Industrial Pumps Compressors - gwf Wasser...Industrial Pumps + Compressors 2015 1 24 Heinz M. Nägel Energy & cost-efficient pumping by diaphragm process pumps 27 Sadko Meusel and

2015

International issue ACHEMA SPECIAL

Industrial Pumps + Compressors

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Industrial Pumps + Compressors 2015 1

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

REPORTS

2 Rotary lobe pump for conveying waste Solvents

3 Investment boosts manufacturing productivity

3 Seal-less magnetic coupled gear pumps

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

6 Stainless steel pump series for a variety of different applications

7 Chemical pumps, for environmental protection

8 Magnetically coupled centrifugal pump with open impeller

8 Smart pump and control solutions

9 Variable plunger pump

9 First reciprocating compressor with contact-less magnetic coupling and a maximum drive power of 110kW

10 Magnetic drive pump made of PP

10 Exceptional efficiency: EBS and FBS blowers

11 Manufacturer celebrates three premiers

12 Progressing cavity pump can be adjusted flexibly

13 New canned motor pumps for chemical and process engineering applications

13 Precise low-pressure chromatography system

14 New hygienic pump

15 Focus on centrifugal pumps

15 Pump manufacturer introduces a new synthetic pump

16 Hydraulic diaphragm metering pump

16 Fibre reinforced plastic pump with cutting unit

17 Electronic and fully automated monitoring system

18 Process safety without compromise

18 New pressure testing pump permits flexible use

19 Mixing plant for sulphuric acid

20 Optimization in filter press feeding process

22 Well meshed without compromises

33 Imprint

NEW PRODUCTS ON ACHEMA 2015

CONTENT

2 Industrial Pumps + Compressors 2015

ACHEMA 2015

Rotary lobe pump for conveying waste solventsA 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 com-mercial 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 pur-pose, 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 suf-ficient 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 devel-oping 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. Liq-uid as well as viscous or abrasive pumped media can be conveyed effortlessly, and even chemically aggressive substances pose no problem.

As the Börger rotary lobe pump at EGN is used in poten-tially 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 oper-ated via a frequency converter. Thus, the flow rate can be continuously adjusted.

Börger rotary lobe pumps are especially suitable for con-veying media of any type. With the wide spectrum of 20 pump sizes (flow rates of 1 – 1,500m3/h), a large selec-tion 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]

Börger rotary lobe pump for conveying A1 liquids


ACHEMA 2015

Investment boosts manufacturing productivity

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.

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 tech-nology 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 Alba-ny Pumps, is delivering real process and productivity improvements.


ALBANY PUMPS GL15 5EQ Lydney, Glos (GB) [email protected]

Photograph shows Lobe pumps parts now produced on this machine

Seal-less magnetic coupled gear pumpsThe new GML/GMB gear pump combines the Dickow Pump-en 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 contain-ment shell replaces the single or double acting mechanical seals with external fluid reservoirs and the necessary con-trol equipment. GML/GMB-pumps therefore offer excep-tional 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 mate-rials 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 encap-sulated, not in contact with liquid. Power is transmit-ted to the hermet-ically sealed liquid end by a bank of 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 suit-able for liquids which are dangerous for the environment.

ACHEMA 2015: Hall 8.0, D54

DICKOW PUMPEN KG 84478 Waldkraiburg (GER) [email protected]

Revolutionary patented lubrication method extends overall life by reducing friction


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 dis-tribution of complex applications and the integration of multiple systems.

In addition to regular automation, modern plants require an increasing amount of certified safety technology. Blue-Line 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, mainte-nance work can be postponed to a convenient time frame.The failsafe and maintenance-free Rotex® Non-Spark-ing 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 dynam-ic properties, excellent vibration damping and a low moment of inertia. The coupling’s precision-machining positively influences its running properties and signif-icantly increases its expected service life. The Rotex® Non-Sparking ensures dampened torsional vibration dur-ing power transmission and absorbs shocks generated from imbalanced machinery. The new coupling is also

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 geom-etry 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]

The new explosion-proof ROTEX® Non-Sparking coupling displaying injected jaw geometry on one side.


