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Chemical Pumps in Graphite Process Technology DIABON ® Broad Base. Best Solutions.
Chemical Pumpsin Graphite
Process Technology
DIABON®
Broad Base. Best Solutions.
SGL Group is one of the leading manufacturers of carbon-based products and has the broadest product and technol-ogy portfolio, a global sales network and state-of-the-art production sites in Europe, North America and Asia.
Carbon has unique properties. It is indispensable in the production of steel, aluminum and solar energy systems. Carbon increases the performance of wind turbines and reduces the weight of airplanes, cars and sports equipment.
CCarbon substitutes other materials and contributes to a reduction in CO2 emissions.
Carbon is Future. SGL Group – The Carbon Company.
The Business Unit Process Technology is a premium technology provider for chemical and related industry process systems, equipment and after sales services. Our focus are high-tech materials for demanding chemical applications. With smart and sustainable solutions for an in-creasing number of industry we give proof of our strong innovation culture.
Broad Base
Our range of materials: E graphiteE SiCE PTFEE reactive metalsE steel
Our range of services: E process designE engineeringE project managementE production and assemblyE commissioningE after sales services.
With 9 manufacturing sites in 8 countries and a continually growing worldwide sales and service network, we are always close to our customers.
Process Technology
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In a business that strongly depends on reliability we never compromise on quality and safety. Our products deliver dependable results; our services are fast and competent. The long-standing loyalty of our customers proves that we keep our promises – on-time, on-spec, on-budget.
Tailor made, innovative solutions and an integrated approach on chemistry, materials, technology and design, ensure outstanding efficiency and improved customer value: higher yields, lower operating cost, lower service and maintenance cost, longer service intervals and less downtimes, and the extended product lifetime sum up to significant lower total cost of ownership and to a higher return on investment for our customers.
In all industries that deal with resource- and energy- consuming processes sustainability is of crucial importance. Based on innovative solutions, more than 60 % of our sales contribute to the saving of resources and energy and to the reduction of greenhouse gases.
Powered by our Broad Base of competencies, products and services, we offer Best Solutions to our customers. For the Business Unit Process Technology, those solutions are characterized by reliability, efficiency and sustainability.
Contents
Criteria for Use 4
DIABON® Standard Chemical Pumps 6
Highly Reliable Mechanical Seals 8
ISO MAG-DIABON® Pumps 9
Characteristic Curves of Pumps 10
Construction Details 12
Quality at Every Step 13
Quality Management and After Sales Service 14
Process Technology – Our Products 15
ReliaBiliTy. effiCienCy. SuSTainaBiliTy.
Best Solutions
E Reliability
E Efficiency
E Sustainability
4
Criteria for the Use of DIABON® Pumps
For more than 50 years now, SGL Group has beenmanufacturing reliable pumps from DIABONgraphite that withstands the most corrosive media(hydrochloric acid, chlorine compounds, sulfuricacid, phosphoric acid) at operating temperaturesof up to 200°C. Our products include a wholerange of ISO 2858 pumps and high-capacitypumps whose thermal stability is unmatched, as aretheir resistance to corrosion and abrasion. Cen-trifugal and axial pumps in DIABON graphite there-fore offer an indisputable technical and economi-cal alternative to fluoroplastic pumps in respect ofboth their high reliability in service and long servicelife under extreme operating conditions.
Any pump operator in the chemical industry willsometime be faced with the application limits ofplastic pumps (PP, PEHD, PVDF, PTFE, PFA). The ser-vice lives of both solid and lined plastic pumps de-cline with an increase in the temperature, pressure,corrosivity, diffusivity or erosivity of the transferredfluid. Owing to the very high expansion coefficientsof plastics, as well as their permeability and ther-moplastic behavior, clearance is difficult to allow forin the design of rotating equipment. As a result, the
reliability of plastic equipment is impaired and itsservice life shortened, as is apparent from the nu-merous failures occurring in chemical plants. EvenPTFE- or PFA-lined pumps see their mechanical char-acteristics and permeabiltiy decline when the tem-perature of the transferred fluid exceeds 140°C.
