- Progressing Cavity Pumps
- Rotary Lobe Pumps
- Multi Screw Pumps
Progressing cavity pumps belong to the group of rotating positive displacement pumps. They are self-priming, valve-less, and due to their high process liability and suction capacity they are often used for the continuous, gentle conveyance and precise dosing - in proportion to speed - of difficult media.
Technical Basic Specifications:
up to 1.000 m³/h
up to 480 m
up to 240 bar
up to 3.000.000 mPas
- 20 °C up to + 200 °C
Technical features of Progressing Cavity Pumps
- high suction capacity up to 9 mWC
- direction of rotation and flow can be reversed
- installation in any orientation possible
- quiet smooth running
- low pulsation
Benefits of Progressing Cavity Pumps
- flow in proportion to speed
- precise dosing
- continuous, gentle and low-pulsation flow
- large free ball passage (up to 150 mm)
- high suction capacity
- low life-cycle costs due to long lifetime
and meantime between failure
- reverse rotation and flow
Rotary lobe pumps belong to the group of rotating positive displacement pumps. Thanks to their compact design, high performance density and operational safety they are often used to continuously and gently convey and dose - in proportion to speed - difficult media.
Technical Basic Specifications:
up to 1.000 m³/h
up to 80 m
up to 10 bar
up to 100.000 mPas
- 20 °C up to + 150 °C
Technical features of Rotary Lobe Pumps
- compact design
- various helical lobe designs and straight bi-lobe rotors
- wide selection of materials for housings, liners and lobes
- wide selection of seals
Benefits of Rotary Lobe Pumps
- flow rate in proportion to speed
- precise dosing
- continuous flow
- low pulsation
- large free ball passage
- high performance density
- easy maintenance thanks to free access
to all conveying elements
- change of rotation causes reversal of flow
Multi screw pumps belong to the group of self-priming, valve-less rotating positive displacement pumps. Due to their design they are specially suitable for lubricating media. Although they are compact in design they can reach high flow rates and high pressure. Some designs are even suitable for non-lubricating or solid loaden fluids.
Technical Basic Specifications:
up to 2.500 m³/h
up to 1.000 m
up to 100 bar
up to 200.000 mPas
0 °C up to + 300 °C
Technical features of Multi Screw Pumps
- continuous flow with low pulsation
- flow with minimla turbulences
- gentle product handling
Benefits of Multi Screw Pumps
- high efficiency
- hydraulically balanced
- long service life
- low pulsation
- quiet operation
- excellent suction capacity
- low maintenance
- low Life cycle costs
NETZSCH Pumpen & System GmbH
Geretsrieder Straße 1
Fon: +49 8638 63-0
Fax: +49 8638 67981
Mr. Michael Groth, Dipl. Ing. (FH)
Head of Global Business Field Environmental & Energy
Phone: +49 8638 63 2206
Mobile: +49 172 6607138
Mr. Roger Willis
Head of Global Business Field Chemical, Pulp & Paper
Phone: +49 8638 63 2182
Mobile: +49 172 6607138
NETZSCH Pumps & Systems is part of the NETZSCH Group, a mid-sized, family-owned company. For more than 60 years, NETZSCH Pumps & Systems has served markets worldwide with different pump technologies, systems and accessories. NETZSCH also provides customised, sophisticated solutions for applications in every type of industry.
Our product range
- Progressing Cavity Pumps NEMO®
- Rotary Lobe Pumps TORNADO®
- Multi Screw Pumps NOTOS®
- Hygienic Pumps for Food & Pharmacy
- Mobile Pumps
- Grinding Machines
- Barrel Emptying Systems
- Dosing Systems
Publications & Brochures
MultiProtector enables digital damage prevention for positive displacement pumps
In addition to regular and preventive maintenance, seamless monitoring of the various operating parameters of a pump ensures the long service life of the system. Furthermore, through targeted monitoring, damage can be localized before it occurs, and countermeasures can be initiated. To further increase your benefits in the field of pump monitoring, NETZSCH has developed a new digital monitoring unit.
From the oil industry to the food industry, pumps form the heart of the complete system in most processes. Unfortunately, depending on the industry and the pumped medium, the pumps are often exposed to extremely challenging conditions, so wear damage is inevitable. In the worst case, this results in a standstill of the entire plant, which leads to high costs for the operator. To reduce the risk of failure to a minimum, critical operating parameters, such as medium temperature, motor voltage or leakage, must be monitored seamlessly. In addition, if specific threshold values are exceeded, a safe shutdown of the plant must be initiated to prevent worse. This is exactly where the newly developed MultiProtector pump protection module from NETZSCH comes in. With the digital monitoring unit, possible malfunctions can be detected quickly and easily via the app, and appropriate countermeasures can be initiated. The tool continuously analyzes data on medium temperature, stator temperature, leakage, overpressure, motor voltage and motor temperature.
If a previously defined threshold value is exceeded, either a warning signal is triggered or, alternatively, the pump can be switched off immediately and automatically. In addition to the definition of a threshold value, the app also enables complete documentation of the error history and live diagnostics. The display is optimized for all mobile devices such as smartphones, tablets or laptops.
