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Pumps for high-temperature technology
STERLING FLUID SYSTEMS GROUP
HOT WATER
Most of the processes in industrial process engineering take place where energy
is absorbed or released simultaneously.
Only a defined temperature level enables
the required reactions or working processes in plants to take place. For precise
control of the process the indirect heat
input using heat carrier liquids is adventageous. In this case a heat transfer medium
is circulated between the heater and heat
consumer. The working temperatures in
these heat carrier circuits are mainly between 100 °C and 400 °C. Different heat
carrier liquids can be used for the transfer
of energy to the heat consumer.
In the temperature range up to approximately 200 °C, water is the preferred
medium as it is non-polluting and has a
high specific thermal capacity. In the temperature range from 200 °C to 400 °C,
organic heat transfer liquids are preferable because the vapour pressure also
rises considerably when the temperature
increases. For handling these heat transfer
media, volute casing pumps have been
specially developed. Because of the
different physical properties of the heat
transfer liquids the hot water pumps are
different in design to the heat transfer oil
pump.
Technical data:
Output: 200 m 3/h
Delivery head: 60 m
Temperature : max. 160 °C uncooled
Casing pressure: PN 16
Material: GGG 40.3 (Ductile iron)
100 -160 °C uncooled
100
80
p
bar
60
ZLI
water
40
Inline hot water pump
range of organic
heat transfer oil
20
100
200
300
400
500
t
°C
Comparison between the vapour pressure of
water and of organic heat transfer liquids
The economical inline design is becomming more acceptable where hot water is
used, as it can be directly mounted into
any pipework system. The ZLI uses a stub
shaft connection which makes it possible
to use a standard motor, giving the pump
a compact design. The max. pumping
temperature for the uncooled ZLI in the
hot water design is limited to 150 °C. The
back pull out design allows the disassembly of the complete pump unit without
removing the pump casing from the
pipework.
ZLN
Standard hot water pump
Up to temperatures of 160 °C, the ZLN, a
standard water pump in accordance with
EN 733/ DIN 24255 , can be used with an
uncooled, balanced mechanical seal.
Product circulation ensures that the
mechanical seal is permanently surrounded by the medium thus preventing dry
running. In plants where the necessary
vapour pressure cannot be maintained,
the ZLN with a throttling device is used.
The throttling device maintains a sufficient pressure level in the mechanical seal
chamber to prevent evaporation.
Technical data
Output: 150 m 3/h
Delivery head: 90 m
Temperature : max. 150 °C uncooled
Casing pressure: PN 25
Material: GGG 40.3 (Ductile iron)
ZLI
ZLN
160 - 230 °C uncooled
The design of conventional single-stage
hot water pumps is based mainly on
standard pumps to EN 733/DIN 24255 and
EN 22858/DIN 24256. Modification to the
seals makes these pumps suitable for
specific requirements.
230 °C
205 °C
180 °C
155 °C
130 °C
105 °C
80 °C
55 °C
mechanical seal
The pumping of hot water makes high
demands on the pump design. Safe operation is influenced, to a high degree, by
the mechanical seal. Therefore the parameters of pressure, temperature and
sliding speed at the mechanical seal are
optimised so that the service life is considerably increased.
30 °C
Thermo-photograph of a ZEN hot water pump
ZEN / ZDN
The hot water pumps
Many other manufacturers of pumps and
mechanical seals allow standard pumps
with uncooled shaft seals to be operated
at temperatures up to 180 °C. However,
high thermal stresses, friction, insufficient
margin from the vapour pressure as well
as deformation of the seal surfaces may
lead to a short service life and an unfavourable cost/benefit ratio.
Therefore, operation at temperatures of
more than 180 °C is only feasible using
expensive cooling measures. Althrough
these measures will reduce the operating
temperature at the mechanical seal, they
will, at the same time, increase the installation and operating costs.
ZEN
This is not the case with the ZEN, a volute
casing pump to EN 22858, where the
mechanical seal has been placed at the
“cold end“/drive end, of the pump. By
means of a double heat barrier, a favourable drop in temperature at the drive end
of the shaft is obtained. Even at inlet
temperatures up to 230 °C, the use of an
uncooled mechanical seal does not cause
any problems as the temperature will not
exceed 100 °C in the seal area.