To overcome these problems, SGL Group’s BusinessLine Process Technology has developed a compos-ite material under the brand name DIABON. Thismaterial, which is manufactured from graphitizedcarbon and phenolic resin, has outstanding corro-sion resistance, thermal stability and mechanicalstrength. In fact, its corrosion resistance is unlimitedeven in the most corrosive media. DIABON graphiteis resistant to the vast majority of acids, including hy-drochloric acid in any concentration, chlorinatedcompounds, sulfuric acid, phosphoric acid andpickling liquors. Even when used in these highly ag-gressive media, it easily withstands temperatures ofup to 200°C. DIABON is fully impervious to gasand liquids; its permeability is almost zero.
Temperature
200°C
140°C
120°C
90°C80°C
50°C
0°C
Resistance to corrosion,Reliability, Service life, Aging behavior, Lower permeability
DIABON®
PTFE-lined
PVDF
PP
PEHD
PVC
DIABON® impeller
Graphite brands
Max. service temperature °C 180 200 200 200
Bulk density g/cm3 1.85-1.90 1.88-1.92 1.88-1.92 1.88-1.92
Dyn. modulus of elasticity MPa 15-20•103 15-20•103 15-20•103 15-20•103
Flexural strength MPa 20 - 25 25 - 35 30 - 40 25 - 35
Compressive strength MPa 40 - 50 60 - 80 60 - 80 60 - 80
Tensile strength MPa >16 >18 >20 >18
Lin. coefficient of thermalexpansion (20 - 200°C)
K-1•106 4 - 6 8 - 10 8 - 10 8 - 10
Thermal conductivity W/mK >120 >120 >140 >5
Coefficient of permeability cm2/s 10-5 10-6 10-6 10-6
Ash content % < 0.5 < 0.5 < 0.5 < 0.5
Property Unit DIABON DIABON DIABON DURABON(guide values) N NS1 NS2
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media. For such special applica-tions, SGL Group supplies arange of vortex pumps with freepassages of up to 50 mm anddesigned for capacities of up to150 m3/h.
Thanks to its carbon matrix, thecomposite material has a verylow coefficient of thermal expan-sion. This provides ideal charac-teristics for the manufacture of ro-tating equipment in which playneeds to be as low as possible inorder to ensure an elevated andconstant level of hydraulic per-formance while limiting the inter-nal recirculation between im-peller and volute at the sametime. Volutes of up to 1.5 metersand large turbines of up to 550mm in diameter – designed forthe manufacture of high -capacitycentrifugal pumps and axialpumps of up to 3000 m3/h – aremachined from large homoge-neous cylinders. For high-pres-sure applications from 16 bar to25 bar, SGL Group suppliespump casings with an optionalcarbon fiber reinforcement ap-plied by the filament windingmethod. This optimized designenables the material to withstandextreme mechanical stressessuch as pressure surges.
For corrosive media with a highsolids content, SGL Group hasdeveloped DURABON®, a specialcomposite material based onamorphous carbon. Sandblast-ing tests conducted in the labo-ratory have shown that this new
Micrograph of DIABON® NS1
material features a hardness lev-el similar to that of ceramics butwithout their brittleness. Pumpsmanufactured from this materialhave outstanding abrasion resis-tance even in the most corrosive
Micrograph of DIABON® NS2 Micrograph of DURABON®
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DIABON® Standard Chemical Pumpsfor Corrosive Process Fluids
Process fluids of up to 200°CSGL Group has a long his to ry of supplying excel -lent pumps for the most cor ro sive and demand ingappli ca tions.
Our knowl edge, expe ri ence and com pe tence inproc ess equip ment have made us a lead er in thefield of corrosive pumps. The stand ard cen trif u galhor i zon tal pumps sup plied by SGL Group – ANSI/ISO 2858, NFE 4421 and DIN 24256 –have a prov en record of excep tion al reli a bil i ty. Ca-pac i ties range from 2 to 2000 m3/h and dis chargeheads from 8 to 174 m. The pumps are avail a blewith DIN or ANSI flan ges.