In summary, the MultiProtector offers you the following advantages:
- Adjustment and operation of multiple sensors with one device
- Easy assembly (Only one device needs to be installed for all sensors)
- Simple commissioning via app
- Increased operational safety due to advance warning and shutdown in the event of a fault
- Increase of the service life by notification for preventive maintenance
- Easy parameterization, diagnostics and reporting in the MultiProtector App
- Simple analysis of diagnostic data
- Optimum condition monitoring via smartphone, tablet or PC
Source & Graphics: NETZSCH Pumps & Systems
High efficiency and maximized performance for the food, chemical and pharmaceutical industries
To cover even more applications in the hygienic sector with special requirements in the future, the pump expert NETZSCH Pumpen & Systeme GmbH is expanding its existing hygienic pump portfolio with the NOTOS® 2NSH twin screw pump.
Most products in the food, chemical and pharmaceutical industries are subject to the highest hygiene and safety requirements. Any risk of contamination of the conveyed medium must be excluded, and the pump's residue-free cleaning must be guaranteed. To further increase customer benefits in the hygienic sector and to be able to cover additional areas of application, NETZSCH Pumpen & Systeme GmbH has added a new model to its product portfolio: The NOTOS® 2NSH hygienic twin screw pump. A combination of the highest product safety paired with the usual high NETZSCH quality.
Whether tomato juice, baby food or even shampoo, they all have one thing in common: any form of contamination makes the respective product unusable and thus ensures high reject costs for the manufacturer. For the conveyance of the medium, this means the following: On the one hand, the pump must be designed in such a way that any kind of contamination by operating fluids or wear-related abrasion can be excluded. Secondly, it must be possible to clean the pump without leaving any residue. All of this, combined with a continuous flow rate, distinguishes the hygienic multi screw pump from NETZSCH.
The NETZSCH product portfolio covers a wide range of positive displacement pumps, also in the food, chemical and pharmaceutical industries. The useful addition of a hygienic multi screw pump to the portfolio allows the customer an even broader range of applications. The new NOTOS® hygienic pump ensures the highest efficiency and maximum performance, combined with total process safety.
For safe operation with demanding media, the NOTOS® hygienic pump features stainless steel spindles with a very efficient profile that allows extra flow with low liquid shear.
The pump is based on the model 2NS of the proven NOTOS® multi screw pump series. This series characteristically stands for high flow rates and pressures while requiring little space. "When the pump is in operation, chambers are formed through the two intermeshing, counter-rotating screw spindles in combination with the pump housing. In these chambers, the pumped medium is continuously moved axially from the pump inlet to the discharge side", explains Rainer Gozzer, Business Unit Manager Food & Pharmaceuticals at NETZSCH in Waldkraiburg.
The NOTOS® 2NSH conveys the medium with flow rates of up to 200 m³/h. Pumping pressures of up to 16 bar are achieved. The transfer is contactless, i.e. the conveying elements do not come into contact with each other. In combination with the pump's all-metal design, there are no potential contamination risks emanating from the pump. Even dry running does not pose a risk for the new aggregate.
The pump can also be efficiently cleaned by the so-called "cleaning-in-place process" (CIP) and subsequently sterilized by the "sterilization-in-place process" (SIP). The system is cleaned or sterilized - without prior disassembly - in a circular or continuous process. The combination of non-contact conveying elements with a flange-mounted gearless three-phase motor enables a high pump speed and thus the flow rate of 1.5 m/s, which is decisive for the CIP process. The dead space-free design supports residue-free cleaning. The all-metal design is insensitive to high temperatures, which are crucial for the SIP process.
The new NOTOS® 2NSH hygienic twin screw pump is available in an FSIP® version, enabling easy service and quick maintenance in the plant. Also, another conventional version, which can be optionally equipped with a heating jacket, is available. The heating jacket enables the medium to be conveyed at a constant temperature. For applications where the pumped medium tends to harden or requires temperature regulation to ensure high quality, this pump is perfect.
In FSIP® (Full Service in Place) design, the NOTOS® 2NSH has a special pump housing that allows quick and easy disassembly of the pump without disconnecting the unit from the pipeline.
With decades of experience in the market for positive displacement pumps, NETZSCH has been able to position itself successfully over the years in a wide range of industries. The well-thought-out and useful expansion of the product portfolio in the hygienic sector will enable customers to use it for various other applications in the future.
For more detailed information feel free to contact NETZSCH directly.
Source & Pictures: NETZSCH
Combination of various displacement pumps for a smooth oil production from NETZSCH
A Floating Production Storage and Offloading Unit (FPSO) is a ship for the offshore production. With the help of drilling platforms or from boreholes it can be used for the production, storage, cleaning and loading of the extracted oil or natural gas. Several different pump technologies from NETZSCH were successfully installed in such a ship.
Immense effort is required to access new deposits: It can take years of preparation before a new oil field is developed. For offshore wells, oil producers now frequently are opting for a Floating Production, Storage and Offloading Unit (FPSO). The FPSO is flexible and can be used to store, process and load the extracted crude oil or natural gas, as well as for pumping. Particularly for offshore operations, establishing FPSO helps to cut down on expensive pipelines leading to the production site. That means even fields with a short life span or far from the coast can be developed cost-effectively. NETZSCH Pumpen & Systeme GmbH impressed with in-depth knowledge for offshore pumping and a pump portfolio that precisely meet the respective requirements of the FPSO.
