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Case study on the STÜBBE E-CLASS and STÜBBE X-CLASS
Recycling company relies on STÜBBE's many years of expertise in plastics for extreme applications
Our partner is a service company specializing in the recycling of salts and aluminum residues as well as the associated logistics and other related services. New processes for reprocessing these materials are of particular importance in order to return these resources to the value chain. A state-of-the-art recycling plant for this type of waste operating in Lower-Saxony uses the dissolution-crystallization process. Metal-plated plastic centrifugal pumps are used to convey the suspension (salts) containing solids.
The salt recycling process requires extremely wear-resistant pumps. In the past, however, the pumps used in the process often had short service lives, which led to downtime in the production process.
Before the optimization by STÜBBE, the longest service life achieved with the heavy-duty pump used was 15 months. At the affected operating site, the abrasive wear caused by the crystallized aluminum salts on the pump casing and on the impeller was enormous. Another risk was foreign bodies such as large undissolved lumps of salt or metal parts becoming wedged between the impeller and the casing. Tests using different pumps had resulted in even shorter service lives, so the company accepted these conditions.
The key factor in the production process is a long service life to ensure continuous 24/7 operation. Failures lead to time-consuming repairs that require the replacement of wear parts.
Two heavy-duty pumps of the STÜBBE X-CLASS type NXHE 80-50-250 and NXHE 65-40-250 with STÜBBE mechanical seals custom-adapted for the specific application.
STÜBBE started a field test under the most extreme pump operating conditions. Its aim was to extend the maximum service life achieved to date. Two pumps from a third-party manufacturer were replaced with STÜBBE X-CLASS heavy-duty pumps. The most critical point in the production process was equipped with the type NXHE 80-50-250, ensuring the required peak volume of 35 m3/h at a delivery head of 22 m. The pump conveys a suspension with a solids content of up to 400 g/l and a density of >1.5 kg/dm3 at a temperature of 45-65 °C. The STÜBBE single-acting mechanical seal with continuous flushing of 70-100 l/h is used to cope with the high solids content. During operation, it was found that the excessively contaminated rinsing water led to limescale deposits that restricted the axial mobility of the mechanical seal. STÜBBE responded immediately and supplied a newly designed mechanical seal solution. This example shows how an intelligent modular system can be used to adapt a pump and shaft sealing to a specific application. The metallic chamber design of the STÜBBE X-CLASS pump absorbs all forces that occur and guarantees a complete separation of force absorption and chemical resistance through its design. This is achieved through use of separate, thick-walled and easily replaceable plastic casings using a variety of materials.
STÜBBE X-CLASS pumps extend the service life even in extremely critical applications with a very high solids content, thus minimizing life cycle costs.
When redesigning the STÜBBE X-CLASS pump, we focused strongly on generously dimensioned components and a robust bearing, which contributes to increased service life and reliability. Even after over 24 months, the pump casing and impeller show extremely low wear for such extreme conditions, something that especially those responsible for the installation were very happy about. In addition, the intelligent modular system makes this series particularly easy to maintain.
The PDF of this case study is freely available. Further case studies with solutions for applications in various industries can be found here.
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Our expert is familiar with the processes in your industry and will be glad to advise you!