ACHEMA 2015

New major version for turbomachinery design softwareA German engineering company specialized in soft-ware 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, compres-sors and turbines, as well as for diffusers, stators, return channels and volutes. Especially all new developed mod-ules 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 par-ametric 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.

ACHEMA 2015: Hall 9.1, C86a

CFTURBO SOFTWARE & ENG. GMBH 01097 Dresden (GER) [email protected]

Turbomachinery Design Software

BungartzMasterpieces

an aBunDanCE OF EMPtInESS

Titanium and fluorocarbon rubber on cast ironA loan from a loyal customer

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.

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


ACHEMA 2015

Conveying of polymer solutions in the adhesive industry

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 devel-oped 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 interest-ing applications can be discussed in detail with the experts of Jung during ACHEMA 2015.Transport of adhesives is viscous and sticky. The char-acteristics 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 hop-per 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 repre-sents 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]

Inside the HYGHSPIN Hopper

Stainless steel pump series for a variety of different applicationsAccording to the motto “pinpoint precision instead of ran-domness”, the company presents individual gear pump solu-tions 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 recommen-dations regarding their respective uses.

ACHEMA 2015: Hall 8.0, E78

SCHERZINGER PUMPEN GMBH & CO. KG 78120 Furtwangen (GER) [email protected] steel gear pumps of the 2030 – 5030 series


ACHEMA 2015

FELUWA Pumpen GmbH | Germany | [email protected] | FELUWA.COM

YOUR Business – OUR TechnologyMULTISAFE Double Hose-Diaphragm Pumps Handling of abrasive, aggressive and toxic mediaFlow 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

Engineered and Made in Germany

Visit

us

June 15-19, GermanyHall 8.0 | Booth G94

Chemical pumps, for environmental protectionGEKO 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 practi-cally unrestricted corrosion resistance, even at tempera-tures 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. Indus-try-wide shortest delivery times and an in time service are additionally preferences.Furthermore Geko has the ability to replace former QVF- and SIHI isolined-pumps one to one.

ACHEMA 2015: Hall 8.0, J28

GEKO-PUMPEN GMBH 65343 Eltville (GER) [email protected]

Seal-less PTFE/PFA-lined chemical pump


ACHEMA 2015

Smart pump and control solutionsOne of the leading worldwide manufacturer of fluid manage-ment 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 excel-lence, Aro provides fluid management equipment for cus-tomers 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, dia-phragm and electronic interface pumps. The Aro one-fourth- through 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 closed-loop 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 appli-cations, 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)

Smart pump and control solutions

Magnetically coupled centrifugal pump with open impellerAt this year’s ACHEMA in Frankfurt, Fristam Pumpen show-cases 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 extreme-ly 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, compa-nies 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

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]

Modular system: shearpump model FSP-MAK with a rotor-stator combination for optimal dispersion


ACHEMA 2015

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 adjust-ment of all three plunger strokes. The transmission incor-porates 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 result-ing in an extremely accurate adjustment of the flow vol-ume 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 hermetical-ly sealed dosing of explosive, toxic or highly pollutant fluids.

ACHEMA 2015: Hall 8.0, G69

HAMMELMANN GMBH 59302 Oelde (GER) [email protected]

VARIO-STROKE plunger pump

First reciprocating compressor with contactless magnetic coupling and a maximum drive power of 110kW

The Swiss HAUG Kompressoren AG is the leading manu-facturer 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 com-pressor 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 com-pressors 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 compres-sor-bare-blocks up to complete solutions with control unit and container installation.


HAUG KOMPRESSOREN AG 9015 St. Gallen (CH) [email protected]

The TIG


ACHEMA 2015

Magnetic drive pump made of PPWith 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 construc-tion 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.