One of the world's largest oil companies decided to realize just such a flexible production unit off the coast of Great Britain. Up to 45,000 barrels per day are produced at the new site. Efficient operation is important to the company, especially in view of volatile oil prices, so the company was looking for a solution to be profitable even at world market prices of less than 40 US dollars per barrel. Efficiency is also a priority for the technology used on the platform, both for the primary tasks associated with oil production and for secondary processes such as crude oil processing. The oil company's partner in charge of engineering and construction therefore turned to NETZSCH for the pumping technology. NETZSCH has an extensive portfolio of technology for pumping liquid media, and the required expertise in the oil and gas industry to meet such high demands. NETZSCH is familiar with the challenges involved in pumping a wide range of media for the industry and offers the right solution for every application. The portfolio includes special technologies for extending the life of oil wells that are drying up, for increasing the efficiency of existing oil fields, and for the safe and efficient production of low-quality or high-viscosity crude oil. "We do especially well in the offshore sector– not least because NETZSCH concentrates its combined knowledge of the industry and its applications in a specialised business field with a global presence," says Ulrich Eibl, Head of the Oil & Gas Mid-/Downstream global business field at NETZSCH. Eibl also knows that, on the high seas especially where every repair job involves enormous costs, customers need very low-maintenance technology that functions simply, is reliable and has long life cycles. "After all, downtime on an FPSO quickly adds up to several million US dollars in losses per day", the pump expert explains. Eibl is also familiar with the dimensioning requirements, as every inch of space is used to operate platforms as efficiently as possible. Therefore the design of the pumping system has to be as space saving as possible.
Three different types of pumps operate off the English coast: a rotary lobe, a multi screw and a progressing cavity pump. Each model has been developed perfectly for its specific application.
The TORNADO® rotary lobe pump T.Proc® is used to clean the marine diesel oil. "Since maintaining and cleaning all the components at a remote site such as an FPSO is expensive and time-consuming, the fuel used for the power supply is cleaned in a separator," Eibl explains. This keeps engines and tanks clean and makes sure that the fuel is of a consistently high quality – an approach that has proven to be valuable and that also ensures a longer service life for the engines.
NOTOS® multi screw pumps are used around the FPSO ship's storage tanks. "Safety is of course the top priority for our customers," says Eibl. "To prevent even the possibility of an explosive atmosphere developing in the storage tanks for crude oil from the outset, an inert gas is produced from some of the ship's diesel fuel, which floats on top of the oil in the tanks". The 3-spindle multi screw pumps, which convey the diesel used to produce the inert gas, therefore have an essential task.
Finally, several NEMO® progressing cavity pumps are used in another area of the floating platform. Because it is a American Petroleum Institute (API) design, the pump is an extremely robust all-rounder that can be used universally. On the FPSO, the pumps take care of the produced water. "This is not waste water in the traditional sense," Eibl explains. "This is in fact reservoir water at a temperature of 50 - 60°C that comes to the surface together with the crude oil". The NEMO® units pump about 2m³ per hour against 15 bar pressure at 240 revolutions per minute. Besides oil droplets, the water contains minute rock particles from the formation deep in the seabed, as well as hydrogen sulphide (H2S) and chlorides. That means that there is a risk of corrosion and abrasion for the pump. In the event of a leak, it can even lead to toxic H2S being set free. The NEMO® comes out top again with its unique wear-resistant design, which ensures a long service life even when media is loaded with rock particles.
Thanks to its in-depth knowledge of the market, NETZSCH was able to interpret and optimally realize the various needs of the oil company. A major advantage of NETZSCH Pumps & Systems GmbH is that different pump types can be individually customized and manufactured to meet the high requirements. Thus, no customer wish remains unfulfilled.
Source & Pictures: NETZSCH Pumps & Systems
Picture: Vinding, Pixabay
NETZSCH delivers rodless progressing cavity pump with underground drive (ESPCP)
In November 2018, a NETZSCH ESPCP system was installed in the oil field of a German oil and gas producer. The picture shows the well, which was converted from a decommissioned pumpjack (right) to the rodless PCP (left).
For almost 70 years, a German oil and gas producer has been operating oil fields south of Bremen. For historical reasons, various types of pumps are used side by side. In an effort to reduce the number of pumping installations, the oil field operator has begun to look for an efficient and durable system capable of combining the advantages of both pump types: a system that combines a submersible motor of a submersible centrifugal pump with a progressing cavity pump.
The company uses different pump types for conveying operations on its crude oil fields. Due to their different design and functions, the different models work with varying degrees of effectiveness in the specific conditions of production wells. “Each type of pump has specific advantages and disadvantages,” explains Jörg Eitler, Global Business Field Manager for Oil & Gas Upstream at NETZSCH. “For example, in the case of pumpjacks and progressing cavity pumps, pump rod fractures occur relatively frequently. Since the rods move constantly during extraction, tubes may become damaged. This is more likely the further the borehole path deviates from the vertical position.” As a result, time-consuming work may be required to repair the damage and resume production. In the case of submersible centrifugal pumps, this risk is much lower. They must be very precisely designed and carefully installed to avoid damaging the underground cable during installation, especially if the borehole path is not vertical. However, once the installation is successfully completed, the cables often have a much longer service life than the rods of progressing cavity pumps and pumpjacks. This is because the cable is not under dynamic load during operation, as is the case with pump rods.
