Experience In Motion

CASE STUDY – Internal Use OnlyINNOMAG® SEALLESS PUMPS

BorsodChem Confronts Pump Issues With HCl Condensation UnitINNOMAG® AND D-TECH DISTRIBUTOR TEAM UP TO SOLVE RELIABILITY PROBLEMS

The Challenge: A chemical plant located in Hungary was plagued with unacceptable levels of production disruption and equipment maintenance due to pump failures while processing hydrochloric acid (HCl). Before building a new HCl unit, these problems had to be solved.

The Solution: With the help of its D-Tech distributor, Flowserve INNOMAG offered a package of lined magnetically driven pumps plus metallic and lined mechanically sealed pumps to successfully address the manufacturer’s safety and reliability issues.

InstallationLocated in the city of Kazincbarcika in northern Hungary, the BorsodChem plant is among Europe’s largest producers of methylene diphenyl diisocyanate (MDI) and toluene diisocyanate (TDI). These intermediate chemicals are sold to other manufacturers who make a host of products, including polyurethane foams and resins, elastomers, coatings, etc.

Both MDI and TDI manufacture involve the use of a poisonous gas, phosgene (COCl2), which is generated when carbon monoxide (CO) reacts with chlorine (Cl) over activated carbon. Hydrochloric acid (HCl) is used as a catalyst but is also generated in large quantities as a by-product in the production of both chemicals. Typically the HCl is recovered, purified and concentrated on the same site and then sold to processors where it is used in the production of a wide range of chemicals, for use in water purification, sewage treatment, additives for the pulp and paper industry, etc.

SituationHCl is a highly corrosive and toxic chemical, demanding specialized processing equipment and careful handling. Hence, equipment reliability and safety are of the highest priority. BorsodChem’s plant managers were becoming increasingly dissatisfied with the frequent failure and high maintenance costs

of their existing pumping equipment. Permeation of the fluoropolymer linings by the acid and subsequent failure of the pump casings were particularly problematic and identified as the main reasons for pump failure. The lined magnetic drive pumps being used were simply not holding up, causing costly production disruptions, hazardous conditions for plant operators and environmental issues.

BorsodChem plant engineers turned to D-Tech for help. This Hungary-based Flowserve pump distributor has established an excellent track record of technical and applications expertise, customer support and service.

CASE STUDY – Internal Use Only

ObjectiveBorsodChem needed a solution that would significantly improve pump reliability while enhancing personnel and environmental safety within its proposed new HCl plant.

EvaluationThe sales and applications engineers of Flowserve and D-Tech made a compelling case for selecting Flowserve. They emphasized the design simplicity and maintenance ease of the TB-MAG™ series pump. Additionally, they focused on these important attributes:

• A cost-effective but robust ductile cast iron (DCI) casing with a pure, rotomolded ETFE fluoropolymer lining which is chemically bonded to the DCI. Impervious to corrosive attack, this seamless, stress-free lining is vacuum rated, ensuring it will not separate from the casing.

• A one-piece, double-walled containment shell along with a one-piece, open-eye impeller and inner magnet assembly. The containment shell exterior is pressure molded Aramid fiber/vinyl ester composite for maximum strength, and the inner shell is molded carbon fiber reinforced ETFE. The impeller is also made from carbon reinforced ETFE while the inner magnet assembly is encapsulated with the same material.

• A revolutionary thrust-balanced design. This proprietary design completely eliminates axial thrust loads in the rotating impeller magnet assembly. Effective over the entire pump operating range, the TB-MAG automatically responds to changes in flow, pressure or viscosity, with no loss of pumping efficiency.

BorsodChem engineers conducted their own corrosion and permeation tests on the ETFE liner. The results: The lining had shown “outstanding resistance showing no signs of degradation” against HCl and free Cl chemical attack.

Acquired in 2013, INNOMAG sealless pumps is an important addition to the Flowserve chemical process pump line, perfectly complementing the Durco® Mark 3™ ISO and ASME (ANSI) standard, CPXS™ and Guardian™ metallic magnetic drive and PolyChem™ non-metallic models.