IWAKI EUROPE GMBH 47877 Willich (GER) [email protected]

Exceptional efficiency: EBS and FBS blowersRemarkably 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 pro-vide 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 applica-tions 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 blow-ers 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 corre-spond precisely to the machines’ actual performance

(as per the conservative tolerances provided for by Standard ISO 1217; measurements validated by TÜV-Süd). 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]

FBS screw blower


ACHEMA 2015

Manufacturer celebrates three premiersPremiere 1: “NETZSCH is now the first progressing cav-ity 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 inspect ion cover allows opening of the pump housing and simply lifting out of the rotor-sta-tor unit. All movable parts of the rotating unit are now accessi-ble through the large opening. This reduc-es assembly and dis-assembly time significantly.The dimensions of the pump remain unchanged. Th is

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. “Howev-er, 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 pro-duction 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-spin-dle pumps. This clearly sets us apart from other compa-nies 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 pres-sure 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.”


NETZSCH PUMPEN & SYSTEME GMBH 84478 Waldkraiburg (GER) [email protected]

Premiere 3: The development department in Pomerode/Brazil has developed three completely new model series of NOTOS screw pumps.


ACHEMA 2015

Progressing cavity pump can be adjusted flexiblyAll of the MX progress-ing cavity pumps from KNOLL Maschinenbau in all model series are con-structed in modular fash-ion. Therefore, the main components of an exist-ing pump can be replaced easily and without special tools for a wide variety of applications. With a pump set change, for exam-ple - 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 (connec-tions 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.


KNOLL MASCHINENBAU GMBH 88348 Bad Saulgau (GER) [email protected]

New canned motor pumps for chemical and process engineering applications

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 stand-ardised 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 low-noise 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 chemi-cal applications, heat transfer fluids, polymerising or fer-rite-containing fluids and a special variant for low-boiling fluids and liquefied gases.The pump sets have been designed to meet the require-ments 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-car-bide-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

KSB will present its new Ecochem Non-Seal canned motor pump type series at ACHEMA 2015 for the first time.


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 num-ber 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 direc-tion-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

Nowhere are the requirements of precision, quality, and reproducibility as strictly regulated as in modern process chromatography. Using the Ecoprime low-pressure chro-matography system developed by Lewa GmbH, batch-to-batch reproducibility in GMP manufacturing of biopharma-ceuticals 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 con-trol 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 conven-tional 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 chroma-tography 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 chromatogra-phy, 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-re-ducing purification processes for the manufacturers of biopharmaceuticals at GMP scale.


LEWA GMBH 71229 Leonberg (GER) [email protected]

With the diaphragm metering pumps of the Ecoprime chromatography system from Lewa, processes can be reproduced with the highest precision.

mailto:[email protected]


ACHEMA 2015

New hygienic pumpHygienic, gentle and safe operational processes are top priorities in the food, pharmaceutical, and cosmet-ics 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, pharmaceuti-cal 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 Sani-tary 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 elasto-mers (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 hygien-ic 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-

semble enabling speedy and thorough mechanical clean-ing 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]

Lutz B70V Sanitary

Focus on centrifugal pumpsFor ACHEMA 2015, OSNA puts a focus on their wide range of centrifugal pumps which come in several varie-ties, especially emphasizing the high pressure pump range NMH and NMV.This pump line comprises a selection of sturdy, wear-re-sistant 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 capac-ity 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 temper-ature 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

ally made of bronze (G-CuSn10) or stainless steel is also available. In order to find the right sealing solution, the

customer can choose from a variety of seal manufacturers. Problematic media can be sealed e.g. with fully encapsu-lated seals. Alternatively, double-acting mechanical seals or auxiliary quench systems are available.Osna is currently extending its pump line NMH by a vari-ation 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.

ACHEMA 2015: Hall 8.0, L44

OSNA-PUMPEN GMBH 49090 Osnabrück (GER) [email protected]

Profile: OSNA-Centrifugal Pump NMH-40/4

Pump manufacturer introduces a new synthetic pumpThe 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 versatileThe 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 220-400V 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 temper-ature 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.

