Pumps + Systems

VDMA Compressors, Compressed Air and Vacuum Technology

VDMA
Pumps + Systems
Compressors, Compressed Air and Vacuum Technology

Lyoner Str. 18
60528 Frankfurt am Main
Germany
Phone +49 69 6603-1296
Fax +49 69 6603-2296
E-Mail [email protected]

Pumps and Compressors

Internet pu.vdma.org
kdv.vdma.org

for the World Market 2014

with Compressed Air and Vacuum Technology

Pumps and Compressors for the World Market 2014

pu.vdma.org
vf 800314-e

kdv.vdma.org
A PASSION FOR PERFECTION

VDMA Publishing

Knowledge

Pumps + Systems
VDMA Compressors, Compressed Air and Vacuum Technology

VDMA
Pumps + Systems
Compressors, Compressed Air and Vacuum Technology

Lyoner Str. 18
60528 Frankfurt am Main
Germany
Phone +49 69 6603-1296
Fax +49 69 6603-2296
E-Mail [email protected]

Pumps and Compressors

Internet www.vdma.org

for the World Market 2014

with Compressed Air and Vacuum Technology

Pumps and Compressors for the World Market 2014

vf 800314-e
www.vdma.org

Pumps and Compressors

for the World Market This is the VDMA specialised magazine for engineers

Vacuum solutions with Compressed Air and Vacuum Technology

and the technical management. Please order

your copy free of charge simply by sending an

from a single source e-mail to [email protected] or register

online via
Pfeiffer Vacuum stands for innovative and custom vacuum solutions worldwide, http://subscription.vdma-verlag.com
technological perfection, competent advice and reliable service. We are the only
supplier of vacuum technology that provides a complete product portfolio: The magazine is published once a year in April.

■ Pumps for vacuum generation up to 10-13 hPa

■ Vacuum measurement and analysis equipment
■ Leak detectors and leak testing systems
■ System technology and contamination management solutions
■ Chambers and components

Are you looking for a perfect vacuum solution? Please contact us:
Pfeiffer Vacuum GmbH · Headquarters/Germany www.vdma-verlag.com
T +49 6441 802-0 · F +49 6441 802-1202
[email protected]
www.pfeiffer-vacuum.com
Pumps + Systems
Compressors, Compressed Air and Vacuum Technology

Pumps and Compressors

for the World Market 2014
with Compressed Air and Vacuum Technology
 2 pumps & systems / compressors, compressed air & vacuum technology

Content
Content
4 Editorial: Striking a new course
6 German pump and compressor manufacturers in 2014:
Still heading for growth

10 Blue Competence – VDMA’s sustainability initiative picks up pace

12 Looking ahead to the International Rotating

Equipment Conference 2016

14 Efficient, safe, convenient:

VDMA Building Systems Forum

17 Introducing the Pump Research Fund (FFP) and

the Vacuum Technology Research Fund (FFVak)

20 Energy efficiency: the VDMA as reliable partner

24 Part I: Pumps & Systems

Submersible pump motor units 24 New submersible pump motors
are used in all parts of the world in for highest requirements
order to drain, for example, mine
pits for coal, rare earth and gold. 29 Multiphase pumps for energy-efficient
Page 24
water and wastewater treatment
37 Piston diaphragm pumps to remove
and transport sludge and sediment
45 Metering technology for biogases and biofuels
52 Screw pumps in tank farms
58 Intelligent design for hygienic pumps:
from barrel emptying systems to dosing
66 Pumps & Systems: products & applications

70 Pumps & Systems: companies & range of applications

78 Part II: Compressors, Compressed Air

& Vacuum Technology
78 Radial turbines for energy generation from
geothermal resources or waste heat recovery
86 Process air production with highest energy efficiency
Energy generation from geothermal
sources relies on generator-loaded, 91 The world’s largest vacuum system:
multi stage integrally geared
CERNs Large Hadron Collider
expansion turbines.
Page 78 97 Reducing carbon footprint with the right vacuum system
103 Compressors, Compressed Air & Vacuum Technology:
products & applications
106 Compressors, Compressed Air & Vacuum Technology:
companies & range of applications

114 Brand name & trade fair register

118 List of advertisers
105 Imprint

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 Pumps Valves Service One goal

On the mark for your success

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■ ■
 4 editorial

Pump and compressor manufacturers:

Photo: Clipdealer
Striking a new course

Dear customer, dear reader,

The sixth edition of “Pumps and Compressors for the World Market” in
2014 strikes a new course. Together with the well-proved printed
magazine, for the first time we also offer an E-Magazine, again in
German and English. This “speaking book” offers possibilities for
supplementing the printed magazine with additional information,
video statements and image films (www.vdmashop.de/puco).

“Pumps and Compressors for the World Market 2014” still provides
information about technical solutions and new possible uses for pumps
+ systems, compressors, compressed air and vacuum technology. Piston
diaphragm pumps for sludge transport or radial turbines for generating
Dr. Sönke Brodersen geothermal energy are just two of the numerous applications for pumps
and compressors presented as examples in this publication.

This issue owes its existence to expert, committed authors from among
our membership. It also includes reviews of significant topics for the
engineering sector, such as sustainability, research and energy. Expres-
sive illustrations and a user-friendly layout give a neutral presentation of
the extraordinary capabilities of our member companies. The authors
and contact partners named in the magazine will gladly deal with your
enquiries about new products and technical innovations described in the
Alexander Peters
publication.

Would you like to know which customer branches a certain manu-

facturer serves? Then take a look at our clearly organised competence
matrix that is featured in the proven manner next to the magazine´s
technical features. This gives readers a good overview of the extensive
information available on the VDMA E-Market (www.vdma-e-market.
com). This highly successful online platform which currently has more
than 250,000 available products helps users to make an efficient,
up-to-date search for manufacturers via products and/or applications
and possible uses. It is also possible to contact the provider directly,
simply using the link to the manufacturer website or by sending an
enquiry by e-mail.

In 2014, the German engineering sector and the associations Pumps +

Systems as well as Compressors, Compressed Air and Vacuum Technology
will be present with their own stands at trade fairs in Germany and
abroad. The trade show highlight in Germany is the IFAT, the world´s
leading trade fair for water, sewage, waste and raw materials manage-
ment.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 Editorial 5

German pump and compressor manufacturers enjoy

a high reputation worldwide thanks to their capabilities
and problem solving quality.

The VDMA is organising more than a dozen German pavilions at events

abroad with a focus on water, sewage, chemistry and petrochemistry
together with oil and gas. Such involvement abroad helps to cultivate
new market potential in good time and on a global scale, which is
important for consolidating the good position and reputation of our
branches.

Dr. Sönke Brodersen Alexander Peters

Senior Vice President Research KSB AG Managing Partner of the
Chairman of the NEUMAN & ESSER GROUP
VDMA association Pumps + Systems Chairman of the VDMA association Compressors,
Compressed Air and Vacuum Technology

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 6 Economic DEvElopmEnt

Still heading for growth

German pump and compressor manufacturers in 2014
Dipl.-Wirt.-Ing. Christoph Singrün and Dipl.-Volksw. Ulrike Mätje

In 2013 the manufacturers of liquid pumps operated slightly above

the turnover level of the previous year, while the manufacturers of
compressors, compressed air and vacuum technology found their
turnover eleven percent above the level of 2012. For 2014, pump
manufacturers expect to see 1 % growth, with 2 % growth in turnover
for compressors, compressed air and vacuum technology.

Liquid pumps: production continues to grow

Price-adjusted incoming orders for Pumps + Systems In 2011, according to the Federal Statistical Office
based on turnover 2010 = 100, moving three-month average the production of liquid pumps (without hydro
pumps) reached € 4.5 bn, which is nearly the re-
160
cord level of 2008. This value was slightly exceed-
150 ed in 2012 (+0.5 %) with an overall value of
Foreign
140 € 4.6 bn. Rotary pump manufacturers took the
Total
130 Domestic biggest piece of the cake with more than 40 %,
while manufacturers of oscillating or rotating dis-
120
placement pumps accounted for 10 % each. In the
110
first three quarters of 2013, production generated
100 € 3.5 bn. This is a growth of 2.6 % compared to the
90 same period in the previous year. The volume for
the whole year 2013 is estimated at € 4.7 bn.
80

70
2006 2007 2008 2009 2010 2011 2012 2013 The incoming order statistics for liquid pumps
obtained from the VDMA members reflects the
Fig. 1 Source: VDMA economic situation of German pump manufac-
turers (Fig. 1). Demand throughout 2013 was
only slightly below (–1 %) the level in the previ-
ous year, with a slight decline in domestic busi-
Pumps + Systems 2012
ness compared to exports which remained on
Main exporting countries, percentage shares
the same level as in the previous year. In January
Total: 30.9 billion Euro
(without hydro pumps)
2014, capacity utilisation, which is a good indi-
Germany 15.7 % cator for the cushion of orders, was in the “low-
Others 27.8 %
er” range with 81%. Turnover generated in 2013
was 2 % higher than in the previous year.
USA 12.4 %

Canada 2.5 %
Denmark 2.6 %
Germany still export world champion
Netherlands 2.6 % China 12.1 %

Great Britain 4.6 % Liquid pump exports also saw moderate growth
France 4.8 % Italy 8.2 %
Japan 6.8 % in 2013, as well as production. In the first eleven
months of 2013, Germany supplied 6.1 % more
Fig. 2 Source: Federal Department for Statistics / VDMA liquid pumps (without hydro pumps) abroad

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 Economic DEvElopmEnt 7

than in the same period for the previous year, Pumps + Systems 2012
corresponding to an export volume of € 4.7 bn. Germany’s main export markets, percentage shares
It looks as if a volume of € 5.1 bn will be achieved Total: 4.8 billion Euro China 8.7 %
for the whole year 2013. And so Germany remains (without hydro pumps)
USA 8.0 %
unchallenged export world champion. In the
world trade volume of around € 31 bn (2012),
Czech Republic 7.3 %
German manufacturers account for about 16 %
(Fig. 2), well ahead of the USA and China (with
Others 45,0 % France 7.0 %
12 % each).

Russia 6.4 %
Europe remains the key sales market for Ger-
Great Britain 4.0 %
man liquid pumps, accounting for altogether Italy 3.9 %
Netherlands 3.6 %
around 58 % of exports. Asia accounts for a fur- Poland 2.8 % Austria 3.2 %
ther quarter of sales, with 9 % of exports going
Fig. 3 Source: Federal Department for Statistics / VDMA
to North America. German pump exports to
North America saw a clear increase in 2012.
Demand for German pumps grew particularly in
the USA with 11.7 %. Mexico nearly doubled its third year in succession. In 2012, the main cus-
imports, but this accounts for only 8% in the tomer countries South Africa and Egypt import-
total volume of exports to the NAFTA. There has ed 5 % respectively 16 % fewer pumps from Ger-
been a clear decline in growth in Asia. Increases many than in 2011. The key customer countries
were only registered in deliveries to Singapore for Germany in 2012 were China, the USA, the
and Thailand. Exports to Africa declined for the Czech Republic, France and Russia (Fig. 3).

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 8 Economic DEvElopmEnt

Price-adjusted incoming orders for Compressors, Compressed Air Compressors, compressed air and vacuum
and Vacuum Technology technology: production is growing again
based on turnover 2010 = 100, moving three-month average
170 According to the Federal Statistical Office, in
160
2011 compressors, vacuum pumps, compressed
Foreign air machinery and tools were produced at a
150 Total
Domestic value of € 4.9 bn. This value decreased slightly in
140
2012 (–1.8 %). Turbocompressors have a signifi-
130
cant share of production with around 38 %, fol-
120
lowed by rotating displacement compressors
110
with 19 %, vacuum pumps with 15 % and parts
100
for vacuum pumps and compressors with 13 %.
90
In the first three quarters of 2013, production
80
generated € 3.9 bn. This is a growth of 10.7 %
70 compared to the same period in the previous
60
2006 2007 2008 2009 2010 2011 2012 2013 year. The volume for the whole year 2013 is esti-
mated at € 5.2 bn.
Fig. 4 Source: VDMA

The incoming order statistics obtained from the

VDMA members for the overall year 2013 show
demand to be 8 % above the previous year’s
Compressors, Compressed Air and Vacuum Technology 2012 level, due in particular to good domestic de-
Main exporting countries, percentage shares
mand (Fig. 4). Turnover generated in the overall
Total: 33.6 billion Euro year 2013 was 11 % higher than in the previous
Germany 15.4 %
year.
Others 28.2 %

USA 11.5 %
Germany still No. 1 for exports

Netherlands 3.1 % Given a slight decline in production, exports by

Great Britain 3.2 % China 8.3 %
German manufacturers of compressors, com-
Switzerland 3.4 %
pressed air and vacuum technology continued
France 4.9 % Italy 8.3 %
Belgium 6.5 %
to increase in 2012. In 2012, Germany supplied
Japan 7.3 %
5.1 % more goods abroad than in 2011, corre-
Fig. 5 Source: Federal Department for Statistics / VDMA
sponding to an export volume of € 5.2 bn.
Volume for the whole year 2013 is expected to
be on a similar level.

Germany’s world trade share still accounts for

Compressors, Compressed Air and Vacuum Technology 2012 15 % (Fig. 5) of the total global trade volume,
Germany’s main export markets, percentage shares
which in 2012 amounted to € 33.6 bn. As in the
Total: 5.2 billion Euro China 13.2 % previous year, Germany is followed by the USA
(11 %) together with China and Italy (each with
USA 9.0 %
8 %).

Others 45.5 % Europe remains the key purchaser of German

Great Britain 5.8 %
compressors, compressed air and vacuum tech-
France 5.2 % nology. More than 51 % of exports remain on
the European continent, of which 81 % go to the
Austria 4.1 %
Spain 3.7 % EU. East and South-East Asia is the second major
Italy 3.7 % purchasing region. Here development depends
Poland 3.2 % Switzerland 3.3 %
Russia 3.3 % crucially on China’s economy, which took more
Fig. 6 Source: Federal Department for Statistics / VDMA
than 60 % of exports to this region in 2012. Pur-
chaser structures on the American continent

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 Economic DEvElopmEnt 9

continue to shift further to the North. While in companies, coordinated by the VDMA, together
2012, two thirds of exports to America went to with maintaining a regular presence on promis-
the North, the share in 2012 had already reached ing foreign markets, including for example the
73 %. This can be seen as a sign of the weaken- promotion of German exports in the German
ing economy in South America and the gradual
recovery in the USA. After all, German exports to
North and Central America increased by more German pump manufacturers remain the
than 22 %, so that this is the region with the
unchallenged export world champions.
largest growth in 2012. China remains the main
customer country with 13 % (Fig. 6), ahead of
countries such as the USA and the United King-
dom, as in previous years. pavilions. There is also an increasing focus on
sustainable production and sustainable prod-
ucts. This results in the constant further devel-
Pumps and compressors “made in Germany” opment of products to ensure they remain com-
still in demand petitive on a global scale.

Defending and expanding its leading position Authors:

on the world market remains the declared ob- Dipl.-Wirtsch.-Ing. Christoph Singrün
jective for Germany’s pump and compressor in- Dipl.-Volksw. Ulrike Mätje
dustry in 2014. Constant effort will be needed to VDMA Pumps + Systems and Compressors,
achieve this, including joint pure research by the Compressed Air and Vacuum Technology

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 10 Blue CompetenCe

Blue Competence –
VDMA’s sustainability initiative picks up pace
Dipl.-Volksw. Ulrike Mätje

Shorter standstill times due to high-strength materials in pump

cogwheels and plain bearings, or recovering helium from leak
testing processes – these are just two practical examples of
implemented sustainability. “Do good and talk about it!” – that’s
the motto of the VDMA’s Blue Competence sustainability
initiative. It positions the engineering sector as the enablers
in the economy – for both sustainable production and also
sustainable products. Meanwhile around 400 companies have
joined in with the initiative which was launched in October
2011, with participation increasing all the time.

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Innovative, efficient, safe:
Compressors, compressed air Companies from 38 product areas together with
and vacuum technology for their associations and organisations are in-
ed Air and increased sustainability.
part of the
members
volved in Blue Competence, where they under-
h excellent
ompanied
take to fulfil verifiable sustainable criteria.
ty.
VDMA Pumps + Systems as well as VDMA Com-
e
ms work pressors, Compressed Air and Vacuum Technolo-
e innovative
a decisive gy are also involved. Blue Competence aims to
of the quality
vement of bring about greater transparency, facilitate
h vision
orientation and give certainty to all those look-
potentials:
ompressed
ing for sustainable solutions and products or
the forefront
ons, they are
an initiative of
sustainably acting companies.
he reduction
ents as well VDMA
Compressors, compressed air
the industrial
and vacuum technology
tor.
Lyoner Strasse 18
60528 Frankfurt am Main

ot just when
Ulrike Mätje Website with double benefit
Phone +49 69 6603-1296
hroughout Fax +49 69 6603-2296
ment. This is [email protected]
essors and
nology take A comprehensive overview of the campaign can
dy working
be found on the website www.bluecompetence.
an initiative of
net. A search function has now been added to
give the website a useful value in the long-term.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 Blue CompetenCe 11

There is a standard layout for success stories political sector, customers and the general pub-
which can be used both as .pdf on the website lic demand measurability and verifiability. The
and also by companies as flyers for trade-fairs facts and figures help to take this into account.
etc. Companies involved in Blue Competence
that submit their success stories in future will Submitted success stories for pumps + systems,
therefore see a double benefit: the success story compressors, compressed air and vacuum
will be presented in the framework of the Blue technology are also available online in the
Competence website and can also be used for E-Magazine.
the company’s own PR work.
Author:
Dipl.-Volksw. Ulrike Mätje
Implemented sustainability VDMA Pumps + Systems and Compressors,
Compressed Air and Vacuum Technology
One important criterion for submitting success
stories consisting in filling the fact box (blue box
on the back of the flyer) with figures and verifia-
ble facts. Background: the success stories sub-
mitted by Blue Competence partners act as
credible, verifiable evidence of their sustainabil-
ity according to the Blue Competence usage
agreement. External stakeholders such as the www.bluecompetence.net

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Contact me for Europe:
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Head of Engineering and Technical Support
[email protected]
Phone: +49 2451 481-312
 12 InternatIonal rotatIng equIpment conference

Looking ahead to the International

Rotating Equipment Conference 2016

After the conference is before the conference. In autumn 2016, the “International
Rotating Equipment Conference – Pumps and Compressors” will be taking place
for the third time, four years after the last event which was held in Düsseldorf at
the end of September 2012. For the third time the VDMA associations Pumps +
Systems and Compressors, Compressed Air and Vacuum Technology will join
forces with the EFRC (European Forum for Reciprocating Compressors) to
combine their three forums: the 11th Pump Users International Forum, the
4th Compressor Users International Forum and the 10th EFRC Conference.

In focus again: rotating equipment motto for 2016”, is how Christoph Singrün,
Managing Director VDMA Pumps + Systems and
The International Rotating Equipment Confer- Compressors, Compressed Air and Vacuum Tech-
ence is known for pursuing the well-used practi- nology explains the event which is held in Eng-
cal approach of forming more and more work- lish and which was attended by a good 850 par-
ing teams to cover the whole field of rotating ticipants from more than 40 countries last time.
equipment. “Even more application-oriented Users and operators made up an impressive
and international than in 2012 – that’s the share of the conference participants, accounting
for a good 30 %.

Established programme

The concept which has been so successful in the

past is being further optimised. Together with
many specific contributions on current aspects
covering pumps, compressors and compressed
air/gas systems, this time once again vacuum
technology will also be on the agenda. Panel dis-

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 InternatIonal rotatIng equIpment conference 13

cussions will provide an opportunity to discuss

current issues with experts. In addition, gradu-
ates can enter into informal contacts with
potential future employers.

The two-day forum will also being accompanied

once again by a technical exhibition. In 2012,
more than 70 companies presented the whole
range of pump, compressor and vacuum tech-
nology on around 700 square meters. The con-
cept of “Meeting Points” within the exhibition
areas is also being maintained. This lets partici-
pants continue their discussions of the technical
contributions or obtain information about new
products.

Outlook

Impressions from 2012 and more information

about the forthcoming event in autumn 2016
can be found on the conference website at
www.introequipcon.com

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 14 VDMA BuilDing SySteMS

Efficient, safe, convenient:

VDMA Building Systems Forum
Dr. Alexandra v. Künsberg and Dipl.-Volksw. Ulrike Mätje

Since September 2011, the Building Systems Forum has been offering an
interdisciplinary, pre-competition approach by pooling the expertise of
those associations and working groups in the VDMA that supply their
products and services for the building systems sector. The forum thus
provides the basis for coordinated solutions in building systems. Building
Systems account for between 400 and 500 VDMA member companies
according to their product portfolio.

The building sector is one of the key sectors of The VDMA Building Systems Forum covers the
the economy. The construction of buildings following areas:
accounts for a good € 180 bn each year. The • Valves
VDMA member companies whose products are • Lifts and escalators
also supplied for building systems generate a • Automation + management for house +
production volume of around € 15 bn p.a. The building
way buildings are equipped with systems and • Decentral energy supply
technology makes a vital contribution to the • Maintenance
conditions in which people live and work in • Refrigeration
developed societies. At the same time, the build- • Air conditioning and ventilation
ing sector is responsible for around 40 % of pri- • Pumps and systems
mary energy consumption. • Security systems

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 VDMA BuilDing SySteMS 15

The VDMA Building Systems Forum thus covers Großmann, Head Solutions & Services Portfolio,
the main elements of technical building sys- Siemens AG, Infrastructure & Cities Sector,
tems and the corresponding services. The need Building Technologies Division. In July 2013, the
for safety and comfort together with the neces- Steering Committee drew up a set of building
sary efficiency of resources and energy are key systems guidelines in cooperation with the
issues for the forum which thus provides a basis VDMA Building Systems Forum. The guidelines
for coordinated solutions in building systems for aim in particular to fulfil the climate protection
both residential buildings and commercial and targets while permitting effective building plan-
industrial buildings. Only an integral, multi-dis- ning and value-enhancing refurbishment of
ciplinary approach will be able to cope with the existing buildings. “Smart, multi-disciplinary
current challenges arising from climate protec- building systems play a key role”, says Dr.
tion and energy policy. This is the key to reconcil- Thomas Schräder, VDMA spokesman for the
ing competing interests, e.g. between investors Building Systems Forum. “At the same time, this
and building users. The forum has two external is the basis for integrating buildings in the smart
bodies - the Steering Committee and the Build- energy networks of the future.”
ing Systems Economic Committee which meet
every six (Steering Committee) or twelve In implementing the energy efficiency and cli-
months (Economic Committee). mate protection targets, attention must increas-
ingly turn to the non-residential building sector.
Up to now, this sector including all public prop-
Building Systems Steering Committee erties has been neglected for the most part. And
yet it is much easier to tap into potential effi-
The Steering Committee plays a central role; it is ciency here, for example through qualified ener-
currently made up of representatives from gy-saving contracting. Taking life cycle costs as a
twelve companies and is chaired by Uwe strict focus is prerequisite.

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 16 VDMA BuilDing SySteMS

But reliable political framework conditions are • Smart combined heat and power systems
needed to implement integrated solutions today can safeguard both the heating and the
and in future. “Our demands are also an invitation power needs of buildings.
for talks with the political sector”, says Schräder. • Modern pumps and pump systems stand
out with particularly low energy require-
The demands include among others: ments.
• Naming a body with central responsibility. • Sustainable drinking water use and hygiene
This will permit appropriate coordination of can be planned. Here it is crucial to select
the various aspects of optimum building the right components with professional
design – resource efficiency, security, quality installation of the drinking water systems.
of life and value preservation – on a national
and European level.
• Together with the efficiency of energy and Safety
resources, attention also has to be given at
the same time to aspects such as health Modern fire safety and air purification systems
protection, operational reliability and make a major contribution to safe and cosy liv-
barrier-free access. ing, working and production conditions.
• Production processes in industry and
manufacturing that are relevant to energy
consumption must be integrated in the Comfort and barrier-free access
energy management and operation of
buildings. Lifts and escalators as part of energetically
• It is vital for attention to focus on the appropriate building systems warrant barri-
non-residential building sector. er-free access to buildings. In the context of
• The public sector must act as a role model, demographic change, increasing significance is
as demanded by the EU in the Energy also being attributed to age-appropriate bath-
Efficiency Directive. room solutions.
• Any kind of funding must apply to all
technologies in all areas.
• Observed deficits in quality must be dealt Building systems:
with by new, integrated training and study experiencing tomorrow today
concepts.
Persistent urbanisation, world population
Together with these concrete demands, the growth and increasing life expectancy together
Building Systems Forum also draws attention to with environmental and climate protection
important aspects in the various sub-areas. demand innovative solutions in the field of
building systems. These are already available on
the market today. In future, buildings will not
Efficiency only consume power but also generate it with
smart control and power sales concepts to
• Refrigeration and air conditioning: optimisa- improve their monthly balance sheet. In this
tion e.g. of compressors, heat exchangers, way, the smart buildings of tomorrow also act
heat recovery and operations management as crucial control points in a smart infrastruc-
offers potential savings of up to 40%. ture.
• Smart building automation offers potential
savings of up to 50% depending on the Authors:
building type. Dr. Alexandra v. Künsberg
• Experience shows that the consumption of VDMA Building Systems Forum
heating energy can be cut back by around Ulrike Mätje
10% already by replacing old thermostat VDMA associations Pumps + Systems and
heads. Compressors, Compressed Air and Vacuum
• Modern lift technology offers an efficiency Technology
advantage of about 40% compared to the
average existing systems.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 RESEARCH 17

Introducing the Pump Research Fund (FFP) and

the Vacuum Technology Research Fund (FFVak)
Harald Frank and Jürgen Eisenreich

For many years, the VDMA has been successfully involved in organising and handling
cooperative research projects. In the framework of pre-competition industrial joint
research, it works together with the Forschungskuratorium Maschinenbau e. V. (FKM)
(Engineering Research Board) and the research associations of the various branches to
offer two efficient, beneficial cooperation platforms: the Pump Research Fund (FFP)
and the Vacuum Technology Research Fund (FFVak).

The Pump Research Fund VDMA’s research network. Joint research pro-
jects are mainly implemented and financed
It was already back in 1973 that the VDMA asso- with public sector funds.
ciation Pumps + Systems set up the Pump
Research Fund (FFP) to conduct joint research in The European Commission estimates that
pump construction. The FFP is part of the throughout the EU, pumps and pump systems

ANDRITZ Ritz - Pumps and Motors

We move water
As the leader for innovation and
technology in the areas water,
mining, sewage, industry and off-
shore, we are in our element wher-
ever fluids need to be transported
safely and efficiently – and as eco-
nomically as possible.

n End suction pumps

n Axial split case pumps
n High-pressure pumps
n Submersible motor pumps
n Submersible motors
n Sewage dry pumps
n Sewage wet pumps

ANDRITZ Ritz GmbH

Gueglingstrasse 50, 73529 Schwaebisch Gmuend, Germany
Phone: +49 (0)7171 / 609-0, [email protected] www.andritz.com

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 18 RESEARCH

Although the products of Germany’s pump

Photo: Abel
industry already embody the highest technolog-
ical standard today, German manufacturers as
technology leaders see their responsibility for
pursuing specific research activities to save
resources in both the production and operation
of the pumps, thus protecting the environment
and offering sustainable concepts.

Promoting future technology

System efficiency, demand-oriented power

pick-up, optimised efficacy, intelligent control
and regulation concepts, optimised selection
and use of materials, Computational Fluid
Dynamics (CFD) and reducing environmental
influences are just some of the key words
describing the scope of research activities in the
Pump Research Fund.
consume around 30% of the energy provided by
electric drives (SAVE study, 2000). Within the EU, At present, 37 companies have undertaken to
electric drives in turn are responsible for approx. pursue or are involved in pursuing future-ori-
30% of all electrically generated energy, so that ented research for the sustained protection of
pumps and pump systems consume about 10% resources and the environment.
of electrically generated energy or 280 TWh p.a.
- in Europe alone. Pumps and pump systems Together with the direct benefit for the compa-
therefore count among the major energy con- nies and the environment, one major side-effect
sumers. of pre-competition joint research consists in
improving the financial situation of Germany’s
Pump manufacturers have to invest in research universities. In Germany’s university system, the
and innovation, among others in view of the research units increasingly depend on obtaining
statutory demands and minimum efficiency external funds to secure the institute’s exist-
requirements made of pumps and pump sys- ence. Accordingly, the Pump Research Fund
tems - take for example the Energy using Prod- helps to sustain and expand top-level research
ucts (EuP) / Energy related Products (ErP) Direc- in Germany. This also fosters the next genera-
tive. tion of qualified engineering for Germany’s
pump manufacturers, which in turn forms the
basis for future technological leadership.
Photo: Oerlikon Leybold Vacuum

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 RESEARCH 19

The Vacuum Technology Research Fund provides the corresponding funds. The results
obtained from the different projects, some of
The Vacuum Technology Research Fund (FFVak) which are financed with the companies’ own
in the VDMA is a bit younger. The founding funds, give the participating firms a competitive
meeting of the FFVak was held on 20 November lead while at the same generating their own
1998, at that point in time with a main focus on next generation of engineers as a side effect. In
vacuum pumps. The FFVak is also embedded in many cases, those involved in a project will sub-
the VDMA’s research network; in the framework sequently find employment immediately after-
of pre-competition industrial joint research, it wards with one of the participating companies.
works together with the Forschungskuratorium
Maschinenbau e. V. (FKM) (Engineering Research Authors:
Board) to offer its members an interesting plat- Harald Frank
form for proceeding today to examine the Pump Research Fund (FFP)
requirements that vacuum technology products Jürgen Eisenreich
will face tomorrow. Vacuum Technology Research Fund (FFVak)

Since it was founded, altogether ten joint

research projects have been concluded at a
value of around €1.5m. These were carried out
mainly in cooperation with the AiF (Consortium
of Industrial Research Associations e. V.), which http://euro.vdma.org/en/forschung

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 20 EnErgy EfficiEncy

Energy efficiency: the VDMA as reliable partner

Friedrich Klütsch

Following a brief period when energy efficiency temporarily receded into the background
with attention focussing on alternative energy sources with their subsequent problems
(grid expansion, storage issues), it is now currently enjoying a renaissance. After all,
energy efficiency is the “energy form” where every individual and every branch of industry
including engineering can assume responsibility for making a major contribution.
The VDMA associations Pumps + Systems as well as Compressors, Compressed Air and
Vacuum Technology have been supporting their members in this respect long before the
efficiency activities of the European Union. By launching the initiative “Druckluft
effizient” in 2001 the compressed air industry was one of the first industries in the
mechanical engineering, that introduced the topic of energy effiency to customer circles.