Two pump types comprise the INNOMAG product offering:

• The TB-MAG thrust-balanced, lined magnetic drive series. It is design and dimensionally compliant with (ASME) ANSI B73.1 and dimensionally compliant with ISO 2858. This ETFE lined pump is widely used in corrosive services throughout the chemical process industries.

• The U-MAG™ lined magnetic drive pump. Intended for lower flows and more specialist applications, the U-MAG is available with a range of fluoropolymer linings, impellers and containment shells. ETFE is standard but it is also available in FEP and PTFE. For high-purity services, e.g. in, pharmaceuticals, semiconductor and circuit board manufacture, PFA components are offered.

INNOMAGAbout

U-MAG

TB-MAG

To find your local Flowserve representative:USA and CanadaFlowserve Corporation5215 North O’Connor Blvd. Suite 2300Irving, Texas 75039-5421 USATelephone: 1 937 890 5839

Europe, Middle East, Africa Flowserve CorporationGebouw HagepointWestbroek 39-514822 ZX Breda NetherlandsTelephone: 31 76 502 8920

For more information about Flowserve Corporation,visit www.flowserve.com or call USA 1 800 728 PUMP (7867).

Latin America Flowserve Corporation Martín Rodriguez 4460 B1644CGN-Victoria-San Fernando Buenos Aires, Argentina Telephone: 54 11 4006 8700 Telefax: 54 11 4714 1610

Asia Pacific Flowserve Pte. Ltd.10 Tuas Loop Singapore 637345 Telephone: 65 6771 0600Telefax: 65 6779 4607

CASE STUDY – Internal Use Only

Bulletin FSG-CS-0010 (E) August 2014. © 2014 Flowserve Corporation

flowserve.com

SolutionFor the most challenging services in the HCl recovery unit, BorsodChem chose 45 TB-MAG series pumps with ETFE linings and components. Operating parameters ranged from 1.6 m³/h (7.0 gpm) to 107 m³/h (470 gpm) with heads between 15 m (49 ft) and 55 m (180 ft) and temperatures ranging from 17°C (63°F) to 70°C (158°F). These ASME (ANSI) standard pumps were installed on the following services:

In many applications, sealed pumps work very well. In others, however, magnetic drive, plastic-lined pumps are preferred. To allow the customer to choose the best solution for their applications, Flowserve offers both options.

In certain applications, a leaking mechanical seal often causes pump failure. If you can eliminate the seal you’ve removed the primary reason for pump breakdown. A magnetic drive pump is sealless, in these cases, relying on a primary and often a secondary containment shell to provide vapor-tight and/or leak-proof service. This is especially suited for chemical processing where toxic, corrosive and/or flammable liquids are being pumped. For this reason, magnetic drive pumps are gaining in popularity, as they can be more reliable and less expensive than metallic, mechanically sealed pumps.

Magnetic Drive Pumps

Growing Preference for Fluoropolymer-Lined,

Pump components lined with, or constructed of, fluoropolymer resins (i.e., ETFE, PTFE, PFA, etc.) offer outstanding, nearly universal corrosion resistance over a wide temperature range and are typically less costly than exotic metals or metal alloys. They can provide more sustainable solutions against equipment failure due to corrosion caused by leakage and emissions. Simultaneously, they can increase process efficiencies while reducing production disruptions. Also, they may offer significant savings in both initial costs and total cost of ownership (TCO).

The balance of unit services was covered with a combination of 10 Durco Mark 3 ASME (ANSI) metallic and PolyChem lined ASME (ANSI) standard mechanically sealed pumps. All 55 pumps were to ASME (ANSI) standard design and dimensional criteria.

• Chlorinated water• Hydrochloric acid solutions to 25 percent• Sulfuric acid solutions to 97 percent

• Caustic soda at concentrations up to 20 percent• Hydrogen peroxide at 35 percent• Salty waste water

For more information, please contact Jochen Schreiner (jschreiner@flowserve.com).