The decision makers considered a combination of progressing cavity pump and submersible centrifugal pump, which combines the advantages of both pump types, to be particularly useful and efficient for the applications in the North German oil fields. The company decided on a special model developed by NETZSCH Pumpen & Systeme GmbH, which does not require a transmission ratio between the motor revolutions and the pump, since the motor selected specifically for this application can be operated at very low frequency. In addition to the progressing cavity pump, the system consists of a permanent magnet motor, sensors, motor protector, bearing unit and a flexible rod, called FlexShaft. Other components are a check valve, a drain valve and a cable that is used to power the motor and to transfer data from the sensor.
Better handling thanks to the special rotor connection and the permanent magnet motor
The ESPCP used by the customer is a model that has a special rotor connection, and is driven from below, from inside the borehole. “The special feature of this pump is that the rotation of the rotor is not driven by the above-ground drive head via a very long shaft or rod, rather the rotor-stator combination and the motor are sunk into the well”, Jörg Eitler explains. The motor and the bearing unit are connected directly to the rotor via a flexible rod. All radial and axial forces of the rotor are absorbed by a special underground bearing housing. There is also a dynamic seal in the well. This moved all critical components of the pumping unit below ground, precluding environmental impact from leaks above ground.
The motor that has been selected for the system is a permanent magnet model (PMM). It is designed to meet the specific requirements of a progressing cavity pump. With this slow-speed 10-pole synchronous motor, the specified speed is the same as the actual speed, eliminating the need for complex slip calculations and speed measurements. Even error-prone, mechanical or magnetically coupled transmission can be dispensed with. A downhole sensor is installed directly underneath the PMM. It provides data for the operation of the production well and data on the machine condition. It also helps to troubleshoot problems in the well.
Significant advantages compared to PCP models with above-ground drive
The design of the ESPCP system, which is installed in Northern Germany, is adapted to local conditions. It can convey the highly viscous medium, which contains bitumen and paraffin sediments, sand content of up to 40 percent, or salt deposits, at a pressure of up to 300 bar. A gas proportion of up to 40 percent of the pump intake does not pose a problem during extraction, because the technology of the progressing cavity pump allows conveyance of different phases of a fluid. It also conveys low volumes of 3 to 20 m³/day as efficiently as medium volumes of 10 to 100 m³/day. Since there is no pump rod, the pump can now be used even for horizontal or heavily deflected boreholes. Eliminating pump rods rules out rod breakage, as well as friction of rods against the piping. This significantly reduces the risk of pipe leakage. It also allows higher flow rates in the tubing and enables use of tubes with a smaller diameter. Pressure losses in the tubing are also lower. “Rods cannot get twisted, which rules out a dangerous backspin”, says the upstream specialist at NETZSCH.
Other advantages of these rodless PCP over conventional PCP models are lower axial load, larger operating window of 180-500 revolutions, integrated pump and motor protection and the choice of a special, highly xylene-resistant elastomer. Other features include an automatic integrated pump control, which starts the pump after a power failure and the remote measurement of real-time pump data for early detection of errors. The system also has a smaller footprint than all systems with above-ground drives.
In November 2018, the NETZSCH ESPCP system was installed and put into operation in the oil field south of Bremen. It worked flawlessly until the first unscheduled shutdown of the production well, which was caused by exceeding external limits that were not related to the pump. The operator therefore plans to purchase additional systems.
Since there is no pump rod, the pump can be used even for horizontal or heavily deflected boreholes. It means that the so-called Dog Leg Severity (DLS) is very high.
Source & Pictures: NETZSCH
NETZSCH Pumps & Systems delivers its 1,000,000th pump
NETZSCH ships its 1,000,000th pump: NEMO® progressing cavity pump with hopper and integrated aBP® module.
In May 2020, global market leader and manufacturer of positive displacement pumps NETZSCH Pumps & Systems delivered its 1,000,000th pump from its subsidiary in Exton, USA. The pump, a NEMO® progressing cavity pump for high-density solids, was developed at the company headquarters in Germany, the factory in Brazil designed and built the components and the pump was then assembled, tested and shipped in the United States. This pump is not only evidence of the smooth and efficient worldwide processes of the globally active company, but also of its productive success. With its 8 production and assembly sites and numerous subsidiaries, NETZSCH sets a benchmark for global production and internal process reliability.
NETZSCH Pumps & Systems comprises 8 production and assembly sites in Europe, China, India, South America and the USA as well as 30 sales companies and over 200 representations worldwide. It offers a portfolio of three pump technologies – the NEMO® progressing cavity pump, the TORNADO® rotary lobe pump and the NOTOS® multi screw pump – as well as dosing technology, grinding systems and an extensive range of accessories, for use in almost any industry. The company has developed from a manufacturer of progressing cavity pumps – a segment where it is still the technology and world market leader – to a solution provider who offers positive displacement pumps with different technologies in a unique way and supports customers even with complex requirements.
