Applied Bionics in Pumps For Hydrotranport & Process
Applied Bionics in Pumps For Hydrotranport & Process
Applied Bionics in Pumps For Hydrotranport & Process
Who is FeLuWa ?
Fe
: Feuer ( Fire )
Lu
: Luft
( Air )
Wa : Wasser ( Water )
Market Segments
Applications
Hydrotransport
Fly & Bottom Ash
Tailingstransfer
Gasifier / Autoclave Feeding
Mine Dewatering
Digester Feeding
Spray Dryer Feeding
Abrasive, corrosive, viscose, homogeneous and especially heterogeneous media
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History of FELUWA
Founded in 1901 as pump manufacturer
Mrlenbach New Works in 1982
Flat & Hose-diaphragm pumps since the 1970ties
Joining the ARCA Flow Group in the year 2000
MULTISAFE double hose-diaphragm pumps from 2001
Design and Innovation Awards in 2003 till 2010
New Office Building and Training Center in 2009
No. E 004.009-1
Centrifugal Pumps
use excess water to transport solids
# Dealing with the rescource WATER
# Excessive energy consumption due the excess WATER
have a hydraulic efficiency of 70% (if new)
Double Hose-Diaphram Pumps have 97%
# energy consumption of PD pumps is 15-25% better
due to up to 35 m/s impellers and wear plates are worn within 2000h
Double Hose-Diaphragm will stand 8000 h and more.
# cost for the parts, recycling cost, environm., CO2, (pro PD)
# operation safty and reliability (pro PD see Multisafe)
Pump Characteristic
- Centrifugal versus PD Pump Centrifugal Pump
Head [bar]
Pressure [bar]
Speed
Capacity [m/h]
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Capacity [m/h]
Copyright FELUWA Pumpen GmbH
Decission Process
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Project Dimensions
Slurry
capacity
pressure
distance
(m/h)
(bar)
(km)
Bauxit
2000
90
240
Cu/Zn
2500
140
300
Bauxit
500
250
150
Cu/Ni/Co
2250
50
10
Minerals
1500
130
700
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No. of PS
Bionics in Pumps
or the
Evolution and Characteristics
of Hose-Diaphragm Pumps
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Piston
Inlet
14
Outlet
Suction stroke
Discharge stroke
Piston
Inlet
Piston
Inlet
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Outlet
Flexible hose
Piston
Piston
Hydraulic liquid
Inlet
Inlet
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Evolution of Pumps
- Hose-Diaphragm Pump Outlet
Outlet
Piston
Inlet
Piston
Inlet
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Evolution of Pumps
- Hose-Diaphragm Pump Housing
Outlet
Piston
Diaphragm
Pumped medium
Inlet
Hydraulic liquid
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FELUWA 1960
traditional design
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20
v
v vv v vv
v
v
v
v
v
v
vv v
v v
v v vv v v
v
v v
v
v
v
v v
v v
v
v
vv
v
v v
vv
v
v
Initial situation
MULTISAFE Pumps
- Double Hose-Diaphragm -
Double safety
Inner
diaphragm
Both hose-diaphragms
are in direct contact
Outer
diaphragm
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Hose-diaphragms are
never stretched!
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Up to 1000m/h 4400gpm
Up to 320bar 4640psi
5 Heads
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MULTISAFE
Double Hose-Diaphragm Pump
Efficiency
Efficiency
Energy
Lifetime
Availibility
Changing Time
Downtimes
Investment
&
Operating Exp.
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Spares
Maintenance
Availibility
Valve System
Ball Valves
Quick Change
Diagnostic
Downflow
Multiple Pump
Control
Foliennr.
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Double hose-diaphragm
filling ratio =
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pumped volume
max medium volume
Pumped medium is
in contact with
diaphragm, only
Example: ZGL 300/250 2K 180 4 SM 460 HD Example: TGK 300/250 K 180 DS 100 HD
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Valve Types
- Corner vs. Linear Valves -
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No. E 2201103-2
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Closed position
Heinz M. Ngel
Valve Types
- Ball Valve Assembly -
steel sealing
Foliennr.
32
revearsable
valve seat
Foliennr.
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Special Configurations
- Double Valves -
Double Valves
Double valves are used for
critical processes, which do not
allow an interrupted flow.
Double valves provide doublesafety against smallest leakages.
Double valves reduce the wear of
the valves and increase
maintenance intervals.
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Diagnosis Systems
- Energy Loss in Case of Leaking Check Valves Leakage in discharge and/or
suction valve
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Diagnosis Systems
- FELUWA Valve Performance System (FVPMS) -
Valve
sensor
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Energy
loss
Start of
valve wear
Time
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Power
Flow Rate
Energy Savings by
Valve Wear Detection
Bladder
accumulator
Additional
air cushion
(air vessel)
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Multiple Pumps
- Pressure Pulse Optimisation -
Pump 1
Pump 2
Pump 3
or
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Optimized
phaseshift
3
2,2%
23,2%
23,2%
1
3 triplex pumps
without phase shift
3 triplex pumps
with optimized phase shift
0
0
100
200
300
400
500
Crankshaft angle []
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600
700
Pump 1
Resulting flow to
pipeline
Optimized
phaseshift
Pump 2
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Homogeneous
MIXTURE
Heterogeneous
Length of
discharge
stroke
Low
sinking rate
Sinking
rate
High
sinking rate
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Special Configurations
- Downflow Transport Downflow Technology
in everyday life!
Flow
PD Ketchup Pump
(hand-operated)
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Downflow Configuration
=
Flow from the top to the bottom
of the pump
Downflow Configuration is the
counteragent against sedimentation
inside the pump
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Hydro Transport
Boleo
750 m/h 46 bar
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Summary
Double hose-diaphragm pumps combines lowest energy consumption and
highest availability and reliability by
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Hydrotransport
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Pump type
Power [kW]
TGK 500
3.000
50 to 250
up to 750
QGK 500
3.500
50 to 250
up to 1000
(e.g. Boleo)
1.100
46
750
50
Pressure [bar]
Flow [m/h]
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No. E 2201052
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Heinz M. Ngel
No. E 2201051
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Heinz M. Ngel
Nr. D 2109499-21
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Heinz M. Ngel
No. E 2201085-1
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Heinz M. Ngel
FELUWA Multisafe
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FELUWA Multisafe
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FELUWA Multisafe
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FELUWA Multisafe
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FELUWA Multisafe
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