Industrial Pumps + Compressors - Industriepumpen + Kompressoren

Transcrição

2015
Industrial Pumps
+ Compressors
International issue
ACHEMA SPECIAL
The Gas Engineer’s
Dictionary
Supply Infrastructure from A to Z
• biogas
• corrosion protection
• grid layout
• metering
• storages
• compressor stations
• dispatching
• LNG
• pressure regulation
DIV Deutscher Industrieverlag GmbH, Arnulfstr. 124, 80636 München
The Gas Engineer’s Dictionary will be a standard work for all aspects of construction,
operation and maintenance of gas grids.
This dictionary is an entirely new designed reference book for both engineers with
professional experience and students of supply engineering. The opus contains the world
of supply infrastructure in a series of detailed professional articles dealing with main
points like the following:
• conditioning
• gas properties
• odorization
• safety devices
Editors: Klaus Homann, Rainer Reimert, Bernhard Klocke
1st edition 2013
452 pages, 165 x 230 mm
hardcover with interactive eBook (read-online access)
ISBN: 978-3-8356-3214-1
Price: € 160,–
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CONTENT
REPORTS
24
Heinz M. Nägel
Energy & cost-efficient pumping by diaphragm process pumps
27
Sadko Meusel and Annette van Dorp
Applied intrinsic safety with centrifugal pumps
30
Andreas Horinek
Best price-performance ratio for air applications
NEW PRODUCTS ON ACHEMA 2015
2
Rotary lobe pump for conveying waste
Solvents
3
Investment boosts manufacturing productivity
3
Seal-less magnetic coupled gear pumps
11
12
Progressing cavity pump can be adjusted
flexibly
13
New canned motor pumps for chemical and
process
engineering applications
4
Process control, safety and monitoring in one
system for your compressor unit
4
New coupling line for maintenance-free use in
potentially explosive environments
5
New major version for turbomachinery design
software
6
Conveying of polymer solutions in the adhesive
industry
Manufacturer celebrates three premiers
13
Precise low-pressure chromatography system
14
New hygienic pump
15
Focus on centrifugal pumps
15
Pump manufacturer introduces a new
synthetic pump
16
H ydraulic diaphragm metering pump
different applications
16
Fibre reinforced plastic pump with cutting unit
7
Chemical pumps, for environmental protection
17
Electronic and fully automated monitoring
8
Magnetically coupled centrifugal pump with
open impeller
18
8
Smart pump and control solutions
18
New pressure testing pump permits
9
Variable plunger pump
9
F irst reciprocating compressor with contact-
6
S tainless steel pump series for a variety of
less magnetic coupling and a maximum drive
power of 110kW
10
Magnetic drive pump made of PP
10
Exceptional efficiency: EBS and FBS blowers
system
Process safety without compromise
flexible use
19
Mixing plant for sulphuric acid
20
Optimization in filter press feeding process
22
Well meshed without compromises
33Imprint
Industrial Pumps + Compressors 2015
1 ACHEMA 2015
Rotary lobe pump for conveying waste solvents
A Börger rotary lobe pump for conveying A1 liquids
(combustible liquids) has been used for seven years in a
special waste temporary storage facility of EGN (waste
management company) in Dormagen (City in North Rhine
Westphalia). The pump was custom-made in line with the
individual requirements of EGN.
Waste solvents can be disposed of at a special waste
temporary storage facility of EGN in Dormagen. Very
often municipal mobile pollutant collectors and commercial or industrial customers deliver their polluted
solvents mostly in barrels with a capacity of 60 to 200l
to EGN.
The special waste storage facility arranges the waste
solvents into economic transportation units. For this purpose, the different solvents are checked and tested in
regard to their compatibility with each other. By means
of safety data sheets, mixing tests etc., EGN disposal
experts can determine which solvents can be combined
in larger units.
After the compatibility has been determined, the delivered
solvents are combined in 1000l large IBCs (intermediate
bulk containers) for temporary storage. As soon as sufficient solvents of one type for a tanker truck load have
been stored, the solvents are pumped from the IBCs to
a tanker truck. The waste solvents are then taken to a
tank farm for further processing or to thermal recycling.
EGN has been using a Börger rotary lobe pump since 2008
for filling the tanker trucks.
Before 2008, the vacuum pumps of the tanker trucks were
used to fill them with the A1 liquids. The vacuum developing in this process sucked the solvents into the tanker
truck. In this process, molecules were extracted from the
solvents. These molecules contaminated the activated
carbon filters in the tanker trucks and could escape into
the atmosphere when the filter was saturated. Due to
the use of the Börger rotary lobe pump for more careful
filling of the tanker trucks, the filters in the tanker trucks
are hardly polluted and the gaseous phase is prevented
from escaping into the atmosphere.
In addition to filling the tanker trucks, the Börger rotary
lobe pump is also used for transfer operations within the
company. In 2008, the pump was custom-made in line
with the requirements of EGN.
EGN chose a type PL 200 rotary lobe pump from the
“Classic” product line. The “Classic” rotary lobe pump
is especially suitable for conveying different media. Liquid as well as viscous or abrasive pumped media can be
conveyed effortlessly, and even chemically aggressive
substances pose no problem.
2 I ndustrial Pumps + Compressors 2015
As the Börger rotary lobe pump at EGN is used in potentially explosive atmospheres, the pump is manufactured
in ATEX-compliant design. A temperature sensor in the
pump cover offers additional protection. In order to be
able to work efficiently in case of the transfer processes
from barrels of different sizes, the Börger pump is operated via a frequency converter. Thus, the flow rate can
be continuously adjusted.
Börger rotary lobe pump for conveying A1 liquids
Börger rotary lobe pumps are especially suitable for conveying media of any type. With the wide spectrum of 20
pump sizes (flow rates of 1 – 1,500m3/h), a large selection of equipment and additional parts, Börger is able to
build pumps which are perfectly suited to every single
application. The large-scale geometry and short passage
enable the medium to be pumped gently. Rotors made
of different materials, pump casings made of gray cast
iron, steel casting, stainless steel or hastelloy, mechanical
seals made of many different material combinations only
give an idea of the wide variety of materials of Börger
rotary lobe pumps.
After nearly seven years of use of the rotary lobe pump
in practice, the responsible members of EGN staff draw
a positive conclusion: The pump is reliable, very easy to
operate and reversible. The content of barrels of any size
can be transferred without problems and very quickly due
to the continuously adjustable speed.
ACHEMA 2015: Hall 8.0, A38
BÖRGER GMBH
46325 Borken-Weseke (GER)
[email protected]
ACHEMA 2015
Investment boosts manufacturing productivity
The machine, installed at Albany Pumps’ facility in Lydney,
is being used to machine a variety of high-precision parts
(e.g. gears, rotors including the bore and keyways, lobes,
pump bodies etc.), for its extensive range of standard
pumps – and is increasingly being used as a front-line technology for the company’s growing and successful prototype
and customized pump design and manufacturing business.
Following an extensive search into the EDM market (that
included a thorough investigation of EDM manufacturers
and their machines), Albany Pumps selected a new CUT 30P.
The CUT 30P, although still in its relative infancy at Albany Pumps, is delivering real process and productivity
improvements.
Photograph shows Lobe pumps parts now produced on this machine
A leading positive displacement gear pump, twin screw
pump and rotary lobe pump manufacturer, Albany Pumps,
invested in its first wire electrical discharge machining
(EDM) machine.
ALBANY PUMPS
GL15 5EQ Lydney, Glos (GB)
[email protected]
Seal-less magnetic coupled gear pumps
The new GML/GMB gear pump combines the Dickow Pumpen magnet coupling design based on more than 30 years
experience with Tuthill GlobalGear® built on a time-tested
design and more than 80 years of gear pump engineering
experience.
The result? An unbeatable pump that offers unparalleled
performance and reliability.
Magnetic driven GML/GMB-pumps are designed to improve
plant and personnel safety, especially when handling toxic,
explosive or other dangerous liquids which react on contact
with the atmosphere. For all these services the containment shell replaces the single or double acting mechanical
seals with external fluid reservoirs and the necessary control equipment. GML/GMB-pumps therefore offer exceptional benefits to the chemical, petrochemical and allied
industries, and protect the environment. The pump handles
everything from bulk transfer, chocolate and asphalt, to
high-temperature fluids and chemical processing.
Robust pump design together with tough and strong materials make the pump last longer. The rotor and idler gears
are made of tough materials, which can handle the stresses
of high viscosity operation. No need for steel rotor upgrade.
The single elements of the multipolar magnetic coupling
are manufactured of permanent magnet material “Cobalt
Samarium” with
unlimited lifetime.
The magnets in
the driven rotor are
completely encapsulated, not in
contact with liquid.
Power is transmitted to the hermetically sealed liquid
Revolutionary patented lubrication
method extends overall life by reducing
end by a bank of
friction
external magnets.
Inner and outer
magnet rings are locked together by magnetic forces and
work as a synchronous coupling.
The containment shell is a one-piece deep-draw design
without additional welds.
The pump is approved for hazardous areas (ATEX) and suitable for liquids which are dangerous for the environment.
ACHEMA 2015: Hall 8.0, D54
DICKOW PUMPEN KG
84478 Waldkraiburg (GER)
[email protected]
3 ACHEMA 2015
Process control, safety and monitoring in one system
for your compressor unit
The enterprise BORSIG ZM Compression GmbH offers
the highly available Borsig BlueLine automation system
with scalable redundancy and up to SIL3 (safety integrity
level) for industrial use.
The system combines control system, functional safety
and machine monitoring for reciprocating and centrifugal
compressors by Borsigas well by other manufacturers.
The BlueLine system family is the basis for integrated SIL3
automation. Safety-related, if required multiple redundant
communication and processing allows the efficient distribution of complex applications and the integration of
multiple systems.
In addition to regular automation, modern plants require
an increasing amount of certified safety technology. BlueLine systems allow the interference-free combination
of safety-related (up to SIL3) and regular components
in one computer system, for efficient handling of all
requirements.
ACHEMA 2015: Hall 4.0, B26
BORSIG ZM COMPRESSION GMBH
08393 Meerane (GER)
[email protected]
New coupling line for maintenance-free use in
potentially explosive environments
KTR has expanded its ROTEX® coupling line with the
new ROTEX® Non-Sparking for maintenance-free use in
potentially explosive environments. This failsafe innovation
assures operation in cases of spider element wear while
reliably preventing sparking. KTR will exhibit this novelty
at ACHEMA.