Smooth, worldwide communication as a recipe for success
The international corporate communication processes are complex. They require clear and defined coordination between the countries, so employees can support each other with a clear understanding of the company and its products and services. The 1,000,000th pump, a progressing cavity pump for dewatered sewage sludge, was developed at the company headquarters in Germany, the factory in Brazil designed and manufactured the components and the NETZSCH team in the USA was responsible for the final assembly. This smooth process is reflected in the clarity of the brand image, products and services, which NETZSCH communicates worldwide with Proven Excellence. Proven Excellence is both a value proposition and a performance commitment. NETZSCH uses this slogan to promise its customers excellent products and services in all areas. That the company is capable of delivering on this promise has been proven time and again since its foundation in 1873, and that is clearly reflected in the loyalty of its customers.
The 1,000,000th pump: a NEMO® progressing cavity pump individually selected from a modular system
The 1,000,000th pump, a NEMO® progressing cavity pump, was built for the sewage treatment plant in the city of San Mateo in northern California. The plant processes around 60 million litres of wastewater every day. In 2017, a problem occurred with the conveying of sludge cake. The double piston pumps which were previously used for transporting the dewatered sludge could not cope with the extreme requirements and a permanent, maintenance-friendly solution with lower lifetime costs was needed. The San Mateo sewage treatment plant has been a customer of NETZSCH Pumps North America for many years and was confident in approaching the pump specialist with this request. The specifications and special requirements of the project were reviewed. San Mateo’s goal was to produce sludge cake with the lowest possible water content. The higher the water content, the higher the volume of sludge to be disposed, which in turn increases transport costs. For this reason, the target is a high solid content of approx. 18 to 22 %. The drier the medium, however, the more difficult it becomes for the pumps to convey. NETZSCH Pumps North America has excellent experience with pumping dewatered sludge cake and was able to obtain this order. Two large NEMO® hopper pumps with attached aBP modules® — to prevent bridging of the dry sludge — will be used in San Mateo in the future. Asked which difficulties this application presents for the pumps, pump specialist Jeff Bye from NETZSCH replies confidently: "This application is no problem for us. Our NEMO® pump is the perfect solution for transporting dewatered sludge and will function reliably in the long term."
NEMO® hopper pumps are part of the extensive NEMO® range known today. It is characterised by the benefits of its modular design, the media-dependent options for shaft sealing and joints as well as the geometrically stepped sizes for the rotor and stator conveying elements. A block construction design is developed from the basic design of the bearing block pump: with a consistent modular approach, the BO and SO models are developed as hopper pumps with optional aBP modules® as bridge breakers, the SF as a sludge pump with screw conveyor and the BT as a submersible pump. In addition to this, the grinders, M-Ovas® cutting plate macerator and N.Mac® double shaft macerator, protect the pumping equipment and ensure that solids are reliably reduced to a pumpable size. Therefore the danger of blockages are safely avoided, to reliably meet every demand of the environment industry.
Additionally the TORNADO® rotary lobe pumps and NOTOS® multi screw pumps from NETZSCH are available in a variety of application-specific variants, allowing NETZSCH to find the right pump for virtually any application worldwide. With this confidence, NETZSCH relies on and builds its future together with its customer from around the world – until the next million.
Source & Picture: NETZSCH Pumps & Systems
Progressing cavity pump from NETZSCH ensures efficient conveying of cold asphalt
The NEMO® progressing cavity pump from NETZSCH has been used at Company for the application of road surface coatings since April 2018. With a pressure of 5 bar, it pumps 1 m³ of the resin/sand/silver sand mixture per hour.
A Dutch company has developed a technology for quickly clearing roads for traffic after repairing minor surface damage such as scoring, milling or accident damage. A special fast-curing, resin-based repair asphalt is mixed in a special vehicle directly on site and applied to the surface. The great advantage of this method is that the surface is ready for traffic again in less than an hour. To further increase the efficiency of the process, a NEMO® progressing cavity pump from NETZSCH Pumpen & Systeme GmbH in Waldkraiburg/Germany has been used since April 2018 to pump the highly abrasive substance from the vehicle tank through the mixer.
As surface damage can endanger road users, it should ideally be repaired as soon as possible – especially as delays will create further wear on the affected area. The technology from the Dutch specialists in the application of road surface coatings is a way of carrying out these repairs very quickly, efficiently and with lasting effect. The technology is suitable for asphalt seams, rim damage, scoring and surface damage. The process differs from others in that only the damaged area of the asphalt surface is removed, rather than larger areas. Usually this can be within 15 minutes after application of the compound. Normally, the blocked section can be opened to traffic again within 15 minutes after application of the mass.
