pumps for fertiliser production · 2016-09-05 · phosphorous, potassium, sulphur or sulphates,...
TRANSCRIPT
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Flexibility, reliability, long lifetimes, simple maintenance and low operating costs are the requirements placed on modern fertiliser production plants. Rheinhütte Pumpen continuously develops the Rheinhütte family of pumps for the fertiliser sector and today offers plant constructors and operators one of the most extensive ranges of pumps to meet these exacting standards.
RHEINHÜTTE PUMPEN THE RIGHT SOLUTION FOR FERTILISER PRODUCTION
CONTENTS
Fertiliser production page 03
Our product portfolio page 04
Our material expertise page 05
Pumps made from metal page 06 – 08
Pumps made from plastic page 09
Our services at a glance page 10
Success is born of experience page 1 1
RHEINHÜTTE PUMPENIf you want to solve demanding pumping tasks in
the chemical industry efficiently, permanently and
economically, you need more than just a coherent
technical concept. Experience of the application,
material knowledge and dialogue with you ultimately
lead to the optimum solution. A way which Rheinhütte
Pumpen has been following for over 150 years.
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RHEINHÜTTE PUMPEN MAKES PLANTS GROW
As well as sunlight, water and carbon
dioxide, plants also need nutrients
and certain trace elements in order to
grow. Providing agricultural crops with
these essential nutrients is of major
significance in today’s world. A plant
can only grow and flourish if it lacks
nothing. The use of suitable fertilisers
can often increase yields many times
over.
Rheinhütte Pumpen –
50 years experience in fertiliser
applications
The main nutrients are primarily nitrogen,
phosphorous, potassium, sulphur or
sulphates, calcium and magnesium.
What are often called “compound
fertilisers” (NPK) combine the primary
and most important elements nitrogen
(N), phosphorous (P) and Potassium (K).
But customised blends and formulations
are also common; the composition of
these blends vary with differing amounts
of primary nutrients and trace elements.
A further point is that the elements
needed by plants in the fertiliser must be
in a bio-available form. There are soluble
rapid release fertilisers, slow release
fertilisers and delayed release fertilisers,
each with a different formulation.
The market is therefore full of fertiliser
products. This wide variety is also
reflected in the manufacturing processes
of the various products and their basic
chemicals. When they have to be pumped
from place to place, these intermediate
products can take the form of suspensions
(slurries), liquefied materials or solutions.
The conveyance of each of these pumped
media can present particular challenges
to a centrifugal pump.
Alongside design adjustments, particu-
larly for the different fertiliser applica-
tions, the choice of material also plays an
important role in many cases. To ensure
that our customised pumps operate relia-
bly, we maintain stocks of a wide range
of special materials which are optimised
for wear and/or corrosion resistance.
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OUR PRODUCT PORTFOLIO
Parameter RCE RN RCEV GVSO R PROP
Assembly type Horizontal Horizontal Vertical Vertical Vertical
Qmax
m3/h (Us.gpm) 1.500 (6,600) 3.200 (14,090) 800 (3,520) 3.200 (14,090) 7.000 (30,820)
Hmax
m (ft) 180 (590) 150 (490) 80 (260) 170 (558) 7 (23)
Medium temperature max. °C
+ 450 + 300 + 160 + 550 + 150
Submersible depth max. m (ft)
––– ––– 2 (6,5) 18 (59) –––
Solid content max. % ~ 35 ~ 5 ~ 35 ~ 2 ~ 30
Impeller design Open, closed Open, closed Closed Closed Propeller
Shaft seal ring type
Hydrodynamic with and without
packing, mechanical seal
Hydrodynamic with packing, mechanical
seal
Lip ring seal, packing
Mechanical seal, packing
Mechanical seal
Materials
Wear-resistant materials, various stainless steels,
nickel-based materials, special
materials
Cast steel, various stainless steels,
nickel-based materials, special
materials
Wear-resistant materials, cast steel,
various stainless steels, nickel-based materials, special
materials
Cast steel, various stainless steels,
special materials
Various stainless steels in the form
of castings or fabricated parts,
nickel-based materials, special
materials
A WIDE RANGE OF DESIGNS FOR FERTILISER PRODUCTION
The Rheinhütte family of pumps offers
specific solutions for all industrial
processes used in fertiliser productions
and are distinguished by the flexibility
and range of designs. With due
consideration of the special require-
ments for the pumped media and the
express wishes of individual customers,
the “appropriate” Rheinhütte pump is
designed, the right material is chosen
and the optimum type of seal is
selected. This approach has ensured
that for more than 50 years we have
been a successful partner in fertiliser
production.