The jaw geometry of the Rotex® Non-Sparking consists
of a conductive high tenacity plastic that is injected onto
the hub body, which continues to be made of steel or
other metals such as aluminum. The newly developed
synthetic material prevents any static charging and is
also designed to be so hardwearing that even in cases
of elastomer wear out, torque will still be transmitted
without any danger of sparking. As a result, maintenance work can be postponed to a convenient time
frame.
The failsafe and maintenance-free Rotex® Non-Sparking is certified under EU directive 94/9/EC (ATEX 95)
and thus deemed suitable for the use in explosive
atmospheres. The shaft coupling has a compact design
and can be axially plugged in. It offers good dynamic properties, excellent vibration damping and a low
moment of inertia. The coupling’s precision-machining
positively influences its running properties and significantly increases its expected service life. The Rotex®
Non-Sparking ensures dampened torsional vibration during power transmission and absorbs shocks generated
from imbalanced machinery. The new coupling is also
The new explosion-proof ROTEX® Non-Sparking coupling displaying
injected jaw geometry on one side.
available in various double-cardanic finishes for large
shaft misalignments that maintain low restoring forces
and ensure sound dynamic properties.
Using injection moulding technology with the cam geometry opens up possibilities for KTR to produce a broad
product spectrum in the ATEX sector with, for example,
necked-in hubs for very compact designs. There is also
great potential to realize customer or application-specific
shaft-cam links.
ACHEMA 2015: Hall 9.0, C4
KTR KUPPLUNGSTECHNIK GMBH
48432 Rheine (GER)
[email protected]
ACHEMA 2015
New major version for turbomachinery design software
A German engineering company specialized in software development, consulting and prototyping for
Turbomachinery components, CFturbo Software &
Engineering GmbH, has released a new software
version of its powerful conceptual Turbomachinery
design system CFturbo®.
The new version CFturbo® 10.0 can be used to design
axial, radial and mixed-flow pumps, blowers, compressors and turbines, as well as for diffusers, stators, return
channels and volutes. Especially all new developed modules to create axial fans, axial turbines, axial pumps and
inducers will allow a much wider range of applications
for CFturbo® then before.
Direct interfaces to all major standard CAD- and
CFD-systems have been extended. Due to its parametric geometry structure the set-up of automated
CAE-workflows and optimization of Turbomachinery
components will be easily possible in collaboration with
various related commercial and open-source software
packages.
Turbomachinery Design Software
ACHEMA 2015: Hall 9.1, C86a
CFTURBO SOFTWARE & ENG. GMBH
01097 Dresden (GER)
[email protected]
Bungartz
Masterpieces
A trend-setting modern creation is needed in order
to completely empty a tanker. The self-regulating
V-an centrifugal pump manages to perfectly
master this art. Whether transporting boiling media
up to the surface from below ground or by means
of suction from above – this pump will immediately
captivate the observer.
an aBunDanCE OF EMPtInESS
Titanium and fluorocarbon rubber on cast iron
A loan from a loyal customer
More information on +49 (0) 211 57 79 05 - 0
and online at: www.bungartz.de/masterpieces2
Visit uns at ACHEMA 2015, Hall 8, Stand C 1
5 ACHEMA 2015
Conveying of polymer solutions in the adhesive industry
Inside the HYGHSPIN Hopper
Enterprises of the chemical industry have versatile demands
with regard to the technology of pumps. Specially in the
sector of the Polymer chemistry the choice of adequate
sealings is most important in order to guarantee failure-free
conveyance of the products. Jung Process Systems developed a special transport solution for a producer of inorganic
adhesives on basis of Polymer using a HYGHSPIN Hopper
with double-acting mechanical seal. This and further interesting applications can be discussed in detail with the experts
of Jung during ACHEMA 2015.
Transport of adhesives is viscous and sticky. The characteristics needed for the final product require tremen-
dous challenges for the production technology. The
product of the customer of Jung Process Systems has
a viscosity of approx.100.000mPas. Besides the high
viscosity also the heavy friction losses in the piping
at the suction side and a resulting very low NPSHa
value demand sophisticated requirements regarding
the pump to be used. Consequently the inflow of the
product into the feed screw chamber is problematic.
Due to these reasons the customer decided for the hopper execution of the Hyghspin twin screw pump series.
However, contrary to the standard version this pump
inlet is executed as a flange because the adhesive is
processed in a closed circuit. A further feature represents the execution of the pump with a double-acting
mechanical seal with pressurized buffer system instead
of a lip sealing. Due to admission of the mechanical seal
with a barrier liquid any kind of product outlet to the
environment will be avoided just as the feed medium
entry between the surfaces. This solution facilitates
that the high-viscous feed medium falls into the feed
chamber and can be transported pulsation-free and
continuously without any problems.
ACHEMA 2015: Hall 8.0, F27
JUNG PROCESS SYSTEMS GMBH
25495 Kummerfeld (GER)
[email protected]
Stainless steel pump series for a variety of different applications
According to the motto “pinpoint precision instead of randomness”, the company presents individual gear pump solutions for conveyor applications and dosing. These pumps are
primarily used in plant, test bed, and process engineering,
as well as the chemical and petrochemical sector.
“We offer application-oriented solutions to our customers
that are specifically tailored to their needs or their systems,”
says Georg Sieffert, sales engineer for the stainless steel
gear pumps series. “The dosing pumps stand out due to
their high system pressure range and their covering of a
wide viscosity range. They furthermore impress with a
long product life cycle, low wear and tear, and a modular
design that is especially easy to maintain,” Georg Sieffert
continues.
Equipped with these features, the stainless steel pump
series can be used for a variety of different applications.
Customers can receive on-site consultation regarding
their applications, as well as individualized recommendations regarding their respective uses.
ACHEMA 2015: Hall 8.0, E78
Stainless steel gear pumps of the 2030 – 5030 series
SCHERZINGER PUMPEN GMBH & CO. KG
78120 Furtwangen (GER)
[email protected]
ACHEMA 2015
Chemical pumps, for environmental protection
Visit us
GEKO offers seal-less PTFE/PFA-lined chemical pumps with
magnetic drive according to DIN EN 22858 compliant with
ATEX and which has been specially designed for pumping
dangerous and chemically aggressive liquids. By the usage
of special materials the pumps are fit for FDA applications.
Geko gives absolute freedom from leakages and practically unrestricted corrosion resistance, even at temperatures of 150°C or higher. Geko offer PTFE-impellers with
curved blades for better efficiency, PTFE-lined carbon-fibre
isolations-shells, PTFE-parts free of metallic framework
and a maximum flow-rate up to 180m3/h. The defined
partial current (bored ceramic-shaft) ensures an absolutely
trouble-free circulation of the fluid.
In case of the modular concept, both pumps, one with
a bare-shaft and one with a close coupled design can
be used, and they are moreover interchangeable. Industry-wide shortest delivery times and an in time service
are additionally preferences.
Furthermore Geko has the ability to replace former QVFand SIHI isolined-pumps one to one.
Seal-less PTFE/PFA-lined
chemical pump
ACHEMA 2015: Hall 8.0, J28
GEKO-PUMPEN GMBH
65343 Eltville (GER)
[email protected]
Hall 8.0 | Booth G94
June 15-19, Germany
YOUR Business – OUR Technology
MULTISAFE Double Hose-Diaphragm Pumps
Handling of abrasive, aggressive and toxic media
Flow rate up to 1000 m3/h Pressure up to 500 bar
| Reactor, Autoclave, Filter Press
and Gasifier Feeding
| Tailings Transfer
| Fly and Bottom Ash Disposal
| Pipeline Transportation
| Wet Oxidation
| Dewatering
FELUWA Pumpen GmbH | Germany | [email protected] | FELUWA.COM
Engineered and Made in Germany
7 ACHEMA 2015
Magnetically coupled centrifugal pump with open impeller
At this year’s ACHEMA in Frankfurt, Fristam Pumpen showcases for the first time a series of magnetically coupled
pumps which combines essential design elements of the
proven centrifugal pumps with special safety attributes for
industrial use. In contrast to the closed impellers frequently
found in this sector, the new FPM series comes with an
open impeller. The product space is sealed off hermetically
from the environment by a separating can, and the impeller
is connected to the drive unit contact-free via a magnetic
coupling.
Industrial pumping tasks are frequently subject to extremely stringent safety requirements, since the liquids to be
pumped are often toxic or aggressive. Such requirements
are found, for example, in the production and processing
of chemical products, and in the production of paints, and
lacquers, cosmetics and perfumes. Such critical products
must at all costs be prevented from leaking out of the
pump into the environment. For safety reasons, companies frequently use magnetically coupled pumps in such
cases instead of pumps with mechanical seals. Compared
to pumps with double mechanical sealing, the FPM series
offers the advantage of hermetical tightness against both
Modular system: shearpump model FSP-MAK with a rotor-stator
combination for optimal dispersion
the product and the surrounding atmosphere. Moreover,
there is no need for a locking or supply system.
FRISTAM PUMPEN KG
21033 Hamburg (GER)
[email protected]
One of the leading worldwide manufacturer of fluid management products expertly engineered to deliver performance
and serviceability, ARO, will be exhibiting a variety of pump
and control solutions at the ACHEMA 2015. With an 85-year
legacy of premier product performance and service excellence, Aro provides fluid management equipment for customers and industries around the globe, including chemical,
manufacturing, energy, pharmaceutical, mining and more.
Aro will showcase simple, yet smart, pump and control
solutions including units from its series of piston, diaphragm and electronic interface pumps. The Aro one-fourththrough three-inch EXP Series Electronic Interface pumps
are air-operated diaphragm pumps that, when paired with
the Aro Controller, provide an accurate, automated system
for batching and container and tank filling. The closedloop system ensures each cycle is complete within a fully
primed pump, delivering a dispensing or batching system
with plus or minus one percent repeatability.
As a system solution, Aro Electronic Interface Diaphragm
pumps paired with the Controller, ensure consistent flow
rates and pinpoint control for a myriad of fluids and applications, from chemical treatment to commercial laundry.