Mixing of the repair material using progressing cavity technology
“To get the special mortar ready for use, the cold asphalt mixture is stored in a tank with an agitator and pumped through the mixer, in a special vehicle directly on site,” explains Max Waser, Engineer Internal Sales bei NETZSCH Pompen Nederland. “The same vehicle then spreads gravel from a reservoir over the cold asphalt.” Until April 2018, a rotary lobe pump was used for the first step of pumping the mixture of resin, sand and silver sand. The pump had to be operated at speeds of around 250 to 300 rpm and suffered high levels of wear due to the highly abrasive medium. “This especially affected the elastomer lobes – in the end the company for the application of road surface coatings had to replace them every two to three weeks, so the vehicle was often out of operation,” explains Waser. Those responsible therefore decided to replace the previous rotary lobe pump with a more suitable progressing cavity pump with less pulsation and wear. A NEMO® progressing cavity pump of type SY from NETZSCH was selected: Due to its special displacement principle allowing smooth pumping with low shearing and pulsation, this pump type is ideal for use on the specialized repair vehicle.
The main components of the pump type are a rotating component – the rotor – and a fixed component – the stator – in which the rotor oscillates. The precise geometrical mating means that conveying chambers are maintained between the stator and the rotor. These chambers continuously move from the intake to the discharge side and transport the medium. The volume of the conveying chambers remains constant with this technology and the actual chambers are self-contained. This ensures that the conveyed medium is moved at stable volume and pressure, so that no shear forces and hardly any pulsation occur which could have a negative impact on the medium.
Low speed and double capacity
The volume of the conveying chambers remains constant with this technology and the actual chambers are self-contained. This not only prevents backflow, but also ensures that the conveyed medium is moved at stable volume and pressure, so that – in contrast to rotary lobe pumps – no shear forces and hardly any pulsation occur which could have a negative impact on the medium. In addition, the consistency and viscosity of the medium are insignificant in terms of product flow with this displacement technology. The progressing cavity pump is therefore ideal for the cold asphalt which has a temperature of 20 °C and a viscosity of 7,000 to 10,000 mPas.
The size of the conveying chambers and therefore the theoretical delivery rate depends on the size of the pump. A 360° rotation when the outlet is free produces the volumetric delivery rate per revolution. In the process, the volume conveyed is directly proportional to the speed, enabling accurate dosing. “We selected the largest possible pump model for our customer which makes optimum use of the space on the vehicle and also ensures low rotation,” explains Waser. “This allowed us to achieve values of around 50 to 75 rotations per minute, meaning particularly slow and precise pumping.” At the same time, the capacity of the pump was doubled to 1 m³/h at this speed.
Particularly wear-resistant design
The NEMO® SY model now used by the customer also features a design with free shaft end, grey-cast iron housing, coupling rod with mixing elements and rotating components made of stainless steel 304 or 316. These materials are particularly corrosion resistant and ensure a long service life of the pump.
The NEMO® progressing cavity pump from NETZSCH has been used at the Dutch specialists in the application of road surface coatings since April 2018. With a pressure of 5 bar, it pumps 1 m³ of the resin/sand/silver sand mixture per hour. Thanks to the stainless steel components and the EPDM elastomer components, the pump has been running without problems so far. That it works without malfunctions in contrast to the previous model has a positive effect on the curing time of the repair asphalt: “If the components of the medium are mixed well continuously, which is supported by the coupling rod with mixing elements, the mortar now needs less time to fully cure. So the road can be cleared for traffic even sooner,” explains engineer Max Waser.
Source & Pictures: NETZSCH Pumps & Systems
This change is particularly positive at pumping media with crystallizing MAP
Until early 2013, a conventional rotary lobe pump was used to pump centrate into the aeration tank of a wastewater treatment plant in Bavaria, Germany. However, significant signs of wear appeared quickly, particularly on the elastomer lobes, due to the high content of magnesium ammonium phosphate (MAP) in the water. The unit required frequent maintenance. For this reason, the decision makers decided to replace the pump with a more robust and reliable model. They chose TORNADO® T2 T.Envi® rotary lobe pump by NETZSCH Pumpen & Systeme GmbH from Waldkraiburg, Germany. It is specially tailored to the requirements on site, and thus guarantees maximum operational safety. Wear could be minimized due to the reversal of material, typical of this particular model series, where metal lobes rotate in elastomer housing. This sets the T2 apart from rotary lobe pumps made by other manufacturers.
Wear could be minimized due to the reversal of material, typical of this particular model series, which makes the metal lobes insensitive to the difficult medium. A big advantage of the NETZSCH TORNADO® T2 T.Envi® rotary lobe pump.
"Water discharged from the centrifuge - that is, the centrate, which is then pumped into the aeration tank - is contaminated with ammonium, nitrogen and MAP," explains the plant supervisor. "The latter is a salt of ammonium, magnesium cations and phosphate anions, which crystallizes during the pumping process. It caused premature wear of the conventional rotary lobe pump, which was used until January 2013. "It affected mainly elastomer lobes. Their tips showed wear on a regular basis, because most of the dynamic forces act on these components. As a result, it was necessary to service the unit annually.