Since 2005 the VDMA association Pumps + Global issue

Systems has actively supported its member
firms in implementing the energy efficiency In recent years there has been increasing pres-
projects launched by the EU Commission in the sure from the political sector and the markets
course of implementing the Ecodesign Directive. for presentable results to be produced more
Since 2011 – when compressors became the quickly. Global climate summits are held,
focus of a preparatory study – the VDMA associ- attended by hundreds of delegates who fly all
ation Compressors, Compressed Air and Vacuum around the planet with the aim of agreeing on
Technology has formed a working group that binding concessions for saving energy. Blame is
aims to become involved in drawing up a techni- apportioned in a manner that is hardly helpful.
cally sound, effective regulation for the
machines that are in focus here. Some try to impose restrictions and regulations
to bring about an equality that will never exist.
Others are held captive by their growth strate-
Energy efficiency: the lowest cost energy source gies and see the necessary changes as an attack
rather than an alternative. On the one hand, it
It is quite apparent that energy which is not con- seems completely illogical to let the developing
sumed does not have to be generated in the first countries make the same mistakes that the
place. Furthermore, energy efficiency is com- so-called industrial nations made in the past
pletely independent of the type of energy gener- and in some cases still make today. On the other
ation. Regardless which type of energy genera- hand, the highly developed countries offer no
tion is given preference by society or the political alternatives on the path to prosperity.
sector, energy efficiency must therefore be the
least critical “energy form”. It needs no additional Global climate summits of recent years failed
effort on the part of those responsible for subse- among others because too many demanded too
quent aspects and, when there is no time pres- much and too many put energy efficiency and
sure along the lines of premature change in prod- sustainability on a par with having to do with-
uct, it can be implemented in the course of out economic growth. But no politician can or
on-going product development along essentially will make any such commitment. Why doesn’t
cost-neutral lines. Energy efficiency is the “energy anyone ask “Is this true at all?”, or why should
form” for which every individual and every branch mistakes be repeated when better solutions and
of industry including engineering can assume the necessary know-how is already available?
responsibility for making a major contribution. Strict refusal is certainly not the right solution!

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
Instead, the aim should consist in being at the forefront

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when the day comes for achieving growth in a more eco-
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here! In certain markets, it is already not possible to sell
many products without a label or some other sign of
energy efficiency.

Commitment shown by the VDMA members

The member companies of the VDMA associations

Pumps + Systems as well as Compressors, Compressed
Air and Vacuum Technology are aware of this and play an
active role in shaping the requirements for a more effi-
cient and “environmentally compatible” generation of
products. Some of the companies that play an active role
in this work are listed on the stock exchange and all of
them are profit-oriented. In this work, which is admit-
tedly not always positive, they see a great chance for
putting their companies in a successful position on the
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What compressor manufacturers are doing ...

For every size:
Formally, compressor manufacturers have taken up the
same approach used eight years ago by the pump man- the complete range
ufacturers. In this procedure, a central role is played by
the specific European sector committee (Pneurop). An
of 100% oil-free products
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It would be a gross strategic mistake not to be involved in
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or there can cause irritations, or the expertise of other
participants seems dubious or the whole process appears
 22 EnErgy EfficiEncy

industry’s proposal for the application range –

Photo: MAN
has been completed. The schedule now features
the follow-up measures
of the last stakeholder meeting, the Regulatory
Committee (without direct industrial participa-
tion) and the draft bill. It is not certain whether
everything will be completed by the end of 2014
because of the forthcoming European elections
in summer 2014. Until the Regulatory Commit-
tee meets, the motto is therefore to keep on the
ball. The same applies to the preliminary study

• ENER Lot 30: Products in motor systems

outside the scope of the Regulation
640/2009 on electric motors, such as special
Since compressors became the focus of a preparatory study, the VDMA associa- purpose inverter duty motors (asynchronous
tion Compressors, Compressed Air and Vacuum Technology has been pursuing
servo motors), permanent magnet motors,
the objective of getting involved in drawing up a technically sound, effective
regulation for the machines that are in focus here. motors cooled by their load (fans), including
motors and products under Article 1, Points
2(b), (c) and (d) and including drives, such as
soft starters, torque or variable speed drives
to be anything but “open” and “democratic”. At (VSD) from 200 W–1000 kW. The study
the moment, the compressor manufacturers are should also cover motors in the scope of the
accompanying the preliminary study Regulation 640/2009 from 750 kW– 1000 kW.

• ENER Lot 31: Products in motor systems This preliminary study is also being accompa-
outside the scope of the Lot 30 and the nied by both associations through the respec-
Regulation 640/2009 on electric motors, in tive sector committees. Even if the compressor
particular compressors, including small or pump manufacturers are not responsible for
compressors, and their possible drives most of the motors, it is still extremely impor-
tant for the branch to know the future statutory
They are involved in open dialogue with the requirements for the motors as soon as possible
study authors, the representatives of the Energy in order to take an active approach in good time
Directorate which is responsible for this study, if the need arises.
and the representatives of the German govern-
ment. The actors are known and most of the
work – data acquisition and verification and What pump manufacturers are doing ...

Apart from the motor study Lot 30, the pump

manufacturers that were already affected by
Photo: ProMinent

the first preliminary study ENER Lot 11 on heat-

ing circulation pumps and water pumps are cur-
rently playing an active role in two pump-spe-
cific preliminary studies:

• ENER Lot 28: Pumps (extended product

approach including motors, VSD and controls,
where appropriate) for private and public
waste water (including all stages including
buildings, networks and treatment facilities)
and for fluids with high solid content
• ENER Lot 29: Pumps (extended product
The VDMA association Pumps + Systems has started work at TU Berlin
to obtain qualified efficiency statements about pumps in waste water
approach including motors, VSD and
applications. controls, where appropriate) for private and

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 EnErgy EfficiEncy 23

public swimming pools, ponds, fountains doesn’t all have to be done simultaneously by
and aquariums, as well as clean water pumps everybody in next-to-no time. When it comes to
larger than those regulated under Lot 11 acknowledged experts, resources are limited,
and good things are known to take their time.
Both studies proceed in the usual fashion with Until then, let us focus on the energy efficiency
an intensive exchange of views through the sec- of our products as the most sustainable option
tor committee EUROPUMP. But with Lot 28, the for saving energy at the least cost.
pump manufacturers are moving beyond the
realm of research backed by existing research Contact:
projects. As far as clean water is concerned, sci- Friedrich Klütsch
entifically sound findings have been available VDMA Pumps + Systems
for years now which can be fed into the legisla- Dr. Andreas Brand
tion process. But as far as waste water is con- VDMA Compressors, Compressed Air and
cerned, right at the start the question arises: Vacuum Technology
“What in fact is waste water?” With the tender
notice for the preliminary study, the association
Pumps + Systems started work at TU Berlin,
financed by the research fund’s own resources,
with the aim of obtaining verifiable statements
for pumps in waste water applications within
the remaining period of time. Following an ini-
tial literature research that produced sobering
results, last year substantial steps were taken to
Energy Efficiency in
obtain reproducible test methods by the end of Chemical Processes
2015 that will supply a definition of waste water
together with calculation methods to permit Save Up to 30 % Energy with
qualified efficiency statements for such pumps.
Here it is worth noting that the availability of a
CP Pump Systems
waste water pump and its maximum possible
efficiency are contradictory requirements. Even
if it will still take a good two years before a pos-
sible regulation comes into effect, a lot of work
and time will still have to be invested in order to
meet the companies’ individual requirements.

Outlook

The engineering sector is already feeling the ini-

As one of the industry’s
tial impact of the announced expansion of the
leading suppliers of premium
Ecodesign Directive from the aspect of manu-
quality centrifugal pumps, we
facturing/resources conservation and recycling help you achieve sustainable
to be incorporated in a product environment environmental improvements
carbon footprint. This entails a new discussion in your chemical process
of the principles involved, starting with the pumping systems.
framework conditions via the rating and weight-
ing of product-specific aspects, leading to the
implementation and documentation of these
statements. It can only be hoped that this dis-
cussion entails sufficient expertise and will To learn more about how you can save energy
remain free of exaggerated demands, self-opin- in your chemical processes, visit:

ionated self-marketing and above all, free of ide- www.cp-pumps.com

ological competition. The demand for such
statements is sensible and worthwhile, but it

cpp 04009-07 Inserat_EECP_SaveUp_en_100x169.indd 1 15.01.13 15:12

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 Photo: Andritz Ritz
Submersible pump motor units are used in all parts of the world in order to drain, for example, mine pits for coal,
rare earth and gold.

New submersible pump motors

for highest requirements
Ludger Gottkehaskamp, Johann Neiszer and Georg Cichon

For the submersible region of mines, water wells and subsea applications pump
motor units of 12 inch size with significant improvements have been developed.
On the pump side, the efficiency levels could be raised from 74 to 80 % and on the
motor side from 88 to 93 %. With the pump, the delivery head per stage was almost
doubled. In the motor, a performance improvement of up to 30 % was achieved with
the same size. These performance increases led to improvements of the overall
efficiency levels from 65 to 74 %, which directly affects significant lower energy
consumption and thus a better efficiency.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 pumps & systems 25

Submersible pump motor units, which consist Parameter for pump and motor
of submersible centrifugal pumps and submers-
P1 = Net power ρ*g*H*Q
ible asynchronous motors, are used in many are- P2 = Shaft power P2 = ƞP
as for the conveyance of waters of different g = Gravity acceleration
water quality. The performances range from a ρ = Density P2
H = Head ƞM =
few kilowatts to some megawatts, the flow P1
Q = Flow
from a few to some thousands of cubic meters ƞM = Motor efficiency
per hour and the delivery heads to over 1,000 m. ƞP = Pump efficiency ρ*g*H*Q
ƞtot = ƞP * ƞM =
For many years, such submersible units are used ƞtot = Total efficiency P1
in all parts of the world in order to drain, for
example, mine pits for coal, rare earth and gold. Fig. 1: Parameter for pump and motor, energy process ρ*g*H*Q

➪
within the aggregate
In arid zones, these units are used for pumping
water from wells for the potable water supply
and field irrigation. This article describes the P
u
results from a development project, which were m
achieved with a new pumping and motor series. (Q) at a given delivery head (H) analogous to the p
pump curve . The ratio delivery head multiplied
with flow, gravity and density to shaft power is
Requirements of submersible expressed through ƞP (pump). The power from the

➪
P2
pump motor units electrical net (P1) is fed into the motor. This
power is largely transferred into rotation (P2 =
Customised requirements and technical innova- shaft power) and to a very small proportion in M
tions are considered in the development, sizing losses (e. g. heat). The ratio of power used (P2) to o
t
and manufacturing of submersible pump motor net power (P1) is illustrated by the motor effi- o
units. Depending upon operating condition of ciency ƞM (Motor) (Equ. 2). The value crucial for the r

the units, certain requirements for the pump operator is shown by the overall efficiency level
and motor must be fulfilled apart from high ƞ total (Equ. 3) of the unit. This number finally

➪
efficiencies, different material adjustments, reflects which energy is used or remains unused.
simple assembly and disassembly, which were P1
listed in the following.

Requirements for submersible pumps:

Photos: Andritz Ritz

• Steady rising pump curve of flow and head
• Maximum hydraulic head per stage
• Minimal material use per stage
• Usable at different pump speeds

Requirements for submersible motors:

• Applicable in connection with a frequency
converter
• High specific power per motor volume
• Internal cooling in connection with heat
exchanger and suction jacket
• Water or glycol water mixture as filling
medium

Energy process in the submersible unit

In Fig. 1 the relationship of the sub-units pump

and motor has been illustrated. The shaft power
supplied to the pump (P2 = shaft power, Equ. 1)
puts the pump in motion and promotes a flow Fig. 2: Pump motor aggregates at commissioning (left) and as sectional model (right)

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 26 InnovatIons & trends

Improvement potentials

Source: Andritz Ritz

in the pump motor units

Significant improvements have been realised on

both the pump side and the motor side. The
main influence was taken on pump and motor
regarding the efficiency levels and areas of
application.

Development potentials with the pump: The

development of new hydraulics in connection
Fig. 3: Distribution of the flux density with specific materials resulted in significantly
in an asynchronous motor
higher pump efficiencies. The new hydraulics
produced up to twice the delivery head per
stage compared to the former hydraulics. The
hydraulic development could be substantially
accelerated by computer simulations (ANSYS). A
comparison of the simulation data (CFD) with
The development of new hydraulics in
the data from the experiments was carried out
connection with specific materials resulted in in a faster manner. With the help of the Rapid
significantly higher pump efficiencies. Prototyping process, the feasibility of the devel-
oped pump parts could be accelerated.
Source: Andritz Ritz

Me a sure me nts a t 50 Hz

260
240
220
200
180
160
Head H [m]

140
120
100
80
60
40
20
0
0 50 100 150 200 250 300 350 400 450 500
F low Q [m³/h]

3-s tage, new Des ign 3-s tage, former Des ign

Fig. 4: Head in dependence of the flow with the former and new design
Source: Andritz Ritz

Me a sure me nt a t 50 Hz

90
85
80
75
70
P ump E ffic ienc y E T A [%]

65
60
55
50
45
40
35
30
25
20
15
10
5
0
0 50 100 150 200 250 300 350 400 450 500
F low Q [m³/h]

3-s tage, new Des ign 3-s tage, former Des ign

Fig. 5: Pump efficiency in dependence of the flow with the

former and new design

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 pumps & systems 27

Development potentials with the motor: By Measurement results of the submersible pump
mathematical optimisation (CFD) of the motor units
geometric conditions and improved selection of
electrotechnical materials, the efficiency of the The following requirements in the new pump
motor was increased (Fig. 3). Torques, speeds, series (12 inch size) with three pump sizes were
voltages, currents were mathematically opti- aimed (flow Qopt, delivery head Hopt in the opti-
mized under different conditions. For the same mum, specific speed nq):
size, a performance improvement between 20 %
and 30 % and an increase in efficiency of 2 % to • The optimisation parameter efficiency has
5 % were achieved. highest priority.
• Qopt = 250 m³/h, Hopt = 45–49 m, nq = 42
The following aspects were considered during • Qopt = 340 m³/h, Hopt = 43–47 m, nq = 51
the motor optimisation: • Qopt = 420 m³/h, Hopt = 38–42 m, nq = 60
• Within the range Qopt ± 20 %, the efficiency
• Selection of suitable lamination qualities shall be ≥ 75 %.
• Design of the rotor bars and short-circuit
rings The measured pump curves for the new and for-
• Reduction of hydraulic losses mer design show a steadily rising upward from
• Improvement of the heat emission maximum to minimum flow. In Fig. 4 the deliv-
• Performance maximisation at same size ery head (H) was applied against the flow (Q) by
a three-stage speed pump. The maximum flow
amounts to 400 m³/h. The new design shows a
nearly double delivery head per stage (48.6 m

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 28 InnovatIons & trends

Fig. 5 shows the dependency of efficiency and

Source: Andritz Ritz

C omparis on of 3 s tage P ump Motor Aggregates

with former and new Des ign
flow in the three-stage pumps with the former

198
200
and new design. The newly designed pump has
174

174
180

80 % degree of efficiency at 340 m³/h at the

162

160

140 optimum, while the pump with the former

120
design has 74 % efficiency at 320 m³/h. The
100 S U 12 - 325 former Des ign
requirement that the degree of efficiency should

93
88
S U 12 - 330 new Des ign
80

80
74

74
be ≥ 75 % over the range Qopt ± 20 % was achieved

65
60
54
48

40 with the new design.

25
22

20

7
3
0
H / S tage P2 P2 P 1 [kW ] eta P [% ] eta M [% ] eta total S tage
In addition, there is the achieved improvement
[m / S tage] [kW ] [kW / [% ] Number
S tage] on the motor side. The aggregates with new
Fig. 6: Improvements with the new pump motor units
design in connection with the new Premium-
EfficiencyMotor (PEM) are compared with the
former version (Fig. 6). With the same flow
(330 m³/h) and delivery head (143 m), the three-
per stage, 146 m per 3 stages at 340 m³/h) at stage pump with the former design requires 24
optimal degree of efficiency compared to the kW more power than the new pump. This corre-
conventional design (21.7 m per stage, 65.3 m sponds to 13.8 % energy gain or less consump-
per 3 stages at 320 m³/h). This has the conse- tion from the power net. The old design needs
quence that fewer steps per application and 12 kW more shaft power in comparison to the
thus less material must be expended for the new design.
pumping stages. The pumps with new design
have a lower weight. The degree of efficiency (ƞP) of the pump led to
an improvement from 74 % with the former
design to 80 % with the new design. The degree
By mathematical optimisation of the geometric of efficiency (ƞM) of the motor could be increased
from 88 % to 93 % (Fig. 6). These efficiency
conditions and improved selection of
enhancements have led to the improvement of
electrotechnical materials, the efficiency of overall efficiency (ƞ total) from 65 % to 74 %. In
the motor was increased. addition, the delivery head per stage was
increased by a factor of 2.1. In this case, this
means reducing the number of stages from 7 to
3. The pump thus becomes shorter and lighter.
The material consumption is lower. The assem-
Source: Andritz Ritz

Effic ienc ies at P umps with New Des ign bly and disassembly is significantly simplified.
90
The fault liability of the pump is reduced due to
80 fewer stages.
P ump E fficiency E T A [%]

70

60
The three developed pump 250, pump 340,
50

40
pump 420 cover the flow range from 250 to
30 420m³/h at the optimum. The measured effi-
20
ciency levels are in the range 79 % to 81 %
10
(Fig. 7). For all pumps, the efficiency levels are at
0
0 50 100 150 200 250 300 350 400 450 500 550 600 least 75 % in the range Qopt± 20 %.
F low Q [m³/h]

P ump 420 P ump 340 P ump 250 Authors:

Ludger Gottkehaskamp
Fig. 7: Pump efficiency levels of the new pump series
Johann Neiszer
Georg Cichon
Product Development
ANDRITZ Ritz GmbH, Schwäbisch Gmünd

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 Photo: Fotolia / Gieri
A large market segment is the water and waste water treatment by means of dissolved air flotation where the multiphase
pumps provide the task of air saturation without the use of compressed air.

Multiphase pumps for energy-efficient

water and wastewater treatment
Dr. Jürgen Holdhof

Multiphase pumps are unique products with outstanding features compared to

conventional centrifugal pumps. The approach consists of using the pumps not
only for transport of liquids but also for partial gas supply and as dynamic mixer
for gas enrichment. Therefore this novel pump conception barely has something
in common with a standard pump. Even the mode of operation does no longer
comply with the common doctrine: the multiphase pumps are slightly throttled
at the inlet side, in order to get automatically sucked in gas contents.
With standard centrifugal pumps this inevitably would result in cavitation.
Multiphase pumps are suitable for many processes. Gassing liquids that also
need to be handled by pumps occur in many applications. A large market
segment is the water and waste water treatment by means of dissolved air
flotation where the multiphase pumps provide the task of air saturation with-
out the use of compressed air.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 30 InnovatIons & trends

Some typical applications are:

Source: EDUR
• Dissolved air flotation with a pressure
saturation system corresponding to
VDMA Specification 24430,
Edition March 2010
• Aeration (Bioreactors)
• Ozonation
• Oil-water separation
• Elimination of lime in the paper industry
• Mineral processing (like copper extraction)

Liq
uid
The use of multiphase pumps provides a lot of
advantages:
• The reduction of the system components
Fig. 1: Sectional drawing of the pump hydraulics
and the simplification of the system design
results in lower investment costs and higher
operational reliability. Compared to conven-
tional system designs compressors, pressure
Multiphase pumps are dynamic mixers per- tanks and complex control are no longer
forming two functions. On the one hand liquids required.
are being enriched with gases, on the other • The high efficiency improves the energy
hand these liquid-gas mixtures are being trans- balance and reduces operating costs.
ported. At the same time during the pressure • High degrees of solution in terms of the
generation in the pump a blending and an excel- utilised gases improve the yield of recyclable
lent gas saturation occurs. By means of follow- fractions.
ing retention lines this gas saturation can be • Good control characteristics and a wide
further enhanced. range of application of the multiphase
pumps lead to an operation that meets the
The multiphase pump only is required for the requirements and avoids uneconomical
gas enrichment. Static mixers are omitted. The method of operation.
gas is supplied directly into the suction pipe line • Process reliability is significantly increased.
or into the inlet flange of the pump. The pump
hydraulics itself then brings the gas contents Consequently the new pump conception amor-
into solution (Fig. 1). tises within a short period of time means that it
is not only of interest for new plants but also for
the retrofitting of existing plants.
Source: EDUR

Operating limits of centrifugal pumps

The usual purpose of centrifugal pumps is the

transport of clean liquids. Unfortunately this
ideal typical utilisation is rare under real operat-
ing conditions. It is frequently the case that the
pumps also need to handle undissolved gases or
vapours. On one hand the reasons may be inter-
nal to the plant, e.g. leaks in the suction pipe
lines, insufficient coverage of the suction pipe
line with liquid in open systems etc. On the
other hand process-related requirements must
also be taken into consideration. In many pro-
cessing applications it is often the case that
Fig. 2: Characteristic curves of a multiphase pump – multiple phases of various media that need to
18.5 kW be handled are present simultaneously.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 pumps & systems 31

Typically liquids need to be enriched with gases, Operation as a dynamic mixer

liquid-gas mixtures are to be transported or gas-
sing liquids are to be handled safely. Under such By doing so multiphase pumps provide the gas
requirements the well-known non-selfpriming enrichment of liquids. The gas is supplied into
centrifugal pumps either fail or do not enable the suction pipe line or directly into the inlet
safe operation. Basically the failures here are flange of the pump. If the pressure of the availa-
caused by the design of the impeller. During ble gas is below that of the separate available
increase of gas contents an increasingly more liquid, the pump only has to be throttled at the
stable stationary gas area is formed in the area suction side.
of the impeller hub that finally blocks the impel-
ler inlet and interrupts the transport. The char- Increase of gas pressure is omitted. The pump
acteristic curve is no longer stable, even at low operates as dynamic mixer as due to the rota-
gas contents. Consequently such standard
pumps are not suitable for meet-
ing the before mentioned oper-
ating conditions. The process
METERING MEASUREMENT & CONTROL TREATMENT DISINFECTION IMPLEMENTATION
automation in particular requires
a controlled and trouble-free
pump operation.

Gas contents influence For those who want more –

The pump hydraulics of a mod- the best Sigma ever!
ern multiphase pump is designed
also for safe handling of gases.
Furthermore in case of separate
supply of liquids and gases a
good mixing of the two phases
resp. a high degree of dispersion
is achieved.
p rl
ri
7. – 11. A
The pump characteristic is essen-
r
tially determined by the gas con- Hannove
tents in the pumped liquid. The
Messe
gas contents influences the flow
Hall 15
rate, the pressure and the Stand G43
required pump power input.
Increasing gas contents tend to
The new Sigma motor-driven metering g pump.
pumm p.
decreasing flow rates and pump
Greater operating convenience, better safety
s
safety,
ty,
pressures but also to decreasing
greater cost efficiency!
pump power input (Fig. 2).

Gas handling percentages of up Standard features with:

to 30% are achieved without that ✓ detachable operating unit
the pumps are stopping opera- ✓ multi-layer safety diaphragm
tion. With regard to the process it
✓ internal overload cut-off
is of advantage that the entire
pump characteristic curves can ✓ state-of-the-art control technology and more
be run with stable operating con- than 10% energy savings potential
ditions.
www.prominent.com/en/sigma
Phone: +49 6221 842-0

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 32 InnovatIons & trends

tion of the special impellers, the gas content is The cleaning result is significantly determined

Photo: EDUR
passed into a solution depending on the adopted by two influence factors: the size of the micro
operating conditions. bubbles and the amount of gas.

During the pressure build-up in the pump a mix- Fine and homogeneously dispensed micro bub-
ture and excellent air saturation takes place. bles must be created in order to collect as much
This air saturation effect can be increased even floating substances as possible. Depending on
more by downstream solution lines. the waste water quality and the saturation pres-
sure, dispersions with bubble sizes of between
Fig. 3: White water Multiphase pumps can not only be used for the 30 and 50 µm successfully achieve an ideal
transport of liquids, they can also be used for the cleaning result. Smaller bubbles do reduce the
transport of liquids with gases and gas enrich- rising speed too much whereas larger bubbles
ment. do disturb the formation of flotate (Fig. 3).

The maximum solubility of air in water essen-

Multiphase pumps cannot only be used for transport of tially depends on the saturation pressure, the
liquids but also for partial gas supply and as dynamic water temperature and the water quality. In
combination with the other system compo-
mixer for gas enrichment.
nents the degree of solubility of the supplied air
amounts up to a maximum of 100%. The operat-
ing performance of the pump also remains sta-
ble even in case of changing flow rates and air
Waste water treatment contents enabling an exact pump control and
by means of dissolved air flotation adjustment to the regarding process.

Dissolved air flotation (DAF) is a proven and well Various gases with their specific characteristics
recognised procedure for the treatment of water are used depending on the particular applica-
and waste water and for the recovery of recycla- tion. For the correct pump selection the solubil-
bles as well. It serves to simply separate sub- ity of the gas in the regarding liquid is of utmost
stances that are suspended or emulsified in liq- importance. As a result the solubility and there-
uids. In doing so saturated water is released to fore the level of gas feeding of air or oxygen is
atmospheric pressure with highly pressurised far below the values of carbon dioxide.
air and guided into the waste water tank. The
micro bubbles that become free during pressure The special design of the multiphase pumps
release do settle on the suspended materials enables a direct gas input into the suction pipe
and float them to the liquid surface. From here line. As a result system components like com-
they are removed by skimming devices. Conse- pressors, pressure tanks, pumps, control devices
quently, the particle stream is the opposite of and valves are not necessary compared to con-
known sedimentation process. ventional systems (Fig. 4).

Typical fields of application include the treat-

ment of oil/water emulsions, fat separation,
phosphate precipitation and heavy metal pre-
Source: EDUR

cipitations as well as secondary clarifications in

Luft Zulauf Schmutzwasser Luft
Air Inflow Waste-water Air
biological purification plants. Multistage flota-
tion systems are also well-known for the treat-
Kompressor
ment of special waste. Many plant manufactur-
Compressor
ers report that by the use of multiphase pumps
savings are not only made with regard to invest-
Lösestrecke Solution Line
Lösestrecke Solution Line
ment volumes but also for the continuous oper-
ating costs that on average amount to between
Standardpumpe Flotat Feststoffe Ablauf EDUR Mehrphasenpumpe
Standard pump Flotate Solids Effluent EDUR multiphase pump 30% and 40% compared to conventional sys-
tems depending on the plant type.
Fig. 4: System design

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 pumps & systems 33

New construction and These pumps have now been replaced by one
retrofitting of existing plants multiphase pump with a 5.5 kW motor for an
operation point of 17 m3/h against 5 bar with
Slaughter house waste water: approx. 15% air contents. Due to the improved
In addition to improved effluent values and a formation of bubbles the effluent results have
reduced utilisation of chemicals, users report of sig- dramatically been improved. Furthermore the
nificant energy savings following the retrofitting of flotate is significantly more compact (Fig. 5).
existing plants. For example by replacing two Additionally less flocculants are required. The
side-channel pumps by an optimised multiphase pump service life instead of formerly 2 months
pump energy costs of the flotation plant installed now is prolonged to actually more than three
in an abattoir have significantly been reduced. years. The energy balance has also significantly
improved (from a total of 2 x 7.5 kW = 15 kW
The installed motor power was more than halved. previously to only 5.5 kW now). For 220 working
Originally two side-channel pumps each with 7.5 days and a 16 hour operating period per day, this
kW motors for an operating point of 9 m3/h equates to savings of more than 3,500 € per year
against 6.7 bar with 8.3% air contents each were (at 0.10 € / kWh) on energy costs only. Conse-
in operation. The aim of these pumps was to sep- quently the retrofitting did amortise after only
arate fat and other contaminations from abattoir six weeks.
waste water that had already been pre-cleaned
mechanically (pH value 7). Here the customer Municipal waste water treatment:
complained about an insufficient flotation effect Since 1929 waste water from the city of Kiel and
(formation of bubbles) and an insufficient pump the connected surrounding communities has
service life of two months only. been pumped through long sewage outfall

efficient. reliable. environmentally friendly.

MULTISAFE Double Hose-Diaphragm Pump

Handling of abrasive, aggressive and toxic media

Flow 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

FELUWA Pumpen GmbH | Germany | [email protected] | www.feluwa.com Engineered and Made in Germany
 34 InnovatIons & trends

compressors and pressure tanks was modified

Photo: EDUR
to the redeveloped system. Four standard
pumps were installed as dispersion pumps, each
with 15 kW of motor power that feed the pres-
sure tanks with recycling water at approx. 8 bar
for air saturation. In order to perform the air sat-
uration of the recycling water a pressure tank,
two dissolving tanks and two compressors with
4 kW power were installed.

The dispersion pumps, pressure tanks and com-

pressors were replaced by three of the success-
ful multiphase pumps, each with 5 kW of motor
power whereby one of the three pumps serves
as a standby pump (Fig. 6). All three components
Fig. 5: Flotate (dispersion pumps, pressure tanks and compres-
sors) were replaced by multiphase pumps dur-
ing the described retrofitting.
channels to the Bülk waste water treatment
plant where it is treated and finally pumped into By throttling the pumps down to approx. –0,2 to
the Baltic Sea . –0,3 bar artificial vacuum at the suction side,
the pumps suck the required air into the pumped
Each year approximately 20 million cubic meters liquid. The pumps simultaneously operate as
of untreated waste water is pumped to the dynamic mixer and, due to the increase of pres-
waste water treatment plant which corresponds sure to approx. 8 bar, achieve an excellent solu-
to a connected value of approx. 310,000 inhabit- tion. This causes a fine-bubble dispersion of the
ants and 65,000 inhabitant equivalents (indus- pumped liquid during the pressure release
trial and commercial). which leads to an excellent flotation result.
By operating in three shift system during
During a retrofitting in 2011/2012 the down- assumed 220 working days, the energy savings
stream flotation that is used to treat the clean- only amount to more than 100,000 € (at 0.10 € /
ing water of the cloth filters consisting of the kWh) annually.
conventional system with dispersion pumps,
Many municipal waste water treatment sys-
tems worldwide have been retrofitting to the
new multiphase system (Fig. 7). All users report
Photo: EDUR

of similar savings.