Known for its industry-leading efficiency and reliability,
EXP Series pumps offer flow rates up to 275 GPM (1041
LPM) within a large range of materials of construction and
porting configurations.
INGERSOLL RAND - ARO FLUID MANAGEMENT
88190 Golbey (F)
ACHEMA 2015
First reciprocating compressor with contactless magnetic
coupling and a maximum drive power of 110kW
The TIG
The Swiss HAUG Kompressoren AG is the leading manufacturer of oil-free and gas-tight reciprocating compressors
for compressed air and gases.
Haug presents at ACHEMA 2015 the new developed
reciprocating compressor type TIG.
The TIG ist technical gas tight and due to it’s dry running
design 100% oil-free. It is the first reciprocating compressor worldwide with a contactless magnetic coupling
and a maximum drive power of 110kW. The compressor
works with very low vibration and is thanks to its modular
design the perfect choice for customer specific solutions.
The new TIG type enlarges the power range from so far
30kW drive power up to 110kW. This power upgrade
requires new technologies to apply a dry running crank
drive and a technical gas tight, contactless and wear-free
drive with a magnetic coupling.
Due to the higher load capacity of the crank drive of type TIG
the benefit is not only more power, but also higher discharge
pressure for example for oil-free gas storage applications.
Convincing quality features characterize Haug gas compressors with magnetic coupling:
■■ Permanent gas tightness - even at standstill
■■ No gas losses during compressor start / stop operation
■■ Gas-tight even with suction pressure up to 16bar
■■ No pollution of the environment by gas leakages
■■ No contamination of the process gas by ambient air
■■ Wear-free magnetic coupling without energy losses
■■ Compressor overload protection with flexible coupling
The scope of delivery is defined by the customer
requirements. Haug provides custom specific compressor-bare-blocks up to complete solutions with control unit
and container installation.
HAUG KOMPRESSOREN AG
9015 St. Gallen (CH)
[email protected]
Variable plunger pump
With the HDP20V Hammelmann offers an adjustable
stroke triplex pump with a maximum power rating of
20kW. This pump enables precise metering of fluids at
pressures up to 3000bar and flow rates up to 6m3/hr.
A novel transmission unit enables simultaneous adjustment of all three plunger strokes. The transmission incorporates a very precise servo motor which controls an inner
shaft with outer eccentric ring segments. This smoothly
adjusts the stroke length from zero to maximum resulting in an extremely accurate adjustment of the flow volume both when the pump is stopped and during actual
pump operation. Accuracy, linearity and flow repeatability
exceed the quality requirements of API 675. The plunger
pump therefore is suitable for highly demanding metering
applications.
The optional “Zero Emission” model enables safe hermetically sealed dosing of explosive, toxic or highly pollutant fluids.
VARIO-STROKE plunger pump
ACHEMA 2015: Hall 8.0, G69
HAMMELMANN GMBH
59302 Oelde (GER)
[email protected]
9 ACHEMA 2015
Magnetic drive pump made of PP
With the model MX-505 IWAKI enlarged the present
performance range of MX series of up to 35.5m and
10 – 520l/min up to 800l/min. In combination with IE2 or
IE3 IEC-motors of up to 4.0kW the efficiency of these
pump models within this performance range continues.
The compact, seal less and easy maintenance construction with different combinations of shafts and bearings
with Carbon, Ceramics and PTFE, as well as O-ring
materials with FKM, EPDM or Aflas®, has been taken
over to assure a leakage free transfer of several liquid
chemicals. In addition, unfavorable conditions e.g. dry
running, have been considered within the construction
and by selected magnet power. All models of the MX
series are operating successfully for several years in
different applications like circulating galvanic baths, wet
scrubber or tank storage filling and refilling with light
acids and alkaline, as well as industrial chiller.
MX505
IWAKI EUROPE GMBH
47877 Willich (GER)
[email protected]
Exceptional efficiency: EBS and FBS blowers
Remarkably quiet, yet highly efficient: energy-saving screw
blowers for the low-pressure range are now available in two
sizes. In addition, the integrated Sigma Control 2 controller
ensures optimum performance at all times, and helps provide a dependable supply of quality compressed air that
is also compatible with the future-oriented ‘Industry 4.0’
philosophy.
The EBS series covers a free air delivery range from 10 to
38m3/min with a differential pressure up to 1.1bar, whilst
the new larger FBS screw blowers are perfect for applications requiring free air deliveries up to 67m3/min.
Kaeser’s new EBS and FBS series screw blowers prove
that the tried and trusted technology which already powers
Kaeser’s compressor ranges to deliver significant energy
savings can also be successfully applied to the low pressure
range. The new Kaeser screw blowers are up to 35 percent
more efficient compared to conventional rotary blowers, yet
they also outclass other comparable screw and turbo blowers through their significant energy advantages. After all,
Kaeser’s motto of “More air, more savings” applies to all of
the company’s products, not just compressors.
The rotors are uncoated so users can rest assured that
their outstanding efficiency remains intact even after
years of use. The data provided for the effective total
energy consumption and usable flow capacity correspond precisely to the machines’ actual performance
FBS screw blower
(as per the conservative tolerances provided for by
Standard ISO 1217; measurements validated by TÜVSüd). This ensures full transparency, since the planned
savings calculated to result from the capital investment
are actually achieved.
KAESER KOMPRESSOREN SE
96450 Coburg (GER)
[email protected]
ACHEMA 2015
Manufacturer celebrates three premiers
Premiere 1: “NETZSCH is now the first progressing cavity pump manufacturer who provides full access to all
rotating parts thereby establishing a benchmark on the
market. After the FSIP concept of the TORNADO® T2
caused excitement in the technical world and among our
customers three years ago, the maintenance-friendliness
for our NEMO® pumps was also redefined. New designs
on the housing and along the rotating parts have reduced
the maintenance time and effort for the installer”, says
Bernhard Murrenhoff, global sales manager.
A newly designed
inspection cover
allows opening of
the pump housing
and simply lifting
out of the rotor-stator unit. All movable
parts of the rotating
unit are now accessible through the large
opening. This reduces assembly and
dis-assembly time
significantly.
The dimensions of
the pump remain
unchanged. This
allows retro-fitting already installed pumps at any time.
Hisham Kamal, manager of the Netzsch development
department, summarizes: “We are proud to be able to
present a pump with a smart-technology solution that, just
like the revolutionary Tornado® T2, truly deserves the title
‘Full Service in Place’.”
Premiere 2: “The smaller version of the Tornado
all-metal pump T.Proc® – specifically developed for
smaller volumetric flow rates in the process industry
and eagerly awaited on the market – is now available
and will be exhibited at ACHEMA for the first time. We
now also cover the demand for larger delivery rates in
Environment & Energy with our new T.Envi® 08/200 and
06/300”, enthuses Erwin Weber, head of the Tornado
team. He and his staff have performed pioneering work
during the past three years for the Tornado® T2, since
they first had to convince the technical community of
the benefits of reversing the materials between rotating
and static parts in the pump cavity and the low-pulsation
characteristics of the straight rotary lobes. “However, after innumerable successful installations we can
truly talk about a success story as is confirmed by the
demand for constantly new pump sizes for additional
applications.”
Premiere 3: Based on 35 years of experience in the production of multiple screw pumps for the Latin American
market, the development department in Pomerode has
developed three completely new model series of NOTOS
screw pumps; they will be presented to the general public
for the first time at ACHEMA 2015. “We are offering an
entire product family, made up of two, three and four-spindle pumps. This clearly sets us apart from other companies who preferably manufacture one model series at a
time. We are in the position of recommending the optimal
pump for the respective application. Optimization of the
geometries ensures improved efficiency and increased
pressure capacity. We are establishing new standards
with this design!” explains Antonio Castilhos, who has
travelled to Frankfurt to support the trade fair team. “The
screw pumps are particularly suitable for media with light
to high lubrication capacity and medium to high viscosity;
we then choose the optimal geometry according to pressure and required delivery rate. Notos pumps are used
in the oil and gas industry as well as in the energy sector
and in the navy. Thus they complement the product range
of the Nemo® and Tornado® pumps and stand for the
development of Netzsch becoming a solutions provider
for nearly all industrial sectors.”
Premiere 3: The development department in Pomerode/Brazil has
developed three completely new model series of NOTOS screw pumps.
NETZSCH PUMPEN & SYSTEME GMBH
84478 Waldkraiburg (GER)
[email protected]
11 ACHEMA 2015
Progressing cavity pump can be adjusted flexibly
All of the MX progressing cavity pumps from
KNOLL Maschinenbau in
all model series are constructed in modular fashion. Therefore, the main
components of an existing pump can be replaced
easily and without special
tools for a wide variety of
applications. With a pump
set change, for example - depending on the
drive rating installed - the
delivery rate and delivery
pressure can be adjusted to new requirements. If a new
application is to be implemented, a seal change may be
necessary. No problem, for each MX (MX10 to MX50) has
the same basic size, with the same shaft diameter. For an
individual adjustment to the operating parameters or system,
there are various suction housing variants available (connections according to the usual standards). If heating or cooling
is required, this can be implemented with a stainless steel
double jacket on the suction housing or on the pump set.
There are additional options with respect to the drive, which
can be either a servo geared motor or a geared motor with
integrated frequency inverter and control unit.
ACHEMA 2015:
Hall 9.0, E33
KNOLL MASCHINENBAU GMBH
88348 Bad Saulgau (GER)
[email protected]
New canned motor pumps for chemical and process
engineering applications
KSB will present its new Ecochem Non-Seal canned motor pump type
series at ACHEMA 2015 for the first time.
ACHEMA 2015 will see KSB Aktiengesellschaft, Germany,
showcase totally leak-free canned motor pumps from the
Ecochem Non-Seal range designed to transport hazardous,
aggressive, flammable and explosive fluids. The pumps
are also capable of handling toxic and extremely hot or
cold media as well as volatile or valuable liquids.
This new type series combines KSB’s MegaCPK – a standardised chemical pump successfully employed for years
in process engineering – with ground-breaking canned
motors built by Japanese cooperation partner Nikkiso.
The pumps’ dimensions comply with ISO 2858 and meet
the requirements of the DIN/EN/ISO 15783 and API 685
standards, with economic operation being ensured via a
new energy-optimised electric motor design. The lownoise motor features a corrosion-resistant can made of
Hastelloy (2.4610).