The pumps for fertiliser production
listed in the table below are presented
in detail in the following pages.
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OUR MATERIAL EXPERTISE
METAL
PLASTIC
STAINLESS STEEL
The standard austenitic grade 1.4408
is generally adequate for simple appli-
cations. However, as the corrosiveness
of the medium increases, highly alloyed
austenitic materials such as 1.4529S and
R3020 become advantageous. These of-
fer a high degree of corrosion resistance
including when exposed to highly acidic
and contaminated media.
Super-duplex materials such as 1.4517
have also proved their worth in pump
construction over very many years,
for example in applications involving
raw phosphoric acid and in phosphate
fertiliser plants. As duplex materials
offer excellent abrasion resistance as
well as corrosion resistance, they are
often an attractive alternative even in
difficult conditions.
Pumps made from the polymers PP,
PE, PVDF or PTFE/PFA represent an
alternative to metal pumps for many
suspensions or solutions. Plastic pumps
can often replace expensive metal
pumps without any loss of functionality.
These cases are often to be found
among pumps positions around the
periphery of the plant where plastic
NICKEL-BASED MATERIALS
Nickel-based materials are often the
best choice for dealing with extremely
corrosive pumped media. They are
distinguished by very good general
corrosion resistance as well as a high
level of resistance to special types of
corrosion and erosion. The C alloys such
as 2.4686 or 2.4602 have particularly
proved their worth.
SPECIAL MATERIALS
The range of metallic materials is
rounded off by special materials such as
the ferritic stainless steel 1.4136S as well
as molybdenum-free austenitic materials
such as 1.4306S and 1.4361. These two
materials are distinguished by particu-
represents an economic and therefore
advantageous solution. Media containing
particularly high concentrations of
chlorides or fluorides as well as highly
concentrated hydrofluoric or fluosilicic
acid can be mentioned in this context.
Emergency pumps or effluent pumps
made from plastic can also be an
attractive alternative.
larly good resistance to intercrystalline
corrosion and are specially suitable for
nitrate salt solutions, molten nitrate salts
and nitric acid.
On the other hand, 1.4136S is outstan-
dingly suited for use with media contai-
ning solids where the material needs to
exhibit excellent wear resistance. This
special material is also extremely resis-
tant to oxidising media.
RHEINHÜTTE PUMPEN – YOUR EXPERT IN INDUSTRIAL PUMP CONSTRUCTION
The potential presence of substances which can sometimes
be highly corrosive and/or abrasive means that fertiliser
applications are quite different from applications involving
easily manageable pumped media. Almost every type of
corrosion can be caused by these media with very different
compositions – as well as serious wear and erosion. The
choice of materials to meet these requirements is therefore
particularly important if customers are going to be satisfied
with the service life of the pump. A broad palette of cast
metallic materials and plastics ensures that a careful selection
of materials can be deployed to adapt our pumps to the
parameters imposed by the pumped media. The materials
at our disposal include alloys which we have specially
developed and are based on our extensive and successful
experience in the field of fertiliser production.
Rheinhütte Pumpen
offers the right
solution in industrial
pump con struction.
Our material expertise
extends way beyond
fertiliser production –
let us advise you on
the best approach for
your process.
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PUMPS MADE FROM METAL
Technical Data
DN 32 to 300
PN up to 64 bar
Q max. 1.500 m3/h (6,600 gpm)
H max. 180 m (590 ft)
Technical Data
DN 25 to 450
PN 16 bar
Q max. 3.200 m3/h (14,090 gpm)
H max. 150 m (490 ft)
RCE – The Robust Pump
The high abrasion resistance of this pump is based on the impeller design with front and back vanes in combination with low flow velocities inside the hydraulic parts. The pump is also capable of conveying media with solid contents of up to 30%. If used in continuous operation, the hydrodynamic shaft seal is often recommended depending on pumped fluids. This guarantees a long working life. Additionally, a high level of reliability is achieved with a large wall thickness of the hydraulic parts. The pump’s easy maintenance properties mean that dismantling and inspection are simple.
