abrasion Resistant, High Open Area Urethane Screens 


9

PHOTO GALLERY 

FLC 2000 4-Panel with Hydrocyclones 

Hydrocyclones Discharge 



10

PHOTO GALLERY 

FLC 2000 4-Panel (Discharge) 

C56 and FLC 2000 (Discharge Pile) 



11

PHOTO GALLERY 

DE-7200 VFD Centrifuge 

DE-7200 Centrifuge (Discharge) 



12

PLANT MODELING VIEW 

MSSP - 1000 ISO Front View 



13


MSSP - 1000 ISO Back View 



14


MSSP - 1000 ISO Side View 



15

MSSP-1000 - Derrickinternational Equipment Company

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