Application: suction and cleaning of tanks containing aluminum processing sludge. In this company, aluminum semi-finished products are produced in three phases: starting from casting to obtaining billets, then many operations are carried out to obtain profiles of various shapes, and finally surface finishing steps are completed with anodization and painting of metal semi-finished product. These operations generate wastewater characterized by chemical aggressiveness and a charge of abrasive metal suspensions. The fluids are collected in tanks and the formation of sludge deriving from the heavy solid suspension precipitation to bottom of tank.
The tanks cleaning operations and the removal of wastewater are performed by submersible centrifugal pumps, but, as is often happens, the formation of thickeners creates large problems of blockage of submersible pumps making them inefficient. Normally an operator goes down into the tank in order to improve the sludge evacuation process through fluidification operations for the sediment homogenization.
This is big problem because during the emptying operations, the operator works immersed in the fluid mass at the same time as the electric pumps running. The potential risk for the operator is clearly evident (electric shock).
Safety and peristaltic pumps in tanks cleaning operations
It was proposed for the task solution , a self priming peristaltic pump hcp 40 complete with speed variator, due this, machine is perfectly adapted to variable viscosity of the sludge, The pump perform a very high suction capacity and completely isolates the operator from a potential electric shock. Insensitive to dry running, the peristaltic pump does not suffer damage resulting from the discontinuity of liquid inflow, moreover, the resistance to abrasion and chemical aggression is assured by the hose membrane perfectly compatible with the fluid. The absolute safety is guaranteed by the fact that the pump operates on the surface by introducing the only suction pipe moving it in the various points of tanks to obtain a perfect cleaning, as it would happen with a vacuum cleaner. No physical contact between mechanical or electrical parts of the pump with the pumped fluid prevents any risk.
Hazardous and aggressive fluids in open areas or without electricity – this is the solution.
How a lightweight and versatile self-priming engine driven pump can expand the operational possibilities in the field of ecological recovery, our customer works in the environmental field for the recovery and treatment of wastewater and hazardous fluids arising from industrial processes, already owner of a self-priming electric peristaltic pump Hose Carrier intended to operate for the same purpose, presented us with the need to possess a self-priming petrol engine driven peristaltic pump for new incoming duties.
Starting from a 35 HCP pump ideal for performance and size, we have created a transmission equipped with a gearbox selected to operate with the speed typical of the current fast petrol engines, combined with a special joint able to power allow the start of the engine without dragging load of the pump. once the engine is started, just act on the accelerator to engage the pump and obtain at the same time a change of rpm that allows the pump Hose Carrier to adapt for different fluids viscosity.
A single self-priming engine driven pump is suitable for all common hazardous fluids.
The possibility to set up tubular membranes in different compounds makes it possible to extend the pump’s compatibility with most fluids and wastewater destined to be recovered by the company for subsequent treatment: the entire group has been set up in a steel tube cage equipped with folding handles and lifting eyes so as to guarantee adequate protection for the pump during the “abrupt” operational use needs, the result is a perfect heavy duty practical unit.
For the past three years, this self-priming engine driven pump has been making its operational contribution to the company’s objectives, making it possible to further expand the range of services offered by the company: maintenance and management costs are so low that it has not yet been necessary to replace any of the various tubular membranes of first delivery.
100,000 cps, up to this value can reach viscosity of fluids that our customer, operating in the food sector, must transfer seasonally from reactor to containers prepared for the following Machining. The operation was carried out by flexible impeller pumps with very disappointing results and very high operating costs. The transfer of normal or viscous products, obviously ,did not generate problems, but as the viscosity raise, difficulty, inefficiencies, and high management costs grew fast. The company reached a level that was no longer sustainable. The increasing viscosity of products generated great discontinuity of suction flow to the pumps, often causing destruction of the rubber impellers and mechanical seals of all the pumps available. Viscous and dense fluids = problems.
This is the fact, without any consideration for the long process pumping times, combined with cleaning, restoring and continuous maintenance time spent for the various pumps involved . The company technical manager finally decide to seek a rational solution to solve the issue, he exposed the problem to several pump producers, proposing them a sample of the most difficult viscous product to verify the transferability. No one proposed a solution, 100000 cps are a limit for almost everyone. We made our own tests with our peristaltic pumps. After that we have realized that we could definitely eliminate the high viscosity transfering problems of this company.