The new type series will be available in four standard
variants featuring one design each for standard chemical applications, heat transfer fluids, polymerising or ferrite-containing fluids and a special variant for low-boiling
fluids and liquefied gases.
The pump sets have been designed to meet the requirements of explosion protection class II 2 G c Ex de IIC
to ATEX, TR and IEC Ex and temperature classes T1 to
T5, and can handle fluids at temperatures from -40°C to
+400°C as standard. The maximum head is 236m and
the maximum flow rate 690m3/h, while product-lubricated
plain bearings made of pure silicon carbide or a silicon-carbide-graphite compound allow the bearing configuration
to be optimally matched to the pump’s operation and the
fluid handled.
If required, the pump casing can also be heated to avoid
a blockage developing due to fluid cooling and becoming
viscous or solid in the event of standstill. The motors
ACHEMA 2015
are rated up to 75kW, and with 16 different motor sizes
available, the drive can be precisely tailored to demand.
Thanks to the motor bearings’ modular design, the number of parts requiring storage can be reduced, cutting
warehousing costs.
An E-Monitor available on option monitors the axial and
radial condition of the bearings, and its integrated direction-of-rotation indicator eliminates the need for phase
rotation measurements during commissioning. As canned
motor pumps operate very quietly, the built-in operating
status indicator provides a very useful function, especially
in loud environments. Power is supplied to the E-Monitor
via the motor’s terminal box so that no external cabling
is required.
ACHEMA 2015: Hall 8.0, H14
KSB AKTIENGESELLSCHAFT
67227 Frankenthal (GER)
[email protected]
Precise low-pressure chromatography system
With the diaphragm metering pumps of the Ecoprime
chromatography system from Lewa, processes can be reproduced
with the highest precision.
Nowhere are the requirements of precision, quality, and
reproducibility as strictly regulated as in modern process
chromatography. Using the Ecoprime low-pressure chromatography system developed by Lewa GmbH, batch-tobatch reproducibility in GMP manufacturing of biopharmaceuticals can be enhanced significantly and the yield of the
product can be enhanced. Unveiled by the manufacturer
at the Achema trade fair this year, the system is notable
within its product family for its extremely precise flow control from 0.03 to 60liters per minute, its unrivaled dynamic
flow rate range, minimal pulsation, and low holdup volume,
allowing better product yield, purity, and safety during
purification. As a consequence, production time and the
costs of validation in the entire production cycle are able
to be reduced.
The pumps installed in the systems and registered for
patent approval with the servo drive from Lewa operate
with the highest precision and allow high reproducibility of
the adjustable parameters. Compared with other systems,
a considerably higher accuracy over the entire flow rate
range can also be covered with its Intellidrive technology.
Each Ecoprime system therefore offers an adjustment
range of 1:150 or more. Because the Ecoprime system
can handle the flow rate of up to three individual conventional process systems, investment costs and valuable
floor space can be reduced. It is therefore ideally suited
for use in cost-intensive GMP cleanrooms.
In the previous year, a license agreement with ChromaCon
AG was sought to extend the Ecoprime batch chromatography platform, which applies to the use of Capture
SMB technology, among others, at pilot and GMP scale
for continuous purification. This allows various process
principles such as batch or multi-column chromatography, Capture SMB, and MCSGP process principles to be
undertaken with the same system platform. In addition,
the contract between both companies enables them to
further accelerate the development of modern cost-reducing purification processes for the manufacturers of
biopharmaceuticals at GMP scale.
LEWA GMBH
71229 Leonberg (GER)
[email protected]
13 ACHEMA 2015
New hygienic pump
Hygienic, gentle and safe operational processes are
top priorities in the food, pharmaceutical, and cosmetics industry. All appliances used for these applications
meet the latest directives and overcome the challenge of
gentle pumping with a design free of bacteria traps. The
design of the new Lutz B70V Sanitary eccentric screw
pumps ensures reliability with low maintenance and full
manual cleaning.
Designed in accordance with hygienic aspects The new
eccentric screw pump Lutz B70V Sanitary was developed
and designed for pumping liquid foodstuffs, pharmaceutical agents and cosmetic products from different vessels
and containers. This new development strictly meets the
constructive requirements of the hygienic design and is
certified and approved according to the latest “3-A Sanitary Standards for Centrifugal and Positive Rotary Pumps
Number 02-10”. All parts coming into contact with the
product are made of resistant stainless steel (1.4571 /
1.4404), 3-A/FDA compliant plastics (PTFE) and elastomers (EPDM). An open type spring loaded mechanical
seal is available or optionally a closed version to avoid
direct contact with the product being pumped.
The entire design of the Lutz B70V Sanitary places hygienic features in the foreground: therefore, only manually
detachable, thread-free connections have been used in the
areas in contact with the medium. The design is almost
free of crevices, thus microbiological problems caused by
germs and bacteria are practically impossible. The Lutz
B70V Sanitary is quick and easy to dismantle and re-as-
Lutz B70V Sanitary
semble enabling speedy and thorough mechanical cleaning and disinfection. All parts coming into contact with
the liquid are easily accessible for inspection and service.
Quickly detachable tri-clamp connections according to DIN
32676 and couplings to DIN 11851 avoid contamination
even at the discharge port.
LUTZ PUMPEN GMBH
97877 Wertheim (GER)
[email protected]
Focus on centrifugal pumps
For ACHEMA 2015, OSNA puts a focus on their wide
range of centrifugal pumps which come in several varieties, especially emphasizing the high pressure pump range
NMH and NMV.
This pump line comprises a selection of sturdy, wear-resistant horizontal or vertical multistage centrifugal pumps
with closed radial impellers. The vertical sump pump type
NMVN completes this vertical and horizontal pump line.
Individual constructions such as can pumps are available,
e.g. for power plant operations.
Trimming the impeller diameters to meet the duty point
leads to optimized energy efficiency of the whole pump.
For a further efficiency upgrade especially in stainless
steel pumps, impellers are cast using the precise lost
wax casting principle. Furthermore, wear rings made of
metallic or non-metallic materials can optionally be used
to reduce internal clearances which are the typical cause
of efficiency reduction in stainless steel pumps. Last but
not least, there are no circlips in contact with the medium
which makes the pump less prone to failure and adds to
reliability and service life.
The performance range includes a maximum flow capacity of 220m³/h and a maximum operating pressure of
40bar, using discharge nozzles sized from DN 32 (1 ¼”)
to DN 80 (3”). The maximum permissible liquid temperature is 110°C for gland packing and 140°C for balanced,
uncooled mechanical shaft seals. Apart from stainless
steel (AISI 316), a cast iron version with impellers option-
ACHEMA 2015
customer can choose from a variety of seal manufacturers.
Problematic media can be sealed e.g. with fully encapsulated seals. Alternatively, double-acting mechanical seals
or auxiliary quench systems are available.
Osna is currently extending its pump line NMH by a variation of the suction end – axial inlet will be available very
soon. A first model exhibit will be shown here.
Typical horizontal or vertical pump sets come with flexible
couplings, driven by highly efficient IEC electric motors.
Alternatively, either diesel engines or turbines can be used
to drive the horizontal pumps.
Profile: OSNA-Centrifugal Pump NMH-40/4
ACHEMA 2015: Hall 8.0, L44
ally made of bronze (G-CuSn10) or stainless steel is also
available. In order to find the right sealing solution, the
OSNA-PUMPEN GMBH
49090 Osnabrück (GER)
[email protected]
Pump manufacturer introduces a new synthetic pump
The manufacturer ZUWA-Zumpe GmbH will exhibit at the
ACHEMA in Frankfurt mainly its range of flexible Impeller
pumps as well as sewage water and submersible pumps,
now also available with ATEX approval.
For the first time a brand new dry self priming flexible
Impeller pump made of synthetics will be displayed to the
public, designed for a wide range of chemical applications.
Various Impeller materials (CR, EPDM, FKM/FPM, NBR
and plastic) make this new pump extremely versatile
The pump is made of PTFE (Teflon®). On account of the
design the pump is dry self priming. It is not necessary
to fill the pump prior to using it.
Even fluids with high viscosities or acids, solvents, bases
or other process fluids can be pumped. Shaft seals made
of VITON guarantee a high level of operational reliability.
This „chemical“ pump is capable of dry self priming from
a depth of 3m, depending on the fluid. The pump head is
up to 50m. Presently the pump can be equipped with 220400V motors with 50 or 60Hz, working at 1400 to 2800
rpm. Depending on the engine, the flow rate is 3 to 30l/
min. Motors are available with frequency converters also.
High grade material permit a maximum working temperature of 90°C.
Conveying fluids containing solids is possible. Depending
on the model, corrosive fluids can be handled. Containers
are drained down to the latest drop, practically. Transport
of the media is pulsation free, another important feature
for many applications.
Impeller pump made of synthetics designed for a wide range of
chemical applications.
An optional, effective dry run protection keeps the pumps
from running hot in case supply of fluid is interrupted. A
temperature sensor mounted to the front side of the pump
stops the energy supply of the motor once a pre-adjusted
temperature limit is reached.
ZUWA-ZUMPE GMBH
83410 Laufen (GER)
[email protected]
15 ACHEMA 2015
Hydraulic diaphragm metering pump
The EF3a is the first of the new Orlita Evolution pump
generation to be launched. It will be unveiled for the first
time at ACHEMA 2015. The Orlita Evolution EF3a hydraulic diaphragm metering pump together with the pumps
EF1a, EF2a and EF4a form an integrated product range
with stroke lengths of 15 to 40mm. This covers the capacity range from 3 to 7,400l/h at 400 – 10bar.
A wide range of drive versions is available, including some
for use in Exe and Exde areas with ATEX certification. The
Orlita® Evolution product range is designed to comply with
API 675.
The new hydraulic diaphragm metering pump is an oscillating diaphragm pump with hydraulically deflected safety
diaphragm. A specially developed diaphragm layer control
system combined with the integrated pressure relief valve
and temperature control reliably protect the new process
pump from almost all incidents and unauthorised operating statuses. Continuous bleeding of the oil chamber
ensures reliable pump operation.
The modular construction with single and multiple pump
versions makes a wide field of applications possible. The
new process metering pump will be used mainly in the
oil and gas industry as well as the chemical industry and
in industrial production engineering
New hydraulic diaphragm metering pump Orlita® Evolution EF3a with
hydraulically deflected safety diaphragm.