Sizes Very flexible due to over 30 different pump sizes
Materials More than 10 materials specially for the fertiliser industry
Seals Hydrodynamic shaft seal with and without stuffing box packing or mechanical seal
Options Open or closed impellersHeatable version
RN – The Flexible Pump
The RN is a reliable and efficient chemical norm pump for use with corrosive media whether containing a low level of solids or free from solids. The wide range of available materials, sizes and shaft seal geometries provides great flexibility and safety for users and planners. The material variants available have been specially customised to meet the needs of the fertiliser industry. In this area of applications a pump with a mechanical seal would be typically recommended. The design of the bearing support ensures quiet running and a long working life. All of the important modules are easily accessible and simple to fit, which saves time and money when it comes to maintenance.
Sizes 47 different pump sizes
Materials More than 10 different metal alloys
Seals Single and double mechanical seals in a standard or cartridge design, Hydrodynamic shaft seal with stuffing box packing
Options Heating jacket for all parts which come into contact with mediaFlange motor designOpen or closed impellersVarious flushing options on the mechanical seal
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Technical Data
DN 32 to 300
PN up to 16 bar
Q max. 800 m3/h (3,520 gpm)
H max. 80 m (260 ft)
RCEV – The Cantilever Pump
The RCEV is the vertical version of the RCE pump and is therefore just as robust, long-lasting and reliable. Its design which does not incorporate any sleeve bearings is ideally suited for heavy-duty applications with high solid contents.This submersible pump is also ideal for safe, leak-free operation due to a pressure-less shaft sealing design. Corrosion and abrasion are reduced to a minimum by using closed impellers with front and back vanes as well as low flow velocities inside the hydraulic parts. This increases both the reliability of operation and the pump’s working life.
Sizes Excellent flexibility through more than 26 pump sizes
Materials 9 different metal alloys
Seals Lip ring seal, packing
Options Extremely flexible for designers thanks to heated models and submersion depths of up to 2 metres (6.5 ft), Open impeller
Technical Data
DN 40 to 450
PN up to 64 bar
Q max. 3.200 m3/h (14,090 gpm)
H max. 170 m (558 ft)
GVSO – The Vertical Pump
This submersible pump with sleeve bearings is extremely reliable and can be used for solid-free media or for media with a low solid content. Until now, submersion depths of up to 18 m have been achieved. This submersible pump is ideal for safe, leak-free operation due to a pressure-less shaft sealing design. Closed radial hydraulics with double volute casings minimise the radial forces that occur. The pump’s easy-maintenance concept means that dismantling and inspection are simple, this saving time and money.
Sizes Great flexibility thanks to over 20 pump sizes
Materials 10 metal alloys specially for the fertiliser industry
Seals Packing (gas-tight), double action mechanical seal
Options Flexible submersion depths from 0.5 m (1.6 ft) to over 8 m (59 ft), Multi-stage, Impeller with front and back vanes
Efficiency – wide range
of alloys
08
PUMPS MADE FROM METAL
Technical Data
DN 200 to 700
PN up to 10 bar
Q max. 7.000 m3/h (30,820 gpm)
H max. 7 m (23 ft)
R PROP – The Axial Pump
The propeller circulation pump type R RPOP is used for high delivery rates with low delivery heads. Abrasion is low due to its slow rotation speed so that the pump is characterised by a particularly long working life. The R PROP is particularly well-suited for evaporators/vaporisers or crystallisers. Even with high solids contents in these applications, the pump still demonstrates an exceptional operational reliability which is essential in fertiliser plants.
