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Energy Efficient Pumping Innovative Pump Designs Combine Energy Efficiency and Serviceability

| Author / Editor: Hisham Kamal / Dr. Jörg Kempf

The German pump specialist Netzsch is working on the development of holistic, eco-friendly technologies which conserve natural resources but still deliver low-cost operation. The company has made sustainability a priority during pump production and ongoing operation as well. New mindsets and innovative designs are needed to achieve that goal.

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Netzsch has moved beyond conventional designs on its progressing cavity and rotary lobe pumps, and has made significant enhancements in energy efficiency, material consumption and serviceability.
Netzsch has moved beyond conventional designs on its progressing cavity and rotary lobe pumps, and has made significant enhancements in energy efficiency, material consumption and serviceability.
(Picture: Netzsch)

Netzsch has established an ambitious set of goals: high system availability, low total cost of ownership and continual process optimization along with responsible management of materials and energy resources. One example of this is the latest generation rotary lobe pump. Taking the basic operating principle as the starting point, the Tornado T2 has been completely re-engineered. By changing the materials used, the designers have reduced wear, pulsation and energy consumption.

A Significant Difference to Common Pump Designs...

One of the biggest differences compared to previous pumps of this type is the use of different materials in the pump chamber. On conventional rotary lobe pumps, two elastomer rotors, which can have complex helical shapes, rotate inside a steel housing. One disadvantage of this design is high dynamic loading which places stress on the rubber during each rotation and significantly accelerates material aging. In addition, the rotating lobes repeatedly come into contact with each other, causing wear.

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To prevent this, the rotors on the new-generation pumps are made of steel or stainless steel. They are much harder wearing and withstand the continuous dynamic load for longer. A precision elastomer liner vulcanized onto the edges ensures that at any point during the rotation contact between the lobes is always hard-soft.

A New Material Helps to Save Energy

Most importantly, the new material combination reduces energy consumption. Because the only contact is elastomer to steel, there is a reduction in friction and power loss. In addition, the thin elastomer liner is much less susceptible to temperature fluctuations than the thick conventional elastomer rotors. Dimensional variations are much smaller and easier to manage. As a result, various components can be produced with tighter tolerances. The gaps are very small and that increases system performance and efficiency. Together, these design enhancements reduce energy consumption by around 10 % compared to the previous pump designs...

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