PROMINENT GMBH
69123 Heidelberg (GER)
[email protected]
Fibre reinforced plastic pump with cutting unit
Fibre reinforced plastic pump with special motor
The self-priming pump with asynchronous motor and integrated frequency converter is used if water or others, but
not aggressive fluids have to be delivered.
These media might be dirty, contaminated with substances such as leaves, straw, grass, or e.g. plastic particles.
The fluid does not have to be filtered before entering the
pump. Before entering into the pump hydraulic, the solid
matters are crushed. This happens by a cutting device,
which is integrated in the suction chamber. No additional
machinery is necessary.
To ensure the suction function of the pump, a split case
has been developed. The case is provided with an additional servicing window, to ensure light access to the
cutting device for cleaning and assembling.
A new, speed variable asynchronous motor with display
serves as a drive, the frequency converter is fitted on the
shaft, axially to the motor. It has an energy saving function, and the operating data recording system is protected
against mains failure. The data are stored up to six hours.
SCHMALENBERGER GMBH + CO. KG
72072 Tübingen (GER)
[email protected]
ACHEMA 2015
Electronic and fully automated monitoring system
IN-1000 was developed specifically for Allweiler pumps for maintenance and spare parts go down and the long
that are used in operationally-critical and environmental- service life of each Colfax Fluid Handling pump/motor
ly-sensitive applications. IN-1000 improves safety while assembly can be utilized to its fullest.
reducing operating costs. The core of the system is a
software program developed by Allweiler.
With its Smart Technology IN-1000 Series, Colfax Fluid ALLWEILER GMBH
Handling is defining a new generation of Condition Moni- 78315 Radolfzell
toring. IN-1000 is an electronic and fully automated mon- [email protected]
itoring system. The modular
1502019_Dickow_Anzeige_GML_EN_www.terme.de 26.02.15 14:18 Seite 1
design of IN-1000 permits
easy integration into pump
systems, with pre-configured settings that are the
foundation of rapid, individualized startup. IN-1000 may
be retrofitted at any time
and allows central monitoring of up to 21 pumps with
one control.
The new Smart Technology IN-1000 series is ready
to handle anything from
straightforward condition
monitoring to more complex
monitoring activities, including operation monitoring of
multiple pumps for simultaneous fulfillment to ensure
your safety and operating
cost requirements are met.
Operations are monitored
continuously and automatically, with activity logging
and storage for evaluation
of your process. If unusual
operating conditions occur,
both audible and visual
alerts are triggered and
shown on a graphics-capable color display.
Because of these capabilities, maintenance and
repairs can be planned
Hall 8 / D54
June 15 - 19
in advance, there are no
unplanned production
downtimes or consequenDickow Pumpen KG
tial damages, and mainteSiemensstraße 22, D-84478 Waldkraiburg
nance intervals are extendPhone 0 86 38/602-0, Fax 0 86 38/602-200
E-Mail: [email protected] · [email protected]
ed. As a result, expenses
Internet: http://www.dickow.de
New Product
The new GML Gear Pump with
Magnet Coupling and Tuthill
Global Gear combines decades of
experience and offers unparalleled
performance and
reliability.
17 ACHEMA 2015
Process safety without compromise
Side channel pumps by SERO are specially designed to
meet the requirements of industrial and processing operations in all applications where self-priming ability, entrained
gas-capability, low flow - high heads and high pressures
are an issue. Pump users, plant designers/contractors
and operators, just as all interested are very welcome to
visit Sero at the ACHEMA.
SHP 110 Barrel-Pump for High Pressure Applications
Designed to meet wide-ranging and even challenging
requirements as e.g. in HPI (hydrocarbon) pro-cessing,
the SHP pump comes with the following features: double barrel for increased operational safety, extremely
low NPSH values, nominal pressure 100bar (1450 PSI),
designed according to API 610.
SEMA-S 660 Multifunction Pump for the Process
Industry Engineered to meet demanding process conditions in industrial services: for high head applications (e.g.
in storage tank plants), seal-less with magnetic drive acc.
to API 685, self-priming, ability to handle gas entrainments
of up to 50% vol.
Side channel pumps by Sero
SERO PUMPSYSTEMS GMBH
74909 Meckesheim (GER)
[email protected]
New pressure testing pump permits flexible use
Wherever industrial pipes, pipe assemblies, valves or
housings must be tight the leak integrity is tested with
test pumps. The required test pressure can be created
with them right on site, depending on the model. The drive
can be designed as manual, electrical or petrol-powered
drive. Respective controls and valves thereby permit the
reproducible “tracing” of test pressure curves and also
the generation of test protocols.
The new pressure testing pump VP602 with combustion
engine - petrol or diesel type - supplements the electrically powered equivalent and permits the flexible use of
the pump independently from the power supply. Apart
from its mobility, the unit stands out by its rugged construction, reliability and ergonomic handling. In addition to
the standard applications the pump is primarily used with
sanitary, heating and solar systems as well as sprinkler
installations; it is also used with compressed air, steam
and cooling systems in the area of boiler, pressure tank
and fittings construction.
VP602 with combustion engine
URACA GMBH + CO. KG
72574 Bad Urach (GER)
[email protected]
ACHEMA 2015
Mixing plant for sulphuric acid
Sulphuric acid is one of the technically most important
chemicals of all and ranks among the most-produced raw
materials.
The chemical is used in various concentrations in many
industrial areas. Its production quantity is considered – in
addition to chlorine – as a benchmark for the industrial
development and performance level of a country. The
annual production volume globally is around 200 million
tons, five million in Germany alone.
The largest part of the production goes into the production
of fertilizers.
As battery acid, 37% sulphuric acid is a key component
of lead batteries, as used in the automotive industry, for
example, in starter batteries.
Furthermore, the chemical is one of the most common
raw materials in chemical laboratories and is used in many
fields, among others, in adjusting pH values or as a catalyst.
Safety and efficiency as the uppermost objective
Sulphuric acid is required in different concentrations for
different applications. The 96% base product is diluted
with water for this purpose. This process is accompanied
by a strongly exothermic reaction. Temperatures of up to
approx. 140°C can occur, depending on the initial concentration. When designing a mixing unit this must be taken
into account, and for the safety of the operating personnel
as well as that of adjacent plant parts the heat must be
dissipated by a cooling section. Due to the high production
volumes, precision and economic efficiency of the mixing
plant lie squarely in the focus of the manufacturer. The
demands on the system are +/-1% for density and quantity.
Everything from one source In the mixing plant, two
sera dosing units convey the concentrated sulphuric acid
and the required dilution water. The volumes conveyed
by the pumps are regulated depending on the desired
final concentration. To do this, a density measurement
captures the initial concentration of the chemicals and on
this basis the plant control system determines the basic
setting for the output of the dosing units.
The water and the sulphuric acid are blended in a reactor
with an integrated cooling circuit. This ensures that the
resulting reaction’s heat is discharged directly at its source.
After the reaction, a batch of up to 5,000litres is stored
in a charging tank. The concentration is measured automatically while the tank is being filled.
The capacities of the two dosing units are adjusted according to this measurement. In addition, during production
of the various solutions, the production quantities are
recorded with a magnetic inductive flow meter.
At the end, the batches are stored or bottled. Three storage tanks that can each hold 30m3 are available for the
concentrations of 37%, 50% and 70%.
If sulphuric acid is required and manufactured in different
concentrations, these amounts are poured directly into
a delivery container.
High process reliability The heart of the system is the
corresponding controller, based on a PLC S7-1200. All
the important parameters for the preparation of different
solutions are recorded and visualised via a control panel.
The production start is controlled by recipes. The dosing
units are regulated depending on the concentrations. At
the most important points in the reactor and cooling circuit, the temperatures are recorded and the cooling water
pump’s output is adjusted.
An Ethernet interface is available for the connection to
the parent process control. Batch- and material number,
concentration and production amounts are logged for later
checks.
The outcome of the complex systems- and control technology is, in addition to full automation, the improvement
of the precision of the system from the original +/- 3% for
the old system to approx. +/- 0.1% for the new system,
thus meeting and exceeding the customer requirement
of +/- 1%.
ACHEMA 2015: Hall 8.0, K63
SERA PRODOS GMBH
34376 Immenhausen (GER)
[email protected]
19 ACHEMA 2015
Optimization in filter press feeding process
In order to maintain or improve competitiveness, it is crucial to optimize one’s own processes, particularly production processes. A North German company that specializes
in the production of edible oils contacted the Swiss pump
manufacturer, Emile Egger, with the goal of improving
the production processes, in particular for the filter press
feeding of raw edible oils with filtration aids and of oils
for the production of biodiesel.
Egger has worked intensively on the design of filter press
feeding and can already look back on great success in
both the paint sector of the automotive industry and in
mechanical process technology in the chemical industry. In the chemical industry there are a wide range of
mechanical separation processes such as hydrocyclone
and decanter feeding, as well as filtration processes of
all kinds. The greatest challenge here is frequently posed
by the feeding of chamber filter presses.
High demands The edible oil producer and Egger as
pump manufacturer defined the following demands in
the common requirement specification:
■■ Improvement in the availability of the machine
■■ Energy saving
■■ Improved filter cake build-up
■■ Simple discharge of the filter cake after opening of
the press
■■ Identical pump technology and shaft seals as far as
possible to minimize spare part stocking and ensure
maximum interchangeability of the feeder pumps.
The company originally used standard centrifugal pumps
or positive displacement pumps (eccentric screw pumps)
Figure 1: Filter press feeding with a horizontal Egger Turo® free-flow
pump
for filter feeding. The abrasive filtration additives in particular, such as pearlite, dicalite or fuller’s earths, resulted
in a service life of only a few days for the hydraulics or
shaft seals.
A crucial aspect for the filter feeding is the gentle conveying of the solids to be filtered and of the filtration
additives with efficient feeding of the filter cloths. From
the beginning an efficient filter cake has to be built up
in the filter frame over a large area with large quantities
and low pressure and largest possible solid particles;
the filter cake then reaches an optimum during the
filtration process by increasing the feeding pressure.
This filtration process naturally has to be adapted to
each process.