Other projects

Limy circulation water in the paper industry:

In the paper industry calcareous deposits from
the circulation water in pipes, cooling systems,
heat exchangers, etc. are avoided by the use of
lime traps. As a result the freshwater demand is
significantly reduced and a sustainable improve-
ment of the process reliability is achieved. The
costs associated with repair and maintenance of
the systems are also significantly reduced. Orig-
inally in a paper factory a partial flow of approx.
288 m³/h was saturated with compressed air in
a pressure reactor.
Fig. 6: Municipal waste water treatment plant Bülk, Germany

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
The fed quantity of compressed air was adjusted
SZ – THE ORIGINAL.
CUT
to approx. 400-500 l/min. For the flotation aera-
tion a standard pump with 75 kW motor power
(QN 288 m3/h, HN 6.5 bar, pump power input at
QN approx. 68 kW) as well as a 7.5 kW compres-
sor, a pressure reactor for the preparation of the
air-water mixtures and a compressed air tank
were conventionally installed.

Under the same operating conditions two mul-

tiphase pumps each 18.5 kW with air input in
front of the pumps were installed. The results
indicated a perfect operation of the lime traps at
a flow rate of 45 m³/h and a pressure of 4 bar
incl. approx. 20 % air as well as a pump power
input of approx. 13 kW per pump. A total of 75.5
kW (motor and compressor) was required in the
conventional system. In contrast no compressor
is required since the multiphase pumps have
been used. The pump power input of the two
pumps amounts to 26 kW only.

Consequently the total motor power is reduced

by 49 kW or remarkable 65.6%. At an energy
price of 0.10 € / kWh and an annual operating
integrated cutting element
time of 8,000 hours (three shift system), the
annual energy savings amount to approx.
39,600 €. The energy-efficient reconstruction of
the plant was amortised after approx. 5 months.

THAT‘S MODERN METALCUTTING!

Renewable energy:
In the processing of regenerative energy carriers CRUSHING – DELIVERY – RECYCLING –
– such as biofuel, wood, waste fractions with THE BEST WAY TO HANDLE COOLANT.
high heat value, or animal meal – the inert CO2
has to be washed out of the synthesic gas. A
 Ideal for aluminium, steel, wood, brass and plastic chips
compressor forwards the gas into an absorption
cell, where it flows ascendingly through a sup-  Save costly chip crushers
port medium aggregate. This aggregate is being  Universally applicable
sprayed from above with water that is conveyed  Minimum space requirements
by a multiphase pump. During this process the  Tank installation or dry installed as NBOcut
water is enriched with the CO2 out of the syn-
 Energy efficient drive concepts
thesis gas. Afterwards the water is led into a
desorption tank, in which most of the CO2 will  Cost-effective and economic
outgas. As this water is still saturated for 100 %,
gas bubbles occur during priming, that however CONTACT US – WE HAVE YOUR PUMPING
are soluted again by the multiphase pump – the SOLUTION!
circuit starts again.

Raw materials production:

It is historically proven that the flotation tech-
nology began with the production of raw mate-
rials. Most copper mining depends on crude ore

Schmalenberger GmbH + Co. KG · D-72013 Tübingen · Telefon: +49(0)7071-7008-0

Fax: +49(0)7071-7008-10 · Email: [email protected] · www.schmalenberger.de
 36 InnovatIons & trends

Cooling water treatment by ozone:

Photo: EDUR
The innovative conception of the multiphase
pumps did lead to participation at seventh
frame programme of the EC for research and
technological development. Marine bio-fouling
is a major problem for materials in constant
contact with seawater. Accumulation of marine
organisms has impact on the proper function-
ing of engines and further appliances on board
that need constant und proper cooling, and on
the safety of the vessels. The project comprises
the development of a system for avoiding
bio-fouling, by means of ozone improving the
Fig. 7: Municipal waste water treatment plant Ohio, USA quality of the seawater for cooling the ship’s
engines and by this avoiding considerable main-
tenance costs and at the same time assuring a
reliable operation of the seagoing vessels.
that is cracked, grinded in rock crushers and sub-
sequently supplied towards the flotation. Fine Crude oil-water separation:
air bubbles transport the small mineral particles Instead of hydro cyclones the separation of the
to the water surface and keep them in the flo- mixture can also be performed using flotation
tate. By means of the water-air mixture and technology and multiphase pumps. There is
adding of flotation additives at the same time generally a significant amount of oil-water mix-
the copper ore is separated from other ores. The ture when conveying crude oil. Flotation plants
ore concentrate subsequently is smelt in the fol- equipped with multiphase pumps separate the
lowing process. oil and water. The recovered oil is further pro-
cessed and the water is sent back to the drill
holes. However, in contrast to industrial applica-
tions, the multiphase pumps must be designed
Supreme process reliability, energy efficiency, the simpli- as super-duplex pumps for resistance reasons.
fication of the plant concept and the associated reduction The shaft sealing is executed according to the
so-called API plan (API 682 / ISO 21049). Essen-
of plant components that are susceptible to problems and
tially, methane is used in place of ambient air in
are maintenance-intensive result in a wide acceptance of order to achieve separation.
the innovative multiphase concept.

Result

Ammonia stripping plant: Supreme process reliability, energy efficiency,

Downstream the fertilizer production process a the simplification of the plant concept and the
stripping system is installed and serves for associated reduction of plant components that
reducing the ammonia nitrogen content and are susceptible to problems and are mainte-
also the chemical oxygen demand (COD) in the nance-intensive result in a wide acceptance of
process waste water to the standard values. Ini- the innovative multiphase concept. Both the
tially the waste water is fed into the tank near immense savings and the significantly lower
ground level. From there it is conducted into the running costs compared to the previous plant
multiphase pump where air is aspired along structure lead to extremely short amortisation
with the water and brought into solution under times. Even the retrofitting of existing plants
pressure. After pressure release the generated paid for itself after a short period of time.
water-air mixture is delivered back into the tank
through nozzles from above. Due to this sprin- Author:
kling the ammonia releases gaseous from the Dr. Jürgen Holdhof
waste water. It can be conveyed by a gas pipe to EDUR Pumpenfabrik
the fertilizer production process again. Eduard Redlien GmbH & Co. KG, Kiel

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 Photo: Abel
Ore and coal sludge accumulated in mining can be transported economically over long distances by means of piston diaphragm pumps.

Piston diaphragm pumps to remove

and transport sludge and sediment
Dipl.-Ing. Friedrich Wiechmann

Rising raw material prices mean that ore and coalmines even in
remote and little developed or exploited regions of the world have
become profitable. The local infrastructure in those regions is usually
not comparable with the infrastructure in Europe. Road and rail
connections are usually absent across large parts of the areas in
question, which is why pipelines are built alongside rivers, through
deserts, mountains, and jungles. The line does not follow the
geologically most favorable route but is instead the shortest route to
the next harbor or the next processor. This is why it might be favorable
to transport the accumulated ore and coal sludge by means of pump
units.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 38 InnovatIons & trends

Heterogeneous sludge: This type of sludge con-

Photo: Abel
sists of different phases, each with different
flow rates and directions in the flow. For exam-
ple, the flow rate must be above the “critical
flow rate” to prevent the pipes from becoming
blocked. Sediments in the pipes reduce the
available cross-section of the pipeline so that
flow rate as well as pressure losses increase. The
flow profile of heterogeneous sludge is asym-
metrical; the solid particles are not distributed
evenly.

Quasi-homogeneous sludge: At a sufficiently

high flow rate, this sludge exhibits the same
Fig. 1: Diaphragm pumps in use behavior as heterogeneous sludge.

Wear/abrasion due to sludge

Hydraulic transport of sludge can be described
as “two-phase flow.” It is a suspension consist- All solid materials have a specific hardness –
ing of solid particles mixed with a carrier liquid from talcum powder to diamonds. The hardness
located in a sealed pipeline. Certain flow rates of any given material contributes significantly
must be maintained in the pipe in order to to the wear and abrasion of pump components.
pump sludge from A to B; different values apply Similarly, shape and size of the particles is
depending on the consistency of the sludge. another important factor.
Sludge is classified as homogeneous, heteroge-
neous, and quasi-homogeneous sludge based Different types of wear and abrasion (e.g. corro-
on the composition, type, and flow behavior. sion, erosion, and/or combination of both) occur
in pumps. Correspondingly, various methods are
Homogeneous sludge: This type of sludge con- used to determine the type of wear and abra-
sists of different phases but flow rates and sion behavior. However, a method to predict the
directions are nearly identical. The reason for actually expected wear behavior accurately
this can be found in the properties of the solid does not exist.
particles, the concentration, and the flow rate.
The flow profile is symmetrical; the solid parti- One of the most reliable tests is the Miller Num-
cles are distributed evenly. ber, standardized according to the ASTM Stand-
ard G 7582. The Miller Number makes it possi-
ble to draw a conclusion about the relative abra-
siveness concerning a 27 % chrome steel with a
hardness of 62 HRC (hardness test according to
Source : Abel

Rockwell).

Examination of wear behavior

according to Miller(1)
Miller-Number
Bauxite sludge 9–400
Ash sludge 10–120
Copper sludge 20–120
Iron ore sludge 25–130
Coal sludge 6–57
Kaolin sludge 7–30
Tailings 24–644
Fig. 2: Sectional view of a diaphragm pump

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 pumps & systems 39

Parameters for the Miller Number are as follows: Selecting a suitable pump
• Hardness Pump type Miller-Number
• Size
Rotary pump 1–50
• Form
Piston pump 50–70
• Particle distribution
Piston diaphragm pump 70–higher
• Brittleness
• Concentration
• Specific weight
the suction and pressure side are primed with
The following also have an impact: the sludge to be pumped. The pipelines must
• Sludge temperature have very thick walls because they are exposed
• pH value to the pressures as well as the abrasion of the
• Pressure sludge and sediment flowing through the pipe.
• Flow rate Flow rates of 2.5 m/s are usually the limit. Such
high speeds, coupled with the parameters of
hardness, size, shape, particle distribution, brit-
Structure of diaphragm pumps tleness, and the spec. weight of the sludge, gen-
erate high abrasion rates in the pipeline.
The structure of a piston pump for high-pres-
sure sludge transportation follows a classical Diaphragm pumps with high pressures and high
model. The product valves, pump casings, as outputs are usually connected upstream of
well as the pipelines damping mechanisms on slower running booster pumps (e.g. rotary

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 40 InnovatIons & trends

Source: Abel
between the diaphragm and the damper wall.
The diaphragm constantly rolls over the built-up
layer and becomes worn when the spot is so
damaged that gas starts to leak. With corrosive
fluids, the damper case must also be selected
carefully.

Dampens with diaphragm receptacle on the

bottom do not have problems with a built-up
layer and adjustment to the pumped material to
the same extent. The bottom flange and the dia-

Fig. 4: Types of valves

Fig. 3: Diaphragm pulsation dampers

Source: Abel
pumps). A suction flow stabilizer is integrated
into the suction side as a dampening element
(usually a gas dampener). This design prevents
cavitation and increases the load degree of the
pump.

Thick-walled pipes must also be used on the

pressure side (pressure, abrasion). A gas damp-
ener is installed in the pressure line as well, con-
nected downstream of the pump. The dia-
Ball valve
phragms of the dampener must be adjusted to
the sludge. The gas charge pressure is 0.6 x oper-
ating pressure because this setting achieves an
optimal dampening. However, to do so, the
dampener must be properly dimensioned.

Pulsation dampers

Pulsation dampers are available as

• non-regulated gas dampers
• regulated diaphragm pulsation dampers
Conical valve
Non-regulated gas dampers are set to a specific
operating pressure. This type of damper cannot
be regulated and does not work under the
preload of the gas charge. To separate product
and gas charge, a diaphragm is installed that
prevents the gas charge from dissolving, which
would require constant refilling. The dia-
phragm’s pressure is balanced above the preload
pressure; below it, the diaphragm moves to the
wall of the damper and uses it as a support. The
position of the gas damper’s diaphragm (recep-
tacle at the top or bottom) affects the service
life of the diaphragm. If the diaphragm recepta-
Mushroom valve
cle is at the top, the product can become lodged

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 pumps & systems 41

phragms must be selected carefully to match

Source: Abel
the product.

Regulated gas dampers adjust to the respective

pressure conditions automatically, i.e., non-
damped pulsation does not occur. This type of
damper is a combination of open pulsation
damper and the gas damper.

Pump valves

Product valves are dimensioned in such a way

that the specific valve load and the valve speeds
are as low as possible. This way, the service life
of the product valves is extended as much as
possible. All valve components can be installed Fig. 5: Pump valve
or removed through inspection openings, i.e.,
the valve boxes do not have to be disassembled
to replace wear parts.
sealing force so that hydraulic fluid cannot flow
The valve seat has a conical receptacle, the valve into the product, or product into the hydraulic
box a hydraulic connection to press out the fluid.
valve seat, which is made from through-hard-
ened steel the same as the closing element. The diaphragm is designed in such a way that it
Elastomers are used for the seals incorporated will not stretch and/or fold under normal oper-
into the closing element. ating conditions. NBR (Acrylonitrile Butadiene
Rubber), HNBR (Hydrogenated Nitrile Butadiene
Types of valves: rubber), EPDM (Ethylene Propylene Diene Mon-
• Ball valve omer), FKM (Fluororubber) etc. have been
• Conical valve proven excellent materials for diaphragms. The
• Mushroom valve outer seal is created with an annular O-ring.
Moreover, a metal disk is vulcanized into the
Mushroom valves are a combination of the pos- center of the diaphragm, which centers and sta-
itive properties of ball and conical valves and bilizes the diaphragm. The disk also serves as a
offer the following, for example: holder for the diaphragm rod and protects the
• Dynamic behavior hydraulic area from sludge penetration. The
• Easy installation through valve cap opening metal disk withstands system pressures up to
• Additional degree of freedom compared 250 bar so that the diaphragm cannot be
with the ball valve destroyed by a defective or improperly closed
pressure valve.

Characteristics of the pumps The diaphragm is controlled with the diaphragm

rod, with the front and rear diaphragm position
The product side of the pump must be dimen- being monitored. The control is not activated
sioned in such a way that the shaped dia- during normal operation so that the diaphragm
phragm, the operating pressure, and the is able to pulsate freely. The service life of the
expected wear are considered. The pump case diaphragm is not reduced by a stress situation.
cover must be removable for maintenance with- The described measures have yielded a service
out the necessity to disassemble the suction life of more than 8,000 hours for the diaphragm.
and pressure side tubes. A so-called diaphragm
clamping ring is installed behind the pump case The diaphragm keeps the sludge away from crit-
cover; this ring or spring presses the diaphragm ical and moveable components, which is neces-
against the pump case and thus maintains the sary since these are not coordinated to match

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 42 InnovatIons & trends

(lip seal) running dry. Lubricating the piston

Source: Abel
spreads the required oil to the rear side of the lip
seals and abducts the friction heat as well. This
also creates a “water barrier” that prevents air
from entering the hydraulic area.

Triplex pumps have an identical displacement

volume per piston. Double duplex pumps have
different piston front and piston rear side vol-
umes. This is due to the piston rod’s dimensions
that must be deducted from the displacement
volume of the piston rear side. This unevenness
Fig. 6: Molded diaphragm leads to worse residual pulsation values com-
pared to the triplex pump. The additional seal-
ing between piston rod and cylinder is another
the product (as those parts are that are in con- disadvantage. Since this area is subject to the
tact with the product) but instead originate high operating pressure and must be sealed
from a modular system (e.g., cylinder liners, pis- against air penetrating, packing, lip seals, or
tons, piston rods, plungers, gland seals). combinations of both must be used. The sealed
area must also be cooled and lubricated.
The hydraulic system contains components to
monitor the diaphragm, to discharge the gas, The piston rod seal to the pump gears uses bel-
and effect the overpressure protection. Hydrau- lows or lip seals or packing. The latter two seals
lic oil or emulsion is used as the hydraulic fluid. must also be cooled and lubricated. This is usu-
The reservoir above the control mechanism is a ally done with gear oil. The bellows is thus the
substitute option for any missing hydraulic fluid easiest seal.
in case of a leak.
The demand for pumps with high capacities,
Piston and cylinder lining are designed for heavy great reliability, and long service life has led to
duty; the cylinder liner is hard-chrome plated the development of hydraulic diaphragm pumps
and honed. The piston is equipped with heavy for the transport of abrasive and highly abrasive
lip seals and piston guide rings. Due to the great sludge. These are horizontal piston diaphragm
positioning forces of the lip seals on the cylinder pumps that run slowly due to their long strokes
lining, the piston lubrication must be extensive. and large pistons. Stroke rates are max. 60/min;
The lip seal strips off all deposits on the cylinder some smaller pumps and in special cases with
wall (including the oil), which leads to the piston max. 120 strokes per minute are possible as well
(2). The max. piston or plunger speed and unbal-
anced masses (eccentric, eccentric rods), as well
as the valve speeds are the decisive factors.
Source: Abel

The pumps are either triplex (single-action) or

double duplex (double-action) pumps. The two
models have different gear designs. Due to the
machined allover crankshaft, the triplex gear is
able to run at higher rpms; the crankshaft has a
crank offset of 120° and because of that a more
balanced volume flow. The rigid crankshaft
guided by two swivel-joint roller bearings is
driven by an external reducing gear. The pistons
are pressurized on one side.

Due to the large eccentric, the double duplex

gear is unable to run at rpms above 60 strokes
Fig. 7: Pump side per minute; the eccentric offset amounts to 90°;

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 pumps & systems 43

the piston is pressurized on both sides and actually pump any liquid or sludge from the
exhibits a worse volume flow and higher resid- pipeline. The bypass is slowly closed once the
ual pulsation. The double duplex gear is pump has reached the working rpm; the flush-
equipped with an internal gear reduction (her- ing fluid starts to move slowly until the bypass is
ringbone gearing). The herringbone gearing closed completely and the required flow rate
does not generate any forces that have an effect has been reached. Today, the following devices
in axial direction and normally must be absorbed are used to start the pump:
by the gearbox. Contrary to a crankshaft, the use
of the eccentric shaft makes it possible to install • Fluid turbo couplings
encased main bearings into the eccentric rod. A • Soft starters
V-belt intermediate gear is used for capacities • Frequency converters
up to approx. 200 kW; higher capacities require
reducing gears designed to match the capacity. The pumps available are models HMT (triplex,
The electric motor is used primarily as a drive single-action) and HMQ (double, duplex, dou-
motor followed by diesel motors. ble-action). The two models have different gear
designs. Piston speeds are below 1 m/s; valve
Pumps can no longer be started directly because speeds range from 0.8 to 1.8 m/s. This results in
the masses in the pump and the gear are too very low pump rpms, which significantly reduce
great. The liquid column in the pipeline must be wear of the components in contact with the
accelerated slowly if the pump is started when product.
it is connected to a filled pipeline. Bypasses were
used for this process in the past. During the The die line of the gears leads through the main
start phase, the pump’s pressure and suction bearings. This type of division makes it possible
sides are short-circuited so the pump does not to fit the large and unwieldy components into

Diagnostics
before Damage

Innovation:

SIHIdetect
· Cavitation
· Wear before damage
· Simple to connect
· LED display
· Available Ex
· All rotating machinery

Pumping Technology For A Better Future

Wherever you need a pump. We design and manufacture liquid

pumps, vacuum pumps, compressors and engineered systems.
Since 1920.
Sterling SIHI GmbH
[email protected]
www.sterlingSIHI.com
 44 InnovatIons & trends

Application example

Source: Abel
At the KCM copper processing facility in Chingola, Zam-
bia, graded copper tailings must be transported from a
thickener and cyclone station to a subterranean mine
across a distance of 3.5 kilometers where they are used
as backfill. Approx. 70 tons of dry solid material must be
transported per hour.

A triplex piston diaphragm pump like the one described

above was installed for transporting these tailings. The
solid concentration in the sludge amounts to 59 %, the
Fig. 8: Piston with cylinder liner
sludge volume is 90 m³/h, and the required pressure for
the distance of 3.5 km is 50 bar.

the gear. With at least 1.5 x the stroke length, The operating costs have been extremely low since the
the lantern is dimensioned generously. It is pro- pump has been commissioned: Due to the high effi-
tected from dust, dirt, and water by an inspec- ciency of the new unit, the power consumption amounts
tion panel. to 90 m³/h and 50 bar as well as 160 kW.

Splash or centrifugal lubrication can no longer The parts replacement is limited to replacing the valves
be used with these gears since the pumps reach every 5,000 to 7,000 operating hours.
the necessary operating speeds slowly and are
then set back. The pressure circulating lubrica- The diaphragms are replaced every 12,000 to 16,000
tion supplies the pump gear with the necessary hours as part of the preventative maintenance.
lubricant. The treated oil flow is adjusted for the
individual consumers; oil pressure, oil tempera- The piston diaphragm pump used in this case also incurs
ture, and oil pollution are monitored continu- low operating costs due to the physical separation of the
ously. abrasive sludge from the most important moveable
parts of the pump using preformed caoutchouc (rubber)
These large pump systems can be equipped diaphragms.
with a smart monitoring system that indicates
the real condition and status of the pump at any Only the product valves at the suction and pump side as
time. Regardless of the application location of well as the diaphragms are in direct contact with the
the pump, the parameters of the pump can be sludge. The reciprocating principle of the piston dia-
logged on site or at the control station and ana- phragm pump ensures a very high efficiency of at least
lyzed by means of remote diagnosis using a 93 %. The pump costs of this type of pump are thus min-
modem and/or the Internet. imal and more economic than compared with other
methods of sludge removal and transport.

Author:
Photo: Abel

Dipl.-Ing. Friedrich Wiechmann

Manager Engineering and Design
ABEL GmbH & Co. KG, Büchen

Literature:
(1) Miller, John: The Reciprocating Pump. Theory, Design and
Use. Krieger Publishing 1995
(2) Zöllner, Jörg-Peter: Membranpumpen mit hydraulisch und
mechanisch angelenkten Membranen zur Förderung von
feststoffbeladenen Fluiden. Industriepumpen und Kompres-
soren 4/1998

Fig. 9: Konkola copper mine, Chingola (Zambia)

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 Photo: Fotolia / Jürgen Fälchle
Diaphragm metering pumps for very low flow rates are used among other things for the odorizing of biogas.

Metering technology for biogases and biofuels

Rainer Sonnenfroh and Walter Richter

Biogas, as a CO2-neutral energy source, is a future market. The addi-

tives used for odorizing or to increase combustion values, however,
are just as hazardous as the products that are conveyed during the
manufacture of synthetic fuels from biomass. So the pumps used for
this purpose must be hermetically tight even under critical process
conditions like extreme temperatures and high pressure. Diaphragm
metering pumps – especially if the diaphragm consists of multiple
layers – have the best characteristics for this purpose, since they can
completely eliminate the need for dynamic seals. The pumps work
thermodynamically optimally and can be used over a very wide range
of temperatures.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 46 InnovatIons & trends

The additives to be handed in biogas applica- as Gasodor S-Free. For the consumer, the addi-
tions are potentially hazardous according to the tion of an odorant to an odorless gas is an
applicable EU Hazardous Materials Directive important safety measure, so that leaks or
(EC) 1272/2008 (CLP) and EU Chemical Directive defective systems can quickly be identified dur-
1907/2006 REACH. The hermetic tightness of ing distribution, reloading, or transport.
the pumps used is thus essential. Particularly
critical systems include the shaft seals of pro- Since biogas is generally not used for power
cess pumps and compressors, since their failure generation directly on-site, but rather fed into
not only causes high consequential costs but the public gas network or at least transported a
danger to life and limb. The strict requirements few kilometers to the direct consumer (co-gen-
of the Federal Emission Protection Law (BIm- eration facility), it must first be refined. The raw
SchG – section TA-Luft 5.2.6.1 - Pumps) can best gas provided by the farmer consists primarily of
be met by the consequent elimination of methane and carbon dioxide. During prepara-
dynamic seals, for example by the use of leak- tion, it is purified and the methane gas propor-
free diaphragm pumps. tion is increased to about 97 percent. In the ini-
tial step, the gas is desulfurized using doped
activated carbon filters, rendering it odorless.
Odorization of biogas The carbon dioxide is then removed and the gas
odorized with the typical warning odor.
Diaphragm metering pumps for very low flow
rates are used among other things for the odor- Gas flow controlled diaphragm pumps ensure
izing of biogas with highly volatile, typi- optimum metering of odorant
cal-smelling sulfur compounds such as tetrahy-
drothiophene (THT) or sulfur-free odorants such In the past, wick odorization, by-pass odoriza-
tion, or simply adding odorant without control
have been used. However, there should be no
problems with odor during transport or mainte-
Photo: LEWA

nance work. At the same time, staff should not

be endangered at any time. The exact metering
of additives is therefore very significant and it is
essential to work with absolutely leak-proof sys-
tems. Today, odorization must also be moni-
tored in nearly every country, and be carried out
proportionally and continuously. In 90 percent
of cases, users decide on a flow-controlled dia-
phragm pump, because these pumps have the
best characteristics for quantity-proportional
metering of odorant.

A particularly cost-effective solution to meter

fluid components in proportion to a variable ref-
erence value are hydraulically controlled meter-
ing pumps with metal diaphragms and mag-
netic drives. The different systems in which
these are installed use 24 VDC or 230 VAC and
are equipped with the core components of
pump, flow meter, and controller, along with a
stationary container. This container is equipped
with a visual level control and can also be used
for calibration of the pump. Since at very small
stroke frequencies of less than ten pulses per
minute there can be a backflow of odorant, an
Fig. 1: The difficulty in odorization is in the high-precision
metering it requires, because the gas shouldn‘t have either additional solenoid valve is built into the pres-
too strong or too weak an odor. sure line. This reliably prevents any backflow.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 pumps & systems 47

The system is also equipped with an activated carbon filter in the ventila-
tion line, and has a flushing system for cleaning the diaphragm pump
head and the suction and pressure lines before maintenance. All the units
and components installed must meet the requirements of EC Directive
94/9. All the parts installed are approved for Ex zone 1.

Efficient
The smallest dosage is 0.01 milliliters
conveying
Biogas can in principle be odorized at a pressure of up to 100 bar. The of liquids
DVGW (German Technical and Scientific Association for Gas and Water)
G280 regulations specify the exact quantity of odorant to permit even the
slightest leak to be perceived. At a throughput of 100 cubic meters per
hours, the odorizing additive is mixed in about once a minute. The small-
est quantity that can be metered is 0.01 milliliters per pump stroke. The
micro flow meter KMM 1 also measures small volume flows at an error
range of ± 1 percent, so the odorant is metered safely, proportionally, and
economically.

Standard odorizing systems have a modular structure that can be fit

together perfectly, with all significant components individually configur-
able. Depending on the application, not only solenoid driven metering
pumps can be used, but also pneumatically or electrically operated meter-
ing pumps and well-tested controllers with Internet connections. Only
mature, approved components are used that meet international require-
ments like DVGW G280, WHG, the Pressure Equipment Directive, ISO
9001, GOST-R, ATEX, and TA-Luft. Odorizing systems can also optionally be
provided in a stainless steel cabinet with leak pans in various sizes. Lewa
also provides overfilling protection, manometers for pressure lines and GEA Tuchenhagen
tanks, and stand-by pumps with automatic switchover. offers a complete range
of normal-priming and
self-priming centrifugal
pumps, perfectly tuned
Improved process for BtL fuel manufacture
to the task at hand.

BtL fuels (Biomass to Liquid) are synthetic fuels made from biomass. The
energy revolution has also brought biofuels such as biodiesel and bioeth- Whatever your process,
anol into greater focus. Due to climate change and due to the limited GEA Tuchenhagen has a
quantity of petroleum available and therefore its rising cost, the industrial clever solution for you.
nations invested in large capacity for first-generation biofuels (for exam-
ple, biodiesel from rapeseed). Recently, BtL fuels have especially received
strong political support in Europe as second-generation biofuels, since
their contribution relative to the agricultural acreage required and the
resulting transportation power are significantly superior to those of other
alternative fuels. In comparison: One liter of BtL fuel corresponds to 0.97
liters of a conventional fuel. For first-generation biodiesel, that value is
only 0.9 liters, and the acreage required is more than twice as much. GEA Mechanical Equipment
GEA Tuchenhagen GmbH
Am Industriepark 2–10
To obtain biofuel from biomass, there are currently a number of pilot sys- 21514 Büchen, Germany
tems in use around the world. The multi-phase processes are generally Phone +49 4155 49-0

based on Fischer-Tropsch synthesis, a high-pressure process that was [email protected]

www.gea.com
developed in Germany back in 1925 for liquefaction of coal. Diaphragm
metering pumps are used at different points in the process, for example as
engineering for a better world
a supply pump conveying the liquid biomass into the high-pressure reac-
tor. Due to the temperatures, some of which are very high (up to +400 °C),

GEA_TUC_Pumpen_48x241mm_engl_RZ.indd 12.11.13
1 15:36
Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 48 InnovatIons & trends

Photo: Fotolia
Fig. 2: Waste incineration systems also produce biogas that can be reused: Either by odorizing it and directly
delivering it to filling stations, or fuel can be made from it using Fischer-Tropsch synthesis.

the pumps are often built with a so-called struction of a normal metering pump makes
“remote head” design. this impossible.

There are a whole series of structural options

Remote head designs that make it possible to separate the valve head
spatially from the pump drive. The underlying
The principle of the remote head design is also principle is this: The transmission of the dis-
used for suspensions at high temperature and placement movement is carried out by a liquid
radioactive, explosive, or toxic fluids in order to column contained in a connection line, the
keep these critical conditions remote from the so-called “hydraulic link”. This is set into an oscil-
displacement system, to protect the facility as lating movement by the displacement body that
well as the surroundings. The compact con- is transmitted to the valve head. The alternat-
ing, pressure-controlled opening and closing of
the check valve namely forces the pulsating flow
of the fluid in only one direction in the valve
head. It can therefore work with temperatures
from –60 °C to +400 °C.