HOT WATER
160 - 230 °C uncooled
When pumping hot water it is not merely
sufficient to place the seal at the cold end,
because this particular medium tends to
vaporise during heating. Due to centrifugal forces, gas bubbles will be deposited
on the smallest rotating parts, these being
generally the sliding surfaces of the
mechanical seal. The ZEN counters these
physical effects by using patented gas separator in the mechanical seal chamber. At
the highest point is a collecting chamber
for the resulting gases, which can be ventilated by a valve both during standstill
and start up of the plant. Vaporisation in
the mechanical seal chamber can also
be avoided as the chamber is
connected through the flushing
bore of the sleeve bearing so that
the consequential low temperature
maintains the liquid above its
vapour pressure.
Shaft deflection also contributes to
excessive wear of the shaft seal and
to overcome this, deflection has been
minimized in the ZEN by maintaining a short distance from the ball
bearing to the mechanical seal. The
sleeve bearing at pump end is hydrodynamically balanced and is lubricated by
the medium; it has a special geometry in
order to promote the proper flow of lubricant. The internal bearing is of wear-resistant tungsten carbide. This combination
has optimum properties for the handling
of hot water. The slotted pump feet compensate for thermal expansion and thus
prevent additional tension in the pipe
system.
This programme includes a multistage
centrifugal pump to cover the range up to
12 m3/h.
Additional
annual expediture of
cooling
water,
approx. 50%
Installation
cost for
cooling
water
supply 30%
Cost for
pump with
uncooled
shaft seal
100 %
The hydraulic parts of the ZEN 31 are
enclosed by a barrel. Dimensions of the
pipe connection remain unchanged, even
when the duty parameters are altered, because of the adaptibility of the hydraulic
parts. Apart from the hydraulics, this
pump is identical with the volute casing
design and consequently can be operated
uncooled up to 230 °C.
The series ZDN is based on the same
technology as the ZEN; the maximum
operating temperature is 185 °C.
Cost for
pump with
cooled shaft
seal 70%
Comparison of cost of ownership
above: Conventional hot water pump
below: The new generation of hot water
pumps ZEN
Technical data:
Output: 600 m 3/h
Delivery head: 90 m
Temperature : max. 230 °C uncooled
Casing pressure: PN 40
Material: GGG 40.3 (Ductile iron)
ZEN 31
100 - 350 °C uncooled HEAT TRANSFER OIL
Organic or synthetic heat transfer liquids
offer the possibility to heat or cool without
high system pressures.
350
300
200
In the course of the development of heat
transfer installations and their liquids, the
standard DIN 4754 has been compiled.
This standard determines, among other
things, safety requirements for the operation of pumps in hot oil circuits. Volute
pumps in accordance with EN 733/DIN
24255 are also generally accepted for this
specification.
100
°C
ZTK/ ZTI
Compact design thermal oil pumps
The ZTK and ZTI have been specially developed for installation in compact machinery. The series only differ from each other
in the shape of the pump casing.
The ZTK has a volute casing with axial
inlet and radial discharge branches, whereas the ZTI has an inline casing which
can be installed directly in the pipe
system. Both pumps are designed as
monobloc units and are fitted with a stub
shaft which makes it possible to use standard motors. Furthermore the stub shaft
principle is able to compensate for heat
stresses between the pump and motor.
The back pull out design allows the disassembly of the complete pump unit without removing the pump casing from the
pipe work system.
ZTI
ZTK
By means of the double acting heat barrier and a ventilation fan, a favourable drop
in temperature is obtained at the drive
end. Heat losses at the product end are
effectively prevented and the use of an
uncooled standard mechanical seal becomes possible. In order to prevent the
medium leaking from the pump in the
case of sudden failure of the mechanical
seal, a radial shaft seal ring has been
installed as additional protection.
Technical data:
Output: 200 m 3/h
Delivery head: 60 m
Temperature : max. 350 °C ungekühlt
Casing pressure: PN 16
Material: GGG 40.3
HEAT TRANSFER OIL 100 - 350 °C uncooled
ZTN
Thermal oil pump
The new series ZTN has been developed
for handling thermal oil up to 350 °C in
the heating prosesses. The increased
demands on operational safety, environmental protection and the reduction in
running expenses have consequently been
considered in this design. This also applies
to the standards DIN 4754 and EN 733.