The demands on such a feeder pump are very complex:
■■ The solids and filtration additives have to be transported gently and with the least possible shear stresses.
■■ The pump must be able to cover a wide operating
range from approx. 5-65m3/h and be able to generate
pressures from 2.0 to 8.0bar.
■■ The conveying principle, the materials and the shaft
seal must be selected so as to achieve high availability
and a long service life.
Control concept using pump speed control Egger uses
its Turo® free-flow pump with four-stage hydrodynamic
shaft seal very successfully for such applications. The
unique free-flow hydraulics with completely retracted
impeller and a design without sealing gap guarantees
gentle transport without any shearing or grinding of the
delicate structures. In combination with a control con-
Figure 3: Oily filter cake after opening the chamber filter press
ACHEMA 2015
cept using pump speed control, all these demands are
perfectly satisfied.
The North German edible oil producer currently has four
filter press feeders equipped with the Egger control concept. Despite the widely differing demands of the filtration,
Egger has managed to cover all the feeding applications
with the same pump mechanism.
In summary, after five years of cooperation with Egger,
the edible oil producer has achieved the following process
optimization:
■■ The filtration result (filter cake) has been improved by
20%.
■■ The personnel costs have been significantly reduced
as the filter cake can be removed more easily from
the cloths after the filtration process.
■■ The service life of the feeder pumps and in particular
of the shaft seals has been increased from, in some
cases, a few days to over three years.
■■ The spare part costs have been reduced by approx. 15%.
■■ The energy consumption has been reduced by 12%
thanks to the intelligent control concept.
Since these process optimizations are seen as a great
success, the North German edible oil producer together
with the Swiss pump manufacturer Egger are looking
positively to the future. The internal production processes
are continuously being evaluated for similar improvement
measures.
Conclusion The process optimization has not only significantly improved the processes and production operation
thanks to the new control concept and the modified pump
technology, but has also had a very positive impact finan-
Figure 2: Control concept for the feeding of a filter press
cially for the edible oil producer. The plant availability has
been significantly increased thanks to the longer service
life of the pumps, and the annual maintenance costs have
been reduced by figures in the five digit euro range. The
higher productivity per unit of time and the significantly
improved filtration result now allow the company to develop new products and to generate additional turnover in
the six digit euro range.
Jörn Scharnweber and Richard Layes
EMILE EGGER & CO. GMBH
[email protected], www.eggerpumps.com
Egger: Your partner to handle
multiphase liquids
The Egger Reactor Loop Pump HT/HPT for high
temperature and high pressure applications
www.eggerpumps.com
ACHEMA
15 th – 19 th June 2015:
Hall 8.0, Booth B64
Emile Egger & Cie SA
2088 Cressier NE (Switzerland)
Phone +41 (0)32 758 71 11
[email protected]
Emile Egger & Co. GmbH
68199 Mannheim (Germany)
Phone +49 (0)621 84 213-0
[email protected]
21 ACHEMA 2015
Well meshed without compromises
A provider of ANSYS simulation software and computing services, CFX Berlin Software GmbH, is opening up
new possibilities. With the help of meshing software
TwinMesh developed by CFX Berlin, computational fluid
dynamics (CFD) has become an efficient development
tool for the first time for manufacturers of rotational displacement machines.
Computational fluid dynamics (CFD) is often used by
design engineers today as a tool for the analysis and
optimisation of the fluid mechanics and thermal properties of machine and system components. An important
prerequisite for the development of efficient calculation
models capable of making reliable predictions is the creation of numerically high-quality computational grids that
mimic the computational domain as precisely as possible,
but without producing a total of too many elements, as
increasing model size (number of grid elements) can significantly lengthen the computation times of computer
models.
The creation of such computational grids poses two particularly significant challenges for calculation engineers
when working with rotary pumps, gear pumps and screw
compressors, which make numerical simulation (CFD) of
only very limited use for these machines. The complexity
of the geometry to be recorded by rotational displacement
machines results from the flow volumes in the working
chambers of the machine which vary over time. The second challenge are the extremely small gaps between the
rotors and between the rotors and the housing, because
to calculate the gap flows properly, these areas must
be resolved with a very large number of very small grid
elements.
Automatic methods have not been applicable to date
There are unfortunately not yet many practical approaches
for addressing the particular challenges of the rotational
displacement machines. One way to build a CFD calculation model for a rotational displacement machine is
automatic remeshing. In this case, whenever the flow
volume changes due to turning of the rotors, this is adapted by deformation or a completely new computational
grid is automatically created by the calculation software
if the flow volume falls below certain quality criteria and
the calculation results are interpolated between two time
steps from the old to the new grid. Unfortunately, this
method has drawbacks which can in practice lead to
the fact that it is not practical to use: the automatic grid
generation does not work for cuboid-shaped elements,
only for triangular elements (tetrahedrons). However, the
topology of these elements results in enormous calculation models if gap resolution is satisfactory. In addition,
significant computational overhead incurs due to frequent
remeshing and there are significant numerical errors due
to the continuous interpolation between the individual
computational grids.
As an alternative to automatic remeshing, approaches that
work with overlapping computational grids exist. Here, a
computation grid for the solids of the rotors is rotated by
a further computation grid for the fluid volume. Wherever
the computational grids intersect, the flow field is manipulated using mathematical tricks. Unfortunately, these methods cannot be coupled with all physical models required
to correctly account for phenomena such as turbulence,
cavitation, compressibility or rheologically complex material properties. However, since such
effects constitute the functioning of
rotational displacement machines to
a significant degree, these methods
are also not applicable.
Figure 1: Screenshot of the TwinMesh software shows the mesh of a 2D cross section of a
rotary lobe pump
Manual meshing as a way out The
best possible way so far to produce
reliable results within reasonable computing times is manual meshing with
structured hexahedral grids (cuboidshaped elements). For a number of
rotor position predetermined by the
calculation engineer, the computational grids are generated manually prior to
the simulation to then be automatically
read out during the simulation by the
ACHEMA 2015
calculation software. If the grid topology does not change
when doing so (number of elements and nodes), the faulty
interpolation between the computational grids of single
time steps can be dispensed of because the computational grid for the solver always remains the same. Advantage
of this method: best numerical quality; due to the elemental form, an excellent gap resolution is achieved with still
manageable overall model size and all physical models
available in the calculation software can be used. The only
disadvantage of this method: manual grid creation takes
a few months for relevant three-dimensional geometries.
Thus, economic use as an analysis and development tool
is hereby inconceivable.
Rethinking meshing CFX Berlin Software GmbH rose
to the challenge of tackling the problem with a brand
new approach. The tradeoffs between long computation
times, great manual effort and ensuring a high quality of
results should be permanently discounted, meaning the
numerical flow simulation will finally become a technically
and economically successful, efficient tool for the development of rotational displacement machines.
With the help of new meshing software TwinMesh developed by CFX Berlin, for the first time, the time-varying flow
volumes in the working space of rotational displacement
machines can be automatically meshed with high-quality
structured hexahedral meshes. The workflow of TwinMesh thus needs only a few steps. First, the flow volumes
of the machine in the stationary and rotating spaces are
broken down in the CAD system or in the ANSYS DesignModeler. In the field of stationary components (inflow,
outflow), automated high-quality grids can be generated
as usual with e.g. ANSYS Meshing or ANSYS ICEM CFD.
The rotating parts of the machine are read in as curves of
the rotors and the housing contours in TwinMesh and then
meshed in an automated fashion for a number of angular
positions specified by the user. The resulting computational grid consists exclusively of hexahedral elements
(cuboid-shaped). The axial and radial grid resolution are
defined by the user and special areas (boundary layer and
column) can be refined separately on request. By using
a smoothing algorithm contained in TwinMesh, the node
distributions always remain homogeneous, and the interior
element angle remains nearly orthogonal. Another feature
of the software is the ability to assess the networks with
respect to their numerical quality before the simulation.
If the desired quality criteria for the computational grid
achieves all angular positions, the project can be exported. In this case, in addition to the computational grids,
TwinMesh also stores special routines which the ANSYS
CFD software needs for further processing during the
Figure 2: Simulations results of a rotary screw compressor, showing
absolute pressure
actual simulation. The generated computational grids for
the rotating and the stationary parts of the machine are
now assembled into a simulation model in the software
in the final step. And here, too, CFX Berlin has come
up with something special: for all typical displacement
machines, TwinMesh provides special macros which also
take care of the actual simulation setup in ANSYS CFD at
the press of a button.
Conclusion The numerical flow calculations based on the
TwinMesh computational grid provide valid statements
about pressure rations, output, mass flow, pulsation or
efficiency as well as the occurrence of cavitation in rotational displacement machines. The software developed by
CFX Berlin thereby fills a market gap and makes it possible
for the first time to use CFD efficiently for the analysis
and optimisation of rotational displacement machines.
Moreover, experiences have already been gathered with
a variety of clients and machines.
Sebastian Vlach
CFX BERLIN SOFTWARE GMBH
10243 Berlin, Germany
[email protected]
23 REPORT
Energy & cost-efficient pumping
by diaphragm process pumps
HEINZ M. NÄGEL
As more than 30% of the industrial power consumption is used by the drives of pumps and compressors, the
legislation imposes more and more the demand towards energy initiatives and efficient energy usage. Under
consideration of such regulations, key requirements such as reliability, availability, life cycle costs or diagnostic capabilities that have previously characterised process pumps, nowadays increasingly rank behind the
topic of cost and energy efficiency.
A
great number of different pump types are typically applied in process engineering systems, such
as centrifugal, progressive cavity or positive displacement pumps. Although centrifugal pumps have market dominance, positive displacement pumps tend to
be specified for high pressure applications. In many
high pressure applications, however, hydro abrasion
and chemical attack results in elevated wet end wear,
which in turn culminates in correspondingly high
operating expense (OPEX). Prior to considering a
final decision in terms of pump selection, it is highly
recommended to focus on criteria other than solely
capital expenditure (CAPEX) and carefully balance
other important, individual and contributing factors,
such as pump design, configuration, footprint, driving power, efficiency, speed, flow path, number of
wetted/wearing parts, lifetime expectancy, wearing
parts accessibility, pollution control and finally, cost
and energy-efficiency.
SOFT SPOT: PRODUCT IN CONTACT WITH THE
PUMP CASING
With traditional diaphragm piston pumps, wet end
and drive end are separated by a flat diaphragm.