Graphite impellerThe impeller is machined from a single DIABONgraphite block. Back vanes and recirculation holesallow pressure relief on the shaft seal and balanc-ing of the axial thrust on bearings. The impeller,threaded and cemented to the metallic shaft, per-mits trouble-free rotor torque transmission inde-pendently of the direction of rotation.
For use in liquids containing solids, the impellercan be protected by a ceramic coating or made ofDURABON in order to substantially improve its resistance to erosion and abrasion.
Graph ite voluteThe volute case is machined from a sin gle block ofDIA BON. It is clamped between two metal licplates that absorb the tight en ing force of the attached pip ing. For extreme ly abra sive appli -ca tions, the volute case can be pro tect ed by a ce-ram ic coat ing or made of DURABON.
1
2
1 2 3 4
DIABON® NS1 graphite pump
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Seal cas ingThe seal cas ing is made from a sin gle block of DIABON as well.
Bear ing hous ing designed for high per form anceThe bear ing hous ing is made of cast iron and de-signed for maximum rigidity. The dis tance betweenthe bear ings is max i mized to restrict shaft deflec-tion and to guar an tee a long serv ice life of the me-chan i cal seals. Further more, our pump shafts aremuch “stiff er” than required by ISO 2858 and en-sure the highest performance. Assem bly hard wareincludes chromatized steel bolts.
Lubri ca tion sys temA constant-level oiling system comes standard onthe new ISO pumps.This ensures continuous lubrication and excellentheat distribution. The system maintains the correctlevel of lubricant and allows rapid visual checking.
Coupling guardThe coupling guard is available in two versions: A carbon steel version and a non-metal variant forapplications in an explosive environment. “Back-pull-out” design
Our standard chemical pumps are of the “back-pull-out” type. This design allows the inspectionand maintenance of the bearing housing assemblywithout disconnecting the piping and volute. More -over, the bearing housing assembly can be replaced in an emergency, thus simplifying on-siteoperations and considerably reducing downtime.
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45
5
6
Coupling guard Back-pull-out design
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Highly ReliableMechanical Seals
Our mechanical seals are designed to meet the lat-est standards of quality and safety. The materialsfor our mechanical seals are selected on the basisof our experience to match the abrasion and cor-rosion characteristics of the process fluid. Since allparts in contact with the process fluid must with-stand corrosive conditions and high temperatures,we specify silicon carbide and/or carbon sealfaces.
Sin gle mechan i cal sealOur stand ard seal for graph ite pumps is suit a blefor clean cor ro sive flu ids, non-crys tal liz ing flu ids,tem per a tures up to 100°C and pres sures up to 16 bar.
An exter nal flush ing device can be added for appli ca tions involv ing the risk of crys tal li za tion.
Dual mechan i cal seal (tan dem or dou ble)These seal arrange ments are suit a ble for those me-dia which con tain solids or involve a high risk ofcrys tal li za tion. They are also suit a ble for appli ca -tions where leak age of toxic or cor ro sive media into the envi ron ment must be avoid ed. Suit a ble for
flu ids with a low lubri cat ing power, hightem per a tures up to 200°C and pres suresup to 16 bar.
A thermosiphon may be added to ensure that noproc ess fluid can pass to the atmos pher ic side ofthe seals.
Single mechanical seal SiC/Carbon
SiC/SiC
Dual mechanical seal SiC/Carbon SiC/Carbon
SiC/SiC SiC/Carbon
Process side Atmospheric side
Single mechanical seal
Dual mechanical seal
Mechanical seal
SiC = Silicon carbide
Our ISO MAG-DIA BON pumps com bine the advan ta ges of our DIABON pump with those of themag net ic drive coup ling. The absence of mechan -i cal seals vir tu al ly elim i nates the need for main te -nance. The num ber of wear ing parts is limited,which prolongs the pumps’ service life.
Key fea tures of the ISO MAG-DIABON pump include the fol low ing:
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ISO MAG-DIABON® PumpsMagnetic-Drive Chemical Pumps
Mag netsThe mod u lar mag nets are made of high-qual i tysama ri um cobalt adapt ed to the drive assem bly.They are char ac ter ized by a high-den si ty mag net icfield, which per mits a com pact drive.The inner rotor encap su lat ed in graph ite allowshigh er proc ess tem per a tures than those pos si blewith PTFE pumps.
