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.
Application purpose: chemical cleaning and descaling, industrial plants, recovery of wastewater and sludge with peristaltic pump.
This company operates in the field of chemical cleaning and washing of industrial systems, plants and components. These operations take place inside the company in the special tanks prepared for the purpose or directly on the customer plant, in case it is not possible to disassemble it. This last condition, also known as CIP (cleaning in place),for the obvious reasons is the most widespread.
The cleaning and washing operation is effected by the flushing special chemical cleaning agents acidic, basic and neutral. Are generally used, sulfuric acid, hydrochloric acid, sodium carbonate, soda etc. All the substances used for these operations, have characteristics of aggressiveness certainly relevant, it is taken for granted that the machines and pump equipment used for that task must be perfectly compatible in order to ensure the expected service life. But the important point of this application is another, during the washing operations, sometimes mud and abrasive media resulting in the waste.
The normal pumps used by our customer certainly are chemically compatible, but totally unsuitable for the treatment of muddy and abrasive sewage. In addition, during the washing phases, in certain situations, the liquid flow is discontinuous, exposing the conventional pumps to a dangerous operation in dry condition or intermittently, with continuous phases of priming, condition that sometimes resulted in damage to the sealing system of the pumps.
The peristaltic pump solution.
Sometimes the fluid is collected in flexible tanks placed and moved from time to time in different areas of the plant, these tanks having modest heights. The required pump must be capable of operating with minimum flooded condition level, the pump must be suitable of operating intermittently and with speed priming capabilities. The perfect solution was found by choosing a peristaltic pump HCP 25, with compact dimensions, good performance, absolute capacity and rapid priming, full chemical compatibility, and capable to operate with fluids with a very different viscosity, with solid abrasive suspension and obviously dry proof capabilities. Simple tasks for HCP 25 peristaltic pump .
The purpose of the application: pumping sulphuric acid and waste products.
This company deals with the recovery of metal, plastic materials and other chemical substances for the subsequent regeneration.In a production site, there is a particular type of plant that has the aim of recovering the industrial and automotive batteries. From the recovery cycle, will get the lead, plastics and chemicals, sulphuric acid, sodium sulfate. In one of the initial steps of the recycling process the sulphuric acid accumulated by the emptying of the batteries must be pumped. The acid is collected in tanks and is contaminated by solid substances of various types, crystal formations, particles of plastic, metallic powders, acid slurries. The result is a fluid with significant characteristics of chemical and mechanical aggression properties. The fluid must be pumped with surface pumps in order to limit any security issues, the experiences in the past with centrifugal pumps have been very disappointing, with great difficulty on priming, rapid eterioration of the sealing systems, very frequent impeller clogging, continuous machine stoppages. The company experimented the use of pneumatic diaphragm pumps, but also in this case, there were significant problems on priming and aspiration (uncertain due to wear of the valve system, in case of rupture of the membranes, it often happened that the contaminated fluid passing through the membrane deteriorated, to the air distribution device destroying it irreparably. In both cases, the centrifugal pumps and the pneumatic ones, required the complete removal of the pumps from plant for maintenance. Given that the past experiences were not certainly positive, it was not easy to convince the company to experiment a different solution with another pump not very conventional. At the end we were able to introduce into the production cycle a HCP 50 peristaltic pump in 2010. From that moment the company no longer had problems arising from the pumping of contaminated sulfuric acid. The peristaltic pump has an operating cost of three peristaltic hoses every year, without machine stops and substantial significant costs. In the course of 2016 another peristaltic pump HCP 50 has joined the existing one for further increase potential production .
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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