The right solution for very viscous and dense fluids.
Now, a peristaltic HCP 50 pump equipped with special accessories has replaced the previous pumps in the suction and transfer operations. Our peristaltic pump is equipped with additional vacuum system and Inverter panel for the management of the speed variation. The possibility to change the speed allows the adaptation of the pumping capacity to the characteristics of most of the less problematic fluids. With the few high viscosity fluids, increased vacuum system allows to obtain the suction efficiency required, needed to work with high viscous products (up to 100000 cps).
The pump capability of realizing a vacuum up to 95% and the ability to keep it stable even with different speeds allows the HCP 50 peristaltic pump to satisfy the customer’s requirements for high viscosity fluids. Low operating cost and effectiveness in operation have consolidated the trust of our customer to our peristaltic pumps. We can expect the introduction of some other machine in future
Inox pumps? when using peristaltic pumps in stainless steel.
If there is a peculiarity that in principle distinguishes the peristaltic pumps from the others in general, it is the characteristic of being “contactless” This means there is no physical contact between the pumped fluid and the pump’s mechanical organs. The treated fluid remains entirely contained in the peristaltic hose. This peculiarity excludes, in fact, that materials that are compatible with the liquid to be treated must necessarily be used to make the pump as inevitably applies to all other types of pumps, often made in stainless steel.
What is the purpose of a inox peristaltic pumps, and what advantages are obtained?
Essentially, not many, there are no real practical advantages to make the difference between a common pump and one entirely INOX made . It is possible to make wider and different considerations than the search for a “functional” purpose. We can consider the environment where the machine is to be applied, the environmental characteristics may still be chemically aggressive, so the pump would suffer “passively” the consequences. Other environmental conditions require very high cleaning levels, the ability to intervene quickly on machines easily and effectively ensures the sanitary levels required by these situations. Sectors such as food, pharmaceutical and cosmetics are the most common example in which the highest level of direct and indirect cleaning is to be guaranteed. it’s not a casuality in these cases, entire machines and production lines are made using stainless steel in considerable quantities.
Other criteria that may determine the choice of using a stainless steel peristaltic pumps may be more subjective. Sometimes the customer chooses a peristaltic inox pump to make it easy to operate the machine’s normal handling and maintenance process, having the highest resistance to atmospheric or environmental impacts from the pump’s structural components. It is possible to say that a machine made of stainless steel makes it much simpler to perform more intensive and accurate cleaning operations (such as pressure and steam scrubbing) or facilitates the use and handling of the machine in the most extreme environmental cases , characterized by summary and corrective maintenance, or vice versa, very frequent and intense.
Finally, there are good reasons that make the choice to use a completely stainless steel peristaltic pumps substantially mandatory.
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The purpose of the application: hydrochloric acid and Aluminum anodizing.
This company deal with surface treatments, and there is a lot to do with an annual production of about 7000 tons of Aluminum. The quality of the finishes has distinguished this company in the market, making it among the most important companies in Italy in this sector. Evidently to reach this important goal, it is necessary to pay particular attention to all production processes, and especially those in the preliminary analysis, and control, before each processing step.
The hydrochloric acid is widely used to perform the repeated chemical controls necessary to achieve a process of high quality finish that the company shall ensure. The sampling is done by drawing directly from the baths the liquid to test, and subject it to various chemical controls. For dosing hydrochloric acid is used, a peristaltic pump HC 10 low pressure pump, with a fixed rotation speed, and particularly slow, in order to obtain a tubular membrane long lasting time.
Ease to use, high reliability in the priming, and the absolute compatibility with the hydrochloric acid, allow this little HC 10 peristaltic pump to make its important contribution in order to achieve the high quality standards desired by the company in the production processes.
The HC 10 is a small proportions peristaltic pump, but very sturdy and accurate, easy to use, does not suffer damage in case of dry running and is capable of developing a vacuum of 8 meters. Provides a instant and continuous self-priming effect. The tube membrane is compatible with a very broad spectrum of aggressive chemicals, its replacement is quick and simple and requires no special skills. Given the obvious talents shown by the first peristaltic pump, the customer introduced a second unit as a complement to the first.