Desulphurization Pump
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Desulfurization pumps are a type of industrial pump specifically designed for use in flue gas desulfurization (FGD) systems. Flue gas desulfurization is a process used to remove sulfur dioxide (SO2) from exhaust gases produced by the combustion of fossil fuels, particularly in power plants. The removal of sulfur dioxide is crucial for environmental reasons, as it helps reduce air pollution and the formation of acid rain. Desulphurization pump are corrosion-resistant pumps, mainly used for the transportation of corrosive liquids. It is a widely used pump among general equipment pumps. The desulfurization pump is usually a horizontal cantilever single-stage single-suction centrifugal pump, which is specially designed and developed for transporting corrosive media containing fine particles. The flow material of the desulfurization pump is required to be wear-resistant and corrosion-resistant.
Our desulfurization pumps are constructed with materials that resist corrosion and abrasion, such as high-chrome alloys or other wear-resistant materials.
Specialized seals and sealing systems are employed to prevent leakage and ensure the efficient operation of the pump over an extended period.
Given the critical nature of the desulfurization process, our pumps are designed for high reliability and extended service life.
The pumps are engineered to handle the specific characteristics of FGD slurry efficiently, minimizing energy consumption and optimizing overall system performance.
Desulfurization pumps are designed with considerations for the density and composition of the slurry, as well as the operating conditions within the FGD system.
We offers a comprehensive selection of dredger pumps designed to meet the demanding requirements of the dredging industry. Our products are built to handle a wide range of slurry pumping applications, including dredging, sand and gravel extraction, mining, and more.
Our Desulphurization pumps are specially designed to handle high-pressure slurry pumping applications, including the transportation of corrosive and abrasive materials. They are ideal for use in power plant desulphurization processes, where they can effectively pump limestone slurry and other abrasive materials.
Our Sludge Recirculation Pumps are designed to handle the transfer of sludge from one location to another, making them ideal for use in wastewater treatment plants, chemical processing facilities, and other applications. They are built to handle high volumes of sludge and are available in a variety of sizes and configurations to meet the specific needs of your application.
A cement factory in Texas was among the first in the U.S. to install wet flue gas scrubbers in order to reduce the sulfur dioxide emissions. This is a demanding application for pumps because the gypsum slurry that &#;scrubs&#; the gas is highly abrasive and corrosive.
Special pump systems with housings and impellers made of mineral cast proved to be an ideal solution for this specific application.
Wet flue gas desulfurization scrubber systems can be vital components in various industries due to strict environmental regulations of those applications. First applications were coal-fired power plants and waste incineration plants. Today, other industries use wet scrubbers in their day-to-day operations as well to scrub flue gas emissions from burners that use coal as a fuel source.
The scrubbers remove toxins from coal- fired flue gas streams in the process.
This is accomplished by spraying a mixture of limestone slurry over incoming flue gas. This creates a chemical reaction that removes or &#;scrubs&#; the toxins from the flue gas. Once the limestone slurry reacts with the incoming flue gas, it is converted to a gypsum slurry.
The gypsum is then dewatered and can be sold to end users for use in various industries. Concrete manufacturers are able to use the dewatered gypsum in the concrete production process.
The selection of pumps for this application is a crucial task.
Due to its significant corrosive and abrasive characteristics, gypsum slurry is a very difficult medium to handle. An American cement plant with a yearly capacity of about 2 million metric tons has found a good solution for that issue when it installed the first of two scrubber systems in .
The housings of the eight pumps in the limestone slurry cycle are not made from metal materials, but from a special material that was designed specifically for extremely harsh conditions. This material is a mixture of silicon carbide (SiC) and epoxy resin that is poured into precision molds and heat cured to form the pump components. The material must be machined with diamond tools due to it exhibiting a hardness close to that of diamonds. The material is completely impervious to corrosion and exhibits extreme abrasion resistance given its metallic-free composition and high hardness value.
