solved problems in suction and transfer dangerous or hazardous fluids

29 June 201615 January 2018

Pumps Hose Carrier for bonder and glues for papermaking an converting.

Bonder and glues pumping solution.

An important multinational company active in the production of food packaging industry, uses peristaltic pumps for transferring the adhesives in the production process. The first experiments have been made long ago with a peristaltic pump that gave promising results. The application of the pump consists on sucking and transfer bonder and glues to forming lines of product (carton packaging). The bonder has sorely tested the conventional pumps double diaphragm previously in use, the formation of the layers of glue film makes the valve system of pneumatic pumps if not useless, certainly very unstable. Interruptions, and discontinuity in productive activity generated a “nuisance” no longer sustainable.

Cleaning and restoring frequently not solved the problem in an acceptable manner. The rupture of the diaphragm was often a problem for pneumatic pumps due to spill of the glue in distribution air system making unusable. The activity of dosage was complicated by the fact that the pneumatic equipment do not combine with constancy and uniformity required for the operation. Complicated electro-pneumatic devices are necessary to allow the control of the flow rates. But even these devices require careful maintenance and control to ensure their (precarious) operation.

The turning point came some years ago by inserting into the cycle a HCP 25 peristaltic pump with variable speed controlled by an inverter. The pump characteristics were studied with particular attention precisely to meet an efficient operation, economic and possibility of rapid intervention in the site, without having to stop for a long time the job (replacing the tubular membrane worn out). From that day, the peristaltic pump HCP 25 had only one destiny, work hard, and that is exactly what it will do for many years more .

Recently, to a confirmation of the excellent service provided by pump, the company add another, almost identical pump, with small modifications which improve the utilization in order to further limit the dead times in the stage of replacement of the peristaltic hose for cleaning or restore. The company can also count on this pump for a long time, obtaining a service of high efficiency, management costs certainly not very significant.

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21 June 201615 January 2018

Hose Carrier Pump for suction of stone and marble working sludge.

A small company had the problem of intermittent sludge disposal which settle during the various steps of the marble and stone working. The fluids are collected in suitable unground tanks buried, placed in different areas of the plant. The water required to the machining process obviously is recycled, , after a certain period of tranquillity, solid substances in suspension precipitate separating from the water. The latter is recovered and restarted to the processing cycle.

The company had to carry out the operations of suction with submersible pumps equipped with sealing systems based on mechanical seals in Silicon Carbide. Despite this important characteristic, the pumps had a duration unsatisfactory, failures to the sealing system appeared after 8 -10 months of operation. The first time the pumps were repaired, it was subsequently adopted the habit to replace them ex-novo, choosing in the market “sacrificial” pumps among the less expensive. In a few years the pumps destroyed and replaced have become too many.

Probably the submersible pumps used have done their job as best as possible. But we know that the liquid mixture which had to deal was composed of water and dust generated by the cut with diamond tools. As far as a submersible pump can be adapted to the required work, operating with similarly liquid abrasive mixtures , there is no mechanical seal able to resist a time to meet the expectations of the user. The failure of the mechanical seal caused the flooding of the electric motor causing the “burning”.

Of course the submersible pumps, suffered the effect of the sedimentation of the deposited mud. in the course of time, frequent failures were generated. “Desperation” forced company to use the first pump available to replace the previous unusable, often with new one found on market but totally unsuitable for.

By purchasing a Hose Carrier HCP 5.0, this company has been able to solve two problems with one pump alone. The recovery of the limpid waters (or almost) in complete safety and with great easiness by moving the pump or the only suction hose on the various tanks. Occasionally one or two times per month with the same pump retrieving the sludge thicker from the bottom of the tanks to send them to the appropriate bag filters for subsequent disposal.

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10 June 201615 January 2018

Pumps Hose Carrier and sewage electroplating sludge.

The object of application: Aspiration from tanks of wastewater with suspensions resulting from electroplating and galvanic processes.

The company has the need to aspirate from underground tanks various wastewaters arising from their production process. These fluids in addition to maintaining a variable chemical aggressiveness (but always consistent), are also characterized by the presence of metallic particles accumulated during the various manufacturing processes. In the past were used pumps of various types, centrifuges, pneumatic membrane also submersibles. No pump previously used, has never solved the problem. For one reason or another, when you had the need to pump out some decanting, the pump designed was broken, does not prime, clog, worked well until the time but not now. It should be keep in mind that the nature of the fluid, as well as corrosive due to presence chemicals necessary to pre-treatment, also has the metal micro deposits.During the electroplating operation , the preparation of the products to be treated also provides cleaning cycles with acids and alkalines fluids that serve to improve the quality of the galvanic final treatment. In these baths that focuses a good part of the metallic particles. The combination of chemical corrosion and metal abrasion , creates a wastewater mix very damaging for the pumps, see why:

centrifugal pumps have their weak point in the system hydraulic sealing, constituted by the mechanical seal or rubber rings. The sealing system is resistant to chemical corrosion, but not against abrasion. After indefinitely time, but always too short the sealing system yields and the pump fluid releases can attack components not protected against contact of electroplating aggressive liquids.

The centrifugal pump as well, must be used below the level of the liquid to run correctly, poorly adaptations of a general service centrifugal pump is not a good choice. Also is not suitable for fluids transfer of high viscosity media as sludge is.

But the sludge is generated, and must be removed in some way. The centrifugal pumps exist also in version self-priming, and are much more suitable to treat galvanic wastewater with suspensions or slurries dissolved.

The times of priming of a self-priming pump are long sometimes up to 15-20 minutes, if the pump takes air suction for some unfortunate reason, the pump must be re-primed, with consequent waste of time. When the levels in the tanks are minimal this phenomenon is guaranteed.

The centrifugal pumps run fast (2800 revolutions per minute) the sealing organs responsible to the barrier of the liquid, suffer for this reason, a strong abrasion occur due to the action of the rotation speed mixed to presence of particulate abrasive metal. In a relatively short time the pump loses its suction capacity and it will be necessary to set in on maintenance of the pump. The pump must be completely removed to replace the sealing device, often this type of intervention is carried out by specific repairers in external workshops, this operation is not economically insignificant.

Let us come to the double diaphragms pneumatic pumps , cost perhaps less than all of the other, but beware, if you accept the cost of compressed air handling (considerable on balance).

The limited cost of purchase in relation to other pumps, attracts a lot. Diaphragm Pumps work quite well, better of centrifuges.

The limit in these pumps consists in the fact that there is a valves system to operate, especially in the suction phase and priming, all work fine in the presence of normal fluids. The situation changes in presence of wastewater with solids. The valve system no longer provides a linear operation, when the valve does not work in a perfect way the pump loses the ability to prime and must be re-primed again. Are rather noisy even if this is a problem. The real problem is absence of preventive maintenance, when diaphragm breaks, the the galvanic aggressive fluids spill out into the distribution system creating damage such as to have to replace it completely.

A solution for electroplating and galvanic wastewater, the peristaltic pump Hose Carrier.

A few years ago that company purchased a HCP 35 peristaltic pump, always in use, without too many concerns , even for reasons different from original needs . Once every year and a half, one tubular membrane is purchased and replaced internally at low costs.

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