All pressure loaded components are of
ductile materials, e.g. GGG 40.3 (ductile
iron). The complete field chart for the new
heat transfer pump is covered by 29 sizes
making it an economical selection for your
application. The heat losses of the ZTN
were able to be reduced considerably by
installing a heat barrier arranged behind
the hydraulics. Furthermore the pump is
fitted with a thermally isolated bearing
carrier. A sliding sealing cartridge compensates for possible thermal expansion
and thus prevents distortion between the
pump and coupling. By additional throttling a favourable drop in temperature in
the shaft seal area is achieved. This allows
the use of single, uncooled shaft seals.
Technical data:
Output: 1000 m 3/h
Delivery head: 90 m
Temperature : max. 350 °C uncooled
Casing pressure: PN 16
Material: GGG 40.3
Because of increasing environmental consideration, more stringent regulations are
being applied by various Health & Safety
authorities and the legal demands on
greater safety, glandless pumps are increasingly being used, in particular when
handling synthetic heat transfer liquids
which are considered as damaging to a
operators health. For these applications,
pumps with magnetic couplings are becoming more and more acceptable. A
leakproof magnetic coupling is the
optimum solution in such cases where
leakage to atmosphere of the heat transfer
medium must be totally prevented,
especially where oxygen is present. After
careful examination a plants requirements
and the required operating conditions not
only can permanent trouble free operation
be expected but also an active contribution to environmental protection be made.
By moving the magnetic coupling to the
cold end of the pump and keeping to the
standard dimensions (DIN 24255/56) we
have succeeded in operating thermal oil
pumps safely, without cooling, at inlet
temperatures up to 400 °C.
350
300
200
100
°C
range of the temperature
curve of ZTN
As an alternative, a cartridge of several
sealing rings or a mechanical seal can be
fitted.
The back pull out design allows the disassembly of the complete pump unit without removing the pump casing from the
pipe system.
Technical data – ZTK magnetic drive:
Output: max. 600 m 3/h
Delivery head: 90 m
Temperature: max. 300 °C uncooled
Gehäusedruck: PN 16
Materials: GGG 40.3 (Ductil iron),
stainless steel
ZTK
magnetic drive
Compact magnetic pump – up to 300 °C
uncooled
The ZTK magnetic drive in monobloc
design has proved successful when operating at temperatures up to 300 °C. This
magnetic coupling design is not only completely leakproof but also practically maintenance-free. New higher wear-resistant
sleeve bearings of silicon carbide/tungsten
carbide give a long service life and the
deep drawn isolating shroud, with a wall
thickness of 1,6 mm, offers additional
safety. The magnets are of high quality
samarium/cobalt (SmCo); their outstanding
ZTN
ZTK magnetic drive
100 - 400 °C uncooled – with magnet coupling
8
features are: high density magnetic energy, magnetic size and a high temperature
load limit. Unlike the bearing bracket
design, the alignment of pump and motor
is not necessary. The modular design of
the pump range ensures it is suitable for a
comprehensive range of applications. This
can be combined optionally with volute
casings as per DIN 24255/ 24256 or inline
casings. The robust costruction and the
possibility to mount an external filter for
partial flow also makes these pumps suitable for difficult applications.
1 2
400
ZTK
magnetic drive
With a heat barrier – up to 400 °C –
uncooled
For temperatures up to 400 °C, a design
with a heat barrier where a “dead ended“
magnetic chamber is used. The heat barrier separates the pump thermally from the
magnetic coupling and prevents heat flow
into the magnetic chamber. In order to
prevent the generation of additional heat
by eddy current losses in the metallic isolation shroud, a shroud of industrial ceramics (zirconium oxide) is used. This material is not conductive and therefore it does
not generate additional heat in the
magnetic chamber. It is possible therefore
to start the pump without venting the
magnetic chamber.