T.Envi® - wear-free since 2013
In order to avoid this effort in the future, the plant managers decided to replace the previous model with TORNADO® T2 rotary lobe pump of the T.Envi® series. Maximally robust and long-lasting design was at the heart of the development of this type of pump. Its characteristic feature is a reversal of material: Based on decades of experience with progressing cavity pumps, the lobes in NETZSCH rotary lobe pumps of the new generation are made of hardened steel. Pads vulcanised onto the edges of the lobes create continuous hard-soft contact at any time during rotation, like in progressing cavity pumps. This prevents high-wear friction of rubber against rubber, which is typical for other models. The specially attuned shapes of the rotary lobes and housing not only improve the pumping capacity, but also reduce friction and energy consumption. The rotary lobes run in a rubberised and flow-optimised housing.
The T.Envi® has been in service at the German sewage treatment plant since February 2013. Its special design dramatically reduced pump wear: The metal lobes are insensitive to the difficult medium and do not wear out.
Extended service life and simple maintenance
Extremely high-quality materials and components were also used for the other parts of the rotary lobe pump. Torsion- and bend-resistant shafts, for example, guarantee reliable operation even at high pressure. Robust angular contact ball bearings guarantee the axial and radial stability of shafts and rotary lobes. The belt drive ensures that the pump unit operates extremely smoothly. This results in a reduced load and fewer vibrations, which affect the components. The service life is thus significantly longer overall.
The maintenance is also much simpler, compared to the previous rotary lobe pump. Since the sys-tem is not lubricated, time-consuming lubricant changes and the risk of leakages are a thing of the past. If T.Envi® requires service or repair nonetheless, direct access to the pump chamber means work can be performed quickly and, above all, easily. After removing the drive cover, also the en-tire synchronised belt drive can be accessed. Workload is kept to a minimum and downtimes are shorter.
The management of a German wastewater treatment plant decided to replace its previous rotary lobe pump with a TORNADO® T2 T.Envi® pump by NETZSCH Pumpen & Systeme GmbH. It is specially tai-lored to the environmental requirements on site, and thus guarantees maximum operational safety. The T.Envi® has been pumping centrate into the aeration tank since February 2013 - with an annual conveying volume of approximately 22,000 m3, but no wear.
Source & Pictures: NETZSCH Pumpen & Systeme GmbH
This pump from NETZSCH performs bilge pumping and conveying tasks maintenance-free in extremely limited space
Look behind the scenes
Two things are severely limited on ships: space and time. Compactness is particularly vital in the machine room, as each centimeter means a loss at the expense of valuable transport capacity. At the same time, the systems have to be robust, as manpower can hardly be switched to repairs at sea and interim port stops are to be avoided at all costs for reasons of time. So maximum demands are placed on safety-critical systems such as bilge pumps.
Compact, weight-reduced, robust and simple to use – the main requirements for pumps in ships. The pumps must also be as versatile as possible for universal use to keep down the cost of servicing and spare part provisioning.
TORNADO® rotary lobe pumps have been performing the job reliably for years. NETZSCH is now offering additional advantages with the new generation, TORNADO® T2. The new drive concept and the more compact pump design make the system practically maintenance-free and reduce the required installation space to a minimum. The heart of the TORNADO® T2 is an oil-free synchronised gear with belt drive instead of a complex and space-eating timing gear. The new gear not only reduces the weight of the pump by at least 30 percent, the entire mechanism is also almost error-free and the range of spare parts is thankfully low. As the system is not lubricated, time-consuming lubricant filling and the risk of environmentally hazardous leakages are a thing of the past.
The TORNADO® from NETZSCH Pumpen & Systeme GmbH has proved its worth in ships over many years.
Statistics tell us that every German citizen eats around 9.5 kg of chocolate a year, in the form of bars, hollow figures, pralines and such like. There is a particularly steep rise in consumption at Easter and Christmas. The sweet may be very popular, but it is extremely complicated to make. In particular, the temperature has to be precisely controlled at all times to achieve the later melt-in-your-mouth effect. To avoid there being any gap in the processing chain here, NETZSCH Pumpen & Systeme GmbH has developed a special tempering positive displacement pump. It is designed to meet the strictest hygiene requirements and is also easy to clean. “Chocolate pump” at NETZSCH means a special designed progressing cavity pump. Because of a really wide range of tasks in chocolate production there is also a rotary lobe pump with simi-lar features in a compact full-metal design, the T.Sano®.
The secret of high-quality chocolate is ensuring that the fat crystals contained are configured in the best possible way. This is directly dependent on tempering. If the temperature is too high or too low, chocolate will no longer melt in your mouth or will not have an attractive, shiny finish, but a milky, lacklustre look instead. The viscosity also changes along with the crystal content, and this may lead to problems further on in processing or when filling. Tempering is therefore crucial in terms of quality: Good chocolate needs smooth conveyance at a constant temperature.
An adjustable heating jacket has been added to the NEMO® progressing cavity pump for tempering. This encloses the whole length of the pump, from the mechanical seals to the pressure ports. It allows the required heat to be kept constant through the various stages of the process. As an option, the complete heating module can also be split into several sections which are controlled separately and can generate different temperatures. This means it is possible for instance to ensure a permanent supply of heat to the mechanical seals, where the fats otherwise often cool down and crystallise.
