Tesla Disc Pump Engineering Assessment
Tesla Disc Pump Engineering Assessment
Engineering assessment with 1 mm disc spacing for dirty water serviceYou have now specified the key parameter that drives a Tesla disc pump’s behavior: disc-to-disc gap = 1.0 mm. With that, we can tighten the estimate for both capacity and efficiency, and make practical recommendations for gold-sluice duty where water is dirty and abrasive.I am still anchoring the analysis to the geometry implied by your drawings:• Disc outside diameter is 6.000 inches • The assembly shows 10 disc plates plus 10 disc spacers 1) What 1 mm spacing means physicallyA Tesla disc pump relies on viscous shear coupling in the boundary layers on each disc surface. For clean water at 3600 rpm, the effective boundary layer thickness is far smaller than 1 mm. Practically:• 1 mm is a wide gap for water, so viscous coupling per disc-pair is weaker than it would be at tighter spacing.• But 1 mm is a strong choice for dirty water, because it: • passes grit better • reduces clogging risk • tolerates small fibrous debris • reduces the chance that a single rock chip locks the rotorSo the trade is simple:• tighter spacing yields higher hydraulic efficiency and higher pressure capability for the same horsepower• wider spacing yields better solids tolerance, lower clogging, and better survivability in abrasive serviceFor gold-sluice water that may be dirty, your 1 mm choice is defensible.2) Capacity, head, pressure, and efficiency for a 6 inch, 10 disc, 1 HP unitBecause we still do not have an empirical pump curve, the most honest result is a bounded operating envelope. For wash plant supply, the typical duty is high flow and low to moderate head. That aligns with where a Tesla pump can do useful work on 1 HP.Assumptions used for this estimate:• Pump rotor: 6 inch disc diameter, 10 discs • Speed: up to 3600 rpm via VFD• Fluid: water with suspended solids (density close to water, viscosity close to water unless heavily loaded)• Spacing: 1.0 mm• Overall efficiency target range for this configuration in dirty water: 15% to 30% (wide gap reduces coupling, solids add slip and losses)Practical operating envelope at 3600 rpmThese are realistic values for wash plant supply head levels.A) Low head supply, best case for sluicing• Differential pressure: 10 to 15 psi (0.7 to 1.0 bar)• Head: 23 to 35 ft (7 to 11 m)• Flow: 40 to 90 gpm (9 to 20 m3/h)• Notes: this is where the pump will feel strong on 1 HP, assuming plumbing is not restrictive.B) Moderate head, longer hose runs, restrictive spray bars• Differential pressure: 15 to 25 psi (1.0 to 1.7 bar)• Head: 35 to 58 ft (11 to 18 m)• Flow: 20 to 55 gpm (5 to 12 m3/h)• Notes: expect noticeably lower flow if your system necks down to smaller lines, tight valves, or many fittings.C) Upper pressure range, closer to shutoff behavior• Differential pressure: 25 to 40 psi (1.7 to 2.8 bar)• Head: 58 to 92 ft (18 to 28 m)• Flow: 8 to 25 gpm (2 to 6 m3/h)• Notes: possible, but not the preferred region for a 1 HP wash plant supply pump. Also more wear from high internal slip.Unit conversions used• 1 gpm is about 0.227 m3/h• 1 psi is about 0.069 bar• 1 ft of head is about 0.305 m of head3) Is 1 mm optimal, and what spacing should be used for gold sluicingFor your application, optimal is a balance of:• solids tolerance and non-clogging behavior• acceptable efficiency• survivability under abrasive wearRecommended gap ranges by dirtiness• Cleaner water, sand only, minimal gravel fines: 0.5 to 0.8 mm • Higher efficiency and higher pressure at the same horsepower • More sensitive to grit jams if coarse particles get into the rotor• Typical sluice water, muddy with sand and fines, occasional small grit: 0.8 to 1.2 mm • This is your current design point and is a good compromise• Very dirty water, high grit content, occasional small pebbles, fibrous debris risk: 1.2 to 2.0 mm • Maximum survivability, but efficiency drops and the pump curve softensIf your wash plant needs flow more than pressure, and you expect real grit, 1.0 mm is a practical choice.4) Is 10 discs optimal, and should you change disc countDisc count affects two competing factors:• More discs increases shear surface area and can improve head and flow at a given slip condition• More discs increases drag torque and can overload a 1 HP motor, especially in viscous or gritty waterFor a 1 HP, 6 inch rotor• Recommended disc count band: 8 to 14 discs• Your 10 disc stack is a sensible baseline How to choose disc count for gold service• If you need more flow at low head and want maximum solids tolerance: • stay around 8 to 10 discs • keep 1.0 to 1.5 mm spacing• If you need more pressure capability and your water is not extremely gritty: • go to 12 to 14 discs • reduce spacing toward 0.6 to 0.8 mm • confirm motor current on the VFD so you do not stall or overheatMy best recommendation without test data• Keep 10 discs and 1 mm spacing for the first field unit• Offer two rotor cartridges as options: • High flow dirty water cartridge: 8 to 10 discs, 1.0 to 1.5 mm gap • Higher pressure cleaner water cartridge: 12 to 14 discs, 0.6 to 0.8 mm gap5) Dirty water realities for a Tesla disc pump in a gold wash plantKey advantages versus typical centrifugal pumps in this niche• Better tolerance to suspended solids and slurry-like flow• Fewer tight blade passages that plug• Can be built with larger clearances and still move water• VFD speed control is very useful for matching the wash plant duty and conserving powerKey failure and wear risks you must engineer around• Abrasion at the disc edges and in the housing clearance• Seal wear if grit