Technical data – ZTK magnetic drive
with a heat barrier:
Output: 600 m 3/h
Delivery head: 90 m
Temperature : max. 400 °C
Casing pressure: PN 25
Material: GGG 40.3 (Ductile iron),
stainlees steel GS-C25
ZTK magnetic drive with a heat barrier
3
1
2
4
3
5 6 7
4
9
10
5 6 7 8 9 10
11
11
12
12
13 14
13 14
350
325
300
250
200
150
100
50
°C
Pump temperature and temperature measure points
The application of ceramic isolation shrouds is also recommended
if the medium tends to polymerize, crystallize or solidify in case of
heat input. A throttle bush near
the internal magnet additionally
prevents heat entering during operation. The sleeve bearing at the
pump side is hydrodynamically
balanced and lubricated by the
medium; it has a special geometry in
order to secure proper flow of the lubricant. The internal bearing is of wear-resistant tungsten carbide, the external bearing of solid silicon carbide. This combination has optimum properties for the handling of thermal oils. The casings or the
pressure loaded components, are of GGG
40.3 or stainless steel respectively. Above
350 °C, according to DIN 4754 high-temperature steels are required which means
that cast steel GS-C25 must be used for
casings.
Otherwise the 400 °C design corresponds
to the previously mentioned version. At
present the max. temperature limit is
400 °C.
Sterling Fluid Systems (Europe)
www.sterlingfluidsystems.com/europe
Sterling SIHI GmbH
Lindenstrasse 170,
D-25524 Itzehoe, Germany.
Telephone: +49 (0)4821 77101
Fax: +49 (0)4821 771274
Sterling SIHI GmbH
Halbergstrasse 1
67061 Ludwigshafen, Germany.
Telephone: +49 (0)621 56 12 0
Fax: +49 (0)621 56 12 209
Sterling Berkefeld (Germany)
Lückenweg 5
29227 Celle, Germany.
Telephone: +49 (0) 5141 8030
Fax: +49 (0) 5141 803172
Sterling Fluid Systems (UK)
Theale Cross, Pincents Lane
Calcot, Reading,
Berkshire RG31 7SP, UK.
Telephone: +44 (0)118 932 3123
Fax: +44 (0)118 932 3302
Sterling Fluid Systems (UK)
Mansion House, Manchester Road, Altrincham,
Cheshire, England WA14 4RR.
Telephone: +44 (0)161 9286371
Fax: +44 (0)161 9252129
Sterling Fluid Systems (France)
Zone Industrielle de Trappes-Elancourt,
1-3 Avenue Georges Politzer, Boite,
Postale 41, F-78193 Trappes Cedex, France.
Telephone: +33 (0)1 34 82 39 00
Fax: +33 (0)1 34 82 39 61
Sterling Fluid Systems (Netherlands)
Havenstraat 22-28, Postbus 27,
NL 1940 AA Beverwijk, The Netherlands.
Telephone: +31 (0)251 263 232
Fax: +31 (0)251 226 309
Sterling Fluid Systems (Belgium)
Zone Gosset, ‘t Hofveld 1,
B-1702 Groot-Bijgaarden, Belgium.
Telephone: +32 (0)2 481 7711
Fax: +32 (0)2 481 7737
Sterling Fluid Systems (Italy)
Via degli Orsi e dei Boschi 7,
I-20093 Cologno Monzese (Milano), Italy.
Telephone: +39 (0)2 253 091
Fax: +39 (0)2 253 092 59
Sterling Fluid Systems (Austria)
A-1100 Wien,
Oberlaaer Strasse 228, Austria.
Telephone: +43 (0)1 680 050
Fax: +43 (0)1 680 0521
Sterling Fluid Systems (Spain)
Avenida Italia No. 2,
E-28224 Pozuelo de Alarcón (Madrid), Spain.
Telephone: +34 (0)91 709 1310
Fax: +34 (0)91 715 97 00
Sterling Fluid Systems (Schweiz)
Schweizersbildstrasse 25,
P O Box 110,
8205 Schaffhausen, Switzerland,
Telephone: +41 (0)52 6440606
Fax: +41 (0)52 6440616
Sterling Fluid Systems (Hellas)
4, Clisouras Street,
GR-176 72 Kallithea, Athens, Greece.
Telephone: +30 (0)1 9570783
Fax: +30 (0)1 9568121
Sterling Fluid Systems (Hungary)
Radnóti Ter 2/A,
H-8200 Veszprém. Hungary
Telephone: +36 (0)88 40 63 33
Fax: +36 (0)88 40 66 35
Sterling Fluid Systems (Czech Republic)
Kosmonautu 8,
CZ-77211 Olomouc, Czech Republic.
Telephone: +420 (0)68 551 66 51
Fax: +420 (0)68 551 66 53
Sterling SAT
Lindenstrasse 170,
D-25524 Itzehoe/Holstein, Germany.