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]

Impeller pump made of synthetics designed for a wide range of chemical applications.



ACHEMA 2015

Fibre reinforced plastic pump with cutting unit

The self-priming pump with asynchronous motor and inte-grated frequency converter is used if water or others, but not aggressive fluids have to be delivered.These media might be dirty, contaminated with substanc-es 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 addi-tional 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 func-tion, 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]

Fibre reinforced plastic pump with special motor

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 hydrau-lic 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 capac-ity 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 oscil-lating 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 oper-ating 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


PROMINENT GMBH 69123 Heidelberg (GER) [email protected]

Hydraulic diaphragm metering pump

New hydraulic diaphragm metering pump Orlita® Evolution EF3a with hydraulically deflected safety diaphragm.



ACHEMA 2015

Electronic and fully automated monitoring systemIN-1000 was developed specifically for Allweiler pumps that are used in operationally-critical and environmental-ly-sensitive applications. IN-1000 improves safety while reducing operating costs. The core of the system is a software program developed by Allweiler.With its Smart Technology IN-1000 Series, Colfax Fluid Handling is defining a new generation of Condition Moni-toring. IN-1000 is an electronic and fully automated mon-itoring system. The modular design of IN-1000 permits easy integration into pump systems, with pre-config-ured settings that are the foundation of rapid, individu-alized startup. IN-1000 may be retrofitted at any time and allows central monitor-ing of up to 21 pumps with one control.The new Smart Technolo-gy IN-1000 series is ready to handle anything from straightforward condition monitoring to more complex monitoring activities, includ-ing operation monitoring of multiple pumps for simulta-neous fulfillment to ensure your safety and operating cost requirements are met. Operations are monitored continuously and automat-ically, 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-capa-ble color display.Because of these capa-bilities, maintenance and repairs can be planned in advance, there are no unplanned production downtimes or consequen-tial damages, and mainte-nance intervals are extend-ed. As a result, expenses

for maintenance and spare parts go down and the long service life of each Colfax Fluid Handling pump/motor assembly can be utilized to its fullest.

ACHEMA 2015: Hall 8.0, D63 ALLWEILER GMBH 78315 Radolfzell [email protected]

Dickow Pumpen KGSiemensstraße 22, D-84478 WaldkraiburgPhone 08638/602-0, Fax 08638/602-200E-Mail: [email protected] · [email protected]: http://www.dickow.de

The new GML Gear Pump withMagnet Coupling and TuthillGlobal Gear combines decades ofexperience and offers unparalleledperformance and reliability.

June 15 - 19 Hall 8 / D54

New ProductNew Product

1502019_Dickow_Anzeige_GML_EN_www.terme.de 26.02.15 14:18 Seite 1


ACHEMA 2015

Process safety without compromiseSide channel pumps by SERO are specially designed to meet the requirements of industrial and processing opera-tions 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: dou-ble 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 condi-tions 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.


SERO PUMPSYSTEMS GMBH 74909 Meckesheim (GER) [email protected]

Side channel pumps by Sero

New pressure testing pump permits flexible useWherever 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 electri-cally 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 con-struction, 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.


URACA GMBH + CO. KG 72574 Bad Urach (GER) [email protected]

VP602 with combustion engine


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 concen-tration. 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 auto-matically while the tank is being filled. The capacities of the two dosing units are adjusted accord-ing 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 stor-age 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 cir-cuit, 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 tech-nology 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]



ACHEMA 2015

Optimization in filter press feeding processIn order to maintain or improve competitiveness, it is cru-cial to optimize one’s own processes, particularly produc-tion 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 indus-try. 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)

for filter feeding. The abrasive filtration additives in par-ticular, 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 con-veying 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 transport-ed 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 1: Filter press feeding with a horizontal Egger Turo® free-flow pump

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 con-cept. 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-

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 devel-op 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