is allowed near the shaft seals• Internal recirculation increases at higher pressure and raises wear rateField-proven practices I would treat as mandatory• Flooded suction from your tank, no suction lift if possible• A simple rock screen on the suction intake so stones do not enter• Replaceable wear surfaces where the disc rim clearance is tightest• A controlled bypass or recirculation line so the pump never runs fully dead-headed• Instruments you already described, especially discharge pressure and motor power, so operators can stay in the safe regionArticle draft for gold mining and wash plant water supplyPage TitleTesla Disc Pump Skid for Gold Wash Plant Water Supply High Flow Dirty Water Pumping with VFD ControlMeta DescriptionA Tesla disc pump skid can supply high flow water to a gold wash plant while handling dirty water with sand and fines. This article explains expected flow and pressure on a one horsepower unit, why disc spacing matters, and how to configure a reliable sluicing pump system.TeaserGold wash plants need steady water flow to break up clay, wash rocks, and drive sluice boxes. Dirty water with sand and grit is hard on conventional pumps. A Tesla disc pump skid with variable speed control offers a modular, serviceable approach designed for abrasive water service.Why a Tesla disc pump fits gold sluicing dutyGold sluicing and wash plants are a high flow application. Water is used to wash dirt from gold bearing rocks, power spray bars, and maintain consistent slurry motion through classifiers and sluice runs. In the field, the water is rarely clean. Fine sand, silt, and grit quickly reduce the life of many pumps, especially when small passages clog or when abrasion concentrates at an impeller edge.A Tesla disc pump moves fluid using viscous shear along rotating discs. With appropriately chosen disc spacing, this architecture can pass dirty water more reliably than pumps with tight vane passages. The result is a pumping skid that prioritizes uptime and serviceability in abrasive environments.Reference pump configuration and expected performanceA practical reference unit uses a one horsepower, three phase motor driven by a VFD. The pump rotor uses a six inch disc pack with ten discs and one millimeter spacing between discs. This spacing is intentionally selected for dirty water.Expected performance range at up to 3600 rpm depends on plumbing restrictions and discharge pressure requirements.Typical wash plant supply duty• Differential pressure 10 to 15 psi, flow about 40 to 90 gpm• Metric equivalent, differential pressure 0.7 to 1.0 bar, flow about 9 to 20 m3 per hourModerate head duty for longer hoses and restrictive spray bars• Differential pressure 15 to 25 psi, flow about 20 to 55 gpm• Metric equivalent, differential pressure 1.0 to 1.7 bar, flow about 5 to 12 m3 per hourHigher pressure operation is possible, but it is not the preferred region for a one horsepower wash plant pump because wear rises as internal slip increases.Disc spacing and disc count recommendations for mining waterDisc spacing is the main control knob for balancing efficiency versus solids tolerance.Recommended spacing bands• 0.5 to 0.8 mm for cleaner water when higher pressure and efficiency are required• 0.8 to 1.2 mm for typical sluice water with sand and fines• 1.2 to 2.0 mm for very dirty water where non-clogging reliability matters mostDisc count is the second control knob. More discs can increase shear surface area but also increases torque demand. For a one horsepower class unit, a practical range is eight to fourteen discs. For gold sluicing duty, ten discs is an effective baseline that balances hydraulic coupling and motor load.Skid architecture for field reliabilityA mining pump skid should be designed around harsh reality: grit, operator variability, and the need for fast maintenance.Key design practices• Flooded suction from a water tank or sump to avoid suction lift and reduce cavitation risk• Suction rock screen to stop stones and large debris• Discharge bypass or recirculation path so the pump is never forced to operate fully dead-headed• Discharge pressure sensor and motor power monitoring through the VFD so operators can stay within safe limits• Replaceable wear surfaces near the disc rim clearance zones to manage abrasion economicallyOperating guidance for wash plant crews• Run the pump fast enough to achieve steady wash plant flow, then trim rpm down until pressure is stable and power draw is reasonable• Avoid running at high discharge pressure for long periods, because abrasive wear accelerates• If discharge pressure rises but flow falls, check for downstream restrictions first, then inspect suction screening and inlet conditions• Keep a spare disc pack or rotor cartridge on hand so the pump can be restored quickly without extended downtimeSummaryA Tesla disc pump skid configured with one millimeter disc spacing is a practical solution for pumping dirty water in gold sluicing operations. The system favors reliability and solids tolerance while still delivering wash plant level flows on a one horsepower drive when the duty is low to moderate head. By offering disc pack options and using VFD control with basic instrumentation, a wash plant can maintain consistent water delivery and reduce pump-related downtime in abrasive conditions.If you tell me the specific wash plant target, meaning required flow and required discharge pressure and the approximate hose length and diameter, I will narrow the estimate to a tighter expected point and recommend an rpm setpoint range for the VFD.
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