Telephone: +49 (0)4821 77101
Fax: +49 (0)4821 771501
Sterling RWO
Leerkaempe,
28259 Bremen, Germany.
Telephone: +49 (0)421 537050
Fax: +49 (0)421 5370540
Sterling Berkefeld (Netherlands)
Cairostraat 55,
NL-3004 AC Rotterdam.
Telephone: +31 (0)10 2622525
Fax: +31 (0)10 2622822
Sterling Fluid Systems (Americas)
www.sterlingfluidsystems.com/americas
Sterling Fluid Systems (USA)
2005 Dr M. L. King Jr. Street,
P O Box 7026,
Indianapolis, IN 46207-7026, USA.
Telephone: (1) 317 925 9661
Fax: (1) 317 924 7388
Sterling Fluid Systems (USA)
303 Industrial Boulevard,
P O Box 460.
Grand Island, NY 14072-0460, USA.
Telephone: (1) 716 773 6450
Fax: (1) 716 773 2330
Sterling Fluid Systems (Canada)
225 Speedvale Avenue West,
P O Box 728,
Guelph, Ontario N1H 6L8, Canada.
Telephone: (1) 519 824 4600
Fax: (1) 519 824 7250
Sterling PCU
2280 West Dorothy Lane,
Dayton 45439-1882 Ohio, USA.
Telephone: (1) 937 299 5594
Fax: (1) 937 299 3843
Sterling Fluid Systems (Mexico)
Av. Milimex No. 115, Franco Industrias Milimex
Carr. Miguel Aleman Km. 16.5
Apodaca, Nuevo Leon Mexico CP666000
Mexico
Telephone: (52) 83 693 644
Fax: (52) 83 693 649
Sterling Berkefeld (Canada)
225 Speedvale Avenue West
P O Box 728
Guelph, Ontario, N1H 6L8, Canada
Telephone: (1) 519 824 4600
Fax: (1) 519 824 7250
Sterling Fluid Systems (Asia)
www.sterlingfluidsystems.com/asia
Sterling Fluid Systems (Asia)
37 Tech Park Crescent,
Tuas South Avenue 4,
Singapore 637851
Telephone: (65) 8630 828
Fax: (65) 8630 868
SIHI (Australia)
820 Mountain Highway,
Bayswater, Victoria 3153,
Australia.
Telephone: (61) 3 9720 1500
Fax: (61) 3 9720 4076
Sterling Fluid Systems (Malaysia)
No. 2, Jalan TPK 2/2, Taman Perindustrian
Kinrara, Section 2, 47100 Puchong,
Selangor Darul Ehsan, Malaysia.
Telephone: (60) 3 5700198/99
Fax: (60) 3 5700204
Sterling Fluid Systems (Philippines)
Suite 404 & 405, Alabang Corporate Centre,
Km. 25 West Service Road,
South Superhighway,
Muntinlupa City, Philippines.
Telephone: (63) 2 809 4908
Fax: (63) 2 807 2013
Sterling Fluid Systems (Hong Kong)
Unit 2605, Apec Plaza,
49 Hoi Yuen Road, Kwun Tong,
Kowloon, Hong Kong.
Telephone: (852) 2508 9025
Fax: (852) 2508 9032
Sterling Fluid Systems (Thailand)
1st Floor, Solid Group Building,
104 Thavorn, Patanakarn Road,
Suan-Luang,
Bangkok 10250, Thailand.
Telephone: (66) 2 321 8422/3
Fax: (66) 2 321 8413
Sterling Fluid Systems (Middle East/Africa)
www.sterlingfluidsystems.com/middle-east
Saudi Berkefeld-Filter
P O Box 9419, 11413 Riyadh, Saudi Arabia
Telephone: (966) 14982085
Fax: (966) 14982349
1,5-IV.00-14
150.22200.53.01 E
Sterling Fluid Systems (Middle East)
P O Box 61491, Jebel Ali, Dubai U.A.E.
Telephone: +971 (0)4 8838 733
Fax: +971 (0)4 8838 735
www.sterlingfluidsystems.com/africa
www.sterlingfluidsystems.com
Sterling Fluid Systems (South Africa)
8483 Edleen, 1625 Johannesburg, R.S.A.
Telephone: (27) 11 394 3922
Fax: (27) 11 970 2472