Figure 2: Control concept for the feeding of a filter press

The Egger Reactor Loop Pump HT/HPT for high temperature and high pressure applications

www.eggerpumps.com

Egger: Your partner to handle multiphase liquids ACHEMA

15th – 19th June 2015: Hall 8.0, Booth B64

Emile Egger & Cie SA2088 Cressier NE (Switzerland)Phone +41 (0)32 758 71 [email protected]

Emile Egger & Co. GmbH68199 Mannheim (Germany)Phone +49 (0)621 84 [email protected]


ACHEMA 2015

Well meshed without compromisesA provider of ANSYS simulation software and comput-ing 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 dis-placement 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 proper-ties of machine and system components. An important prerequisite for the development of efficient calculation models capable of making reliable predictions is the cre-ation 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 sig-nificantly lengthen the computation times of computer models. The creation of such computational grids poses two par-ticularly 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 sec-ond 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 cal-culation 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 adapt-ed 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 calcula-tion 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 manipu-lated using mathematical tricks. Unfortunately, these meth-ods cannot be coupled with all physical models required to correctly account for phenomena such as turbulence, cavitation, compressibility or rheologically complex mate-

rial properties. However, since such effects constitute the functioning of rotational displacement machines to a significant degree, these methods are also not applicable.

Manual meshing as a way out The best possible way so far to produce reliable results within reasonable com-puting times is manual meshing with structured hexahedral grids (cuboid-shaped elements). For a number of rotor position predetermined by the calculation engineer, the computation-al grids are generated manually prior to the simulation to then be automatically read out during the simulation by the

Figure 1: Screenshot of the TwinMesh software shows the mesh of a 2D cross section of a rotary lobe pump


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 computation-al grid for the solver always remains the same. Advantage of this method: best numerical quality; due to the elemen-tal 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 devel-opment of rotational displacement machines. With the help of new meshing software TwinMesh devel-oped 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 Twin-Mesh 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 Design-Modeler. 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 computa-tional 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 export-ed. 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

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 rota-tional 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]

Figure 2: Simulations results of a rotary screw compressor, showing absolute pressure


REPORT

Energy & cost-efficient pumping by diaphragm process pumpsHEINZ 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 diag-nostic 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 typical-ly applied in process engineering systems, such

as centrifugal, progressive cavity or positive displace-ment pumps. Although centrifugal pumps have mar-ket 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, dri-ving 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 CASINGWith 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 contami-nates the hydraulic control area and can culminate in considerable expense, as well as induce unplanned and inconvenient pump downtime for decontamina-tion and repair.

SOLUTION: TWIN CYLINDRICAL HOSE-DIAPHRAGMSHydraulically actuated double hose-diaphragm pumps offer decisive advantages vs. traditional piston dia-phragm pumps (Fig. 1). They are designed to eli- minate flat diaphragms and their obligatory clam- ping 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 normal-ly in the event of a failure of either. These tubular diaphragms avoid all of the disadvantages of tradi-tional 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 mate-rials. Unlike peristaltic hose pumps, double hose- diaphragms 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 hose- diaphragm pumps is the linear flow path from the suction to the discharge side. However, the hose- diaphragm design does not just influence the flow path, but also the efficiency of the pump. Traditional diaphragm pumps are characterised by their circu-lar 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 MONITORINGDouble 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 monitor-ing 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 pre-ventative maintenance into the process as appropriate, in order to avoid unscheduled shutdown of the system. Since the leak-free sealing of check valves plays a decisive role, an innova-tive system for the early detec-tion of wear in check valves has

been developed for double hose-diaphragm pumps in cooperation with a well-known German electron-ics 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

Figure 1: MULTISAFE Double Hose-Diaphragm Process Pump

Figure 2: Diaphragm Pump Housing


REPORT

of the measuring results by means of a dry contact (such as Internet or Intranet). Intrinsically, this pro-vides the operator the opportunity of well-directed advance planning of maintenance or repair action,

as well as the precise determination of MTBR val-ues. 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

HEINZ M. NÄGEL

FELUWA Pumpen GmbH

54570 Mürlenbach (GER)

Phone +49 6594 10-0

[email protected]

Figure 3: Overall diagnostics, control and web-based service by means of touch panel


REPORT

In order to minimise the failure risks in pump appli-cations, 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 detec-tion in recent times. Those extra safeguards, how-ever, often lead to problems themselves. Moreover, the average expense from planning and procurement, integration, repair and maintenance to documenta-tion, etc. can amount to up to 10,000 euros per signal.