Depending on the fluid characteristics and the

background conditions, the displacement sys-
tem and valve head can be implemented in
either a piston or a diaphragm design. Depend-
ing on what pressures and temperatures are
reached, it is also possible to locate the valve
head geodetically higher or lower than the dis-
placement system. Since the pump drive is
located with the displacement system outside
Fig. 3: Triplex high-temperature process pump for the manufacture
Source: LEWA the danger zone, a piston design is unproblematic.
of second-generation biofuels using Fischer-Tropsch synthesis

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 pumps & systems 49

Hermetically tight – thanks to der is no longer an issue. The option of decentral

sandwich diaphragm co-generation in small production facilities not
only reduces dependence on energy imports but
Modern, process-reliable metering pumps are also strengthens the regional economy. In the
generally built with multi-layer diaphragms end, BtL fuels are thus also a hopeful option
(also called sandwich diaphragms). The dia- because they can be burned in today’s diesel
phragm layers are ideally made of pure Teflon engines with no modification and can be dis-
(PTFE) and are therefore suitable for nearly any tributed through the existing filling station net-
fluid. Especially at extreme temperatures from work.
–30 to +150 °C, the sandwich diaphragm has
proved ideal. A service life of over 18 months is The emission values for BtL are lower in compar-
normal. The diaphragm, which also works as a ison with fossil fuels, but there are differences
static seal, keeps the pump hermetically tight at depending on the type of biomass used. The use
all times. Dynamic seals, on the other hand, eas- of waste or forestry byproducts burdens the
ily become brittle and fail in cold temperatures, environment very little. For energy plants, on
which is particularly dangerous for poisonous or the other hand, the emission values are higher
highly explosive materials. and fewer greenhouse gases are saved. Another
important criterion is conversion efficiency,
The sandwich diaphragm ensures that the which depends among other things on whether
pump remains hermetically tight even in the the process selected can also produce electric
case of damage to one of the diaphragms. The power and heat. It will probably take a few years
pump can then continue to be operated for a for market readiness to be achieved, but
limited time. This is particularly important dur- together with the Karlsruhe Research Center,
ing the manufacture of fuel, to ensure that the
controlled chemical reaction can be completed
and none of the highly poisonous or flammable
gases in the system, such as hydrochloric acid or
hydrocyanic acid, reach the surrounding envi-
LEISTRITZ PUMPEN GMBH
ronment. Monitoring of the diaphragm status
therefore takes on greater importance. How-
ever, a series of simple, leak-free signaling sys-
tems can meet safety requirements at every
level. Of course, the materials for the pump, in
particular the parts in contact with the fluid, The Screw of Archimedes Tradition meets Innovation
must be selected in such a way that these haz-
ardous materials can be pumped without prob- Leistritz Screw Pumps and Systems
lems. For this purpose, there are different spe- Leistritz Pumpen GmbH, with its headquarters in
Nuremberg/Germany, has been producing Screw Pumps
cial materials available, such as hardened or
since 1924.
high-strength stainless steels or high-quality
With the widest range of Screw Pumps Leistritz serves all
nickel alloys like Hastelloy. kind of markets and applications.

Multiple Screwpumps
Energy of the future

So far, only a few pilot facilities have been built

for this type of synthetic fuel production, but
even now it can be seen that the process offers a Capacity max.: up to 22,000 GPM (up to 5,000 m3/h)
whole series of advantages. For one thing, the
entire plant can be used, so that the yield rela-
Differential Pressure max.: up to 4,060 psi (up to 280 bar)
Leistritz Schraubenspindelpumpen
tive to the biomass used is higher than for Markets & Industries
& Systeme
first-generation fuels. If semi-liquid manure,
wood chips, compost, or dairy waste or food
waste from restaurants are used, competition
with agricultural acreage for food or animal fod-
Leistritz Pumpen GmbH
Markgrafenstrasse 29-39 | D-90459 Nuremberg
Phone: +49 (0)911/4306 - 0 | Fax: +49 (0)911/4306 - 490
E-Mail: [email protected] | www.leistritz.com
 50 InnovatIons & trends

Source: LEWA
Fig. 4: 3D CAD of a multiplex pump with remote head design for metering under extreme operating temperatures

work is proceeding on further improvements to up to 200 bar. Remote head designs can also be
the manufacturing procedure. used here. However, in this case they aren’t used
due to extreme temperature, but to permit the
immersion of the pump head in the propane/
Strict requirements for injection butane tank, creating the optimum suction con-
processes in biogas filling stations ditions for the pump.

Most European vehicle manufacturers follow Since during tanking of a truck, in comparison
ISO/DIS 15403, which requires a gas quality of with passenger car tanking, the absolute
at least 96 percent methane content. Since this metered additive quantity must be temporarily
value is not achieved with biogas, but the oxidiz- increased, it is important for the flow regulation
able compound determines how much energy is range to be very broad with an evenly high effi-
released in the combustion process, propane or ciency, while the pump continues to run in its
butane is added during tanking to increase the optimum operating range. For diaphragm
combustion value. Both materials, however, metering pumps, the flow follows the reference
have a negative influence on pinging that must value over a very wide adjustment range using
be taken into consideration. To prevent uncon- the stroke frequency of the drive. The quantity
trolled self-ignition, DIN 51626 therefore limits can also be adapted to requirements using an
their proportion to a maximum of two to six electronically controlled stroke length adjust-
percent. ment.

To ensure that the additional metering of easily Each facility operator must meet specific
flammable gases results in no danger to the sur- requirements due to different gas qualities. The
roundings, the propane/butane is stored under- design parameters for the pumps must there-
ground at normal soil temperatures. During fore always be recalculated from the material
tanking of the vehicle, the metering pump must data, volumes, and background conditions such
meter the propane/butane against a pressure of as temperature.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 pumps & systems 51

Energy efficiency and low lifetime costs

Photo: Fotolia
Biogas itself may well be CO2-neutral, but the
energy required over the course of its manufac-
ture, refinement, and transport by pumps can
be enormous. The goal is to keep electric drive
power as low as possible even for large quanti-
ties conveyed. At the same time, the quantity
must be accurately and reproducibly specified
for metering tasks. In filling stations, a high,
flexibly regulated power range must be pro-
vided, since the quantity continually fluctuates.
Accuracy and adjustability are therefore equally
important in order to ensure the energy effi- Fig. 5: Draff is a waste product of the process of brewing beer. It can be
transferred into a biogas process and used for the manufacture of process
ciency of the processes. In particular rotating
heat, which can contribute to reductions in energy costs in the brewery.
pumps, however, can only be designed for multi-
ple working points with great difficulty. Their
efficiency is often unsatisfactory under these
conditions. Process diaphragm pumps are sig-
nificantly more flexible in this respect, causing a diaphragm from the fluid metered, and run
up to 50 percent lower power costs – with corre- without wear in oil in the hydraulic part. This
spondingly positive effects on the overall bal- also simplifies their quick replacement if service
ance sheet of the biogas application in question. is needed. The pump heads are entirely sealed
inwards and outwards and therefore meet one
In principle, these high-performance pumps can of the most important requirements for safety
also be used in industry or for power and heat and environmental protection. Wear parts must
generation in residential units, hospitals, and only be replaced after up to 18 months. As a
schools. Regardless of whether the fuel is trans- result, there is also a faster return on invest-
ported over several stories or from storage to ment than, for example, for rotating pumps, in
the vehicle, these applications are continuous which a period of about two years is recom-
processes. The pumps used must therefore be mended for amortisation of the purchase costs.
very low maintenance. To ensure this, they are
built to prevent dry running and have outstand- Authors:
ing safety characteristics even in case of opera- Rainer Sonnenfroh
tor error. Sales Engineer Process Industry
Walter Richter
Leakage problems in the piston seal in contact Product Manager Odorization and
with the fluid metered are entirely eliminated: Gas Distribution
The piston seal and the piston are separated by Lewa GmbH, Leonberg

made in Germany

Pumps and Valves - Experience, Responsibility, Passion.

www.klaus-union.com
 Photo: Fotolia / Ralf Gosch
Tank terminal with loading arms: Innovative and more flexible pumping systems can make big contributions to a flexible,
smooth and cost-efficient operation of oil and tank farms.

Screw pumps in tank farms

Thomas Talarczyk

Oil and tank farm installations have experienced a real boom

over the past few years. New tank farms are being built
worldwide to cover the growing demand for crude and
refined oil products. And there seems to be no end in sight
to this trend. Innovative and more flexible pumping systems
can make big contributions to a flexible, smooth and cost-
efficient operation of oil and tank farms.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 pumps & systems 53

Apart from conventional centrifugal and gear charge. The rotors have to be manufactured
pumps, an increasing number of screw pumps from one single piece of material which elimi-
are being used to transport stored oil products. nates the risk of contact between the rotors and
The big advantage is that oil products with vari- casing.
ous qualities and viscosities, different back pres-
sures and suction conditions such as presence of This feature increases the structural integrity
entrained air or gas can be pumped without dif- and service life of the spindles resulting in a
ficulties by just one pump. The versatility of the greater operational reliability. If necessary a spe-
screw pump and its use in low, medium and
high-pressure applications up to 100 barg is a
huge advantage. Pump speeds of up to Over the past few years, the focus in pump
3,500 rpm are acceptable, depending on the
individual application. Screw pumps are found
developments have been on energy consumption,
in services like occupational safety and reduction of operating
costs for the tank farm owners and operators.
• transfer pumps for different flow rates and
pressures
• loading/unloading pumps for tanks /
trucks / trains / ships / tank barges cial modification can be done to the spindle pro-
• circulation pumps (tank-to-tank circulation / file, which leads to lower pump noise. The drive
in-tank circulation) spindle torque is transferred to the driven spin-
• tank draining pumps / stripping pumps dle via oil-lubricated timing gears. This ensures
an operation of the pump without any contact
The pumping of stored and refined oil products between the spindles and the replaceable casing
are done by various pump types. Most familiar insert and the spindle profiles themselves.
are double-flow, self-priming, rotating posi-
tive-displacement twin-screw pumps, having An important feature of this type of pump is its
totally four spindle profiles. These pumps are ability to pump fluids in the viscosity range from
axially and radially fully balanced so as to avoid 0.4 cSt to over 10,000 cSt. Furthermore, flow
the need of special thrust bearings and to guar- rates of up to 5,000 m³/h can be transported
antee for long service life. The flow is split when with just one pump. This type of positive-dis-
entering the pump casing and transferred to placement pump also allows for dry running
each side of the double flow spindle package with fluids having low vapor pressure and when
where it is pressurized to the common dis- emptying tanks or pipelines.

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 54 InnovatIons & trends

low-pressure operation of up to 16bar (232 psi)

Source: Leistritz

and can transport a wide variety of oil products,

from low-viscosity fluids such as „light“ gas oil
(VGO) to high-viscosity asphalt and bitumen.
Fluids with a viscosity of 1 – 100,000 cSt with
operating temperatures of up to 280°C can be
pumped. The flow rate goes from a few litres per
minute up to 1,700 m³/h depending on the
pump size selected. One common use of these
pumps is the circulation of fluids for mixing and
heating of various oil products as well as trans-
fer and loading pumps.

Their design is similar to the more familiar dou-

ble-flow twin-screw pumps. For example, the
casing of these pumps is also in steel with
Fig. 1: Sectional drawing of a double-flow twin-screw pump replaceable pump liner and the spindles are
made from a single piece to ensure their struc-

Double-acting mechanical seals with a barrier

fluid system are also used for applications
where longer periods of dry running can be
expected.

Innovative, operator friendly and

energy efficient pumping systems

Over the past few years, the focus in pump

developments have been on energy consump-
tion, occupational safety and reduction of oper-
ating costs for the tank farm owners and opera-
tors. The self-priming, single-flow positive-dis-
placement pumps with 2 or 5 spindle profiles Source: Leistritz
Fig. 3: Sectional drawing of a single-flow
can also be used to meet the new market positive-displacement pump with 5 spindles
requirements. These pumps are designed for a

tural integrity. The pumps are also axially and

Source: Leistritz

radially balanced eliminating trust bearings,

which guarantees a long service life.

What is special about these pumps is the fact

that the idler spindle is not driven by gears. The
torque is transmitted hydraulically by the flanks
of the drive spindle‘s profile. The special profile
of the spindle ensures the perfect closure of the
pumping chambers so that the fluids are con-
veyed in an axial direction with no pulsations.
This pump design ensures a greater pumping
efficiency with reduced power consumption, as
Fig. 2: Sectional drawing of a single-flow positive- result, leading to lower cost of ownership, as
displacement pump with 2 spindle profiles pump procurement cost as well is low. It should

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 pumps & systems 55

also be pointed to the biggest difference in design

Photo: Leistritz
to the double-flow twin-screw pump: the mechan-
ical seals to the atmosphere are reduced from
four to only one seal. The single-flow positive-dis-
placement pumps have no separately oil-lubri-
cated gears or bearings. This permits the use of
single-acting mechanical seals with an oil quench
on the atmospheric side of the seal to ensure an
oil film is present between the rotating parts of
the seal when operating with negative suction
pressure. Optionally, a double-acting mechanical
seal can be used. This seal should be provided Fig. 4: Crude Transfer Pump
with an external barrier system that is adapted to
the pump system and supplies the mechanical
seal independently of the pumped fluid. The pipe connections on the inlet and outlet
side does not have to be removed.

Simplified maintenance
Advantages over conventional
When considering the aspects of maintenance centrifugal pumps
and service, the single-flow pumps are very cost
efficient and stand out positively. The following Tank terminals around the world are getting
bullet points really hold true for these pumps. bigger and bigger and an increasing number of

• Fewer spare parts: An innovative and

parts-saving pump design guarantees
simplified stocking of spare parts by the
operator or service contractor. The operator
can thus calculate the benefits of an optimal
stock keeping of parts with a lower service High pressure process pumps
budget and capital tie-up. Plunger pumps up to 3800 bar – Flow rates up to 120 m³/h

• Simplified service and faster overhaul: This

means in the field service! In the majority of
cases, service work can be carried out with Chemical industry pumps
less work and with smaller and lighter
Fatty alcohol CO2 extraction
components directly on site, without the
LDPE Homogenisation
pumps having to be brought to an external Wet oxidation
shop.
• Less downtime for servicing (longer running
times): Only pumps that are in operation
contribute to the operating company’s
profit. Thus, less downtime during servicing Offshore injection pumps
have a direct impact on the company‘s Methanol Diesel
financial result. LDHI Corrosion inhibitor
Glycol Scale inhibitor
Completely preassembled and tested cartridge
units are available to speed service work even
more. The operator only has to change the car-
tridge or the „pump‘s entire internals“ at the Water injection pumps
time of service. The cartridge is simply slid out of Sea water
the pump casing. A new cartridge can then be Produced water
slid back into the pump casing and the pump is Wash water
ready for operation again. The pump does not
have to be removed from its base for this work.
Hammelmann Phone: +49 (0) 25 22 / 76 - 0
Maschinenfabrik GmbH [email protected]
Zum Sundern 13 – 21 www.hammelmann-process.com
59302 Oelde, Germany www.hammelmann.com
 56 InnovatIons & trends

Centrifugal pump viscosity correction

factors (related to water in %)

Viskosity (cSt) 50 100 160 220

Flow reduction –8 –14 –19 –23

Head reduction –5 –11 –14 –18

Power increase +20 +30 +50 +65

Photo: Leistritz
Fig. 5: Pump „suction side view“

different oil products are being stored and trans- change of pump flow which can be controlled
ported. Striving for the maximum flexibility of automatically. No bypass to control flow is
facility use, it is the job of the pump manufac- required which eliminates loss of energy and
turer to implement this flexibility in his pump overheating (which would be the case with a
design. This kind of flexibility is not always pos- throttled centrifugal pump). This means that
sible to achieve with a centrifugal pump. With a tanks and pipelines can be quickly and effi-
typical limited operating window, a centrifugal ciently drained and stripped using speed control
pump can very quickly run into undesirable to lower axial velocities.
operating points, leading to cavitation, vibra-
tions and increased wear or simply stop work- With typical centrifugal pumps operating with
ing. A single-flow or double-flow positive-dis- viscous fluids, the following correction factors
placement pump with variable speed control, on related to water data have to be taken into
the other hand, can cover much wider and account . Ignoring these correction factors can
demanding conditions of operation. Another lead to selecting an incorrect pump size, which
advantage is that these pumps are always will operate outside of its best efficiency point
self-priming. The change of speed results in in most cases.

6
A
5

4
3 3
B B

6
A
5
4

1 6
A
5

6
A
5

2 4

6
A
5
oversimplified illustration

Crude Oil 1 On-Board Crude Cargo Pump A Storage Tank

& Refined Products Booster Pump Station
2 Crude Unloading Pump B
3 Booster Pump
4 Circulation Pump
5 Stripping Pump
6 Loading and Transfer Pump
Source: Leistritz
Fig. 6: Flow chart for the distribution, storage
and transport of oil products in tank farms 6
A
5

4
3 3
B
Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014 B

6
A
5
 pumps & systems 57

It is very important that the vapour pressure and single-flow screw pump is ideal for this service.
NPSH are taken into account when designing It can be installed vertically in the tank or on
the pumping system. The NPSH available by the deck to save space. The flow rate is practically
facility can be influenced by several factors. In independent of backpressure and the transfer
tanks with a floating roof the liquid level can rate can easily be controlled by adjusting the
only go down to a certain minimum without pump speed, protecting the receiving tank from
endangering the structure of the tank. That is overfilling.
normally the lowest static liquid column or pres-
sure available. The pressure drop from piping, Circulation and blending:
strainers and valves has to be deducted from Screw pumps are also used to mix oil products
this value. The vapour pressure and specific with different viscosities in tank farms. A contin-
weight at a given liquid temperature are further uous, pressure-independent pumping rate using
corrections. The pump has to be able to operate speed control is the guarantee to achieve prede-
under such conditions which is referred to the termined blending ratios. This can be used par-
lowest NPSH available operating point at a given ticularly for heavy oils blending with light NAFTA
viscosity. or other light hydrocarbons to produce a desired
commercial quality.
Of these variables, the relationship between
vapor pressure and temperature is the biggest An increased production of very heavy crude
element of uncertainty. Screw pumps, and in oils, bitumen, asphalt, carbon black, pitch etc. is
particular single-flow positive-displacement being supplied to the global market. Purposely
pumps are designed to operate with very low built tank terminals and pump stations are
NPSH available. The risk of cavitation, vibration required for trading these products. Centrifugal
and vapor locking is greatly reduced and the pumps cannot be used in these applications due
operator can fully exploit the inherent proper- to poor efficiencies with high viscosities and
ties of these pumps to his advantage. unpredictable operation characteristics. The
speed-controlled, single-flow screw pump as
well as the double-flow, positive-displacement
Application examples twin-screw pump are the reliable alternatives.

Loading and unloading: Author:

In tank terminals for ship loading, large volumes Thomas Talarczyk
of oil products must be transferred in the short- Director Sales Middle East
est possible time. The pumps have to be able to Leistritz Pumpen GmbH, Nürnberg
operate quickly and reliably. That is also the case
in bunker stations or bunker ships or barges. The

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 InnovatIons & trends

Photo: Clipdealer
Hygiene and processing requirements in the food and pharmaceutical sector are increasing all over the world. For some years now,
progressing cavity technology has become increasingly established in the market for conveying foodstuffs and other critical substances.

Intelligent design for hygienic pumps:

from barrel emptying systems to dosing
Rainer Gozzer

EHEDG, QHD and FDA make exact demands on machines for the food and
pharmaceutical area. These not only involve production facilities themselves,
but also all conveying systems which come into contact with the medium. So
as to make the progressing cavity pump fit for this area of application and to
bring it into compliance with the strict regulations, numerous changes have
been made to the proven design, including materials, construction and seals.
The hygienic pumps which emerged from this process have now come into use
not only purely for transporting materials, but also to take on emptying and
dosing tasks.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 pumps & systems 59

Hygiene and processing requirements in the with the media, the conically shaped stator
food and pharmaceutical sector are increasing aperture ensures consistent and complete fill-
all over the world. Many things that were previ- ing of the conveying chambers. If the uptake of
ously standard practice have now become out- material proves to be difficult in the area of the
dated in terms of the safety of consumers and stator inlet, for example due to high viscosity or
are no longer permitted. There are also ever lumpiness of the conveyor medium, the cou-
more sensitive media which have to be mixed pling rod upstream from the rotor can be fitted
together and processed. For manufacturing with conveying screws as a support measure.
industries, this also means increasing demands
on their conveying systems, which had until
now often been given little attention in compar-
ison with the production facilities. At the same For some years now, progressing cavity
time, maintenance expenditure and service life technology has become increasingly established
are nowadays crucial factors in terms of a com-
pany’s commercial efficiency, considering global
in the market for conveying foodstuffs and other
competitive pressure. In order to be able to critical substances.
tackle all three issues – hygiene, material sensi-
tivity and efficiency – pumps have now been
developed with intelligent component design
that corresponds to various task profiles, for In addition, the rotor-stator geometry can be
example both in insulin synthesis and in fruit selected to correspond to the relevant applica-
juice production. tion. The S-geometry is therefore suited to a
large inlet cross-section and low flow speeds for
compacted products or those with a proportion
Progressing cavity technology of coarse solids. On the other hand, the L-geom-
is gaining ground etry is characterised by a pitch twice as long and
thus by a significantly higher capacity. Because
After a long period when centrifugal and dia- the size of the transport chambers always
phragm pumps had controlled the market for remains the same, use of this technology means
conveying foodstuffs and other critical sub- the medium is conveyed continuously and in
stances, for some years now progressing cavity stable volumes. There is no pressure fluctuation
technology has also become increasingly estab- or backflow which could have a negative impact
lished in this area. The main reason for this is on the medium and there is hardly any occur-
particularly smooth transport, which can be rence of pulsation or shear forces either.
attributed to the special operating principle of
the progressing cavity pump. A helix rotor
rotates within a flexible, reverse-helix stator
Photo: NETZSCH

which is geometrically adapted to it. Identically

shaped conveying chambers are formed
between the two components.

As the rotor turns, it continuously conveys the

medium from the inlet to the discharge side.
The chambers are closed off by a sealing line
which is effective along the full length of the
rotor-stator combination. As a result, there is
hardly any backflow and no valves are needed to
limit the chambers.

The precise matching of the two components to

one another enables conveying chambers to
open on the inlet side between the stator and
Fig. 1: Progressing cavity technology is characterised by particularly smooth
rotor and then to move to the discharge side conveyance. In order to be able to use this in food and pharmaceutical sectors,
with the rotation. When these are being filled the pumps have now been tailored to their hygiene requirements.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 60 InnovatIons & trends

contrast, progressing cavity technology with its

Photo: NETZSCH
sealed conveying chambers enabled constant
throughput rates without any unwanted altera-
tions to the medium, even with 11 bar back
pressure.

A similar picture also emerged with biotechno-

logical insulin analogue production. There is an
ever growing need for these analogues due to
the increasing number of diabetic illnesses, but
the plate filters used in the synthesis process
present a problem for some types of pump,
because they are subject to varying differential
pressures depending on the filling level. A high
Fig. 2: In order to make the hygienically critical points at the connections of the level of stability in terms of quantities is
coupling rod less problematic, special open joints have been developed which
extremely difficult to achieve with these fluctu-
are rinsed by the medium.
ations without a uniform conveying principle
that is not dependent on pressure. However, it is
particularly important for the bacterial and
Conveying sensitive substances yeast cells with recombinant DNA used in the
under difficult conditions process to be transported to the various pro-
cessing stations with great care. Mechanical
One example of this feature being used is with a stresses, for example shear forces, could slightly
chocolate producer in Norway. The intention damage the cell walls of the cultures or even
there is to convey 25 to 40 litres of egg white per destroy them, which would make the cell mass
hour at a back pressure of 4 to 6 bar. Of the two worthless in terms of further production. The
types of geared pumps which were used on a smoothest possible conveyance is therefore
trial basis, one triggered the curdling of the egg essential, as with many other modern pharma-
white due to the friction heat on the shafts. This ceutical applications too, and this has led to one
made it unusable for processing. With the other of the largest hormone manufacturers now
model, this was in fact prevented by special using progressing cavity pumps to feed filters
shaft seals, but the pump could not build up and to transport cultures.
enough pressure due to backflow. A piston
pump was also unsuitable due to it being over-
sized and to the combination of low capacity, Optimum cleanability by avoiding dead spaces
high conveying pressure and low viscosity. In
However, in order to be approved at all for these
kinds of critical areas, pumps are subject to a
whole series of hygiene directives, from EHEDG
via the 3-A Sanitary Standard through to the
Source: NETZSCH

requirements of the US Food and Drug Adminis-

tration (FDA) and the German Federal Institute
for Risk Assessment (BfR). The food compatibil-
ity of the installed materials and the cleanability
of the design lie at the heart of all these regula-
tions. The progressing cavity pump has there-
fore been appropriately adapted for uses in
hygienically sensitive areas. A modified mechan-
ical seal housing therefore results in a huge
improvement in terms of cleaning efficiency in
the area of the seal and means the pump has no
dead spaces. In addition, attention has been
Fig. 3: The seals also are intended not to provide any contact
surface for product deposits. Mechanical seals with encapsulated
paid here to a design which optimises flow, so as
wave springs are therefore available for exacting demands. to prevent any conveyor medium remaining in

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 pumps & systems 61

this area during the production phase. For the

Source: NETZSCH
same reason, all surfaces that come into contact
with the medium are also electropolished and,
when required, achieve an average roughness of
under 0.8 microns. Even for the shaft sealing a
special seal version with encapsulated wave
spring and a completely smooth, seamless outer
contour is used if necessary, instead of conven-
tional seals with elastomer bellows and exposed
wave spring, and this enables viscous or adhe- Fig. 4: Tangential inlet and cleaning ports, along with a bypass line, enable cleaning or
sive substances to slide off easily as well. The sterilisation of the pump in accordance with CIP or SIP processes.
most suitable solution where maximum safety
is required is the use of closed double seals
which can be exposed to sterile condensate or
detector fluid, so that any possible leaks can be Tangential ports for better cleaning
seen straight away. and complete emptying

The pin joints on the end of the coupling rod, Cleaning is however not only an important fac-
which transfers the torque from the drive to the tor for the joints, but also for the pump as a
rotor, are a typical additional challenge in most whole. The systems are subjected to the CIP
cases. To prevent deposits here, an open joint (Cleaning in Place) or SIP (Sterilisation in Place)
design has been developed in-house which has processes for hygienic or aseptic cleaning. In
few seams and dead spaces and is rinsed by the order to achieve the cleaning fluid flow speed of
medium from all sides. This means the surfaces
are not only constantly rinsed during the con-
veying process, but need no external lubricant
either, thanks to lubrication via the conveyed
medium. Furthermore, the head of the coupling Gear pumps for chemical, plastics, cosmetic,
rod is provided with two flushing holes which pharmaceutical and food industries
not only improve the lubrication of the joint, but
also the efficiency when cleaning. That is
because this hole optimises the circulation of
the cleaning solution in the area of the articu-
lated joint. The joint pin itself is made a little
over long, so that the articulated joint is even
more accessible for both the medium, which
improves lubrication, and also for the cleaning
solution, which enables more thorough rinsing.
A flexible rod is offered as an alternative for
non-lubricating or abrasive media, where open
articulated joints are not possible, or for more
exacting demands right up to the aseptic area.
This is heat-shrunk with the rotor and connec-
tion point and therefore hermetically sealed. It
also includes no other parts which move against
one another, apart from the joint, which means WITTE PUMPS & TECHNOLOGY manufactures
it can work without lubrication or seals in a precision gear pumps for the plastics, chemical,
wear and maintenance-free way. Even the high- pharmaceutical, cosmetic and food industries for Esinger Steinweg 44a
over 30 years. D - 25436 Uetersen
est ambient temperatures and pressures do not
affect its functionality. Both the pin and hygiene Tel.: + 49 (0) 41 22/92 87-0
Many years of experience and an optimal choice of
Fax: + 49 (0) 41 22/92 87-49
joint meet the requirements of the 3-A Sanitary materials make our pump series BOOSTER, CHEM, [email protected]
Standard. POLY and EXTRU so successful and reliable. www.witte-pumps.de

Our core business are not only tailor-made special

solutions for specific customer requirements, we also
offer a range of standard pumps.

WITTE also provides comprehensive service

packages for gear pumps from other manufacturer.
 62 InnovatIons & trends

mated replacement intervals of one stator and

Photo: NETZSCH
one and a half rotors per year and pump. In fact,
it has been demonstrated that the stators can
run for around five years, and the rotors even for
ten years, without any significant signs of wear.

Versatile applications for the hygienic pump

The special conveying technology of hygienic

pumps makes them suitable for a wide range of
different media, from shear-sensitive, adhesive
or highly abrasive materials to low and high-vis-
Fig. 5: When fixed vertically cosity materials. The pump housing and stator
and provided with a suitable can also be provided with a heating or cooling
follow plate, the hygienic
pump can also be used for
jacket, if this is necessary for the flow character-
barrel emptying. istics or to protect the medium for technical pro-
cessing reasons. To prevent damage to the sta-
tor due to dry running, there are in addition
optional stator protectors which use one or two
at least 1.5 m/s required through the whole sys- thermal sensors to register rising friction heat in
tem during the CIP process, the progressing cav- good time when there is unauthorised opera-
ity pumps are also fitted with additional tan- tion without any medium, and switch the sys-
gentially arranged cleaning ports and equipped tem off. Depending on the space available and
with a bypass line. In the context of reworking requirements for incorporation into the produc-
the design, the vertical inlet ports on the pump tion process, the pump is made in a block design
housing have also been positioned tangentially with a flange-mounted motor or with a bearing
for technical flow optimisation, which means it housing. It is manufactured and tested in
has been possible to achieve a huge increase in accordance with both EHEDG and QHD direc-
cleaning efficiency. The cleaning port also ena- tives and fulfils the international requirements
bles complete emptying of the system. This is of the American 3-A Sanitary Standard as well
because its tangential position prevents any as the Russian GOST-R. All materials are
rinsing water remaining in the pump housing approved according to FDA specifications.
after cleaning has finished. The eccentrically
positioned end connection on the stator side Because hygienic pumps can be used vertically
also contributes to this. This design means the as well as horizontally and can also provide suc-
rinsing water can flow out of the pump housing tion through to the creation of a vacuum, you
unhindered, without leaving any residue. can also use the model in designing a barrel
emptying system for foods and other sensitive
It is not just a case of the pump materials need- substances. Barrels, particularly those with a
ing to be tailored to the conveyed medium, the low viscosity content, are usually clamped in a
cleaning temperatures and cleaning solutions tilting unit and emptied into the conveying sys-
which are needed, depending on the applica- tem or a collector tank via a hopper. The fasten-
tion, have to be taken into account in the choice ing and pivoting of the barrels, which are often
of materials as well. The example of insulin syn- heavy, involve a certain amount of effort, but
thesis, where diluted sodium hydroxide and above all it is impossible to guarantee that the
phosphoric acid are used for flushing in addition product is free of contamination during this
to deionised water, shows how high the mate- open decanting process. Air pockets, dust and
rial stress can be here. Stainless steel compo- even insects can easily get into the medium.
nents and particularly robust elastomers have
been fitted, which nevertheless comply with the
FDA directives. This choice has enabled service
lives to be achieved which, in spite of the aggres-
sive cleaning, are still above the originally esti-

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 pumps & systems 63

Contamination and almost residue-free as the sensors report the emptying of one bar-
barrel emptying rel, suction automatically switches to the sec-
ond, while the first is changed.
In order to avoid this and to ensure extensive
usage of all the medium deployed, the hygienic
barrel emptying system works with a follow Fast processing of larger barrels too
plate made of polished stainless steel. This is
selected according to the size of the barrel and is Users of this technology include a Swedish pro-
surrounded by a joint seal made of FDA-compli- ducer of bakery products which procures fruit
ant elastomer, which means it seals the barrel jelly in barrels to decorate cakes and similar
during the discharge process and prevents the items. So that it has the required malleable con-
ingress of impurities. The plate is fitted to the sistency suitable for spraying, the mass must be
inlet ports of a vertically installed hygienic pressed through a filter using a special machine.
pump and this creates a vacuum in the con- Until now this had been filled by hand, with
tainer after it is switched on. As a result of the workers pouring the heavy 20-litre buckets into
vacuum generated, the design automatically the device manually. The hygienic barrel empty-
provides suction towards the bottom of the bar- ing system means this effort is no longer
rel, whereby the follow plate sits on the medium needed, as the fruit purée is cleanly transported
and this prevents any air pockets. At the same to the system via a pipe. In addition, the com-
time, the medium is gently pushed into the inlet pany can in future procure the raw material in
port to ensure continuous emptying. The con- more efficient 200-litre drums, which it would
tent is almost completely discharged using this
method, with a residue amounting merely to
around one percent remaining in the barrel. The
sealed follow plate, used as a protection against
contamination, also improves the usability of
the product deployed and reduces the effort
involved in cleaning the barrels. In particular,
the wall is already pre-cleaned thanks to the
flexible levelling collar.