The scrubber recycle pumps in this plant have operated at a flow rate of 1,310 cubic meters per hour (m3/h), 21.1 meters (m) of head and 630 revolutions per minute (rpm) for nearly 20 years, requiring minimum attention and service. Of course, the mechanical seals were exchanged from time to time. Apart from that, four impellers, one casing cover and some minor components were replaced. An additional 24 pumps are installed in the second scrubber system and other applications in the plant.
This installation is a true testament to the superior performance of these pumps in the harshest environments. It shows why this type of pump is installed not only in this cement factory, but also in wet flue gas desulfurization systems in multiple power plants and other industrial facilities all across the world.
The pumps are not restricted to flue gas desulfurization. They are also used in processes such as ammonia phosphate and titanium dioxide (TiO2) pigment production, salt solution mining, sugar beet processing and sea water desalination.
1. The wet parts of desulfurization pump adopt advanced CFD flow simulation analysis technology, with reliable design and high operation efficiency
2. This series of pumps are equipped with X-shaped bracket with a compact structure, which can greatly save floor space, wide flow range, high efficiency, and energy saving, simple structure and convenient maintenance
3. The dual pump casing structure with replaceable cemented carbide lining or rubber lining has good wear resistance, corrosion resistance and high reliability.
4. The back pull-out structure is another highlight design of TL(R)series desulfurization pump. It doesn&#;t need disassemble water inlet and outlet pipeline anymore. Easy construction make easy maintenance.
5. The shaft seal adopts the cartridge mechanical seal specially used for desulfurization process, with long service life and less maintenance.
6. Design of direct connection between pump and driver. A variety of speeds and variants are adopted to make the pump run under the best working condition. It has long service life and high operation efficiency, and can meet many kinds of bad transportation conditions.
7. Double row tapered roller bearings are used at the pump end, and the bearings are lubricated with thin oil to improve the working conditions of the bearings and greatly improve the service life of the bearings
If you want to learn more, please visit our website Desulphurization Pump factories.
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FLUE GAS DESULFURIZATION
Over the past twenty years, scrubber pumps have continued to grow in size and capacity, with individual units handling flows in excess of 5,000 gal/min. Pump capacities to 10,000 gal/min or greater, at heads ranging from 13-20 meters are necessary in order to operate with a minimum number of pump units. Pumps must accommodate lower levels of operation due to unit outages or off-peak electrical demand. Today's pump net positive suction head (NPSH) is met by the normally high (10-15 meters) suction head. FGD pumps must be durable, able to withstand constant operation at specified conditions, able to accommodate a range of pipe loads and system transients and be virtually maintenance-free for at least 24,000 hours of continuous operation. FGD units use several types of pumps, three of which will be discussed below.Feed Pumps
Concentrated slurry feed is usually handled by rubber-lined centrifugal pumps. Positive displacement pumps with variable-speed drives are also applicable. Cast-iron, corrosion-resistant alloy, and rubber-lined pumps are common in limestone systems. Some utilities prefer to use rubber-lined pumps from a single manufacturer for uniformity throughout the plant.
Although centrifugal pumps are widely used, the screw pump that handles limestone slurry feed is a special type of rotary positive displacement pump in which the flow through the pumping elements is truly axial. Thus, the screw pump with its unique axial flow pattern and low internal velocities offers a number of advantages in those few applications where centrifugal pumps cannot be used.
Fresh Water Pumps
In a limestone FGD system, the most likely points at which fresh water would enter are the ball mills, pump seals, and the mist eliminator wash system. A fresh water plump for this service can be a standard centrifugal pump. The important items to be specified are properties of the service water, available net positive suction head (NPSH), materials of construction, type of drive, and type and size of motor.
Recycle Slurry Pumps
The typical slurry pump has many features that set it apart from the typical centrifugal pump used for clear liquids. Wall thicknesses of wetted-end parts (casing, impeller) are greater that in conventional centrifugal pumps. The cutwater, or volute tongue (the point on the casing at which the discharge nozzle diverges from the casing), is less pronounced in order to minimize the effects of abrasion. The radial and the axial-thrust bearing on the slurry pump are heavier, too, than those on standard centrifugal pumps.
