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User Success Story: Preventing Wear to the Pump Caused by Slurry and Product Quality Degradiation due to Insufficient Flow Rates with Smoothflow Pumps

In our process, a drop in the flow rate occurs due to wear to the pump's slinding parts caused by slurry. There is also diviation in the mixing ration of the raw materials.

Finding a Solution with Smoothflow Pumps to Prevent Wear to the Pump Caused by Slurry and Product Quality Degradation due to Insufficient Flow Rates.

Paper Manufacturer P Company

Production Department

Problems: Deviations in the Mixing Ratios of the Raw Materials Leads to Unstable Production Quality

Company P, a paper manufacturer, produces synthetic paper, and in its manufacturing process, water is mixed with a resin solution using a rotary type metering pump. In order to adjust the production volume depending on the supply and demand situation, the flow rates of water and the resin were changed between 6~60 L/min and 12~120L/min, respectively.

Mr. F, who is in charge of the equipment, was struggling with a big problem that was happening during this mixing. The slurry contained in the raw material resin was causing the sliding parts to wear out, and even if the parts were replaced, the pump became unable to maintain the predetermined flow rate after just a short period of time.

If the decrease in flow rate was left as it was, then the mixing ratio of water and resin would also deviate, resulting in a serious problem in which the final product’s quality became unstable.

As the production volume increases, a pump that is capable of controlling a wide range of flow rates is needed.

The previous problem was not the only one that was troubling Mr. F. From the production facilities headquarters, in anticipation to the demand for synthetic paper increasing in the future, he was instructed to raise the maximum flow rates of water to 300 L/min and resin to 600 L/min.

When the demand for synthetic paper is low, it is expected to operate at the current minimum flow rates, so they needed a pump that could control a wide range of flow rates. Also, one of the conditions was to maintain the same precision as the rotary metering pump that was being used.

“Even though the problem with slurry was not resolved, it was more apparent that having a wider control range of the liquid transfer would be the big problem.”

It was clear that the cause of the flow reduction was wear on the pump due to slurry. On the other hand, is there not any other way besides just having to change replace the worn consumable parts frequently? Is there no other solution? Are there no pumps that are strong against slurry? Mr. F was at his wit’s end about what to do about this problem.

Problem Points

・The pump wears out due to slurry, and the flow rate decreases unless the consumable parts are replaced frequently.

・The mixture ratio of water and resin deviate which adversely affects the quality of the product.

・Wide-range control of the flow rate is required (aiming to keep the same discharge accuracy as the current condition.)

Solution: Introduction to a pump without sliding parts

Mr. F recalled a visit from Tacmina who previously proposed a new type of pump to him. “I remembered that there was a proposal of a diaphragm pump that was able to control a wide range of flow rates at minimum pulsation called ‘Smoothflow Pumps’. Even though we had still not confirmed this pump’s resistance to our slurry, the fact that we could expect this pump to transfer liquid accurately over a wide control-range of flow rates gave me hope. I immediately contacted Tacmina, brought in my actual transfer liquid and decided to perform a test with one of their Smoothflow pumps.”

Mr. F’s vision for an ideal pump became a reality. “As a result of the actual liquid test, a control range of 1:50 was cleared and the accuracy of the liquid transfer was stable. In regards to wide-range control, I heard that pump can be controlled up to a range of 1:100 we were provided with sufficient potential for our demands.”

Finally, in regards to Mr. F’s biggest problem with resistance to slurry, favorable results were also obtained.

“From Tacmina’s salesperson, I heard that since Smoothflow pumps do not have any sliding parts, there would be no abrasive wear caused by slurry and thus it would be difficult for the flow rate fluctuations to occur even over long periods of use.

“Six months have passed since we implemented the Smoothflow pump, but there have been no drops in the flow rate, the mixing ration has not deviated, and there have been no problems with the discharging accuracy or the wide control range, so all of our concerns have been resolved,” Mr. F reflected satisfactorily.

Solution Points:

・The Smoothflow pump without sliding parts is resistant to wear and has a stable flow rate even over long term operation.

・The pump can be controlled widely at a range of 1: 100.

Synthetic Paper

Details

  • Osaka, Osaka Prefecture, Japan
  • TACMINA CORPORATION

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