The apparatus itself – like the pump – can also Innovative Coolant Pumps for
be quickly cleaned, because the design is kept Various Applications
very lean overall, and only a very small number
© iStockphoto

of individual parts are fitted. The outer compo-

nents can easily be removed for cleaning, as
they are fixed on with connecting clamps.
Thanks to the compact design, the emptying
system is also suitable for mobile use and can
easily be transported to the relevant application
site on rollers. The systems can be controlled
using various input methods, from the classic
start-stop switch to the modern touch panel,
which clearly shows all the device parameters as
well as the control functions. Even integration www.brinkmannpumps.de

into an automated processing line is possible.

The barrel emptying system’s special sensor  Machine Tool Coolant Supply by Medium and
High Pressure Pumps
technology comes into play here: sensors on the
 Chip Handling with Lifting and Cutter Pumps
pneumatic cylinders recognise when the fill
 Plastic Pumps for Water Applications
level is approaching zero and interrupt the suc-
 Immersion and Miniature Centrifugal Pumps
tion before dry running can occur. Twin systems, for Temperature Control
each for two containers, also use this monitor-
ing option to minimise the interruption of con-
veyance as a result of changing barrels. As soon

BRINKMANN PUMPEN Tel. +49 2392 5006-0

K.H. Brinkmann GmbH & Co. KG [email protected]
 64 InnovatIons & trends

A manufacturer with these types of filling lines

Photo: NETZSCH
has therefore switched their products to suction
via progressing cavity technology and inte-
grated a system which achieves a throughput
rate of 11.6 cubic metres per hour with a pres-
sure of up to twelve bar. The emptied containers
can be replaced easily and quickly by full ones
via a roller conveyor, so that users can empty an
average of one barrel a minute with it. Barrel
emptying systems are generally suitable for
containers from 0.5 to 200 litres, with special
customised models having also been developed
for up to 1,000 litres. The standard range of pos-
sible conveyance rates goes from six millilitres a
minute to ten cubic metres an hour.
Fig. 6: The plate provides airtight sealing of the barrel and prevents contamination.
At the same time, the pump automatically moves downwards due to the vacuum
generated during the emptying process.
Dosing proportional to speed

An additional advantage of emptying using the

progressing cavity principle is that you can dose
have been impossible to handle with the old directly from the barrel. The reason for this is
process, instead of in small 20-litre barrels. In conveyance between rotor and stator in identi-
order to make the switch easier, the emptying cally shaped chambers, which means the quan-
equipment was provided with an adapter, which tity of the transported packages of medium is
both sizes of follow plates can fit onto. only dependent on speed and can be continu-
ously adjusted using this. The maximum dosing
Another application is fruit juice filling. This tra- accuracy of barrel emptying systems is therefore
ditionally works with expensive tipping sys- between three and five percent. For even higher
tems, which do not completely empty the bar- levels of accuracy, you can connect more pro-
rels either and thus make it necessary to carry gressing cavity pumps with smaller chamber
out time-consuming subsequent cleaning. volumes right through to dispensers, which
achieve a volumetric accuracy of one percent
from 90 degree rotor rotation – but also only
convey a half to ten millilitres per revolution.
Photo: NETZSCH

With these models, a universally adjustable

retraction system prevents any falsification of
the quantity through subsequent dripping.

Dosing proportional to speed for instance helps

with the production of mayonnaise, as the addi-
tion of oil must at all times be precisely adjusted
to the existing oil-water ratio in this process.
Even the smallest errors in composition would
otherwise make the sensitive emulsion unsta-
ble. Very precisely measured doses of oil are
therefore transported to the mixing container
using a progressing cavity pump.

Fig. 7: Where robustness or high pumping capacity is

required in a limited space, the hygienic version of the
rotary lobe pump represents a sensible alternative to the
progressing cavity pump.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 pumps & systems 65

Hygienic rotary lobe pump

Source: NETZSCH
for special requirements

In very confined spaces, the long form of the

progressing cavity pump does however have its
limitations. Another displacement pump with a
more compact design, the rotary lobe pump, is
offered as an alternative and there are also
hygienic versions of this available. These are also
suitable for a multitude of different materials,
including shear-sensitive, thixotropic and
high-viscosity types. They work reliably over a
wide range of temperatures in this area and
achieve throughput rates of up to 150 cubic
metres an hour. As a rule, tri-lobe or four-lobe
Fig. 8: Thanks to its large free ball passage, the rotary lobe pump can also transport
rotors are fitted here, so as to keep unwanted whole fruits without any damage.
pulsation effects to the minimum possible level
and to protect the medium. Nevertheless, the
free ball passage between the rotary lobes,
which rotate in opposite directions, is wide
enough for larger objects, such as pieces of fruit double-acting mechanical seals can also be
for example, to pass through undamaged and used in different versions. The housing port is
without any risk of clogging. The shaped intake attached directly on top without any dead
aperture improves the flow of the product as it spaces, which means deposits during convey-
comes into the pump chamber, and an inlet ance are avoided. For residue-free self-empty-
with an enlarged cross-section can also be used ing, the installation direction of the pump can
if required for high-viscosity media. be turned through 90 degrees, so that the con-
nections are positioned vertically above one
The compact design of the rotary lobe pump another. In general, the hygienic rotary lobe
means it fits into small spaces and can easily be pump is designed for CIP and SIP processes in
taken from one application to another as a terms of construction and materials and it can
mobile model on a hand trolley or its own chas- even be used itself to generate the cleaning
sis. In addition, importance was attached to a fluid flow speeds required for these, thus being
high level of robustness in the design. The gear able to act as both a conveying pump and a
box housing is therefore made of grey cast iron cleaning pump.
and the shafts are carried by tapered roller bear-
ings which have a high concentricity tolerance Author:
and can withstand severe stress. A timing gear is Rainer Gozzer
used to synchronise the rotary lobes and its hel- Manager Business Field Food & Pharmaceutical
ical gearing guarantees optimum positioning of NETZSCH Pumpen & Systeme GmbH,
the rotary lobes with respect to one another, Waldkraiburg
and so ensures low-noise, low-friction and
low-vibration operation. The physical separation
of the pump chamber and gear box excludes a
complete write-off of the system due to leakage.

To make cleaning easier, the housing cover can

be removed, which then means that the rotary
lobes and shaft seals are easily accessible. Even
replacement is easy to carry out, because nei-
ther the housing nor the pipes need to be disas-
sembled to do this. Single mechanical seals
which are not dependent on the direction of
rotation are normally used as shaft seals, but

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 66 Products & APPLIcAtIoNs

Read more in our online magazine

under www.vdmashop.de/puco

The sixth edition of “Pumps and Compressors for the World Market”
in 2014 strikes a new course: Together with the magazine you hold
in your hands, if you go to www.vdmashop.de/puco, you will find
our first E-Magazine with additional features. The heading
“Products & Applications” provides a user-oriented look at the
latest technical developments, trends and products in the respective
branches – as a brief summary in the printed version and in greater
detail in the E-Magazine with in-depth information about the
respective topics. The flags indicate the languages in which the
articles are available.

LEWA develops high-pressure

KSB Aktiengesellschaft: micro metering pump
New zero-leakage refinery pump Metering tasks in laboratories demand highest
In early September 2013, KSB Aktiengesell- precision when hazardous fluids are used.
schaft, Frankenthal, Germany, launched a Plunger pumps can handle high pressures, but
zero-leakage mag-drive pump series in back- the piston seal leaks. This problem is solved by
pull out design: RPHmdp. The horizontal, LEWA intellilab, a hermetically sealed high
radially split volute casing pump to US standard pressure micro-metering pump with the
API 685 has been developed to reduce mainte- mechatronic drive technology.
nance costs and ensure a maximum service life.
www.lewa.de
www.ksb.com

Read more in our online magazine under www.vdmashop.de/puco • Read more in our online magazine under www.vdmas
 pumps & systems 67

Read more in our online magazine

under www.vdmashop.de/puco

Sterling SIHI GmbH: ANDRITZ Ritz: Energy efficient pumps

Online condition monitoring help to save energy
Considering the life cycle cost of pumps, it For RWE, using electricity efficiently and
becomes obvious, that cost for maintenance responsibly is a high priority. The pumps used
and repair – beside energy cost – are offering for mine drainage in lignite open-cast mines
the biggest potential for savings. Hence it are gradually being replaced with more energy
should be aimed to reduce the repair and efficient models. Developed by ANDRITZ Ritz,
maintenance cost and in addition to avoid cost new, highly efficient submersible motor pumps
for production downtime by utilisation of with PEM technology allow significant annual
efficient and intelligent condition monitoring energy savings.
systems.
www.andritz.com
www.sterlingSIHI.com

ProMinent: Energy efficient

Impeller cutterpump SZcut and safety conscious
from Schmalenberger The completely redesigned product range of
The patended pump SZcut reliably suctions motor driven metering pumps Sigma control
chip material and coolant, crushing the chips type set new complete new benchmarks: Their
during this process. The mixture is then precise and requirements-controlled metering
pumped to a filtersystem where the chips and serves to reduce the consumption of chemicals
coolant are separated and delivered to their to a minimum. Safety and efficiency are not
respective destinations. The cutterpump SZcut only options. It is a feature of the standard
is utilised in chip processing specially developed equipment.
for plant manufacturers and users.
www.prominent.com
www.schmalenberger.de

shop.de/puco • Read more in our online magazine under www.vdmashop.de/puco • Read more in our online magazine unde
 68 Products & APPLIcAtIoNs

Read more in our online magazine

under www.vdmashop.de/puco

Wilo in building services:

High-efficiency pumps for every need
A long service life and energy efficiency – these
HERMETC-Pumpen: are the most important criteria for investors,
“Russian oil and gas industries’ consultants and installers when selecting
best centrifugal-pump manufacturer pumps applied in building services. The pump
for 2013” expert WILO SE offers “everything from one
HERMETIC-Pumpen GmbH was recognised source”: Its particularly energy-saving product
with the “Russian oil and gas industries’ best range covers all areas – ranging from the
centrifugal-pump manufacturer for 2013” single-family house to large buildings.
award during the NefteGasPererabotka
www.wilo.com
conference for Russian refineries. The award
was presented recently in Moscow and is the
result of an independent survey involving 60
Russian refineries.

www.hermetic-pumpen.com

NeoMag®:
Energy-efficient centrifugal pump
The new NeoMag® is an especially cost-effec-
tive magnetically coupled centrifugal pump.
A new range of double volute twin The NeoMag® pump is high-performance,
screw pumps from Klaus Union reliable in operation, and is designed for
Klaus Union is well known as one of the world’s universal use. With this pump, users can
leading manufacturers of magnet driven and achieve energy savings of up to 30 % as
conventionally sealed centrifugal pumps. compared to conventional models.
Since 2013, Klaus Union’s product portfolio has
www.neomag-pump.com
been complemented with a range of rotary
positive displacement pumps.

www.klaus-union.com

Read more in our online magazine under www.vdmashop.de/puco • Read more in our online magazine under www.vdmas
 pumps & systems 69

Read more in our online magazine

under www.vdmashop.de/puco

Uraca:
Most efficient marathon runners
URACA high pressure pumps are designed in
HAMMELMANN: compliance with API 674 for pumping toxic and
VARIABLE-STROKE plunger pump flammable fluids at continuous operation. The
With the HDP20V Hammelmann introduces a particular advantage of these pumps is the
new adjustable stroke triplex pump with a high and constant volumetric efficiency
maximum power rating of 20 kW to the market. allowing economical operation, independent
This new pump enables precise metering of from flow rate and operating pressure.
fluids at pressures up to 3,000 bar and flow rates
www.uraca.de
up to 6 m³/h.

www.hammelmann.com

FELUWA delivers the first set

KTR Kupplungstechnik GmbH of gearboxes of the advanced
Our product managers provide for customised TGK 500/400 series
advisory service and detailed support with the FELUWA supplied seven MULTISAFE double
selection of the optimum coupling. The product hose-diaphragm pumps of the advanced TGK
portfolio covers a wide range of compact and 400-3DS230 series with reinforced triplex
maintenance-free, torsionally flexible or stroke gears. The new gear generation achieves
torsionally rigid couplings on every kind of an increase in performance of more than 25 %
pumps for fluid or gaseous media. for high pressure pumps with the same
footprint and thus provides an enormous
www.ktr.com
increase in efficiency to the customer.

www.feluwa.de

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 70 COMPANIES & RANGE OF APPLICATIONS

Applications
Pumps &

Groundwater conservation/lowering

Drainage, irrigation, lifting stations

Nuclear power station technology

Water supply/wastewater disposal
Systems

Swimming-pool technology
Sewage treatment plant

Seawater desalination
Construction industry
Sewage engineering

Overhead irrigation

Hygiene/cleanliness

Dosing technology

Beverage industry
Water treatment
Reverse osmosis
Cellar drainage

Mine drainage

Food industry
Water supply

Biochemistry

Odorisation
Agriculture

Laboratory
Cosmetics
Deep well
Irrigation

Drainage

Fountain

Injection
Brewery
Garden

Dairy
Well
ABEL GmbH & Co. KG
l l l l l l
www.abel.de
Alltech Dosieranlagen GmbH
l l l l l l l l l l l l l l l l l
www.alltech-dosieranlagen.de
ALLWEILER AG
l l l l l l l l l l l l l l l l l l l l
www.allweiler.de
ANDRITZ Ritz GmbH
l l l l l l l l l l l l l l l l l l l
www.andritz.com
Apollo Gößnitz GmbH
l l l l l l l
www.apollo-goessnitz.de
Beinlich Pumpen GmbH
l l l l l l l
www.beinlich-pumps.com
bielomatik Leuze GmbH + Co. KG
www.bielomatik.de
ITT Bornemann GmbH
l l l l l l l l l l l l l
www.bornemann.com
Brinkmann Pumpen K.H. Brinkmann GmbH & Co. KG
l l l l
www.brinkmannpumps.de
Paul Bungartz GmbH & Co. KG
www.bungartz.com
CP Pumpen AG
l l l l l l l
www.cp-pumps.com
Crane Process Flow Technologies GmbH
l l l l l l l l l l l l l l
www.cranechempharma.com
DELIMON GmbH
l l l l
www.bijurdelimon.com
Deutsche Vortex GmbH & Co. KG
www.deutsche-vortex.de
DIA Pumpen GmbH
l l l l l l l l l l l l l l l l l
www.dia-pumpen.de
Dickow Pumpen KG
l l
www.dickow.de
Düchting Pumpen Maschinenfabrik GmbH & Co. KG
l l l
www.duechting.com
EDUR-Pumpenfabrik Eduard Redlien GmbH & Co. KG
l l l l l l l l l l l l l l l l l
www.edur.com
FELUWA Pumpen GmbH
l l l l l l l l l l l l l l l l l l
www.feluwa.com
FRIATEC Aktiengesellschaft – Division Rheinhütte
l l l l l l l l l l l l
Pumpen / www.rheinhuette.de
FRISTAM Pumpen KG (GmbH & Co.)
l l l l l l l
www.fristam.de
Gather Industrie GmbH
l l l l l l l l l l l l l
www.gather-industrie.de

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 l
l
l
l
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Pharmaceutical industry

l l
Sample taking

l l l
l l l
l
l l l
l
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Sterile technology
Industry-/chemical industry processes

l
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Tank, container, barrel

l l
l
l
l
l
l
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Chemical industry

l
l l
l l l
l l l
l l
l l
l l
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Draining
Gas dehydration

l l
Gas washer

l
l
l
l

l
l l l l l
Industrial technology

l l
l l
l l
l
Surface treatment

l
l
l l l
Steel construction and vehicle construction industries

l
l
Stone, earth and glass industries

l
l
l
Storage tank installation

l l
l l
Textile industry

l l l
l l l l l l l l l l l l
l l l l l l l
l l l l l l l l l l l l
l l l l l l l
l l l l l l l l
l l l l
l l l l l l l

l l l
l l
l
l
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l l l
l l
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Environmental technology
Building applications; heating and cooling

l
l
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Pressure boosting

l l
Fire-fighting system

l
l
l l l
l l l
Building controls and systems

l l
Heating technology

l
Refrigeration and air-conditioning engineering

l l l l l l

l l
l
l
l
l l l l l l

l l
Heat-transfer technology
Energy generation

l
l
l
Energy engineering

l l
District heating

l
Firing technology
Geothermics
Prime movers

l l l l l l
l l l l l l
l l
Power station technology

l l
l l
l l
l l
l l

l
l l l
l l
l l
l l

Flue gas purification

Petrochemical; Oil

l
l
l
Oil and petrochemical industry

l l

l l
l l
l l
l l
l l
l l
l
l l

l l
Off-shore technology
Mining; Metallury and rolling technology

l
Mining
l l

Iron and steel industry

l l l

l l l
l l l
l l l
l l
l l l
l l l
l l l
l

l l l
l l l

Rolling-mills
Chemical engineering/Process technology
l

l
l

l
l
Process engineering

l l

l l
l l
l l
l l
l l
l l
l l

l l
l l
l l
l l
l l

Sugar industry
Oil supply/Hydraulics
Lift manufacturing

l
Oil hydraulics
l
l l l

l
l

Centralized lubrication system

pumps & systems

Testing

l
l

Hydrostatic (pressure) test

Cleaning
71

l
l
l
l

High-pressure cleaning
Pulp and Paper

l
l

l
l
l
l
l
l

l
l

l
l
l

Paper and cellulose industry

Marine, shipyard technology

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
l
l
l

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l
l

l
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l
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Marine, dockyard
 72 COMPANIES & RANGE OF APPLICATIONS

Applications
Pumps &

Groundwater conservation/lowering

Drainage, irrigation, lifting stations

Nuclear power station technology

Water supply/wastewater disposal
Systems

Swimming-pool technology
Sewage treatment plant

Seawater desalination
Construction industry
Sewage engineering

Overhead irrigation

Hygiene/cleanliness

Dosing technology

Beverage industry
Water treatment
Reverse osmosis
Cellar drainage

Mine drainage

Food industry
Water supply

Biochemistry

Odorisation
Agriculture

Laboratory
Cosmetics
Deep well
Irrigation

Drainage

Fountain

Injection
Brewery
Garden

Dairy
Well
GEA Tuchenhagen GmbH
l l l l l l
www.tuchenhagen.de
GEA Wiegand GmbH
l l l l
www.gea-wiegand.de
GRUNDFOS GMBH
l l l l l l l l l l l l l l l l l l l l l l l l l l l
www.grundfos.de
A. Habermann GmbH & Co. KG
www.habermann-gmbh.de
Richard Halm GmbH & Co. KG
www.halm.info
Hammelmann Maschinenfabrik GmbH
l l l l l l
www.hammelmann.com
Hauhinco Maschinenfabrik G. Hausherr,
l l l
Jochums GmbH & Co. KG / www.hauhinco.de
Herborner Pumpenfabrik J.H. Hoffmann
l l l l l l l l l l l l l
GmbH & Co. KG / www.herborner-pumpen.de
HERMETIC-Pumpen GmbH
l l l l l
www.hermetic-pumpen.com
HNP Mikrosysteme GmbH
l l l l l l l
www.hnp-mikrosysteme.de
HOMA Pumpenfabrik GmbH
l l l l l l l
www.homa-pumpen.de
Iwaki Europe GmbH
l l l l l l l l l l l l l l l l l l
www.iwaki.de
Jung Pumpen GmbH
l l l l l l l l l l l l l l
www.jung-pumpen.de
KAMAT Pumpen GmbH & Co. KG
l l l l l l l l l l
www.kamat.de
Klaus Union GmbH & Co. KG
l l l l l
www.klaus-union.de
KNF Neuberger GmbH
l l l l l l l l l
www.knf.de
Körting Hannover AG
l
www.koerting.de
KRACHT GmbH
l l
www.kracht.eu
KSB Aktiengesellschaft
l l l l l l l l l l l l l l l l l l l l l l l l l l l l
www.ksb.com
LEISTRITZ Pumpen GmbH
l
www.leistritz.com
LEWA GmbH
l l l l l l l l
www.lewa.de
Lincoln GmbH – Lincoln is an SKF Group Brand
l l l l l l l
www.lincolnindustrial.de

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 l
l
l
l
l
l
l
Pharmaceutical industry

l l
l l
Sample taking

l
l l l
l
l
Sterile technology
Industry-/chemical industry processes

l
Tank, container, barrel

l
l
l
l l
l
l
l
l l
l
Chemical industry

l
l l
l l l
l l
l
l l l
l l
l l
l l
Draining

l
Gas dehydration

l
l
l
l l
l
Gas washer

l
l
l l
l
l
l
Industrial technology

l
l
l
Surface treatment

l l l
l

l
l
l
l l
Steel construction and vehicle construction industries

l l
l l l l
l l l l
l l
Stone, earth and glass industries

l
l
Storage tank installation

l
l l
l
Textile industry

l l
l l
l l l l l l l l

l
l l
l l
l
l

l
l
l

l
l
l
Environmental technology
Building applications; heating and cooling

l
l
Pressure boosting

l l
l
Fire-fighting system

l
l
l
Building controls and systems
Heating technology

l
l
l l l l l

l l
Refrigeration and air-conditioning engineering

l l l l l l
l l
l l
l l
l
Heat-transfer technology
Energy generation

l
l

l
l
l
Energy engineering

l l
l
District heating
Firing technology

l
l
l

l
l
l
l
Geothermics
Prime movers

l
l

l
l l
l
l
Power station technology

l l
l l
Flue gas purification
Petrochemical; Oil

l
l

l
Oil and petrochemical industry

l l l l l

l
l l

l l
l l
l l
l l
l
l l
l l
l
l l

Off-shore technology
Mining; Metallury and rolling technology

l
l
Mining
Iron and steel industry

l l l
l l l

l
l l l
l l l
l l l

Rolling-mills
Chemical engineering/Process technology

l
l

l
l

l
l

Process engineering

l l l l l l

l l
l
l l

l l
l l
l l
l l
l l
l l

Sugar industry
Oil supply/Hydraulics
Lift manufacturing

l
l
l
l

Oil hydraulics

l
l l
Centralized lubrication system
pumps & systems

Testing
l
l

l
l
Hydrostatic (pressure) test
Cleaning
73

l
l
l
l

High-pressure cleaning
Pulp and Paper

l
l
l

l
l
l
l
l

l
l
l
l
l
l

Paper and cellulose industry

Marine, shipyard technology

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
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l
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Marine, dockyard
 74 COMPANIES & RANGE OF APPLICATIONS

Applications
Pumps &

Groundwater conservation/lowering

Drainage, irrigation, lifting stations

Nuclear power station technology

Water supply/wastewater disposal
Systems

Swimming-pool technology
Sewage treatment plant

Seawater desalination
Construction industry
Sewage engineering

Overhead irrigation

Hygiene/cleanliness

Dosing technology

Beverage industry
Water treatment
Reverse osmosis
Cellar drainage

Mine drainage

Food industry
Water supply

Biochemistry

Odorisation
Agriculture

Laboratory
Cosmetics
Deep well
Irrigation

Drainage

Fountain

Injection
Brewery
Garden

Dairy
Well
Maag Pump Systems GmbH
www.maag.com
Mahr Metering Systems GmbH
l l l l l
www.mahr.de
MATO Maschinen- u. Metallwarenfabrik
Curt Matthaei GmbH & Co. KG / www.mato.de
Munsch Chemie-Pumpen GmbH
l l
www.munsch.de
NETZSCH Pumpen & Systeme GmbH
l l l l l l l l l l l l l l l
www.netzsch-pumpen.de
Nikkiso-KSB GmbH
www.nikkiso-ksb.com
oddesse Pumpen- und Motorenfabrik GmbH
l l l l l l l l l l l l l l l l l l l l l l
www.oddesse.de
Oerlikon Barmag, Zweigniederl. der Oerlikon Textile
l l l l
GmbH & Co. KG / www.barmag.oerlikontextile.com
ORPU Pumpenfabrik GmbH
l l l l l l l l l l l l
www.orpu.de
OSNA-Pumpen GmbH
l l l l l l l l l l l l l l l
www.osna.de
PCM Deutschland GmbH
l l l l l l l l l l l l l l
www.pcm.eu
PF Pumpen und Feuerlöschtechnik GmbH
l l l l l l l l l l l
www.johstadt.com
Ponndorf Gerätetechnik GmbH
l l l l l l l l l l l l
www.ponndorf.de
ProMinent Dosiertechnik GmbH
l l l l l l l l l l l l l l l l l l l l l l l l l l l l
www.prominent.com
Pumpenfabrik Wangen GmbH
l l l l l l l l l l l l l l l l l
www.wangen.com
Putzmeister Solid Pumps GmbH
l l
www.pmsolid.com
REBS Zentralschmiertechnik GmbH
www.rebs.de
Richter Chemie-Technik GmbH
l l l l l l
www.richter-ct.com
Rickmeier GmbH
www.rickmeier.de
Ruhrpumpen GmbH
l l l l l l
www.ruhrpumpen.de
Pumpenfabrik Ernst Scherzinger GmbH & Co. KG
l l l
www.scherzinger.de
Schäfer & Urbach GmbH
www.schaefer-urbach.com

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 l
l
l
l
Pharmaceutical industry

l l
l l
l l
Sample taking

l l l
l
Sterile technology
Industry-/chemical industry processes

l
Tank, container, barrel

l
l
l
l l
l
l
Chemical industry

l l
l l l
l l l
l l l
l l
l l l
l l l
l l l
l l
l l l
Draining
Gas dehydration
Gas washer

l
l
l
l
l
l

l
l
Industrial technology

l
Surface treatment

l
l l l
l
l l l
l l l l
l l
Steel construction and vehicle construction industries

l l l l l l l l l
l l l l

l
Stone, earth and glass industries

l
l

l
l
l
l
l
Storage tank installation

l
Textile industry

l
l l l l l l l
l l
l l
l l l
l l

l
l
l
l
l
l
l
l
l
l
l l l
Environmental technology
Building applications; heating and cooling

l
l
Pressure boosting

l
Fire-fighting system

l l l
l
l l l
Building controls and systems
Heating technology

l l l
Refrigeration and air-conditioning engineering

l l l l
Heat-transfer technology
Energy generation

l
l

l
l
Energy engineering

l
l l
District heating

l
Firing technology

l
l
l

l
Geothermics

l
Prime movers

l
l
l
Power station technology

l l
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Flue gas purification
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 Photo: Atlas Copco
Energy generation from geothermal sources relies on generator-loaded, multi stage – in this case two stages – integrally
geared expansion turbines (Shown here: Geothermal power plant outside the town of Pamukören, Turkey).

Radial turbines for energy generation from

geothermal resources or waste heat recovery
Prof. Dr. Pall Valdimarsson and Dipl.-Ing. Markus Sauerborn

The implementation of sustainable solutions is becoming a

major focus of mechanical engineering. This emerging trend
is also reflected in the growing number of geothermal power
plants. From a market perspective, we are seeing a major push
towards geothermal resources with low enthalpy. The key
technology for unlocking these power sources is the Organic
Ranking Cycle (ORC), a process in which turboexpanders generate
electricity from working fluids other than water vapour. In terms
of engineering, ORC-based processes rely on turboexpanders
with a radial turbine design.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 COMPRESSORS, COMPRESSED AIR & VACUUM TECHNOLOGY 79

Geothermal energy – Organic Rankine Cycle – unlocking geothermal

renewable energy source with future potential resources with low enthalpy

Heat from geothermal resources is considered a One of the key technologies behind the growth
renewable and clean energy source. The world’s of the geothermal energy market is the Organic
first geothermal power plant was built in 1913 Rankine Cycle (ORC). This thermodynamic pro-
in the Tuscan town of Lardarello, Italy. Today, cess allows for generating electricity from heat
installed capacity of global geothermal energy sources, in which the temperature gradient
generation has grown to 11 GW. Major drivers between heat source and heat sink is too low for
behind the exploration of geothermal energy powering a traditional condensing steam tur-
generation are measures to halt climate change bine. However, using ORC technology as an
and related efforts towards the reduction of alternative also requires higher investments.
greenhouse gases. Since high-enthalpy geother- The current installed base of ORC-driven power
mal resources in close proximity to metropoli-
tan areas are, for the most part, already being
leveraged for energy production, the market is
increasingly focused on low-enthalpy resources. When it comes to energy production from
Faced with rising market prices for renewable geothermal heat sources, the market is increasingly
energies, companies are willing to make larger,
focused on low-enthalpy resources.
more targeted investments, mobilizing larger
technology budgets in the process.

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 80 InnovatIons & trends

costly working fluid presents a more economical

Source: Atlas Copco

choice. Low-cost options include hydrocarbons
such as those used in cigarette lighters. But
since carbon hydrides are highly flammable,
their usage in power plants is subject to strict
safety guidelines, on par with those applicable
to petrol stations.

Overall, the selection of the working fluid should

match the thermodynamic properties of the
heat source, as well as the geographical location
of the power plant.