Materials of Construction
Pumps are made in two types of materials: all-metal pumps and rubber-lined cast-iron pumps. European and American engineers have tended to use different materials of construction. American power plants have generally installed rubber-lined cast-iron pumps while European plants have generally installed all-metal pumps. Since the pump parts in contact with the slurry are subjected to abrasive-corrosive action, the "wetted" parts must be constructed of a corrosion-resistant material that is either harder than the slurry solids or resilient. As David Root observed in "New Technology Throws Down Challenge to Pump Industry," International Power Generation, March , pp. 59-60, the hard iron pump is a single casing, back pull-out design that increases ease of maintenance. It is constructed of duplex stainless steel for highly abrasive media. The cast-iron pump casing is split vertically with through-bolting used to connect the halves as well as the piping to the suction and discharge nozzles. In the rubber-lined cast-iron pumps each casing half is lined with easily replaceable, bolted-in segmented rubber liners. A good design provides for 100 percent reinforcement of all liners. This approach precludes collapse of the liners if a vacuum is inadvertently created. Rubber has advantages for modern scrubber pumps because it offers excellent abrasion resistance, has natural corrosion resistance and effectively dampens hydraulic noise. Rubber liners are less expensive and weigh less than metal liners or cases, so they reduce the cost and allow for easier handling during maintenance.
Most impellers today are metal. The advantage of metal is based on its durability and the fact that it allows for optimized pump efficiency through proper geometry. The maximum diameter impeller is employed regardless of the flow and head. This tactic is used to keep rotational and eye speeds at a minimum so wear life is enhanced and damage due to cavitation is minimized. Manufacturers of rubber-lined impellers claim impeller performance is maintained over 97 percent of the useful water life of the component while metal impellers slowly degrade over their working life.
The selection of impeller metallurgy normally includes either duplex stainless steel (CD4MCU) or a high-chrome martensitic white iron. The latter is typically 27-28 percent nominal chrome content. Certain formulations with carbon content under two percent enhance resistance to slurries having a pH level exceeding three, with chloride content of 75,000 ppm and higher. While duplex stainless steel can be used over the widest range of pH and chloride levels, maximum hardness with heat treatment may be 325-340 Brinell, while the available white irons may range from 450 BHN to 600 BHN, based on carbon content and heat treatment.
Generally, the advances made in elastomer compounds and metal alloys have resulted in typical wear life of five years for casing liners and three years for impellers.
Pump Accessories
Seals
Today's pumps are sealed with slurry mechanical seals, that operate without the need for flush water. It is now reasonable to expect seal wear-life of three years or more. The metallurgy of the components of the seal or shaft sleeve is important because the low pH conditions and presence of chlorides is conducive to corrosion problems.
Roller Bearings
The mechanical end of the pump features a heavy-duty shaft and bearing assembly in a cartridge that can be easily removed for maintenance in a non-contaminating atmosphere. A cylindrical roller bearing is employed to absorb radial loads imposed hydraulically and by the weight of the impeller. Double-tapered roller bearings accommodate hydraulic thrust loads. The location of these bearings provides the most efficient design for bearing size and life, while minimizing the displacement of the shaft caused by thermal gradients. A B-10 bearing life of 100,000 hours is normally specified for recycle pumps.
Pump Suppliers
The two largest suppliers of pumps for FGD units are KSB AG and The Weir Group PLC. These two companies sell more than half of the pumps for this industrial group. Weir purchased EnviroTech Pumpsystems in and Warman International in . KSB is the largest supplier of pumps to the German power industry for FGD units. In KSB wholly purchased the remaining part of Georgia Iron Works and set up GIW Industries, which sells and manufactures their slurry pumps. Weir Warman is a major supplier worldwide. Weir had its own first experience with pumps for FGD units at the Drax Station power plant and has both direct and acquired experience with the purchases of EnviroTech and Warman.
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