Sizes 7 different pump sizes
Materials 17 metals specially for the fertiliser industry
Seals Simple mechanical seal in a standard design or double acting cartridge-type seal
Options Can be used in all types of assemblies Available in either a cast or fabricated version, depending on the size, Flange motor version up to size 500
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PUMPS MADE FROM PLASTIC
Technical Data
DN 32 to 400
PN up to 16 bar
Q max. 2.000 m3/h (8,800 gpm)
H max. 100 m (328 ft)
Plastic Pumps – The Alternative
In many cases plastic pumps are an economical alternative to metal pumps. Plastics are often advantageous for handling effluents of varying compositions and for pumping media with high hydrofluoric acid or fluosilicic acid contents, as is often the case with raw phosphoric acid or in the production of phosphate fertilisers. Some plastic pumps are highly resistant to abrasion, for example our CPRF horizontal vortex pump made from PE1000. Our range of plastic pumps includes horizontal chemical norm pumps with a closed, open and vortex impeller. The pumps use mechanical seals or magnetic drives. Plastic pumps are also available as vertical pumps and, depending on the solid content of the pumped medium, with or without footstep bearings.
Sizes Over 20 pump sizes provide great flexibility
Materials Many different materials: PFA, PTFE, PVDF, PE1000, PP
Seals Mechanical seal
Reliable alter natives made
from high- quality plastics
CPRF – horizontal vortex pump made from plastic
RVKu – vertical pump made from plastic
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OUR SERVICESAT A GLANCE
PUMP DESIGN
The success of an installation starts with
selecting the right pump. The type, size
and seal must satisfy the requirements
presented by the pumped medium.
Thanks to modern, computer-optimised
hydraulics, Rheinhütte pumps are ideally
suited to meet any applications.
MATERIAL ADVICE
Which materials are best suited to your
particular application? Whether you
require pump materials, seal materials
or changes in process affecting the
pumps- our material specialists will
offer you an individual recommendation,
with full commitment.
OPERATING CONCEPT
Whether you want to monitor centri-
fugal pumps or operate complex vacuum
installations, we will work with you to
devise the right operating concept
which meets your needs – from manual
to fully automatic.
DOCUMENTATION
You need specific documentation?
Whether standard or project - according
to your requirements we create your
individual project documentation.
INDIVIDUAL APPROVAL
All Rheinhütte centrifugal and vacuum
pumps as well as Rheinhütte vacuum
compact installations are tested at
our factory before they are delivered:
Together with our customers, specific
details, processes and basic principles
are tested and discussed.
ON-SITE SUPPORT
Whether it is for initial start-up or for
training your personnel – our engineers
are also available to assist you on site.
We offer the right solution for your project.
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SUCCESSIS BORN OF EXPERIENCE
150 YEARS OF RHEINHÜTTE PUMPEN
As pump manufacturers to the world, Rheinhütte Pumpen
is your expert for demanding pump applications – and
has been for over 150 years. Our experience for designing
pumps for conveying abrasive, corrosive and toxic media,
our product innovations and the supreme product quality
have made Rheinhütte Pumpen a proven component of
many major plants – all over the world.
YOUR RELIABLE PARTNER FOR PUMPS IN FERTILISER INDUSTRY
For over 50 years now, we have been developing and
fabricating special pumps for conveying a wide range of
different media in fertiliser plants.
We work together successfully with prestigious plant
constructors and operators such as Prayon, Incro, Uhde,
SNC-Lavalin, Toyo. Our pumps are used by many fertiliser
plant operators, for example OCP, Belaruskali, Yara, K+S,
Petrokemya, Uralkali and Deepak Fertilizer.
With our customised solutions for conveying media in
fertiliser production plants, in particular the extensive
documentation requirements and testing of the pumps,
we along with our customers are constantly setting
new benchmarks.
RHEINHÜTTE PUMPEN – your
specialist for sophisticated
pumping applications
YOUR INDIVIDUAL REQUIREMENTS ARE OUR BENCHMARK
Our customers benefit from our customized advisory
services on materials, sealing systems and maintenance
concepts. Experienced project teams will draw up
individualized documentation in line with your requirements.
Our customers’ specifications are what counts for us and
are integrated in our Quality Management systems, testing
processes and the official approval procedure for pumps
and installations.
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RHEINHÜTTE PUMPENGLOBAL EXPERTISE
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RHEINHÜTTE Pumpen GmbHRheingaustraße 96-98 – 65203 Wiesbaden – GermanyTel +49 (0)611 604-0 – Fax +49 (0)611 604-328 [email protected]