Fig. 1: Basic ORC process for geothermal applications The ORC process for geothermal applications

In an ideal geothermal power plant process

(Fig.1), heat is applied to the working fluid inside
plants is at 1.2 GW worldwide, spread across the preheater and evaporator. Due to the sub-
approximately 240 facilities. cooled condition of the working fluid upon exit-
ing the condenser and the rise in pressure in the
working fluid pump, the working fluid tempera-
The ORC process – ture will initially rise until reaching the boiling
choosing the alternative working fluid point (sensible heat). During vaporization, the
supply of heat continues, while the working
Technically speaking, the ORC process is based fluid temperature remains stable (latent heat
on a steam power cycle according to Clausi- during phase transition). After the rest of the liq-
us-Rankine. But instead of water, the ORC relies uid is evaporated, the temperature of the work-
on organic working fluids chosen in accordance ing fluid rises once again.
to the temperature conditions at the respective
geothermal heat source. Another major factor During the process design stages, the ratio of
for selecting the working fluid is its sustainabil- sensible to latent heat can be adjusted to condi-
ity. For instance, operating a geothermal power tions at the heat source: The closer the boiling
plant in densely populated areas with high elec- pressure of the working fluid is to its critical pres-
tricity costs calls for a non-flammable, rather sure, the smaller the share of latent heat.
costly working fluid. In regions with low popula- Pre-evaluation of the heat source calls for a num-
tion density and lower costs of electricity, a less ber of observations. In case the heat source is
available in liquid state only, its temperature will
fall due to heat extraction in the pre-heater and
evaporator. But, if the heat source is also partially
supplying vapour or non-condensable gases,
Source: Atlas Copco

both the cycle and the working fluid need to be

geared towards a larger share of latent heat.

The ORC process

for waste heat recovery applications

Energy generation from waste heat – also

known as waste heat recovery – with an ORC
process is similar to the design of geothermal
power plants. Practical applications include
waste heat from gas turbines or incineration
Fig. 2: Basic ORC process for waste heat recovery applications engines, as well as processes during which heat

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 COMPRESSORS, COMPRESSED AIR & VACUUM TECHNOLOGY 81

is released as a waste product, e.g. cement man- design from a turbocompressor, the main differ-
ufacturing. Due to the comparatively high tem- ence lies in the direction of power transfer: In a
perature levels at the heat source, heat transfer compressor, power is transferred from the drive
from the source passes through a conducting shaft to the flow (turbo working machine),
medium, for instance a heat transfer oil that while in an expansion turbine, power is trans-
passes on the heat to the ORC process (Fig.2). ferred from the flow to the blade row (turbo
Also due to the high level of heat at the source, power machine).
power generation from waste heat is also suita-
ble for so-called trans-critical ORC processes. In The Euler turbine equation relates the power
these processes, the high pressure side exceeds transferred between the flow and blade row by
the critical pressure of the working fluid. During means of angular velocity, direction change of
heat transfer, the working fluid does not fluids’ tangential velocity and the geometry of
undergo a phase change by means of condensa- the turbine.
tion, but a continuous change in density instead.

Radial expansion turbines –

perfectly suited for ORC processes

Both the geothermal and waste heat recovery

ORC process rely on radial expansion turbines.
While an expansion turbine, also called a turbo-
expander, hardly differs in terms of its basic

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 82 InnovatIons & trends

ing edge of the rotor blade is kept correct, even if

Source: Atlas Copco

the flow changes (for instance, minimum inci-
dence angle). The turbine rotational speed can
be used as a constant controlled variable.
Thereby, the performance curve of a genera-
tor-braked radial turbine in terms of a constant
isentropic efficiency and rotational speed across
the entire performance map can be considered
optimal. The efficiency performance curve only
decreases slightly under off-design conditions.
Therefore, radial turbine design is an excellent
match for the requirements of an ORC-based
power plant.

The technology is also perfectly suited for cli-

Fig. 3: Main components of an expansion turbine mate zones with considerable seasonal varia-
with radial inflow design tions in ambient temperature, leading to devia-
tions in condensing pressure in facilities where
air-cooled condensers are used. Another usage
scenario includes block heat and power plants
The amount of power transferred is determined with combined heat and power (CHP) genera-
by the tangential velocity and flow radius at the tion, in which the amount of heat used to gener-
inlet and outlet of the turbine. Flow capacity at ate electricity is reduced during the cold season
turbine inlet is limited by the speed of sound. In in favour of direct injection into the district
order to optimise performance, the inlet radius heating grid.
should be designed at a larger size than the out-
let radius. Overall, a stable performance curve is beneficial
for all applications, in which the process is run
under off-design conditions as well as processes,
Turbines with radial inflow design – in which off-design conditions differ signifi-
the perfect choice for ORC applications cantly from initial operating conditions.

The radial turbine can be adjusted by means of

variable Inlet Guide Vanes (IGV). By adjusting Advantages of radial turbines compared to
the guide vanes, or “nozzles”, the flow cross-sec- axial or impulse turbines in ORC-based waste
tion, or “gap”, as well as the angular velocity at heat recovery processes
the guide vane can be modified. This ensures
that the angle of attack of the flow on the lead- As opposed to the radial turbo expander design
described above, an axial turbine can only be
controlled by means of a throttling valve at the
machine inlet. When the flow is changed from
the design volume flow, then the angle of attack
Photo: Atlas Copco

at the blade leading edge will change, which

leads to reduced efficiency This also directly
leads to a decrease in efficiency. As a counter-
measure, tolerances towards angle of attack
changes in axial turbines can be increased by
modifying the profile of the rotor blade, e.g. by
increasing the radius at the blade leading edge.
But this also leads to diminished aerodynamic
efficiency of the entire stage.

Fig. 4: Example of a two-stage generator loaded turbine,

integrally geared type, photographed in a facility outside Under these conditions, the impulse turbine
the town of Pamukören, Turkey design is also inferior to radial turbines with var-

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 TURBOVAC i
Turbomolecular
iable Inlet Guide Vanes (IGV): The option of partial
admission of the blades is hardly more than “dam-
age control”.
Pumps
Radial turbines support higher pressure ratios
and broader areas of applications

Due to their design, radial turbines can achieve

much higher pressure ratios per stage than axial
turbines. In practice, pressure ratios up to 10 are
common for single-stage radial expanders. In order
to achieve the same pressure ratio, an axial design
turbine would require three to four stages. Addi-
tionally, radial turbines are suited for much higher
maximum temperatures at the inlet – up to 300°C.

These performance features make radial turbines

first choice for ORC-based, trans-critical waste heat
recovery applications with their high temperature
levels and exclusively sensible heat transfer pro-
cesses.

Integral design for several turbines on one drive

In cases where a process requires more than one

turbine stage, these can be mounted on a single
gearbox. This integral design approach, also com- A giant leap in vacuum performance!
monly used in multi-stage radial compressors, can
be suited towards individual customer and process
requirements. For an example, please see Fig. 4. The It has never been easier to improve your processes
turbine shaft serves the function of a pinion shaft than today! Our new TURBOVAC (T) 350 i and 450 i with
of the gearbox, thereby increasing the compact- integrated electronic drive will allow you to optimize
ness and sturdiness of the design. This is especially
pump-down times and consistently hit your target
suited as a cost-efficient solution in ORC-based
regarding pressures and gas flows. Designed to offer
power plant applications where a single turbine
alone cannot transfer the entire power provided by the best performance:size ratio available in the
the process. The same applies to processes with ISO 100/160 size range, they feature a rotor and drag
multiple pressure levels. stage design to achieve maximum performance and
unparalleled speed, especially for light gases.

Advantages of gas-lubricated mechanical face Discover the new TURBOVAC i series:

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For the gas-side shaft seal in radial turbines for ORC
Leybold Vacuum GmbH
applications, gas- and oil-lubricated mechanical Bonner Strasse 498
face seals are both viable alternatives. Both designs D-50968 Köln
offer minimal leakage and smallest possible over- T +49 (0) 221-347-0
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optimal degree of rotor dynamics. Gas-lubricated [email protected]
mechanical face seals (or dry face seals) rely on
inert sealing gas to prevent the already minimal
leakage of process gas to be released into the envi-
 84 InnovatIons & trends

plant operator’s perspective, but the process

Source: Atlas Copco

gases, e.g. refrigerants, are costly materials that

also add to the emission of greenhouse gases.
This is in sharp contrast to the underlying prom-
ise of sustainability achieved through geother-
mal power generation.

The advantages of dry face seals include maxi-

mum rotational speeds for optimal turbine effi-
ciency. Their main disadvantage, especially
when it comes to ORC-based applications, lies in
the requirement for cost-intensive sealing gas
recovery units.

Advantages of oil-lubricated mechanical face

Fig. 5: Rendering of an ORC-based waste heat recovery power plant in Canada. seals – maximum leakproofness

As an alternative, oil-lubricated mechanical face

seals in ORC-based processes offer a maximum
ronment. Together with the appropriate process degree of leakproofness. This design option also
configuration, this also helps to prevent con- eliminates the need for a costly and work-inten-
tamination of the working fluid with inert gas. sive sealing gas recovery unit.

However, in this process the rest leakage of the But the use of oil-lubricated mechanical seals is
working fluid mixes with the flow of sealing gas. not without downsides: Compared to gas, oil is
This requires an additional step in the process to a highly viscous fluid. Used as a sealant medium,
separate both gases in a seal gas recovery unit. it creates a high level of friction between the
Afterwards, the leaked process gas is reinserted rings rotating with the turbine shaft and the
into the ORC process. The elimination of work- static rings along the sealing gap. This ulti-
ing fluid leakages is not only a priority from a mately leads to increased heat generation at the
seal, limiting the maximum rotational speed of
a turbine combined with an oil-lubricated face
seal. For this reason, a turbine based on such a
Photo: Atlas Copco

design may fall short of achieving its maximum

efficiency. This method also requires a sealing oil
system, which may necessitate degassing of
process gas released from the oil. In sum, the ini-
tial cost advantage of oil-lubricated seals com-
pared to dry face seals with a sealing oil recovery
unit is minimised.

For this reason, neither of the two options is

inherently superior to the other. Choosing the
right sealing system thereby requires considera-
tion of all project parameters to weigh all the
pros and cons of each option.

Power plant for waste heat recovery in Canada

Fig. 6: Geothermal power plant in Pamukören, Turkey: epicted in front, the liquid This project leverages waste heat from two gas
storage tank (white) holding liquid isobutene downstream from the condenser; in the
middle, the process-fitted turbine and starting from left, a condenser bay stretching turbines to generate electricity with a total net
105 metres in total. output of approx. 2 MW. The turbines are driv-

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 COMPRESSORS, COMPRESSED AIR & VACUUM TECHNOLOGY 85

ing pumps in a process for recovering raw oil double turbine design, operated in parallel via a
from oil sands in the Alberta province. The pro- gearbox. The plant also features air condensers
cess directs waste heat from the jet blast of the at 105 x 35 metres in size and heat exchangers
gas turbines towards a heat exchanger, which in covering a total area of 400,000 square metres,
turn transfers the heat via a thermal oil cycle to adding to the impressive size of the operation.
a second heat exchanger. This exchanger serves
as the interface to the ORC process. In order to Currently, an additional geothermal power
achieve maximum efficiency, the plant was plant project is being executed in Southern
designed as a trans-critical process with R134a Germany. Construction work has recently begun
as the working fluid, making it one of the first and the facility will be operational by summer
operational processes of its kind. 2014.

Authors:
Geothermal power plant in Turkey Prof. Dr. Pall Valdimarsson
Manager Research & Development Geothermal
One of the world’s largest ORC-based geother- Competence Center
mal power plants generates clean power out- Atlas Copco Gas and Process Division
side the town of Pamukören, Turkey. The plant Dipl.-Ing. Markus Sauerborn
has been put into operation since October 2013. Package Design and Process Development
It consists of two trains, which produce in total Manager
more than 40 MW nominal power. The high per- Atlas Copco Gas and Process Division
formance of each train is achieved through a Atlas Copco Energas GmbH, Köln

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Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 Photo: Fotolia / darknightsky
The process air demand of a wastewater treatment plant can be produced with highest possible energy efficiency
when it is implemented by various machine types with different ratings.

Process air production with highest energy efficiency

Stephan Brand

In biologically working municipal and industrial wastewater treatment

plants the production of oil free process air requires a considerable amount
of electrical energy. However, an optimal solution with highest possible
energy efficiency can only be achieved when the compressor performances
can be adjusted continuously to the alternating consumption due to
unsteady waste water quantities and degrees of pollution.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
As the consumption not only varies due to the highly fluctuating load in

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the morning or late at night, but also by additional waste water from
industrial plants working during the week and by alternating amount of
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In biologically working big sewage plants
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Preconditions for an efficient process air production
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An essential base for the optimal operation of a biologically working generator in
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These days, oil-free turbo compressors, positive displacement blowers and

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having operated in the meantime or oil-injected plants with subsequent ENERGYEFFICIENCY
oil-free treatment of the produced process air are these days only oper-
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 88 InnovatIons & trends

Air-bearing turbo blowers

Photo: Aerzener
Speed-controlled, air-bearing turbo blowers
have become broadly established in aeration
tanks of biologically working wastewater treat-
ment plants. Thanks to the economical, reliable
and low-maintenance operation this new gen-
eration replaces more and more the classical
roller- and magnetic bearing turbo compressors.

The turbo blowers work with high-speed per-

manent magnetic motors (PM-motors) and may
be adjusted via a frequency converter without
Fig. 1: Manufacturer-specific turbo blowers with air suspension work additional mechanical adjusting devices
absolutely oil-free.
infinitely variable between 40% and 100% opti-
mally adjusted to fluctuating process air con-
Plain- and antifriction bearing, sumption.
mechanically controlled

The originally used turbo compressors with

Source: Aerzener
plain and antifriction bearing type of construc-
tion with mechanical control do not correspond
anymore to the current state of the art. These
turbo machines worked with upstream gearbox
and a classic three-phase asynchronous motor
with fixed speed. The plants are very big and
cause extensive maintenance work by their vast
actuating mechanism. In addition, it was only
possible by means of filigree technology and to
a lesser extent that these systems could be
adjusted to fluctuating air consumption by
costly mechanical inlet and outlet guide vanes.
This system is characterised by very high wear Fig. 3: Cross-section through a modern turbo blower
with air suspension
potential.

Frequency converter and line choke with RFI-fil-

ter are integrated in the units. In these air-cooled
Source: Aerzener

PM motors the electromagnetism is used as in

usual electric motors, combined with the per-
manent magnetism of the rotor. Therefore, this
rotor does not require any energy for its magne-
tisation. Only the stator is magnetised electri-
cally. The PM motors distinguish from standard
motors by higher efficiency.

Thanks to the turbo impeller directly mounted

on the motor shaft, an adjustable, low-mainte-
nance compact unit is the consequence. In case
of standstill the shaft is located on a foil strained
by springs. Immediately after start-up an air
cushion builds up between foil and shaft, how-
ever, which is produced by the rotation of the
Fig. 2: Manufacturer-specific turbo blower unit

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 COMPRESSORS, COMPRESSED AIR & VACUUM TECHNOLOGY 89

The new turbo blowers offer the following

Source: Aerzener

advantages:

• Further improvement of the energy

efficiency by the application of an
additional cooling air turbo and an
improved cooling air guide within the unit
• Low maintenance and service costs;
reliability and durability by absolutely
oil-free, contactless air lubricated bearing
• Reduced sound level by innovative acoustic
hood and improved sound insulation
• Space-saving installation by immediate
side-by-side installation
Fig. 4: Manufacturer-specific turbo blowers use perma- • High operator convenience, simple installa-
nent magnet motors for maximum energy efficiency.
tion and commissioning good accessibility
to all electronic components by extensible
drawer concept, integrated control with
touch screen, complete ready-for-connection
shaft and not by compressed air. The system delivery
works absolutely oil-free. Therefore, in these
units the only medium to be compressed is air In addition, the Turbo does not blow the waste
that is used for the bearing of the shaft and for heat into the environment, but provides the
cooling the system.

A further characteristic feature of these turbo

blowers is the impeller made of stainless steel
which is corrosion-resistant and robust. Due to Efficient compressors for continuous operation
its high strength, the walls of the impeller are AirMaster screw compressors
thinner and, therefore, better aerodynamics and
higher efficiency can be achieved as well as the
manufactured frequency converter. In case of
unforeseen pressure fluctuations an uncon-
trolled shutdown of the machine to the surge
limit can be avoided. This frequency converter is
perfectly designed for the safe operation of
turbo blowers. Compared to standard convert-
ers, this is a big step ahead in terms of operation
behaviour and efficiency.

Further developments and their advantages Benefit from the modular system and choose your compressor for your
individual requirements:

Speed controlled turbo blowers are available in

Performance categories: 4,0 kW/7,5 kW /11 kW/15 kW/18,5 kW/22,0 kW
the following performance ranges:
Vessel volume: 90 l / 270 l / 500 l
• Volume flows: 17–220 m³/min Pressure stages: 8 bar / 10 bar / 13 bar
(1,000–13,200 m³/h)
Additional equipment: cold dryer and sound absorbing cover
• Pressure range: 400–1,000 mbar,
higher pressures upon request
• Fields of application:
air overpressure production

www.schneider-airsystems.com
 90 InnovatIons & trends

user with the exhaust air by means of a separate

Source: Aerzener
flange for further use. This is unique. Positive
side effect: Cool operating rooms, no unneces-
sary heating of the sludge basin and free-of-
charge heat available where it is needed.

Speed-controlled, air-bearing turbo blowers have

become broadly established in aeration tanks of
biologically working wastewater treatment plants.

Fig. 5: Turbo impeller wheel made

of stainless steel
Compound design concepts for highest
possible energy-efficiency
load units depending on their constructive fea-
The process air demand of a wastewater treat- tures and performance ranges. The physical
ment plant can be produced with highest possi- advantages of a continuous-flow machine – the
ble energy efficiency when it is implemented by high efficiency of the design point – can be per-
various machine types with different ratings, fectly combined with the advantages of rotary
that can be defined as ideal base-/ and peak piston machines – the high controllability and
Mehrer Anzeige, VDMA Verlag the good efficiency, also in part-load operation.
105 x 146 mm (1/4 hoch), englisch The programme includes the following for the
customised process air generation.

• For generation of the base load requirement:

Adjustable turbo blowers (available volume
flows: from 1,000–13,200 m³/h,
pressure range from 400–1,000 mbar,
control range: 40–100%).
• For generation of peak- or light load
requirements:
• Adjustable positive displacement blower
Food & Beverages
Chemistry
Petrochemistry
Machine Construction
Raw Materials
Environment
Special Engineering

(available volume flows: 100–14,400 m³/h,

pressure range from 0–1,000 mbar,
control range: 25–100%).
• Adjustable rotary lobe compressor
(available volume flows: 670–5,900 m³/h,
pressure range 0–1,500 mbar,
control range: 25–100%).
Competence in Gas
& Air Compression By means of this three-point-programme, the
ideal preconditions are established for the
implementation of a very energy-efficient pro-
Development of oil-free crosshead piston compressors cess air station. An optimally adapted overall
Your Partner for compressors and compressor plants concept, for highest operation safety, reliability
since 1889 and efficiency can be realised.
Manufacture and Development from one source
Author:
Bringing into Operation, Servicing
Stephan Brand
and Maintenance
Aerzener Maschinenfabrik, Aerzen
Wear and Spare Parts Service and Service Training
Global Partner Network for Sales and Service

Josef Mehrer GmbH & Co KG Maschinenfabrik

Rosenfelder Str. 35 · 72336 Balingen · Germany
Phone +49 (0)7433 2605-0 · Fax +49 (0)7433 2605-41 · www.mehrer.de · [email protected]
 Photo: CERN
The LHC accelerator of CERN, with a circumference of about 27 kilometers, is the largest particle accelerator in the world.
An extraordinary machine such as this places very specific requirements on the vacuum technology installed there.

The world’s largest vacuum system:

CERNs Large Hadron Collider
Florian Henss

The search for the Higgs boson was one of the key scientific projects that
were carried out in the Large Hadron Collider (LHC) at CERN. With a circum-
ference of approximately 27 km, the LHC is the largest particle accelerator in
the world. Here, particle beams are accelerated to nearly the speed of light
and brought to collision. An important factor in the work of the particle
accelerator is a powerful and reliable vacuum. The specific requirements
relating to the accelerator require customised vacuum technology.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 92 InnovatIons & trends

On the trail of the Higgs boson collision at defined locations in large detectors.
During this collision process new particles are
The European particle physics laboratory, CERN, produced. The records of the detectors provide
based in Geneva, Switzerland, is the largest conclusions about the characteristics of the col-
research center for particle physics in the world. lided as well as the newly created particles.
Founded in 1954, it houses approximately 2,500 This way, scientists hoped to be able to prove
employees and over 10,000 guest scientists the Higgs boson. In July 2012, the research
from around the world. The main task of CERN is groups for the ATLAS and CMS detectors repor-
to discover what the universe is made of and ted that they found the Higgs boson.
how it works. In doing so, the aim is to complete
the standard model of elementary particle phy- This earned Peter Higgs of Britain and François
sics, which describes the basic building blocks of Englert of Belgium the 2013 Nobel Prize in Phy-
matters and the forces acting between them. sics. As early as in the 1960s, the two scientists
This model was missing an important compo- predicted the existence of this particle in their
nent, which has not yet been experimentally theories and thus contributed significantly to
proven: the Higgs boson. our understanding of particle physics.

To meet the high demands of a particle accelerator, The importance of vacuum

special vacuum solutions for vacuum generation,

An important factor for the operation of a par-
vacuum measurement and vacuum analysis had to be ticle accelerator is a reliable, powerful vacuum
developed and implemented. system. However, an extraordinary machine
such as the LHC also has very specific require-
ments for the installed vacuum technology. The
In order to implement its research, CERN opera- smallest errors could put the entire accelerator
tes a number of particle accelerators. The most out of service for several hours. Therefore, the
extraordinary of them is the LHC (Large Hadron entire vacuum system must be extremely relia-
Collider), installed in an underground tunnel. Its ble. In addition, all equipment used within the
circumference measures 26.7 km, making it the accelerator must be able to withstand radiation
largest particle accelerator in the world. In the levels of up to 1,000 Gy/a.
LHC, two opposing particle beams are accelera-
ted to nearly the speed of light and brought to Equipment leaving the accelerator‘s radiation
area for reasons such as maintenance must
undergo very complex measurements. For this
reason, it is extremely important that the equip-
ment can be maintained on-site. In order to
Photo: CERN

meet these especially stringent requirements,

special vacuum solutions for vacuum genera-
tion, measurement and vacuum analysis were
developed and implemented in coordination
with CERN.

Fig. 1: The Large Hadron Collider at CERN: In a 26.7 km

long underground ring tunnel (marked by the yellow line)
protons or lead nuclei are accelerated to nearly the speed
of light in opposite directions and brought to collision.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 COMPRESSORS, COMPRESSED AIR & VACUUM TECHNOLOGY 93

these pumps is that they have a very large com-

Photo: Pfeiffer Vacuum

pression ratio for light gases. This is especially

important as hydrogen, the lightest gas in the
atmosphere, determines the ultimate pressure
in the ultra-high vacuum domain. After the
pre-evacuation, a NEG (Non-Evaporable Getter)
coating developed by CERN is thermally activa-
ted inside the beam lines. This coating acts as an
additional absorption vacuum pump for gas. It
absorbs the remaining gas molecules, creating
the necessary ultimate pressure of 10–11 hPa.

Insulation vacuum

Extremely powerful superconducting magnets,

cooled down with liquid helium to 1.9 K (approx.
–271 °C), ensure that the particles in the LHC are
kept in their orbit.To maintain the the low tem-
Fig. 2: Test system to measure the gas emission perature of the magnets, a good thermal insula-
behavior of the LHC parts
tion of the entire cooling system is essential. For
this purpose, an insulation vacuum, similar to a
thermos flask, is created around the magnets,
Vacuum generation

The LHC differentiates between two vacuum

systems: the beam vacuum and the insulation
vacuum.

Turbopumps are used for both applications.

These were modified to fulfill the special requi-

More air,
rements of the LHC. In order to be able to ope-

more savings...
rate the turbopumps in the radioactive radia-
tion, no electronic components can be used in
the pumps. For this purpose, a sensor-free drive
concept was developed which makes it possible
to completely separate the mechanical part of
Kaeser’s new fluid-cooled BSD rotary screw compressors*
the pump and the electronics from each other.
save energy in four ways with:
Using this concept, the electronics can be loca-
ted up to 1,000 m away from the turbopump • energy-saving SIGMA PROFILE airends
and localised in a shielded area. • ‘Super Premium Efficiency’ IE4 motors
• efficient 1:1 direct drive
• integrated intelligence:
Beam vacuum
SIGMA COntROL 2
In order to prevent the fast particles from colli- Specific power improved
by up to 6%.
ding with gas molecules on their paths through FAD: 5.7 to 8.2 m³/min. at 7.5 bar.
the accelerator, the beam lines must be under
*) Optionally available with
an ultra-high vacuum of 10–11 hPa. This so-called
integrated dryer and / or
beam vacuum is created in a multi-stage pum- variable speed control
ping process.

First, the beam lines are pre-evacuated to

Visit us at our stands
10–8 hPa using turbopumps. The advantage of from the 5th to 9th of May 2014:
Hall A1 – Stand 133/232
Hall B4 – Stand 135

www.kaeser.com
 94 InnovatIons & trends

used are modified Pirani and cold-cathode

Photo: Pfeiffer Vacuum

vacuum gauges. They permanently monitor the
pressure in the accelerator and ensure that, in
the case of an increase in pressure, appropriate
action can be taken. As the vacuum gauges are
also exposed to high radioactive radiation, they
are constructed as passive sensors without inte-
grated electronics. All electronics are housed in
a radiation-safe area and are connected to the
passive sensors via long cables. The required
cables were evaluated in close collaboration
with CERN. This allows the cold cathode vacuum
gauges to measure pressures up to 10–11 hPa. A
special ignition process offers the advantage of
enabling the cold cathode vacuum gauges to be
turned on easily even at very low pressures. As
Caption: Fig. 3: Generation of the beam vacuum with turbopumps the lifetime of an accelerator is approximately
30 to 40 years, only electronic components that
will be available for a long time were selected.

which reduces the heat input into the cryogenic

system to a minimum. The insulation vacuum Helium leak detection
must be permanently maintained at < 10–6 hPa.
As superfluous helium always leaks into the For the ultra-high vacuum pressures required for
insulation vacuum due to unavoidable leaks in the LHC, it is important that the components
the cooling system, turbopumps are perma- used for the accelerator have extremely low lea-
nently in use in order to maintain the insulation kage rates. Therefore, before installing the com-
vacuum. Due to its high pumping capacity and ponents, an extensive leak test is essential. For
the large compression ratio for light gases, the the leak tests, CERN uses helium leak detectors.
turbopumps are particularly suitable for pum- Using these, even the smallest leakages of
ping down helium. 10–13 Pa m³/s can be detected reliably.

Vacuum measurement Vacuum analysis

The generated vacuum is measured with speci- Not only the pressure but also the composition
ally developed measuring devices. The devices of the residual gas is an important factor for the
proper operation of the accelerator. Using a resi-
dual gas spectrum, conclusions can be drawn
about the outgassing of the materials used in
Photo: Pfeiffer Vacuum

the accelerator. To record residual gas spectra,

CERN uses mass spectrometers. For this residual
gas measurement in ultra-high vacuum, it is
especially important that the analyzers of the
mass spectrometers themselves demonstrate a
low outgassing rate. In addition to a vacuum-an-
nealed ion source, the analyzers used at CERN
also have a vacuum-annealed rod system. The-
refore, these analyzers produce an extremely
low underground signal and are thus particu-
larly well-placed in order to record the actual
residual gas ratios in the accelerator.

Fig. 4: Leak detection system for LHC parts

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 COMPRESSORS, COMPRESSED AIR & VACUUM TECHNOLOGY 95

Photo: CERN
Fig. 5: A realtime proton-
proton-collision in the
CMS detector, where four
high-energy electrons (red
towers) were observed

Interview at CERN
A conversation with Dr. José Miguel Jimenez,
Head of CERN’s Vacuum, Surfaces & Coatings (TE/VSC) Group

Dr. Jimenez, how do you feel working at one of Regarding the role of vacuum technology in our
the world’s largest and most respected centers research work, without a very good ultra-high
for scientific research? vacuum, the accelerator and the detectors
would not be able to operate.
I am very proud and happy to work with CERN.
Looking at it from the outside, many people only What is the purpose of vacuum technology in
see the work of basic physics research. Technolo- the LHC accelerator ring?
gically demanding developments are necessary
in order for CERN to conduct the research, and Vacuum technology is used to generate beam
all this is done in international cooperation. and insulation vacuum in the accelerator. Beam
vacuum is particularly important for our high-
As an engineer, I am excited to see the different energy accelerators. For this purpose, pressures
technologies that are used for the accelerators. of 10–10 hPa are required in beam operation and
10–12 hPa in standby mode. Beam vacuum is par-
Which role does the vacuum technology play in ticularly important in the area before and after
CERN‘s research work? the experiments.

giusto.pdf 3-01-2013 18:15:21

CM

MY

CY

CMY

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 96 InnovatIons & trends

There, the collisions between beam particles Please describe briefly the specificity of the
and the remaining gas molecules in the accele- environmental conditions in the accelerator
rator must be reduced to a minimum. The hig- ring. How did the turbopumps have to be
her the vacuum pressure, the more of these col- modified?
lisions will occur. Radiation is generated with
each collision, this affects the background of the Take, for example, the pumps for the insulation
detectors, resulting in damage to the detectors. vacuum that are permanently installed on the
In order to maintain the insulation vacuum, we cryostat. At 1.9 K (about –271 °C), only a small
use turbopumps. Those are used to pump the fraction of the helium gas can be condensed. If a
helium exiting from the cooling system out of small leak occurs in these complex cryogenic cir-
the cryostat. cuits, the installed turbopumps will ensure that
the LHC continues to operate. These pumps
Even though the deflecting magnets are opera- must be resistant to electromagnetic interfe-
ted at 1.9 K (approximately –271 °C), the amount rence resulting from the magnets.
of helium that we can condense on the cold sur-
faces is very low. This is because helium has a Above all, they must be resistant to radiation
very low condensation temperature. With an that occurs during the operation of the LHC. To
extremely long and complex liquid helium circu- be suitable for the operation on the LHC, the tur-
lation, very small helium leaks can occur. There- bopumps have to withstand a radiation dose of
fore, we must maintain a pumping capacity to up to 1,000 Gy/a. This level of radiation prevents
be able to continue the insulation vacuum and the use of semiconductor components in the
so also maintain the operation of the accelerator. interior of the pump. To overcome this problem,
Most of the vacuum technology we need at we are using a new sensor-free drive concept.
CERN is available on the market. The problem is This concept allows the complete removal of all
the integration of this technology into the very electronic components from the pump body to a
specific environment of the accelerator. These shielded area outside the tunnel. Although the
requirements make it necessary to develop electronics are positioned far away from the
customised vacuum technologies for the LHC pump, they can still notify the users of all the
and for all other CERN accelerators. important status parameters of the turbopump.

