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Transfer Pump Cuts Maintenance Costs

A steel plant was at first using a progressive cavity pump in their abrasive gypsum slurry application. The rotor could not withstand the difficult conditions; its rubber stator and stainless steel rotor needed to be changed every 1 to 2 weeks. After replacing a conventional progressive cavity pump with a Flowrox transfer pump (LPP-T40 peristaltic pump), the plant saw a drastic drop in maintenance costs and lengthened maintenance intervals.

Application: Steel industry, Gypsum slurry from the pickling process

Challenge: Repeated maintenance breaks due to broken rotors

Solution: 1 Flowrox LPP-T40 transfer pump

Results: Cut maintenance costs and extended service intervals

Flowrox Transfer Pump in the Process

The process in question is feeding pickling acid flushing water to a thickener and then its neutralization. This kind of slurry is extremely abrasive and causes high wear on pumps especially in high pressure solutions like the filter feed. The progressive cavity pump rotors kept failing and the customer was looking for a better solution.

Flowrox pump specialists suggested transfer pump LPP-T40. The biggest benefit is a resistant rubber hose which is the pump’s only wearing part. Even when the hose starts to leak, it takes less than an hour to change it.  The Steel plant noticed that for then, the payback time was only a few weeks and the total cost of pump ownership in this part of the process is drastically lower than before.

transfer-pump-steel-process-flow-Flowrox

Let’s have a look at the process flow. The LPP-T40 operates as an underflow pump and transfers the slurry from the thickener to a vertical plate pressure filter five meters above the pump. The total length of the discharge line is 10 meters.

Process conditions:

  • Specific gravity: 1.3
  • Solids Content: 30 %
  • Temperature: 30°C
  • Medium: Abrasive pickling slurry

Operating in cycles, the transfer pump keeps the filter tank pressure between 5 and 8 bar (g). The pump starts when the pressure decreases to 5 bar during the filtration process and stops once the pressure reaches 8 bar (g) in the filter feed line simultaneously pressurizing the in-line pressure accumulator. The maximum flow of the pump is 3 m³/h at a speed of 41 rpm. The LPP-T is equipped with a 2.2 kW helical bevel geared motor.

Overall, changing from a progressive cavity pump to a transfer pump (peristaltic principle) was definitely a good investment.

Key benefits

Reduced maintenance costs

Extended service intervals

Lower total cost of ownership

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