Apart from the diaphragm, check valves and piping,
the product is also in contact with the pump casing
which, as a result, tends to be manufactured from
expensive special materials that are chemically and
abrasively resistant to the slurry. In the event of a
diaphragm failure, the slurry - that is in many cases of
an aggressive nature - penetrates and thus contaminates the hydraulic control area and can culminate in
considerable expense, as well as induce unplanned
and inconvenient pump downtime for decontamination and repair.
SOLUTION: TWIN CYLINDRICAL
HOSE-DIAPHRAGMS
Hydraulically actuated double hose-diaphragm pumps
offer decisive advantages vs. traditional piston diaphragm pumps (Fig. 1). They are designed to eliminate flat diaphragms and their obligatory clamping rings, which is the typical construction of most
diaphragm piston pumps. Instead, they are provided
with twin cylindrical hose-diaphragms (primary and
secondary) although the pump only requires just one
of these to be operational and can function normally in the event of a failure of either. These tubular
diaphragms avoid all of the disadvantages of traditional diaphragm piston pumps, as aforementioned.
They fully enclose the product and provide for double
hermetic sealing between the wet and drive ends.
Moreover, the pair of hose-diaphragms ensures that
the slurry will not come into contact with the pump
casing. Should one of the hose-diaphragms fail, the
second will ensure that the product neither conta-
REPORT
minates the pump casing nor the hydraulic drive area.
For this reason the pump casings are not required
to be manufactured from expensive special materials. Unlike peristaltic hose pumps, double hosediaphragms are not subject to mechanical squeezing,
but are actuated by the piston, utilising hydraulic fluid
as an operating medium.
One of the decisive advantages of double hosediaphragm pumps is the linear flow path from the
suction to the discharge side. However, the hosediaphragm design does not just influence the flow
path, but also the efficiency of the pump. Traditional
diaphragm pumps are characterised by their circular design pump casings. Particularly with high flow
designs, this round diaphragm housing is subject to
minor movement in step with the pulses caused by
the piston stroke, which in turn reduces the overall
efficiency of the unit (Fig. 2). In comparison, tubular
hose-diaphragms allow for cylindrical casings and a
correspondingly small footprint. Fabrication of such
housings, therefore, is much easier to control and
this advantage allows for an increase in hydraulic
efficiency of some 5% (Fig. 2).
CONDITION MONITORING
Figure 1: MULTISAFE Double Hose-Diaphragm Process Pump
been developed for double hose-diaphragm pumps
in cooperation with a well-known German electronics manufacturer. The measuring principle of these
purpose-built sensors is based on the analysis of
solid-borne sound and is capable of detecting leaks
between valve seat and ball or cone respectively, at
a time when the loss of flow is still less than 1.5%.
Multiple options are available for the transmission
Double hose-diaphragm pumps are designed to avoid
sudden deviance from admissible working conditions
and unplanned downtime. For
additional back-up of its failsafe
characteristics, they utilise an
overall diagnostic system for
permanent condition monitoring of essential components
and parameters (Fig. 3).
One of the decisive criteria
of condition monitoring is to
recognise even the merest
indication of wear, or any other
variance from set-points early
enough to permit the operator
to closely monitor any further
developments. This allows the
opportunity to introduce preventative maintenance into the
process as appropriate, in order
to avoid unscheduled shutdown
of the system. Since the leakfree sealing of check valves
plays a decisive role, an innovative system for the early detection of wear in check valves has
Figure 2: Diaphragm Pump Housing
25 REPORT
as well as the precise determination of MTBR values. As an added advantage, it avoids loss of energy,
because any decrease in output resulting from valve
wear is usually automatically compensated by the
necessity of increased pump speed.
Author
Figure 3: Overall diagnostics, control and web-based service by
means of touch panel
HEINZ M. NÄGEL
FELUWA Pumpen GmbH
of the measuring results by means of a dry contact
(such as Internet or Intranet). Intrinsically, this provides the operator the opportunity of well-directed
advance planning of maintenance or repair action,
54570 Mürlenbach (GER)
Phone +49 6594 10-0
[email protected]
REPORT
Applied intrinsic safety with
centrifugal pumps
SADKO MEUSEL AND ANNETTE VAN DORP
Intrinsic safety is an established term in the context of electrical equipment. It denotes systems which, by
design, ensure that even an operating error or a failure of components will not lead to hazardous situations.
The significance attached to intrinsic safety as a design element in centrifugal pumps and the effects of using
intrinsically safe pumps in practical operation will be described in the following article.
I
n order to minimise the failure risks in pump applications, pumps are designed redundantly and the
key spare parts are kept in store. Operators rely on
comprehensive operating instructions and continual
employee training to avoid, for example, operator
errors. Another cost factor is the increasing use of
diagnostic and early-warning systems for fault detection in recent times. Those extra safeguards, however, often lead to problems themselves. Moreover,
the average expense from planning and procurement,
integration, repair and maintenance to documentation, etc. can amount to up to 10,000 euros per signal.
ing originally developed by the company. Essentially
this sealing consists of a distinctive blading at the
rear side of the impeller. Thus, the pumping medium is carried away from the critical shaft gap transition protecting the downstream shaft seal system.
Owing to the physical features the pump is perfectly leak-proof and the downstream seal (mechanical,
magnetic, lip seal, etc. for the idle state) is relieved
(Figure 1). These non-contact hydrodynamic shaft
seals with seal expeller and centrifugally controlled
idle state sealing render the large circulation pumps
CHALLENGING OPERATING CONDITIONS AND
PHYSICAL PRINCIPLES
Frequently, the pump operation is aggravated by
the operating conditions. Examples for rather challenging pumping media are gaseous, corrosive, solid-containing or explosive media as handled in the
petrochemical industry and in chemical companies.
The centrifugal pump manufacturer Bungartz shows
the possibilities of applying physical principles in
the design and manufacture of centrifugal pumps
for such media and how pumps can render external
monitoring systems superfluous.
INTRINSIC SAFETY AS A DESIGN ELEMENT OF
PUMP TECHNOLOGY
The intrinsically safe pump technology offered by
Bungartz is partially based on the hydrodynamic seal-
Figure 1: The large circulation pumps of the M-UMOR type are
legendary. They are particularly suited for solids and are used all
over the world, for instance in the pumping of ammonium nitrate.
27 REPORT
Figure 2: The hermetically sealed chemical pump MPCHDryRun is ATEXcompliant, suitable for molten masses and protected against blockages and
operator errors (e.g. insufficient ventilation).
(1,200m3/h) of the M-UMOR type perfectly intrinsically safe. The legendary pumps (one pump has
been running since 1948!) are particularly suited for
solids and are used all over the world, for instance
in the pumping of ammonium nitrate.
The intrinsically safe MPCHDryRun, a hermetically
sealed chemical pump, also allows use with any
liquid. Its design provides that bearing and magnetic
drive are not in contact with the pumping medium.
Sealing gas flows through the product-free labyrinth
area. This area between the rear side of the impeller
and the shaft bearing provides a heat barrier with
high temperature gradients and thus a low bearing
temperature. The grease-lubricated rolling bearings
need neither monitoring nor maintenance throughout
their minimum service life of 32,000 hours (Figure 2).
Further advantages are that the system is ATEX-compliant, suitable for molten masses and protected
against blockages and operator errors (e.g. insufficient ventilation). There is no need for the usually
required signals and controlled systems.
A unique feature of the pump is its self-regulating
behaviour owing to a special physics principle: The
centrifugal pumps of the V-AN series work without
suction capacity. The principle is based on the pressure
compensation between pump impeller and feed vessel.
This allows the pump to convey depending on the inlet
flow rate, which means that it adapts its behaviour in a
self-regulating manner to the inflowing feed rate. The
V-AN is self-ventilating via a pressure compensation
line (Figure 3). All pumps of the V-AN series are safe
to run dry and intrinsically safe. They work without any
mechanical or electrical regulation equipment.
The design advantages thanks to the intelligent
application of process physics decisively increase
the availability of these special centrifugal pumps.
The following examples from a refinery environment
provide insight into a conversion to intrinsically safe
Figure 3: All pumps of the V-AN
series are safe to run dry and
intrinsically safe. They work
without any mechanical or
electrical regulation equipment.
pumps and describe the preliminary pump selection
for a new construction project.
Practical example: Conversion of a condensate
delivery system
Pump location: refinery
Medium: condensate
Operating data: Q = 42.5 m3/h, minimum feed rate:
Q= 0m3
H = 90m liquid column, temperature = 127 °C, (operating temperature: Tmax 160 °C),
Operating pressure pmax = 10 bar (0)
The use of a standard pump with product-lubricated
slide bearings and the thus occasionally occurring
entrainment of vapour bubbles caused regular standstills with expensive consequential damage. Standard
pumps of this type have a significant disadvantage:
they are not suitable for dry-running operation. The
slide bearings are surrounded by flowing pumping
medium or external water. When used to pump condensate in a refinery here, they trigger additional pulsating pressure surges due to the min/max control,
which cause malfunctions in the plate heat exchanger. This leads to damage with huge follow-up costs.
After numerous failures, the operator finally decided
in 2008 to make a conversion. Now, the self-regulating VKS-AN vertical pump provides a hydrodynamic
sealing during operation, which works as described
above. The use of the back vanes working frictionlessly and being free of wear and tear leads to
REPORT
sealing with a simple graphite gland packing only
being required for the idle state. Neither a sealing
system nor other additional equipment is required.
The low-pulsation delivery is facilitated by the pump’s
direct reaction to the volume flow. There is no need
for a minimum volume flow. With the grease-lubricated rolling bearings and the self-ventilating effect
the pump achieves a high availability. For seven years
now the VKS-AN has been operating without any
maintenance and in trouble-free condition.
Practical example: Conversion of a refinery waste tank
Pump location: refinery, special feature: use of a slop
pump in zone 1 or 0
Medium: viscous refinery waste containing solids,
flammable, outgassing
Operating data: – Q = 5m3/h, H = 40m, P (water) =
10kW, speed = 2900 rpm
The refinery waste contains not only solids but also viscous elements of a hazardous, flammable and outgassing nature. The previously used slop pump with product-lubricated slide bearings failed at least once every
six months. This led to expensive and time-consuming
repair work. Moreover, the safety-relevant location of
the former pump rendered its removal and reinstallation extremely laborious and dangerous. Evacuating
the environment and working with full protection was
mandatory there. The conversion was absolutely necessary. It was made already ten years ago. Since then the
intrinsically safe MPATAN slop pump has been working
without malfunction and even maintenance-free. Experience shows that under these conditions run times of
more than 13 years can be achieved.
