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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