CHALLENGING OPERATING CONDITIONS AND PHYSICAL PRINCIPLESFrequently, the pump operation is aggravated by the operating conditions. Examples for rather chal-lenging pumping media are gaseous, corrosive, sol-id-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 TECHNOLOGYThe intrinsically safe pump technology offered by Bungartz is partially based on the hydrodynamic seal-

ing originally developed by the company. Essentially this sealing consists of a distinctive blading at the rear side of the impeller. Thus, the pumping medi-um is carried away from the critical shaft gap transi-tion protecting the downstream shaft seal system. Owing to the physical features the pump is perfect-ly 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

Applied intrinsic safety with centrifugal pumpsSADKO 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.

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.


REPORT

(1,200m3/h) of the M-UMOR type perfectly intrin-sically 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-com-pliant, suitable for molten masses and protected against blockages and operator errors (e.g. insuffi-cient 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

pumps and describe the preliminary pump selection for a new construction project.

Practical example: Conversion of a condensate delivery systemPump location: refineryMedium: condensateOperating data: Q = 42.5 m3/h, minimum feed rate: Q= 0m3 H = 90m liquid column, temperature = 127 °C, (oper-ating 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 stand-stills 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 con-densate in a refinery here, they trigger additional pul-sating pressure surges due to the min/max control, which cause malfunctions in the plate heat exchang-er. 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-regulat-ing VKS-AN vertical pump provides a hydrodynamic sealing during operation, which works as described above. The use of the back vanes working fric-tionlessly and being free of wear and tear leads to

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.

Figure 2: The hermetically sealed chemical pump MPCHDryRun is ATEX-compliant, suitable for molten masses and protected against blockages and operator errors (e.g. insufficient ventilation).


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-lubri-cated 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 tankPump 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 vis-cous elements of a hazardous, flammable and outgas-sing nature. The previously used slop pump with prod-uct-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 reinstalla-tion extremely laborious and dangerous. Evacuating the environment and working with full protection was mandatory there. The conversion was absolutely neces-sary. It was made already ten years ago. Since then the intrinsically safe MPATAN slop pump has been working without malfunction and even maintenance-free. Expe-rience 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 trucksApplication area: refinery/tanker truck unloadingMedium: sulphuric acidSpecial features of pump use:

Operating data: Q = 30m3/h, Q= 0m3, speed = 2900 rpm

H = 20m liquid column, temperature = 50 °C, density 1.84kg/dm2

Operating pressure pmax = 10 bar (0), operating tem-perature: 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 plan-ning stage. The self-regulating physical feature of the pumps of the V-AN series facilitate easy unloading from below, complete residual liquid emptying with-out exerting pressure, utmost safety and even struc-tural 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, hermet-ically 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


REPORT

Best price-performance ratio for air applicationsANDREAS HORINEK

Compressed air plays a major role in a wide variety of applications and forms an integral part of our every-day 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-bot-tle. 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 relia-bly 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.

All applications have one thing in common: they require reliable, safe and environmentally com-

patible compressor systems and components. Below, some of the most significant compressed air uses and their specific requirements in regard to a com-pressor valve will outline the challenges of the com-pressor industry in the air market.

PET-BOTTLE MANUFACTURINGIn 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. Depend-ing 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 oper-ating 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 ENGINESLarge marine diesel engines are started using com-pressed 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 necessi-tates the use of special corrosion-proof materials.