Which special requirements must be fulfilled How important for you is the technical support
by the pumping system? in terms of the vacuum components?

A powerful vacuum system is important for the All objects leaving the controlled area at CERN
successful operation of a particle accelerator. must undergo very complex release controls.
It must have high reliability, withstand electro- Despite the fact that it is very unlikely that the
magnetic fields and radiation and must ensure components of the vacuum system might get
easy maintenance. activated in terms of radiation and contamina-
ted, even for service reasons a complex proce-
Which specific advantages of the turbopumps dure has to be undertaken to declassify the pro-
are required in this application? ducts to be able ship them outside the control-
led area.
In the LHC, the turbopumps have to provide a
huge compression rate for helium and hydro- Therefore, it is very important to us that the
gen, in order to allow very low final vacuum. The installed equipment can be serviced by service
pumps must be resistant to electromagnetic technicians on site.
fields and radiation. Their reliability must be
very high to reduce LHC down-time. Some of Author:
them require being able to withstand long bake- Florian Henss
out cycles of more than 24 hours at 250 °C, to Bachelor of Business Administration and
reduce the final vacuum even further. Engineering
Research & Development Market Segment
Pfeiffer Vacuum GmbH, Asslar

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 Photo: Fotolia / Nataliya Hora
Using state-of-the-art vacuum technology in material handling procedures, for example in car production,
makes a considerable contribution to improving the carbon footprint and reducing energy consumption.

Reducing carbon footprint with the right vacuum system

Josef Karbassi

The consumption of fossil fuels is one of the main causes for the increase
of CO2 in the atmosphere. Today, electricity is still primarily generated by
power stations fired by gas, oil or coal. Reducing electricity consumption in
industrial systems can therefore make a great contribution to improving the
carbon footprint. One approach is to review the use of vacuum systems for
material handling procedures. Here ultra-modern technology can clearly
reduce energy consumption and improve the carbon footprint.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 98 InnovatIons & trends

plastic and glass utilises air-driven vacuum ejec-

Calculation of the air consumption tors. The handling system is quite often based
on a robot equipped with vacuum lifting devices
volume flow (Nl/s) = mass flow (ρ air *1,000)
mass flow (kg/s) = A*¥*√(P2/(R*T)) and suction cups. There are also many manual
vacuum handling devices designed for sealed
where: objects, as well as dedicated machinery with
ρ Luft = density for air at atmospheric pressure = 101,3251 / (R*T) integrated vacuum handling systems. Examples
A = min. area of the smallest diameter in the ejector nozzle include sheet-metal presses, water and laser
¥ = 0,6847 = “flow factor” for air, used when the compressed air cutters, and glass and woodworking machines.
is higher than app 2.1 bars above atmospheric pressure
The energy consumed by these types of vacuum
P = abs. compressed air pressure (Pascal), i.e. zero is abs. vacuum
(6 bars = 701,325 Pa) handling systems is defined by how much com-
R = gas constant for air = 287 (J/kg K) pressed air the ejector consumes to create vac-
T = air temperature (°K = Kelvin) uum, and often takes into account how much
1
normal atmospheric pressure (Pa) at sea level
compressed air is needed in the blow function
to release the part quickly enough.
Fig. 1: Complete formula to theoretically calculate the air consumption
for an ejector nozzle The amount of compressed air consumed in an
ejector when vacuum is created depends on the
number of nozzle rows, the size of the smallest
Calculating vacuum system energy diameter in the (first) ejector nozzle, and the
consumption and CO2 emissions compressed air feed pressure. The complete for-
mula to theoretically calculate the air consump-
The most common vacuum technology for han- tion for an ejector nozzle is seen in Fig. 1.
dling sealed materials today like sheet metal,
It is quite common that the specified air con-
sumption for ejectors will differ from the theo-
retic value. The actual air consumption should
be very close to the theoretic value (the differ-
ence of a few percentages is reasonable). Fig. 2
demonstrates the theoretic value for some com-
Innovative technology since more than 110 years mon nozzle diameters at varying feed pressures.
Calculations are made at a temperature of
10 degrees Celsius (283.16 degrees Kelvin).

Piston-type compressors The other, and quite often forgotten, energy

for air and gas thief in a vacuum handling system designed for
sealed materials is the blow-off function, which
from 8 – 400 bar is used for quick release of the object. The air
consumed during blow-off is determined by the
Application: flow capacity of the valve that controls the func-
• Industry tion and pressure being used. When utilising a
• Biogas-Feeding large centrally placed ejector (i.e. many cups
• Helium-Recovery connected to the same source), very high levels
• Breathing Air of flow are required in order to quickly break the
• Diesel start seal on remotely placed suction cups. In this
• Natural gas case, flow levels in the range of 200–500 Nl/min
filling stations at 4–6 bars are standard.

• Pressure tanks up to 360 bar In a decentralised system using one small ejec-
• Special applications tor at each point-of-suction, the release func-
• Installation and service tion is in many cases the result of blocking the
exhaust. The air travelling through the ejector
will be forced into the cup so the air consump-
tion will be equal to, or slightly higher than, the

J.A. Becker & Söhne GmbH & Co. KG · Machine Factory

P. O. Box 1151 · D-74148 Neckarsulm
Phone + 49 (0) 71 32 / 367-0 · www .jab-becker.de
 Page 2 of 8

It is quite common that the specified air consumption for ejectors will differ from the theoretic
value. The actual air consumption should be very close to the theoretic value (the difference
COMPRESSORS,
of a few percentages is reasonable). Table 2 demonstrates the theoretic value for someCOMPRESSED AIR & VACUUM TECHNOLOGY 99
common nozzle diameters at varying feed pressures. Calculations are made at a temperature
of 10 degrees Celsius (283.16 degrees Kelvin).

Table 2.
sidering the “dirty” production

Source: Piab
Air Consumption for different ejector nozzle diameters
methods and basing the com-
600 pressor efficiency on 10 kW per
produced cubic metre of air.
500
Air Consupmtion (Nl/min)

How to reduce vacuum system

400 0.7 mm
1 mm
carbon footprint to a minimum
1.5 mm
300 2 mm The ejector’s efficiency is obvi-
2.5 mm
ously an important parameter to
3 mm
200 focus on when attempting to
minimise energy/air consump-
tion. Ejector efficiency is deter-
100
mined by the vacuum perfor-
mance (flow and speed of evacu-
0
ation) in relation to air
3 4 5 6
Feed pressure (bar) consumption. Basically, there are
two main types of ejectors used
Fig. 2: Theoretic value of air consumption of ejectors for some common
The other, and quite often forgotten, energy thief in a vacuum handling system designed for
in sealed vacuum handling sys-
nozzle
sealed diameters
materials at varying
is the blow-off feed pressures
function, which is used for quick release of the object. The air tems today – single-stage ejec-
consumed during blow-off is determined by the flow capacity of the valve that controls the
function and pressure being used. When utilizing a large centrally placed ejector (i.e. many tors and multistage ejectors.
cups connected to the same source), very high levels of flow are required in order to quickly
break the seal on remotely placed suction cups. In this case, flow levels in the range of 200-
air
500 consumption
Nl/min for producing vacuum. An
at 4-6 bars are standard.
alternative solution is a small blow-off check
In a decentralized system using one small ejector at each point-of-suction, the release function
is valve
in many on
casesa
thedecentralised unit,
result of blocking the which
exhaust. typically
The air travelling through the ejector will
be forced into the cup so the air consumption will be equal to, or slightly higher than, the air
allows 100–200 Nl/min to pass through at
4-6 bars.

In order to calculate the energy consumed, it is

required that the compressor efficiency is
known. A normal sized compressor, able to cre-
ate 7–10 bars of pressure, consumes 6–10 kW
per produced cubic meter of air depending on
size and efficiency. The total air consumption for
an ejector system per year can easily be calcu-
lated by adding the air consumed by vacuum
production and the air consumed by blow-off
function in each cycle, and then multiplying by
the number of cycles per year. Even better is to
measure the consumption with a flow meter
over the course of a number of cycles.

The CO2 emissions per produced kWh of electric

power will be as follows, depending on the type
of production:

• Gas: 0.2 kg CO2/kWh

• Oil: 0.27 kg CO2/kWh
• Coal: 0.33 kg CO2/kWh
• Nuclear, wind, water: 0.0007 kg CO2/kWh

Re-calculated for compressed air production,

the result is 0.02–0.033 kg CO2/m3 if only con-
 100 InnovatIons & trends

The multistage design is more complex and tors are centrally placed and serve several suc-
requires more space, but it will always be tion cups. They are usually located a few meters
15–50 percent more efficient (same speed/ away from the points-of-suction. The air-saving
response time with less energy consumption). function turns the ejector off when enough vac-
Therefore, it is important to use a multistage uum pressure is created, and turns it back on to
ejector whenever possible. compensate for any leakage occurring in the
system. One major advantage of this system is
When ejector technology entered the market that the centralised ejector with air-saving func-
for vacuum material handling of sealed parts tion only works for a short period of time during
and started to replace electrical driven vacuum the vacuum duty cycle, and energy will be saved
pumps, the main reasons were the reliability of when compared to the previous decentralised
the products, as well as the ability to easily concept.
control the ejectors’ power during operation.
With the centralised compact ejectors, factors
like operational reliability and safety (one ejec-
The ejector’s efficiency is obviously an important
tor per cup), and speed of vacuum generation
parameter to focus on when attempting to and object release must be sacrificed to a cer-
minimise energy/air consumption. tain degree. Speed can be compensated for with
a very large centralised ejector, but this means
much greater energy consumption. Another
At that time, small ejectors were placed on issue in utilising centralised compact ejectors is
each suction cup, forming a decentralised sys- that the blow-off function has to be very power-
tem. In many cases, a decentralised system ful in order to release parts quickly enough. This
such as this is the most efficient system, as it is because pipes are long and often restricted,
places suction exactly where it is needed. There leading to large amounts of air consumption
is no need for over-dimensioned ejectors to during the time needed for blowoff.
compensate for losses and extra volume. There
is also a reduced risk of leakage from fittings Fig. 3 below shows a typical work cycle in a
and couplings. sealed vacuum handling application utilising a
compact ejector with air-saving function. Air
However, when “air-saving technology” became consumption occurs during the following
available for ejectors, a new trend began: So phases:
called “compact ejectors” (or “smart ejectors”)
with integrated control functions such as • Dark blue: vacuum is started in the system
valves, vacuum switches and air-saving func- before the actual pick to increase pick-up
tions flooded the market. These compact ejec- speed.

Cycle analysis of a centralised compact ejector

Vacuum pump “on” before pick up / actual pick

Vacuum duty cycle
Pump working in duty cycle, compensating for leakage
Actual release
Total compressed air supply per cycle for blow-off function
Return to start position

Source: Piab

Fig. 3: Typical work cycle in a sealed vacuum handling application utilising a compact
ejector with air-saving function.

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
m deutlich reduziert werden können, ist eine neue, kompakte, dezentrale
mit zwei einzigartigen Merkmalen: das vollständig pneumatische und intern
Gerät mit dem Namen Vacustat und ein neues Belüftungsventil (AQR), das den
hen Druck der Umgebung nutzt, um mitgenommene Teile schnell loszulassen.
der einzelnen Saugnäpfe ist so gering, dass nur atmosphärische Luft benötigt
eutet, dass für die Freigabe keine Druckluft notwendig ist und es istCOMPRESSED
COMPRESSORS, eine AIR & VACUUM TECHNOLOGY 101
Luftsparvorrichtung vorhanden.

ing, and there is no need to create a pre-vacuum

Source: Piab

in the system. It will be fast regardless. As Fig. 5

highlights, the pump is only working for an
extremely short period of time. Now we will look
at a typical sealed vacuum handling application:

Cycle time: 10 s
Working hours per year: 6,000 h
Vacuum duty cycle: 5 s
Diam 75 mm cups: 4 pcs
Fig. 4: Fully pneumatic and internal air-saving device
Neu patentiertes Vacustat-COAX® mit AQR-Technologie Response time: max 0.1–0.2 s
with a new release valve (AQR),
Release time: < 0.1 s

•
Previously developed decentralised solutions
use approximately 25,000–40,000 m³ of air
• Blue: enough vacuum is made in the system per year.*
to compensate for leakage from fittings and • A compact ejector with air-saving function
couplings. A few recoveries per cycle are not will reduce air consumption to approxi-
unusual due to leakage. mately 15,000–20,000 m³ of air per year.*
• Red: object release using positive pressure • The new solution will use about 1,000 m³ of
blow-off air per year.
eric Quick Release Valve - Schnellbelüftungsventil), wie es in einem dezentralen
• Dark red: excessive blow-off time *Range varies greatly as it depends on whether
m eingesetzt wird. Das AQR macht doppelte Schläuche für jede dezentrale Einheit überflüssig,
single or multistage ejector technology is used.
allation vereinfacht wird und keine Zusatzkosten für ein separates Steuerventil entstehen.
It is obvious that even with an air-saving func-
pt bietet alle tion in place, there will be a great deal of com-
Vorteile eines dezentralen Ejektor-Systems im Hinblick auf die
t, Sicherheit pressed air consumed during each cycle.
und Geschwindigkeit (Reaktion und Freigabe). Der Luft- und
uch liegt fast bei null. Beim Loslassen der Gegenstände wird keine Druckluft
die Luftsparfunktion muss keine Verluste durch mehrere Anschlüsse und Excellence in Fluid Technology
ausgleichen.CanDasairVolumen ist so
consumption andniedrig,
carbon dass die be
footprint Luftsparfunktion nahezu
Die Zeit, die der Ejektor vor dem Aufnehmen eingeschaltet sein muss, wird
substantially reduced?
in absolutes Minimum reduziert und es muss kein Vorvakuum im System
n. Es reagiert dennoch schnell. Diaphragm compressors up to 1,000 bar
A new, compact, decentralised ejector unit with
two unique features is the answer to the ques-
tion of whether air consumption and carbon
footprint can be substantially reduced with a
vacuum system: a fully pneumatic and internal
air-saving device and a new release valve, which
uses the ambient atmosphere to quickly release
a handled part.

The volume of a single suction cup is so low that

atmospheric air is all that is needed. In other
words, no compressed air is needed for release,
and an automatic air-saving device is in place.
This concept offers all the benefits of a decen- State-of-the-Art
tralised ejector system in terms of reliability,
compressor technology for the industry
safety and speed (response and release). The air
and energy consumed is virtually nonexistent. ATEX type-tested complete systems for the oil and leak-free
There is no compressed air consumption during compression of many industrial gases such as:
the release of objects, and the air-saving func- H2, Cl2, HCL, F2, O2, SiF4, BF3, inert gases, ethylene and
tion does not have to compensate for leakage many more
from multiple fittings and couplings. The volume
is so low that the air-saving function will start
sera ComPress GmbH
almost instantly. Time that the ejector must be Visit us at:
sera-Straße 1
on before pick-up is also reduced to almost noth- Hannover Messe 34376 Immenhausen
07. – 11.04.2014, Hall 27 Booth B65 Germany
F-Cell Stuttgart Tel.: +49 5673 999-04
06. – 08.010.2014 Fax +49 5673 999-05
www.sera-web.com
 102 InnovatIons & trends

Cycle analysis of a centralised compact ejector, new solution

Vacuum pump “on” before pick up / actual pick

Vacuum duty cycle
Pump working in vacuum duty cycle
Release by Atmospheric Quick Release Valve – no air consumption
Return to start position

Source: Piab

Fig. 5: Cycle analysis of a fully pneumatic device with atmospheric quick release valve

It is possible to reduce energy consumption by Reduced cost of energy as a bonus

90–99 percent by simply using the latest vac-
uum handling technology. Today, the CO2 tax for European industries is
between 0.015 – 0.03 € per kg. An automotive
Returning to our previous equation, we can cal- plants could save more than 15,000 € in taxes
culate that 15,000–40,000 m³ of air corresponds alone when switching to the latest technology
to approximately 450–1,200 kg of carbon diox- for vacuum handling. This is a major benefit, as
ide emissions if the electrical power is supplied higher future taxes seem unavoidable. Ulti-
by a coal, oil or gas plant. This is based only on a mately though, the biggest cost savings will
single application/station. A typical automotive come from saved electricity. The typical cost for
plant can have up to 400 of these applications in producing compressed air in a plant with a
operation. The carbon footprint of vacuum han- normal sized compressor (if considering price
dling in these plants can be between 180,000 per kWh, life cycle, interest rate, purchase
and 480,000 kg when utilising traditional vac- price, service cost, working hours per year, etc.)
uum technology (based on conditions above). is usually be in the range of 1–1.2 euro-cents
When utilising the new technology, the carbon per cubic meter of air.
footprint can be reduced to only 12,000 kg. In
comparison, the average amount of CO2 emitted An automotive plant with 400 vacuum han-
from one car is 180 g/km. The reduced carbon dling applications could easily save 67,000–
footprint an automotive plant can achieve per 187,000 € per year in energy costs along if the
year by using the latest vacuum handling tech- latest technology is installed.
nology corresponds to 933,333–2,600,000 km of
driving. Author:
Josef Karbassi
PIAB Business Unit Manager, Automotive
Piab Vakuum GmbH, Butzbach

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 COMPRESSORS, COMPRESSED AIR & VACUUM TECHNOLOGY 103

Read more in our online magazine

under www.vdmashop.de/puco

The sixth edition of „Pumps and Compressors for

the World Market“ in 2014 strikes a new course:
Together with the magazine you hold in your
hands, if you go to www.vdmashop.de/puco,
you will find our first E-Magazine with additional
Oerlikon Leybold Vacuum:
features. The heading „Products & Applications“ TURBOVAC i – the new dimension
provides a user-oriented look at the latest tech- in turbomolecular pump engineering
The innovative turbomolecular pumps of the
nical developments, trends and products in the TURBOVAC i product line always deliver their
respective branches – as a brief summary in the maximum performance even under widely
differing requirements. TURBOVAC (T)350 i,
printed version and in greater detail in the
(T)450i and 350/450 i Multi-Inlet – the
E-Magazine with in-depth information about the performance leap for your vacuum!
respective topics. The flags indicate the languages www.oerlikon.com/leyboldvacuum
in which the articles are available.

Data logger METPOINT® BDL

made by BEKO TECHNOLOGIES
Pfeiffer Vacuum: METPOINT® BDL is the name of the first data
Helium recovery units – the perfect logger that specifically focuses on the employ-
technology for reducing helium costs ment in compressed-air plants. The device
Pfeiffer Vacuum develops and manufactures which has been developed by the compres-
leak detection systems for any facility requiring sed-air system specialist BEKO TECHNOLOGIES
high throughput production when a tightness GMBH optionally allows for the connection of
criteria of parts needs to be guaranteed. The up to 12 sensors, depending on the model. 32
company also provides a wide range of leak limit values on the whole can be freely defined
detectors using helium or hydrogen as tracer and assigned to different alarm relays.
gas for a wide variety of applications.
www.beko-technologies.com
www.pfeiffer-vacuum.de

Read more in our online magazine under www.vdmashop.de/puco • Read more in our online magazine under www.vdmas
 104 ProduCTS & APPLICATIoNS

Read more in our online magazine

under www.vdmashop.de/puco

KAESER KOMPRESSOREN: NEA reciprocating compressor

Efficient compressed air production increases oil and gas yield
with full-flow regeneration Enhanced Oil Recovery (EOR) methods signifi-
i.HOC is the new integrated attachment cantly increase oil and gas extraction yields. In
rotation dryer for dry-running rotary screw this context, NEUMAN & ESSER (NEA) de-
compressors from Kaeser Kompressoren. It veloped a concept saving the operator time and
provides a reliable and stable supply of money. The NEA compressor solution for gas
compressed air with pressure dew points to injection of carbon dioxide (CO2) has already
minus 40 degrees Celsius, even in challenging proven to be successful in practice as an
environmental conditions – and also saves example in the USA has demonstrated.
energy.
www.neuman-esser.com
www.kaeser.com

ALmiG: Maximum operating

convenience with the new
The Cozzani system for energy saving AIR CONTROL family
on reciprocating compressors The compressor controls of the AIR CONTROL
Ongoing positive experience of the stepless range have a long track record and have set a
capacity control system FluxtoFlow™. high standard on the market in terms of
Designed and developed by Dott. Ing. Mario reliability and operating convenience. The new
Cozzani srl, is the first in the world completely generation incorporates a wealth of innovative
electronic stepless capacity control system and ideas and technologies with the aim of
successfully present in the market. achieving maximum user-friendliness.
Simplicity of operation is very important.
www.cozzani.com
www.almig.de

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 COMPRESSORS, COMPRESSED AIR & VACUUM TECHNOLOGY 105

Imprint
Imprint
Editor
VDMA Pumps + Systems
VDMA Compressors, Compressed Air
and Vacuum Technology
BORSIG ZM Compression GmbH: Lyoner Str. 18
Process control, safety and monitoring 60528 Frankfurt am Main
in one system for your compressor unit Germany
Phone +49 69 6603-1296
BORSIG ZM Compression GmbH offers the
Fax +49 69 6603-2296
highly available BORSIG BlueLine automation E-Mail [email protected]
system with scalable redundancy and up to Internet www.vdma.org
SIL3 (safety integrity level) for industrial use.
Responsible editor
The system combines control system, functio- Christoph Singrün
nal safety and machine monitoring for
Frequency of publication
reciprocating and centrifugal compressors by annual
BORSIG as well by other manufacturers.
Copyright 2014
www.borsig.de/zm VDMA Pumps + Systems
VDMA Compressors, Compressed Air
and Vacuum Technology
Frankfurt am Main
Germany
Publishing house
VDMA Verlag GmbH
Lyoner Str. 18
60528 Frankfurt am Main
Germany
Phone +49 69 6603-1232
Fax +49 69 6603-1611
E-Mail [email protected]
Internet www.vdma-verlag.com
Schneider airsystems: Advertisements and distribution
Modular screw compressors Martina Scherbel
Schneider airsystems provides a range of 100 Editorial staff
different compressor types in 12 categories of Dr. Beate Metten
performance from 2.2 kW to 45 kW and three Design
pressure ratings (8 bar, 10 bar and 13 bar). An VDMA Verlag GmbH
innovative modular system is being offered in Production
the compressor category 4 kW to 22 kW. VDMA Verlag GmbH

www.schneider-airsystems.com Printing
Zarbock Media GmbH & Co. KG
Frankfurt am Main

shop.de/puco • Read more in our online magazine under www.vdmashop.de/puco • Read more in our online magazine unde
 106 COMPANIES & RANGE OF APPLICATIONS

Applications
Process &

Gas stations (natural gas, LPG)

Compressed Air

Mechanical engineering
Packaging (except Food)

Petrochemical industry

Handicrafts/Workshops
Natural gas industry
Technology

Medical technology

Cleaning (Purging)
Food industry

Handicrafts
Workshops
Laboratory

Refineries
Breweries

Pneumatic
Oil fields

Garages
Hygiene

Biogas
Oil/Gas
ABN Apparatebau Nittenau GmbH
l l l l l l l l l l
www.abn-drucklufttechnik.de
Aerzener Maschinenfabrik GmbH
l l l l l l l l l l l
www.aerzener.de
AKG Thermotechnik International GmbH & Co. KG
l l l l l l l l l l l
www.akg-gruppe.de
ALMiG Kompressoren GmbH
l l l l l l l l l l l l
www.almig.de
Apex Tool Group GmbH & Co. OHG
l l l l
www.apexpowertools.eu
Atlas Copco Energas GmbH, Gas and Process Division
l l l l l l
www.atlascopco-gap.com
Gebr. Becker GmbH
l l l l l l l
www.becker-international.com
J. A. Becker & Söhne Maschinenfabrik GmbH & Co. KG
l l l l l l l l l l
www.jab-becker.de
BEKO TECHNOLOGIES GmbH
l l l l l l l l l l l l l l l
www.beko-technologies.de
BlitzRotary GmbH
l l l l
www.blitzrotary.com
BOGE KOMPRESSOREN Otto Boge GmbH & Co. KG
l l l l l l l l l l l l l
www.boge.de
BORSIG ZM Compression GmbH
l l l l l
www.borsig.de/zm
CompAir Drucklufttechnik – Zweigniederlassung der Gardner
l l l l l l l l l l l l l l l l
Denver Deutschland GmbH / www.compair.com
Dott. Ing. Mario Cozzani S.r.l.
l l l l l l l l l l
www.cozzani.com
CVS engineering GmbH
www.cvs-eng.de
Donaldson Filtration Deutschland GmbH
l l l l l l l l l l
www.donaldson.com
Drumag GmbH Fluidtechnik
l l l l l l l l l l l l l l l
www.specken-drumag.com
FRIATEC Aktiengesellschaft – Division Rheinhütte Pumpen
l l l l l l l
www.rheinhuette.de
FST GmbH Filtrations-Separations-Technik
l l l l l l l l l l l l l l l l
www.fstweb.de
Gardner Denver Deutschland GmbH
l l l l l l
www.gd-elmorietschle.de
HATLAPA Uetersener Maschinenfabrik GmbH & Co. KG
l
www.hatlapa.de
HAUG Kompressoren AG
l l l l l l l l
www.haug.ch
Josef Mehrer GmbH & Co KG, Maschinenfabrik
l l l l l l l l l l
www.mehrer.de
KAESER Kompressoren GmbH
l l l l l l l l l l l l l
www.kaeser.com

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Instrument air
Chemical industry

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Construction

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Storage and transport

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Filling systems

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Bulk handling

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Sewage plants

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Aerating
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Wind channels

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Coke oven blowers

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Paint plants/Sand blasting plants

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Vehicles and Navigation

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Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 108 COMPANIES & RANGE OF APPLICATIONS

Applications
Process &

Gas stations (natural gas, LPG)

Compressed Air

Mechanical engineering
Packaging (except Food)

Petrochemical industry

Handicrafts/Workshops
Natural gas industry
Technology

Medical technology

Cleaning (Purging)
Food industry

Handicrafts
Workshops
Laboratory

Refineries
Breweries

Pneumatic
Oil fields

Garages
Hygiene

Biogas
Oil/Gas
Körting Hannover AG
l l l l l
www.koerting.de
MAN Diesel & Turbo SE
l l l l l
www.mandieselturbo.com
METAPIPE GmbH
l l l l l
www.metapipe.de
MTA Deutschland GmbH
l l l l l l
www.mta.de
Nash – Zweigniederlassung der Gardner Denver Deutschland
l l l l l
GmbH / www.GDNash.com
Neuenhauser Kompressorenbau GmbH
l l l l l l l
www.nk-air.com
NEUMAN & ESSER GROUP
l l l l l l l l l
www.neuman-esser.com
Parker Hannifin GmbH, Hiross Zander Division
l l l l l l l l l l l l l l l l
www.parker.com/hzd
Piab Vakuum GmbH
l l l l l l l l
www.piab.com
Sera ComPress GmbH
l l l l l
www.sera-web.com
Ultrafilter GmbH
l l l l l l l l l l l l l l l
www.ultraair.de / www.ultra-filter.de
WIKA Alexander Wiegand SE & Co. KG
l l l l l l l l l l l l l l l l
www.wika.de

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Chemical industry

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Chemical industry

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Construction/Woodworking/Textile

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Construction

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Textile industry
Storage and transport

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Filling systems

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Silos

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Bulk handling

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Pneumatic dispatch blowers
Sewage plants

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Sewage plants

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Aerating
Foundries/Wind channels

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Foundries

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Wind channels

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Blast furnace blowers

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Coke oven blowers

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Oil field blowers
Paint plants/Sand blasting plants
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Vehicles and Navigation
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Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 110 COMPANIES & RANGE OF APPLICATIONS

Applications
Vacuum Technology

Energy (Wind, Nuclear, Steam turbines, ...)

Printing and Paper Handling

Vacuum Heat Treatment2

Packaging (except Food)

Vacuum Metallurgy1
Industrial Vacuum
Central Vacuum

Pharmaceutical
Process Vacuum

Petrochemical
Pick and Place
Rough Vacuum

Freeze drying
Air sampling
Conveying

Chemical

Ceramics
Beverage
Medical

Plastics

Textile
Paper
Food
ABN Apparatebau Nittenau GmbH
l l l l l l l l l l l l
www.abn-drucklufttechnik.de
Aerzener Maschinenfabrik GmbH
l l l l l l l l l l l l l l l l l l
www.aerzener.de
Apex Tool Group GmbH & Co. OHG
l
www.apexpowertools.eu
Gebr. Becker GmbH
l l l l l l
www.becker-international.com
CVS engineering GmbH
l
www.cvs-eng.de
Drumag GmbH Fluidtechnik
l l l l l
www.specken-drumag.com
FRIATEC Aktiengesellschaft – Division Rheinhütte Pumpen
l l l
www.rheinhuette.de
Gardner Denver Deutschland GmbH
l l l
www.gd-elmorietschle.de
Gardner Denver Schopfheim GmbH
l l l l l l l l l l l l l l l l l l l l
www.gd-elmorietschle.de
GEA Wiegand GmbH
l l l l l l l l l
www.gea-wiegand.de
HATLAPA Uetersener Maschinenfabrik GmbH & Co. KG
www.hatlapa.de
HAUG Kompressoren AG
www.haug.ch
HERMETIC-Pumpen GmbH
l l l l
www.hermetic-pumpen.com
KAESER Kompressoren GmbH
l l l l l l l l l l
www.kaeser.com
Körting Hannover AG
l l l l l l l l l l l l
www.koerting.de
MTA Deutschland GmbH
l l
www.mta.de
Nash – Zweigniederlassung der Gardner Denver Deutschland
l l l l l l l l l l l l l l l l l
GmbH / www.GDNash.com
Oerlikon Leybold Vacuum GmbH
l l l l l l l l l l l l l l l l l
www.oerlikon.com/leyboldvacuum
Pfeiffer Vacuum GmbH
l l l l l l l l l l l l l l l l l l
www.pfeiffer-vacuum.de
Piab Vakuum GmbH
l l l l l l
www.piab.com

1 (Metal Degassing, Melting, Re-melting, e-beam welding, casting, ...) 4 for Semiconductor including focused ion beam systems and electron
2 (Brazing, Carburising, Nitriding, Quenching, ...) beam systems
3 (c-Si, Thin film deposition, Laminating, ...) 5 (Driers, Centrifuges, Concentrators, …)

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
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Electron Tubes
TV Tubes

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Lamps and Bulbs

l l l l l
Industrial leak detection

l
Refrigeration and Air Conditioning

l l l l l l l
l
l
Automotive (Dehydration, Charging and Test)

l l l l
l l l l l l l l
l l l l l l l l
l l
Electrical (Encapsulation, ...)
Semiconductor Process Vacuum

l
Silicon Semiconductor
Compound Semiconductor
TFT-LCD Displays
MEMS

l l l l l
l l l l l
l
l
l l l l l
Crystal pulling
Thin-Film Deposition (non-Semiconductor)

l
l
l
Glass/Web/Optical
Data storage (CD, DVD, Hi Def. Disc, ...)
Magnetic Data Storage (HDD)
Thin Film Heads

l
l
Surface Coating (wear protection, decorative, …)

l l l l l l
l l l l l l
l l l l l l
Display Coatings (OLED, FED, PDP, SED, …)
Solar

l
Photovoltaic Solar3

l
Thermal Solar (Solar Water heaters, …)

l l l
l l l
l l l
Crystal growth (re-melt, …)
Instrumentation Manufacturers
Mass Spectrometers
Electron Microscopes
Leak Detectors
Surface Analysis

l
Gas Analysis
Metrology/Inspection/Defect Review systems4
Focused Ion Beam systems
l

Electron Beam systems

X-Ray Analysis
MRI and NMR
Compressors, Compressed Air & VACuum TeChnology

l l l l l l l l l l l
l l l l l l l l l l l
Sample preparation5
R&D
111

l
Universities
Government Labs

l l l
l l l
l l l
Scientific Research Laboratories

l l l l
l l l l
Space Simulation

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 112 COMPANIES & RANGE OF APPLICATIONS

Applications
Vacuum Technology

Energy (Wind, Nuclear, Steam turbines, ...)