In order to meet high hygiene requirements in the food industry, the pump has been fitted with open pin joints. These are constantly flushed by the medium which inhibits the deposit of product residues. All wetted surfaces have also been given a polished finish and highly-hygienic mechani-cal seals with no dead spaces have been fitted. The materials used, especially the elastomers, are approved by the FDA and the pumps meet the requirements of the Federal Institute for Risk As-sessment (BfR), along with those of the Russian GOST-R.
The TORNADO® rotary lobe pump was equipped with appropriate features to fulfil the same re-quirements for product protection, residue-free conveying and hygiene.
The model T.Sano with smooth design is a hygienic rotary lobe pump. Its function is based on two rotary lobes in counter-rotation. This moves the medium gently, but continuously from the intake to the discharge side. For the conveyance of chocolate excluding pressure fluctuations or shear forces is fundamental. Additionally, the specially designed internal geometry of the delivery chamber keeps any pulsation at a very low level, ensuring a gentle, continuous product flow. To guarantee the flow of the chocolate it is possible to add a heated lid.
The pump is particularly suitable for use in chocolate and confectionery production due to the material selection. All components used in the T.Sano® rotary lobe pump that come into contact with the medium are made of stainless steel to comply with food safety guidelines. The special oil-free drive of this pump type also helps to protect products and consumers. A toothed belt trans-fers the torque from the motor to the rotary lobes while synchronising their rotation. The motor runs completely without oil, which excludes product contamination. This drive type also makes the pump very compact. The motor is flanged on above the delivery chamber to save space. This also results in a relatively low weight and extremely small installation depth which makes it possi-ble to install the unit into tight spaces. In addition, the cooling ribs in the area of the pump bearing were removed from this type of rotary lobe pump in 2017. Instead, it now has a completely smooth housing to which virtually no dust or dirt can adhere. As a result the pumps are not only EHEDG certified they are also certified with the American 3-A-Certificate.
Food grade elastomer compound allows medium temperature up to 200°C
NETZSCH Pumps & Systems announces the immediate release of a new elastomer compound available in stators for NEMO progressing cavity pumps and housing liners for the TORNADO rotary lobe pumps.
Production of compound
The new compound is suitable for product temperatures from -5° Celsius up to 200 degrees Celsius for stators and up to 160° Celsius for the housing liners and also comes with a FDA certificate for use in food quality applications.
Quality control and laboratory
In addition the new compound, in-house developed and marketed under the brand name “NEMOLAST91” has improved wear resistance over an earlier version and absorbs less water than previously was the case.
Development of new compounds
If you have any questions please do not hesitate to consult NETZSCH Pumps & Systems.
An exclusive study, commissioned by the Wirtschaftswoche magazine and conducted by the Munich Strategy consulting firm, has the answer. This was already the fifth time that the power of innovation of 3500 German small and medium-sized enterprises (SME) was analysed. The consulting firm evaluated balance sheets and presentations and conducted interviews with managing directors, customers and competitors to calculate an innovation score. A third of this score depends on the revenue and profit development and two thirds on the power of innovation of the SME. This results, among other things, from which and how many new products a company launches, how much it spends on research and development and how innovative its competitors think it is.
We are pleased to announce that NETZSCH Pumps & Systems GmbH, one of the member companies of the Star Pump Alliance, was ranked 11th. In addition to the recently published record result, the numerous innovations recently launched by the company were certainly responsible for this achievement. These include products with the FSIP design, ever new series of the TORNADO rotary lobe pump – especially the T.Sano hygiene version – but also the xLC unit for tripling the service life of progressing cavity pumps.
For all new products placed on the market by NETZSCH, customer requirements are always the driver for innovation. In this regard, all innovations in recent years followed the FSIP concept: Full Service in Place, meaning that technical service is conducted at the place of installation. Products with a particularly service-friendly design additionally reduced maintenance times by up to 70%. This benefits operating companies with a high maintenance workload as well as those who only have limited in-house maintenance personnel. The statement from Sebastian Theopold, founder of Munich Strategy, in the Wirtschaftswoche highlights that this is the right path to success: To successfully sell new products, you have to better identify your customers' needs.
Another smart component was added to the product portfolio of the NEMO® progressing cavity pumps: the xLC® unit which is based on the iFD® stator 2.0. This triples the service life of the pump, particularly when conveying difficult, abrasive media – especially for the operator this is a major benefit as the breaks and efforts for maintenance are reduced as well as the amount of spare parts. When wear occurs in the rotor-stator system, this new unit allows the performance of the pump to be re-established by adjusting the tension between the conveyor elements.
It is important for the xLC® stator adjustment system that the elastomer in the rigid metal sleeve of the stator is flexible, which was made possible with the development of the proven iFD stator® 2.0. The xLC® adjustment system uses this characteristic that the elastomer is not vulcanised into the housing but rather fixed through axial pressing. To regulate the tension in the rotor-stator system, the elastomer in the sleeve is extended by pulling or shortened by pressing, which changes the tension between the pumping elements. In case of wear, compressing the elastomer increases the tension and re-establishes the reduced sealing line.
How it works: If the stator has to be adjusted due to declining performance of the pump, the only two setting screws of the system are adjusted, compressing the elastomer in-sert in the metal housing once again. A scale with seven defined stop points facilitates gradual adjustment of the stator with the setting screws while also showing the remaining potential until stator change.