Practical example: New construction project with
unloading station for tanker trucks
Application area: refinery/tanker truck unloading
Medium: sulphuric acid
Special features of pump use:
Operating data: Q = 30m 3/h, Q= 0m 3, speed =
H = 20m liquid column, temperature = 50 °C, density
1.84kg/dm2
Operating pressure pmax = 10 bar (0), operating temperature: Tmax 100 °C)
Pumps for the unloading of tanker trucks are required
in the construction project for a new refinery. Pump
manufacturer Bungartz is involved in the early planning stage. The self-regulating physical feature of the
pumps of the V-AN series facilitate easy unloading
from below, complete residual liquid emptying without exerting pressure, utmost safety and even structural simplifications: The construction of a pit or other
infrastructure adaptations, which would have been
required for standard pumps due to the respective
suction head, is unnecessary because of the use of
the MPVAN. The result: maximum safety, hermetically sealed against leakage, low operating effort
and savings in terms of energy consumption. The
trouble-free unloading of tanker trucks for at least 15
years renders the use of the intrinsically safe pump
highly economical.
Authors
DIPL.-ING. SADKO MEUSEL
Paul Bungartz GmbH & Co. KG
40545 Dusseldorf, Germany
Phone + 49 211 57 79 05 - 60
[email protected]
ANNETTE VAN DORP
c/o Paul Bungartz GmbH & Co. KG
40545 Dusseldorf, Germany
Phone +49 211 577905-0
2900 rpm
29 REPORT
Best price-performance ratio for
air applications
ANDREAS HORINEK
Compressed air plays a major role in a wide variety of applications and forms an integral part of our everyday life. We come in contact almost daily with products that would not exist without compressed air. The most
common example is arguably the widely known polyethylene tereph-thalate bottle better known as PET-bottle. The practical and lightweight design of this plastic bottle has become the undisputed leader in beverage
bottling thanks to compressed air technol-ogy. But bus and rail operators also value compressed air for reliably and safely stopping the heavy vehicles. Finally, while on vacation or during travel, compressed air ensures
that large marine diesel engines of cruise ships can be started or that we have air to breathe during diving
adventures. These examples impressively demonstrate the significance that compressed air applications have
in our modern society. The list of applications for compressed air is endless.
A
ll applications have one thing in common: they
require reliable, safe and environmentally compatible compressor systems and components. Below,
some of the most significant compressed air uses
and their specific requirements in regard to a compressor valve will outline the challenges of the compressor industry in the air market.
PET-BOTTLE MANUFACTURING
In this application, the PET preform is brought into
the desired bottle shape in a stretch blow molding
operation using compressed air. This is done in three
to four compression stages at an air pressure of 35 to
46 bar. Considerable flow rates of up to 6000m3/h are
necessary for mass-producing PET-bottles. Depending on the compressor design, it is also possible
to use rotating displacement compressors, such as
rotary screw compressors, for the first compression
stage. In the stages that are subjected to higher loads,
conventional reciprocating compressors are used.
The last compression stage in particular is critical for
the service life of the valve since here the highest
load and temperature occur. Compressors frequently
operate at partial load, as a result of which the tem-
perature may rise to more than 200ºC. The majority
of PET-machines are therefore equipped with steel
plate valves. Valves containing non-metallic plates
have so far been employed on rare occasions and
are used in well-balanced compressors at lower operating temperatures of no more than 180ºC. To meet
the high air purity requirements, non-lube cylinders
must be used.
In general, durable and efficient valves are required.
The service life and efficiency directly impact the
maximum attainable flow rate, and consequently the
PET-bottle output.
STARTING AIR FOR MARINE DIESEL ENGINES
Large marine diesel engines are started using compressed air. A pressure of 30 bar is applied to the
pistons to press push the pistons in the direction of
rotation. The resulting rotation is used as a starting
aid for the following injection and ignition of fuel
that follows. Starting air compressors are subject to
stringent reliability requirements since failure at high
sea can quickly turn into an emergency. The com-pact
reciprocating compressors compress the air in two to
three stages at rotational speeds of up to 1800 rpm.
REPORT
The cylinders have a lubricated design.
Challenges for the compressor valves are
the high rotational speeds as well as the
seawater environ-ment, which necessitates the use of special corrosion-proof
materials.
INDUSTRIAL AIR
The broad range of applications of industrial air ranges from truck bulk material
transportation (pneumat-ic transport of
cement, gypsum, sand etc.) to the use of
Figure 1: RN pressure capability
compressed air in manufacturing plants.
Small to medium-sized compressors
compress air up to 10 bar in one, maybe two stages. clas-ses. A known use of high pressure is that of
Very high rotational speeds of up to 1800 rpm are not filling breathing air tanks used by divers or the fire
uncommon here. Depending on use, the cylinders are depart-ment, for example.
lubricated or oil-free.
As many as five compression stages are needed to
The compressor valves must function reliably, despite achieve the high pressure of up to 414 bar in the tank.
high rotational speeds and temperatures as well as In addition to the high pressure level, a mandated
contamination of the air by foreign particles.
oil-free cylinder design poses a particular chal-lenge.
Still, this is the only way to guarantee purity of the
BRAKING AIR
respiratory air. The valves therefore must be of high
In addition to the production of PET-bottles, braking strength and extremely resistant to wear and tear.
air is another key use of air, without which everyday The rotational speeds of the compact units reach up
life would be severely limited and less safe. Com- to 1500 rpm.
pressed air is used in particular for reliably deceler- Other high-pressure applications range from seisating trains and trucks. A final pressure of 10 bar is mic analyses to the exploration of underground ressufficient to ensure reliable operation of the brake. er-voirs, to the filling of smaller air tanks for paintball
The basic principle of air brake applications is to first guns.
store the compressed air in an air tank (reservoir) and
to conduct it from there via a distribution system to ONE VALVE FOR THESE AND FUTURE AIR
the particular brake circuits.
APPLICATIONS
The necessary 10 bar of air pressure is achieved in In addition to the outlined technical challenges that a
single- or two-stage compressors. The rotational modern compressor valve must meet for air appli-catspeeds cover the medium to high range (up to 1500 ions, economic aspects must be taken into considrpm). Cylinder may be lubricated or oil-free.
eration. Competition in the industrial air compressor
In this application, maximum requirements in regard market is very dynamic, and in particular the costs of
to the reliability of the compressor must be met. Fail- the (service) components is a top priority.
ure of the compressor during operation results in The launch of the RN valve at the beginning of 2013
immediate stoppage of the train or truck for safety has managed to bridge the gap between meeting all
reasons (fail-safe principle). Experience has shown the technical requirements and the best price-to-perthe compressor valve to be the component most formance ratio. The RN valve is able to cover all the
likely to fail. As a result, the valve must have a very described air applications - from low- or high-pressure
robust and durable design.
uses to small or high flow rate applications. These
highly standardized components can be freely adaptHIGH PRESSURE
ed to any circumstances of the compressor with little
The above-described uses are all in lower pressure effort using a modular design. As a result, the valve
ranges. However, in some applications the air is series requires only a small number of compo-nents,
com-pressed to more than 400 bar. Figure 1 shows minimizing delivery times and positively impacting
some of the key air applications and their pressure the overall budget.
31 REPORT
Figure 2: RN valve for air applications
PROVEN CONCEPT FOR DECADES
The RN valve is based on proven, advanced and optimized technology. Depending on the size, the RN
valve is optimally designed for various specific uses.
A very compact design is used for high-pressure
applications and is able to withstand high differential pressures that act on the valve seat (figure 1).
Larger valves with lower pressures, in turn, require
a maximum flow rate. A special design is used for
these valves, which includes damper plates and helical springs to achieve long operating times.
Some of the most important features of the RN
valves are:
Very small clearance volume due to the use of hanging guards designed as buffer plates made of hardened strip steel for smaller to medium sizes - see
figure 2. These result in a very small height of the
valve. The low installation height allows a very compact cylinder design. This makes the valve particularly
suitable for air applications with high demands in
regard to efficiency and maximum flow rate.
Due to the use of frictionless guided steel plates, the
RN valve can be used both in lubricated and oil-free
environments. In this configuration, the plate parts are
secured in the center. The valve lift is then achieved
by way of what is known as a guide arm. In addition to
applications that have special require-ments in regard
to air purity, a trend in industry toward oil-free compressors can be observed in the re-maining applications. With the RN valve, the possibilities are endless.
In general, the RN valve uses spring plates that have
been tried and tested and found to be extremely
robust. However, where larger valve diameters are
used, in which high flow rates occur, coil springs
en-sure a reliable opening and closing function. To
stabilize the valve plate and reduce the impact velocity, damping plates are additionally used.
The simple and reliable valve design makes long service cycles possible under constant operating condi-tions. After the wear limit is reached, the valves
are replaced with a new set. Servicing is economi-
Figure 3: Explosion view of valve with buffer and spring plates
cally worthwhile for valves with larger dimensions. A
well-engineered and user-friendly design allows fast
dis-assembly and reconditioning of the components.
VERSATILE APPLICATIONS ONE STANDARDIZED SOLUTION
The industrial air market and its extensive applications
continually present new challenges for the com-pressor industry. The market in Europe is largely saturated,
which creates a central requirement for sup-pliers of
performance-defining components such as valves: to
offer high quality at attractive prices. This need is met
by a high degree of standardization of the compressor
and individual components. Count-less expensive variants for different applications are eliminated with one
integral solution. In addition to innovative developments
to boost efficiency and increase reliability, the standardization decisively con-tributes to the successful future
of reciprocating compressors in the industrial air sector
Author
ANDREAS HORINEK, ING.
Product Manager, Compressor Valves
HOERBIGER Ventilwerke GmbH & Co KG
Vienna, Austria
Phone +43 1 740 04 348
[email protected]
Imprint
Special Issue May 2015
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Industrial Pumps + Compressors - Industriepumpen + Kompressoren

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