Printing and Paper Handling

Vacuum Heat Treatment2

Packaging (except Food)

Vacuum Metallurgy1
Industrial Vacuum
Central Vacuum

Pharmaceutical
Process Vacuum

Petrochemical
Pick and Place
Rough Vacuum

Freeze drying
Air sampling
Conveying

Chemical

Ceramics
Beverage
Medical

Plastics

Textile
Paper
Food
SBS Metalltechnik GmbH
l l l l
www.sbs-metalltechnik.de
Sterling SIHI GmbH
l l l l l l l l l l l l l l l l l
www.sterlingSIHI.com
VACOM Vakuum Komponenten & Messtechnik GmbH
l l l l l l l l l l l l
www.vacom.de
VAKOMA GmbH
l l
www.vakoma.de

1 (Metal Degassing, Melting, Re-melting, e-beam welding, casting, ...) 4 for Semiconductor including focused ion beam systems and electron
2 (Brazing, Carburising, Nitriding, Quenching, ...) beam systems
3 (c-Si, Thin film deposition, Laminating, ...) 5 (Driers, Centrifuges, Concentrators, …)

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 Laser Technology

l l
l
Electron Tubes
TV Tubes

l
l
Lamps and Bulbs

l l
l
Industrial leak detection
Refrigeration and Air Conditioning
Automotive (Dehydration, Charging and Test)

l l
Electrical (Encapsulation, ...)
Semiconductor Process Vacuum

l
Silicon Semiconductor
Compound Semiconductor

l
l
TFT-LCD Displays
MEMS

l l l l l
Crystal pulling
Thin-Film Deposition (non-Semiconductor)

l
l
Glass/Web/Optical

l l

l l
Data storage (CD, DVD, Hi Def. Disc, ...)
Magnetic Data Storage (HDD)
Thin Film Heads

l
Surface Coating (wear protection, decorative, …)

l l

l l l
l l
Display Coatings (OLED, FED, PDP, SED, …)
Solar

l
l
Photovoltaic Solar3
Thermal Solar (Solar Water heaters, …)

l
Crystal growth (re-melt, …)
Instrumentation Manufacturers
Mass Spectrometers
Electron Microscopes
Leak Detectors
Surface Analysis
Gas Analysis
Metrology/Inspection/Defect Review systems4
Focused Ion Beam systems
Electron Beam systems
X-Ray Analysis
l l l l l l l l l l

MRI and NMR

Compressors, Compressed Air & VACuum TeChnology

Sample preparation5
R&D
113

Universities
Government Labs
l l l

Scientific Research Laboratories

l l l l

Space Simulation

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 114 Brand name & Trade fair regisTer

Brand name & trade fair register

Alltech Dosieranlagen GmbH Solution preparation and dosing plants for dry, liquid Aqua Nederland Vakbeurs, Gorinchem,
Rudolf-Diesel-Str. 2 and gaseous products, dosing systems for powder Netherlands, 18–20/3 2014
76356 Weingarten and granulate, metering pumps, dosing stations and IFAT, München,
accessories, vacuum dosing systems and chlorine 5–9/5 2014, Hall A2, Stand 504
Phone +49 7244 7026-0
evaporators, agitators and mixers, standard and
Fax +49 7244 7026-50 purpose-built thermoplastic process and storage
[email protected] tanks, control and regulating systems.
www.alltech-dosieranlagen.de

Gebr. Becker GmbH • Rotary vane compressors and vacuum pumps IFAT, München, 5–9/5 2014
Hölker Feld 29–31 • Screw compressors and vacuum pumps Interpack, Düsseldorf, 8–14/5 2014
42279 Wuppertal • Side channel blowers and vacuum pumps
• Radial blowers and vacuum pumps Other worldwide participations
Phone +49 202 697-0
• (centralized) Systems in exhibitions:
Fax +49 202 660855 www.becker-international.com
[email protected]
www.becker-international.com

BEKO TECHNOLOGIES GmbH High-quality product and system solutions: TECHNISHOW, Utrecht, Netherlands,
Im Taubental 7 • BEKOKAT catalytic converter for oil-free compressed air 11–14/3 2014
41468 Neuss • DRYPOINT and EVERDRY compressed air dryers Hannover Industrial Fair, Hanover,
• CLEARPOINT compressed air filters 7–11/4 2014, NRW booth in hall 16
Phone +49 2131 988-0
• BEKOMAT condensate drains
Fax +49 2131 988-900 • ÖWAMAT and BEKOSPLIT oil-water separators For up-to-date exhibition activities please
[email protected] • METPOINT flow and dew point meters, air quality visit our website www.beko.de
www.beko-technologies.com control
• Consulting, Engineering, Training, Service

BORSIG ZM Compression GmbH • Reciprocating compressors for process gases NEFTEGAZ, Moscow, Russia, 26–29/5 2014
Seiferitzer Allee 26 acc. to API 618 in horizontal and vertical design 9th EFRC Conference, Vienna, Austria,
08393 Meerane up to 17,000 kW and 1,000 bar 11–12/9 2014
• I ntegrally geared centrifugal compressors for process 18th Workshop Kolbenverdichter, Rheine,
Phone +49 3764 5390-0
gases acc. to API 617 up to 12,000 kW and 80 bar 22–23/10 2014
Fax +49 3764 5390-5092 • BORSIG BlueLine – combines control system, ADIPEC, Abu Dhabi, UAE, 10–13/11 2014
[email protected] machine protection and condition monitoring for OSEA, Singapore, 2–5/12 2014
www.borsig.de/zm reciprocating and centrifugal compressor units For further fairs please refer to
• Compressor valves • Service and spare parts www.borsig.de/zm

DÜCHTING PUMPEN The DÜCHTING PUMPEN product range mainly Expomin 2014, Chile, 21–25/4 2014
Maschinenfabrik & Co. KG comprises the production of single-stage and EDS Conference, Cyprus, 12–14/5 2014
Wilhelm-Düchting-Str. 22 multistage centrifugal pumps, which are tailor-made Ugol Rossii & Mining, Novokuznetsk,
in their design and construction to meet the needs Russia, 3–6/6 2014
58453 Witten
of the customer. Our strengths include designing, Electra Mining, Johannesburg,
Phone +49 2302 969-0 manufacturing, testing and commissioning of our South Africa, 15–19/9 2014
Fax +49 2302 690-443 products. DÜCHTING PUMPEN can offer the right Mining Turkey, Istanbul, 27–30/11 2014
[email protected] s olution for almost every pumping application. For current trade fairs, please visit our
www.DUECHTING.com homepage: www.DUECHTING.com

EDUR-Pumpenfabrik EDUR offers approx. 60,000 different pumps for Hannover Messe, Hannover,
Eduard Redlien GmbH & Co. KG performances up to 500 m³/h rate of flow and Pumpe DE Pumpenplatz, 7–11/4 2014
Hamburger Chaussee 148–152 40 bar pump pressure: centrifugal pumps, torque- IFAT München, 5–9/5 2014
flow pumps for liquids containing solids, multiphase parts2clean, Stuttgart, 24–26/6 2014
24113 Kiel
pumps for liquid-gas-mixtures, dispersion pumps, Fakuma, Friedrichshafen,
Phone +49 431 6898-68 liquid-ring vacuum pumps. 14–18/10 2014
Fax +49 431 6898-800
[email protected]
www.edur.com

FELUWA Pumpen GmbH Production Line: Exhibitions in 2014:

Beulertweg 10 Process and transport pumps for abrasive/aggressive www.feluwa.com
54570 Mürlenbach fluids and slurries
• MULTISAFE hose-diaphragm pumps
Phone +49 6594 10-0
• Hose diaphragm piston pumps
Fax +49 6594 10-200 • Diagnosis and monitoring systems
[email protected] • Municipal wastewater pumping stations
www.feluwa.com • Pumping stations with solid diverters

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 Brand name & Trade fair regisTer 115

FRIATEC AG For sophisticated pumping applications for corrosive, Phosphates 2014, Paris, France,
Division Rheinhütte Pumpen abrasive and toxic fluids. 23–25/3 2014
Rheingaustr. 96–98 • Centrifugal and vacuum pump types in 9th Euro Chlor Technology Conference &
horizontal and vertical design Exhibition, Madrid, Spain, 1–3/4 2014
65203 Wiesbaden
• In metal, plastic, plastic-lined and ceramic Sulphur Conference 2014, Paris, France,
Phone +49 611 604-0 materials 3–6/11 2014
Fax +49 611 604-328 • Various sealing systems Worldwide participations in trade fairs, for
[email protected] current trade fairs please visit our home-
www.rheinhuette.de The right solution. For any fluid. page: www.rheinhuette.de – Exhibitions.

Hauhinco Maschinenfabrik Hauhinco is one of the leading system providers Our Trade Fairs for 2014
G.Hausherr, Jochums GmbH & Co.KG for water hydraulic systems, high pressure pumps, are listed on our website:
Beisenbruchstr. 10 valves and components. www.hauhinco.de
45549 Sprockhövel
We are looking forward to your visit.
Phone +49 2324 705-0
Fax +49 2324 705-222
[email protected]
www.hauhinco.de

HERMETIC-Pumpen GmbH • Canned Motor Pumps Exhibitions in 2014 visit

Gewerbestr. 51 • Hermetically Sealed Centrifugal Refrigeration Pumps www.hermetic-pumpen.com
• Magnetic Drive Pumps
79194 Gundelfingen • High-Pressure Pumps
Phone +49 761 5830-0 • Centrifugal Pumps, single and multistage
Fax +49 761 5830-280 • Special Pumps
[email protected] • Rotary Piston Pumps
www.hermetic-pumpen.com • Chemical Gear Pumps
• Displacement Pumps
• Hermetically Liquid Ring Vacuum Pumps

HOMA Pumpenfabrik GmbH Pumps for sewage disposal, sanitary engineering, For current trade fairs, please visit our
Industriestr. 1 dewatering and drainage: homepage: www.homapumps.com
53819 Neunkirchen-Seelscheid Submersible drainage water and sewage pumps, We are looking forward to your visit!
grinder pumps for pressure sewage disposal, sewage
Phone +49 2247 702-0
disposal units, drainage water disposal units, conden-
Fax +49 2247 702-44 sate pumps, mixers, tank cleaning systems, garden
[email protected] pumps, electronic booster units, pump control boxes.
www.homa-pumpen.de

KLAUS UNION GmbH & Co. KG Screw pumps, magnetic drive and shaft seal pumps Rio Oil & Gas, Rio de Janeiro, Brazil,
PO Box 101349 for chemistry and petrochemistry as well as for 15–18/9 2014
44713 Bochum the pharmaceutical and bio industry. Centrifugal Expoquimia 2014, Barcelona, Spain,
pumps, side channel pumps, multi-stage pumps, 29/9–3/10 2014
Phone +49 234 4595-0
submerged pumps, vertical and propeller pumps. Adipec, Abu Dhabi, UAE, 10–13/11 2014
Fax +49 234 4595-7000 DIN-EN- and API-685 series and pumps beyond Valve World Expo, Düsseldorf,
[email protected] standard. 2–4/12 2014
www.klaus-union.com More exhibitions in 2014 please visit:
www.klaus-union.com

KRACHT GmbH We at KRACHT, a medium-sized, family-run business, Automotive Testing Expo 2014,
Gewerbestr. 20 are a globally active company with 290 employees Stuttgart, 24–26/6 2014
58791 Werdohl working at the Werdohl-based head office in Germany UTECH ASIA 2014, Shanghai, China,
® Phone +49 2392 935-0
and another 85 members of staff in China, USA
and Hungary. As a manufacturer of transfer pumps,
3–5/9 2014
SMM 2014, Hamburg,
Fax +49 2392 935-209 hydraulic motors, high pressure gear pumps, valves, 9–12/9 2014
[email protected] pump units, flow meters and electronics, we attach bauma China 2014, Shanghai, China,
www.kracht.eu great importance to quality and to satisfy all our 25–28/11 2014
customers’ requirements.

KTR Kupplungstechnik GmbH More than 50 years of experience in power Hannover Messe, Hannover,
PO Box 1763 transmission, more than 40 premises throughout 7–11/4 2014
48407 Rheine the world, that is KTR. As a leading manufacturer IFAT ENTSORGA, Munich,
of couplings, clamping sets, torque limiters, torque 5–9/5 2014
Phone +49 5971 798-0
measuring systems, hydraulic components and Pump Summit, Düsseldorf,
[email protected] high-power brake systems we are the right partner 2–3/12 2014
www.ktr.com for all those who want to set things in motion.
Further exhibition dates see
www.ktr.com

LEISTRITZ PUMPEN GMBH Leistritz Pumpen GmbH has been producing and Arab Oil Dubai, UAE, 17–19/3 2014
Markgrafenstr. 29–39 selling Screw Pumps since 1924. Leistritz pumps CIPPE 2014, Beijing, China, 19–21/3 2014
90459 Nürnberg have internal or external bearings with single- or Neftegaz Moscow, Russia, 26–29/5 2014
double-flow design. The product range includes SMM Hamburg, 9–12/9 2014
Phone +49 911 4306-0
the Type Series L2, L3, L4, L5 with 2 to 5 spindles and KIOGE Almaty, Kazakhstan,
Fax +49 911 4306-490 offers solutions for a wide range of applications, for 30/9–3/10 2014
[email protected] example the oil & gas as well as chemical industry. ATCE Amsterdam, Netherlands,
www.leistritz.com 27–29/10 2014
ADIPEC Abu Dhabi, VAE, 10–13/11 2014

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 116 Brand name & Trade fair regisTer

Josef Mehrer GmbH & Co. KG Mehrer is one of the leading manufacturers of oil- NEFTEGAZ, Moscow, Russia,
Rosenfelder Str. 35 free piston compressors for technically demanding 26–29/5 2014
72336 Balingen tasks. As a partner of the processing and process EFRC, Vienna, Austria, 10–12/9 2014
gas industries, we are specialised in the fail-safe, gat / wat, Karlsruhe, 30/9–1/10 2014
Phone +49 7433 26 05-0
economical and completely oil-free compression TURKCHEM, Istanbul, Turkey,
Fax +49 7433 26 05-41 of gases, gas mixtures and air. 16–18/10 2014
[email protected] Brau Beviale, Nürnberg, 11–13/11 2014
www.mehrer.de Biogas Jahrestagung & Fachmesse,
Bremen, 27–29/01 2015

NETZSCH NETZSCH manufactures positive displacement Hannover Messe, Hanover, 7–11/4 2014,
Pumpen & Systeme GmbH pumps worldwide. Designed specifically for difficult PUMPENplatz Hall 15, Stand G43
Geretsrieder Str. 1 situations, pumps range in size from the industry’s IFAT, Munich,
smallest metering pumps to high-volume pumps 5–9/5 2014, Hall A6, Stand 139/240
84478 Waldkraiburg
for applications in the oil and gas industry. NETZSCH Interpack, Düsseldorf,
Phone +49 8638 63-0 supplies NEMO® progressing cavity pumps, 8–14/5 2014, Hall 3, Stand 3F28
Fax +49 8638 67981 TORNADO® rotary lobe pumps, screw pumps,
[email protected] macerators/grinders, dosing systems and equipment For current trade fairs, please visit our
www.netzsch.com for custom-built and challenging solutions. homepage: www.netzsch.com

Neuenhauser • Starting Air Compressors OTC, Houston, USA, 5–8/5 2014

Kompressorenbau GmbH • Starting Air Receivers POSDONIA, Athens, Greece, 2–6/6 2014
Hans-Voshaar-Str. 5 • Working and Control Air Compressors Marintec South America 2014 ,
• Working and Control Air Receivers Rio de Janeiro, Brazil, 12–14/8 2014
49828 Neuenhaus
• Compressor Skids SMM 2014, Hamburg, 9–12/9 2014
Phone +49 5941 604-0 • Compressed Air Purification Seatrade Middle East Maritime,
Fax +49 5941 604-202 • Condensate Drain and Purification Dubai, UAE, 28–30/10 2014
[email protected] • TDI-Engine Air Starters For current trade fairs, please visit our
www.nk-air.com homepage: www.nk-air.com

NEUMAN & ESSER GROUP Reciprocating compressors and systems of different Gastech, Seoul, Korea, 24–27/3 2014
Werkstr. construction sizes and designs in compliance EAGE, Amsterdam, The Netherlands,
52531 Übach-Palenberg with API 618, API 11P and ISO 8012 as dry-running 16–19/6 2014
or lubricated unit, having a flow rate of up to 9th EFRC, Vienna, Austria, 10–12/9 2014
Phone +49 2451 481-01
100,000 Nm³/h, 10–30,000 kW driving power Rio Oil & Gas, Rio de Janeiro, Brazil,
Fax +49 2451 481-100 and up to 1,000 bar discharge pressure, are the key 15–18/9 2014
[email protected] parameters of our range of supply. Service centres Turbomachinery Symposium,
www.neuman-esser.com at ten locations worldwide will ensure the high Houston, USA, 22–25/9 2014
availability of the units. GMC, Nashville, USA, 5–8/10 2014

oddesse Pumpen- und • Submersible motor pumps IFAT 2014

Motorenfabrik GmbH • Submersible motors World’s Leading Trade Fair
Am Pappelwald 12 • Propeller pumps for Water, Sewage, Waste and Raw
• Multistage centrifugal pumps Materials Management, Munich,
39387 Oschersleben/Bode
• Volute pumps 5–9/5 2014
Phone +49 3949 932-0 • Sewage and waste water pumps Hall A6, Stand 213
Fax +49 3949 932-463 • Sewage lifting systems
[email protected] • Pressure boosting installations
www.oddesse.de • After sales service

Oerlikon Leybold Vacuum GmbH Oerlikon Leybold Vacuum offers a broad range of Analytica, Munich, 1–4/4 2014
Bonner Str. 498 advanced vacuum solutions for use in manufactur- Interpack, Düsseldorf, 8–14/5 2014
50968 Cologne ing and analytical processes, as well as for research SNEC, Shanghai, China, 20–22/5 2014
purposes. Our core competence centres on the Salon du Vide, Reims, France, 11–12/6 2014
Phone +49 221 347-0
development of application- and customer-specific HET Instruments, Amsterdam,
Fax +49 221 347-1250 systems for the creation of vacuums and extraction Netherlands, 30/9–3/10 2014
[email protected] of processing gases. PPMA, Birmingham, UK, 30/9–1/10 2014
www.oerlikon.com/ Vacuum Show, Tokyo, Japan, 6–8/11 2014
leyboldvacuum AVS, Baltimore, USA, 11–14/11 2014

OSNA-Pumpen GmbH • High-pressure centrifugal pumps

Brückenstr. 3 • Booster units
49090 Osnabrück • Low-pressure pumps • Sewage water pumps
• Vertical immersed pumps
Phone +49 541 1211-0
• Submersible pumps
Fax +49 541 1211-220 • Submerged wastewater pumps
[email protected] • Self-priming pumps
www.osna.de • Piston pumps for domestic water supply
• Water purification and treatment

Pfeiffer Vacuum GmbH Pfeiffer Vacuum is one of the world’s leading manufacturers of Pittcon, Chicago, USA 3–6/3 2014
Berliner Str. 43 components and complete systems for generating, measuring DPG Tagung, Dresden,
35614 Asslar and analyzing vacuum. Ever since the turbomolecular pump 30/3–4/4 2014
was invented by Pfeiffer Vacuum, the company has been Analytica, Munich, 1–4/4 2014
Phone +49 6441 802-0
synonymous with innovative solutions and high-technology China Glass, Shanghai, China,
Fax +49 6441 802-1202 products that are used in analytical applications, research 14–17/4 2014
[email protected] and development, environmental technology, chemistry, VTE, Moscow, Russia, 15–17/4 2014
www.pfeifer-vacuum.com semiconductor production, coating technology as well as in Semicon West, San Francisco, USA,
the automotive industry and any number of further sectors. 8–10/7 2014

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 Brand name & Trade fair regisTer 117

Putzmeister Solid Pumps GmbH Complete solutions for transporting and storing sludge Our current trade fair dates:
Max-Eyth-Str. 10 and high-density materials. Applications: • mining and www.pmsolid.com
72631 Aichtal tunnel construction • energy/co-incineration • sewage
Phone +49 7127 599-500 treatment plants • dredging of water sludge • recycling
process of biological or hazardous waste • oil & gas
Fax +49 7127 599-988
industry. Services: • planning of conveyance jobs
Industrial Technology [email protected]
Mining ∙ Energy ∙ Environment ∙ Oil & Gas • consultancy in process-based transportation • deliv-
www.pmsolid.de ery of pumps, silos and pipelines with accessories
• assembly, set up and the complete maintenance.

SKF Lubrication Systems • Centralised lubrication systems for machinery, SMM, Hamburg,
Germany AG, Zentralschmierung all types of vehicles on- or off-road, construction 9–12/9 2014
Motzener Str. 35/37 and agricultural machinery AMB, Stuttgart,
12277 Berlin • Wheel flange lubrication systems for rail vehicles 16–20/9 2014
Phone +49 30 72002-0 InnoTrans, Berlin,
23–26/9 2014
Fax +49 30 72002-111
Wind Energy, Hamburg,
[email protected]
23–26/9 2014
www.skf.com/lubrication

Spandau Pumpen • Sealless immersion pumps for industrial AMB, Stuttgart,

Product division of SKF applications 16–20/9 2014
Lubrication Systems Germany AG • Centrifugal and screw pumps for low-,
Motzener Str. 35/37 medium- and high-pressure applications
12277 Berlin • Centrifugal pumps of high-tech plastic or
Phone +49 30 72002-0 metal
Fax +49 30 72002-261 • Explosion-protected centrifugal pumps
[email protected]
www.spandaupumpen.com

Gebr. Steimel GmbH & Co. • Gear pumps Current fair dates at:
Maschinenfabrik • Rotary-lobe pumps www.steimel.com
Johann-Steimel-Platz 1 • Centrifugal pumps
• Hygienic pumps
53773 Hennef
• Magnetic coupling pumps
Phone +49 2242 8809-0 • ATEX pumps
Fax +49 2242 8809-160 • Special pumps
[email protected]
www.steimel.com

Deutsche Vortex GmbH & Co. KG Deutsche Vortex mainly produces high efficiency- Aqua-therm, Moscow, Russia,
Kästnerstr. 6 domestic hot water pumps for centralized hot-water 4–7/2 2014, Hall 14
71642 Ludwigsburg supply in single or multi-family houses. Further high expoEnergy Wels, Austria,
efficiency-circulators for heating systems are offered. 26/2–2/3 2014, Hall 16, Stand 240
Phone +49 7141 2552-0
SHK Essen,
Fax +49 7141 2552-70 12–15/3 2014, Hall 3, Stand 420
[email protected] IFH/Intherm Nuremberg,
www.deutsche-vortex.com 8–11/4 2014, Hall 5, Stand 209
GET Nord, Hamburg, 20–22/11 2014

Pumpenfabrik Wangen GmbH WANGEN pumps are very successful in a great IFAT, Munich, 05/2014
Simoniusstr. 17 variety of pumping duties in industries such as Interpack, Düsseldorf, 05/2014
88239 Wangen im Allgäu biogas, agriculture, food, in all kinds of industrial BrauBeviale, Nuremberg, 11/2014
and municipal applications – whenever reliable Eurotier, Hannover, 11/2014
Phone +49 7522 997-0
handling of products to be pumped is required: e. g.
Fax +49 7522 997-199 highly viscous products, abrasive media, multiphase
[email protected] mixtures, sticky products and even highly dewatered
www.wangen.com sewage sludge.

Xylem Water Solutions • Pumps and pump systems SHK, Essen, 12–15/3 2014
Deutschland GmbH • Booster sets and variable speed control systems Hannover Messe, Hannover, 7–11/4 2014
Biebigheimer Str. 12 • Single and multistage centrifugal pumps IFH Intherm, Nürnberg, 8–11/4 2014
• Borehole pumps, submersible pumps IFAT, München, 5–9/5 2014
63762 Großostheim
• Sewage and drainage pumps Parts2clean, Stuttgart, 24–26/6 2014
Phone +49 6026 943-0 • Heating and inline pumps SMM, Hamburg, 9–12/9 2014
Fax +49 6026 943-210 • Domestic hot water pumps, condensate pumps Technopharm, Nürnberg, 30/9–2/10 2014
[email protected] • Energy saving systems (HYDROVAR) Brau Beviale, Nürnberg, 11–13/11 2014
www.lowara.de • For industry, municipalities, resident. & commercial Eurotier, Hannover, 11–14/11 2014

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
 118 List of Advertisers

List of advertisers
List of advertisers
Company Internet address Placement

ALMiG Kompressoren GmbH www.almig.de Page 21

ANDRITZ Ritz GmbH www.andritz.com Page 17
Atlas Copco Energas GmbH www.atlascopco-gap.com Page 81
Gebr. Becker GmbH www.becker-international.com Page 87
J. A. Becker & Söhne GmbH & Co. KG www.jab-becker.de Page 98
Beinlich Pumpen GmbH www.beinlich-pumps.com Page 57
BEKO TECHNOLOGIES GmbH www.beko-technologies.com Page 85
ITT Bornemann GmbH www.bornemann.com Page 15
BORSIG ZM Compression GmbH www.borsig.de/zm Page 99
K. H. Brinkmann GmbH & Co. KG www.brinkmannpumps.de Page 63
Dott. Ing. Mario Cozzani s.r.l. www.cozzani.com Page 95
CP Pumpen GmbH www.cp-pumps.com Page 23
FELUWA Pumpen GmbH www.feluwa.com Page 33
GEA Tuchenhagen GmbH www.gea.com Page 47
GRUNDFOS GMBH www.grundfos.com Page 13
Hammelmann Maschinenfabrik GmbH www.hammelmann.com Page 55
HANNOVER MESSE www.hannovermesse.com Page 79
HERMETIC-Pumpen GmbH www.hermetic-pumpen.com Page 19
KAESER KOMPRESSOREN AG www.kaeser.com Page 93
KLAUS UNION GmbH & Co. KG www.klaus-union.com Page 51
KSB Aktiengesellschaft www.ksb.com Page 3
KTR Kupplungstechnik GmbH www.ktr.com Page 7
Leistritz Pumpen GmbH www.leistritz.com Page 49
LEWA GmbH www.lewa.com Page 27
Josef Mehrer GmbH & Co KG www.mehrer.de Page 90
NEAC Compressor Service www.neac.de Page 11
Oerlikon Leybold Vacuum GmbH www.oerlikon.com/leyboldvacuum Page 83
Pfeiffer Vacuum GmbH www.pfeiffer-vacuum.de Inside cover page
ProMinent GmbH www.prominent.com Page 31
RUHRPUMPEN GmbH www.ruhrpumpen.com Page 39
Schmalenberger GmbH + Co. KG www.schmalenberger.de Page 35
Schneider Druckluft GmbH www.schneider-airsystems.com Page 89
sera ComPress GmbH www.sera-web.com Page 101
Sterling SIHI GmbH www.sterlingsihi.com Page 43
URACA GmbH & Co. KG www.uraca.com Page 53
WILO SE www.wilo.de Page 9
WITTE PUMPS & TECHNOLOGY GmbH www.witte-pumps.de Page 61

Pumps and Compressors for the World Market with Compressed Air and Vacuum Technology 2014
A PASSION FOR PERFECTION

VDMA Publishing

Knowledge

Pumps + Systems
VDMA Compressors, Compressed Air and Vacuum Technology

VDMA
Pumps + Systems
Compressors, Compressed Air and Vacuum Technology

Lyoner Str. 18
60528 Frankfurt am Main
Germany
Phone +49 69 6603-1296
Fax +49 69 6603-2296
E-Mail [email protected]

Pumps and Compressors

Internet www.vdma.org

for the World Market 2014

with Compressed Air and Vacuum Technology

Pumps and Compressors for the World Market 2014

vf 800314-e
www.vdma.org

Pumps and Compressors

for the World Market This is the VDMA specialised magazine for engineers

Vacuum solutions with Compressed Air and Vacuum Technology

and the technical management. Please order

your copy free of charge simply by sending an

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technological perfection, competent advice and reliable service. We are the only
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■ Pumps for vacuum generation up to 10-13 hPa

■ Vacuum measurement and analysis equipment
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■ Chambers and components

Are you looking for a perfect vacuum solution? Please contact us:
Pfeiffer Vacuum GmbH · Headquarters/Germany www.vdma-verlag.com
T +49 6441 802-0 · F +49 6441 802-1202
[email protected]
www.pfeiffer-vacuum.com
 Pumps + Systems
VDMA Compressors, Compressed Air and Vacuum Technology

VDMA
Pumps + Systems
Compressors, Compressed Air and Vacuum Technology

Lyoner Str. 18
60528 Frankfurt am Main
Germany
Phone +49 69 6603-1296
Fax +49 69 6603-2296
E-Mail [email protected]

Pumps and Compressors

Internet pu.vdma.org
kdv.vdma.org

for the World Market 2014

with Compressed Air and Vacuum Technology

Pumps and Compressors for the World Market 2014

pu.vdma.org
vf 800314-e

kdv.vdma.org