ENERGY EFFICENT DESIGN
ENHANCING PUMP EFFICIENCY
Without Compromising its Performance
Through the use of non-metallic containment shells instead of the traditionally used metallic containment shells, Klaus Union eliminates eddy current losses and increases the efficiency of magnet drive pumps significantly.
Thanks to the leak-free magnet drive concept, pumps with magnet drives have a huge market share in the chemical and petrochemical industry. For many years, Klaus Union has used nonmetallic containment shells and particularly those made from ceramics for various applications due to their high chemical resistance.
Until recently, the operative range has been limited due to the specific material characteristics. However, pump applications increasingly demand higher operating pressures, temperatures and flow rates whilst still offering maximum efficiency.
Klaus Union‘s ceramic containment shells meet this challenge and provide the following application coverage:
Application Coverage
Nom. Pressure Range: max. PN63
Temperature Range: -200 °C to +450 °C
Transmittable Power: up to 1 MW
Quality is our Success.
Modularity makes the Difference
Klaus Union offers a modular system for all sealless centrifugal and screw pumps. This system consists of the pump hydraulic, the magnet coupling and the bearing bracket. All pump types in this system have an universal casing cover, which easily allows to change an existing containment shell regardless of its material.
Within the modularity, containment shells made of ceramic are available for every magnet coupling size (09E/P/T – 31E/P/T). Our containment shell design is based on the modern Finite Element Method (FEM). This simulation method allows to detect and analyze accurate approximations of tensions and deformations. The result is an optimization of structural parts and its quality as well as the elimination of the risk of failure.
Advantages of Ceramic Containment Shells
Containment Shells made of Zirconium Oxid are not magnetizable. Due to this quality there are no eddy currents impacting the pump‘s performance. In consequence, the pumping fluid is not beeing heated in the process.
This has the following advantages:
- Enables for dry run capable executions (RTZ-design) and executions without flush flow to cool the containment shell (OTZ-design).
- Enables for applications with high gas content.
- Pumps can handle fluids close to vapor pressure curve, e.g. liquid gas applications.
Further advantages:
- High mechanical strength; Extension of the application through higher pump speed.
- Vacuum tight up to 0 bar absolute.
- Large corrosion and erosion allowance; Zirconium Oxide is resistant against most lyes and acids.
- Excellent thermal shock resistance.
- Enhanced energy efficiency.
Retrofit of pumps with shaft seal:
- As there are no eddy current losses, shaft powers comparable to pumps with shaft seals can be achieved.
For quality control purposes, all Klaus Union containment shells are equipped with an individual, engraved serial number. Furthermore, Klaus Union provides material certificates on request.
Cost Savings through the Application of Zirconium Oxid
- Ceramic containment shells are an important part of Klaus Union‘s modular pump system. Due to the universal casing cover containment shells can be easily and savely mounted or replaced. The operator saves stock capacities and service costs.
- Energy consumption can be lowered as there are no performance-impairing eddy currents. In fact, the required motor power can be reduced by 10 to 15 %.
- Due to the lower power requirement, smaller electric motors can be installed.
- The ceramic containment shell per se guarantees an absolute leak-free operation. In conjunction
with the high durability of the material, both the risk and the maintenance costs are minimized.
improve the overall efficiency
Patented development
Pumping aggressive, explosive and highly toxic liquids requires the highest level of process safety. To protect people and the environment, leakage of the pumped liquid must be avoided – including in the event of a pump failure. For these most critical applications a magnetic drive pump equipped with a monitored, double containment shell still remains the safest solution. To reduce the heat generated by a purely metallic, double containment shell and at the same time to improve the overall efficiency of the pump, Klaus Union has developed and patented a new hybrid double containment shell.
Advantages of HYBRID DOUBLE CONTAINMENT SHELLs
- Reduced heat input into the pumped process liquid
- Increased reliability when pumping liquids close to their boiling point
- High corrosion resistance
- Higher efficiency leading to power savings
- Wider application range than full metal, double containment shells
- Fully compliant with requirements for secondary containment system as defined by API 685, 3 rd Edition, § 3.1.71
- Primary and secondary containment integrity is constantly verified by the pressure transmitter
- Easy and reliable detection of containment breach through a standard pressure transmitter
- High spare parts availability by using of standard Klaus Union components
- Ability to flush the area between shells (according API 685, 3rd Edition, § 6.7.9)
- Available across entire Klaus Union mag-drive pump range
- Reliable and maintenance friendly construction
Klaus Union‘s Hybrid Double Containment Shells provide the following application coverage:
Application Coverage
Pressure Rating: max. PN 63 (63 bar at 120 °C / 914 psi at 248 °F)
Temperature Range: – 60 °C to + 400 °C (-76 °F to +752 °F); higher on request
Pump Speed: up to 3.600 rpm
Working Principle
The hybrid double containment shell combines two separate shells. The inner shell is a highly corrosion resistant metallic containment shell while the outer, secondary shell is a non-metallic containment shell made from heavy duty technical ceramics. The increased electrical resistance of the materials used in this hybrid design reduces the eddy current losses. It improves the efficiency of the pump putting it about on par to traditional metallic, single containment shells. Moreover the risk of vaporization, especially when pumping media close to the boiling point or under other critical operating conditions, is significantly reduced.
The gap between both shells is provided with a vacuum and can be monitored with a standard pressure sensor; typically a pressure transmitter following customer instrumentation standards. In the event of damage to either containment shell the sensor immediately detects the change in pressure and alerts the operator, identifying which shell has
been breached. This immediate and detailed information allows the operator to take any necessary steps to avoid any leakage of the dangerous pumped liquid to the atmosphere.
The patented hybrid double containment shell design substantially increases safety and reliability for operators in all kinds of industries reducing operation costs for the most critical applications where leakage is not an option – ever.