INDUSTRIAL AIRThe broad range of applications of indus-trial air ranges from truck bulk material transportation (pneumat-ic transport of cement, gypsum, sand etc.) to the use of compressed air in manufacturing plants. Small to medium-sized compressors compress air up to 10 bar in one, maybe two stages. Very high rotational speeds of up to 1800 rpm are not uncommon here. Depending on use, the cylinders are lubricated or oil-free.The compressor valves must function reliably, despite high rotational speeds and temperatures as well as contamination of the air by foreign particles.

BRAKING AIRIn addition to the production of PET-bottles, braking air is another key use of air, without which everyday life would be severely limited and less safe. Com-pressed air is used in particular for reliably deceler-ating trains and trucks. A final pressure of 10 bar is sufficient to ensure reliable operation of the brake. The basic principle of air brake applications is to first store the compressed air in an air tank (reservoir) and to conduct it from there via a distribution system to the particular brake circuits.The necessary 10 bar of air pressure is achieved in single- or two-stage compressors. The rotational speeds cover the medium to high range (up to 1500 rpm). Cylinder may be lubricated or oil-free.In this application, maximum requirements in regard to the reliability of the compressor must be met. Fail-ure of the compressor during operation results in immediate stoppage of the train or truck for safety reasons (fail-safe principle). Experience has shown the compressor valve to be the component most likely to fail. As a result, the valve must have a very robust and durable design.

HIGH PRESSUREThe above-described uses are all in lower pressure ranges. However, in some applications the air is com-pressed to more than 400 bar. Figure 1 shows some of the key air applications and their pressure

clas-ses. A known use of high pressure is that of filling breathing air tanks used by divers or the fire depart-ment, for example. As many as five compression stages are needed to achieve the high pressure of up to 414 bar in the tank. In addition to the high pressure level, a mandated oil-free cylinder design poses a particular chal-lenge. Still, this is the only way to guarantee purity of the respiratory air. The valves therefore must be of high strength and extremely resistant to wear and tear. The rotational speeds of the compact units reach up to 1500 rpm. Other high-pressure applications range from seis-mic analyses to the exploration of underground res-er-voirs, to the filling of smaller air tanks for paintball guns.

ONE VALVE FOR THESE AND FUTURE AIR APPLICATIONSIn addition to the outlined technical challenges that a modern compressor valve must meet for air appli-cat-ions, economic aspects must be taken into consid-eration. Competition in the industrial air compressor market is very dynamic, and in particular the costs of the (service) components is a top priority. The launch of the RN valve at the beginning of 2013 has managed to bridge the gap between meeting all the technical requirements and the best price-to-per-formance ratio. The RN valve is able to cover all the described air applications - from low- or high-pressure uses to small or high flow rate applications. These highly standardized components can be freely adapt-ed to any circumstances of the compressor with little effort using a modular design. As a result, the valve series requires only a small number of compo-nents, minimizing delivery times and positively impacting the overall budget.

Figure 1: RN pressure capability


REPORT

PROVEN CONCEPT FOR DECADES The RN valve is based on proven, advanced and opti-mized 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 differen-tial 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 hel-ical 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 hang-ing guards designed as buffer plates made of hard-ened 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 com-pact 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 com-pressors can be observed in the re-maining applica-tions. 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 veloc-ity, damping plates are additionally used. The simple and reliable valve design makes long ser-vice cycles possible under constant operating con-di-tions. After the wear limit is reached, the valves are replaced with a new set. Servicing is economi-

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 SOLUTIONThe industrial air market and its extensive applications continually present new challenges for the com-pres-sor 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 var-iants for different applications are eliminated with one integral solution. In addition to innovative developments to boost efficiency and increase reliability, the standard-ization decisively con-tributes to the successful future of reciprocating compressors in the industrial air sector


AuthorANDREAS HORINEK, ING.

Product Manager, Compressor Valves

HOERBIGER Ventilwerke GmbH & Co KG

Vienna, Austria

Phone +43 1 740 04 348

[email protected]

Figure 2: RN valve for air applications

Figure 3: Explosion view of valve with buffer and spring plates

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