Ceramic canOur mag net ic drive pumps are made abso lute lytight by a ceramic can. The absence of welds orjoints means there is no risk of media leak age orpol lu tion. The non-metal lic can also pre vents thefor ma tion of eddy cur rents.
TorqueTorque trans mis sion to the shaft and pump impel -ler is ensured by a torque slip clutch. The pump canthere fore with stand a reverse-direc tion start with outsus tain ing any dam age.
Bear ingsInside wet ted bear ings are made from pure sil i concar bide. They are lubri cat ed by the pumped liq uid.
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2
3
4
1 2 34
Monoblock magnetic drive DIABON® pump
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Characteristic Curvesof Pumps
DIABON® standardISO mag-drive pump
140
100
80
60
50
40
30
20
10
H:(
met
er)
50.32.250
65.40.200
50.32.16065.50.160
80.50.200
125.80.200
80.50.250
80.50.315
100.65.250125.100.250
400Q: (m3/h)
50030020010080605040302010865432
Bearing no. 1
Bearing no. 3
Bearing no. 2
3000 rpm
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Characteristic Curvesof Pumps
400 Q: (m3/h)500300200100 1 000 2000
80
60
50
40
30
20
10
H: (
met
er)
6
5
0
8 Bearing no. 3
Bearing no. 5
Bearing no. 4
Bearing no. 6
Bearing no. 7
200.150.400 300.250.500
150.125.400
150.125.315
200.150.250
200.150.315 250.200.400
250.200.315
300.250.315
300.300.350
350.350.450
250.200.450
300.250.450
1200 rpm
1200 rpm
1200 rpm
1200 rpm
1200 rpm
1200 rpm
1200 rpm
1200 rpm
1500 rpm
H: (
met
er)
60
50
40
30
20
10
8
6
5
4
3
230020010080605040302010865432 Q: (m3/h)
150.125.315
125.80.400
80.50.315 125.80.315
125.100.250
100.65.250
50.32.250
65.40.200
50.32.16065.50.160
80.50.200
80.50.250
125.80.200
Bearing no. 1
Bearing no. 3
Bearing no. 2
1500 rpm
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Besides the stand ard ISO designs, we ful fill spe cialrequire ments and devel op pumps that can also beused safe ly and reli a bly for more demand ing ap-pli ca tions. In such cases, we work close ly with ourcus tom ers; our team of engi neers and spe cial ists isable to design equip ment per fect ly adapt ed toyour needs or spec i fi ca tions.
Open impel lerOpen impel lers are our stand ard for diam e ters upto 400 mm. They are suit a ble for media con tain -ing solids, as these impel lers are less sen si tive toclog ging. The gap between impel ler and front faceof the volute is adjust ed to the ideal value.
Closed impel lerFor larg er impel ler diam e ters, our graph ite pumpscan be equipped with closed impel lers in order todecrease the axial stress es on bear ings and to op-ti mize their effi cien cy.
ConstructionDetails
Special productsWe offer spe cial pro ducts, which include:� Large pumps such as 300-300-350
(flow: 100 to 1000 m3/h, dis charge head: 1 to 50 m) made of DIA BON NS1
� Axial pumps (flow: 100 to 3500 m3/h, dis -charge head: 1 to 15 m) made of DIA BON NS1
� Closed-cir cuit lubri ca tion sys tems for dou blemechan i cal seals
� Cool ing or heat ing of the pump casing� Cool ing or heat ing of the bear ing hous ing� Prim ing sys tems on base plate
DIABON® impellersDIABON® volute case
Performance test
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Quality at Every Step –Pump Design and Production
Design and devel op ment stepOur team of devel op ers con sists of many expe ri -enced engi neers of var i ous dis ci plines with spe-cialist knowl edge of hydrau lics, mechan ics andchem is try.
For design, we use the most advanced 3-dimen -sion al com put er-aided design soft ware such as Solid Works and ANSYS. Each graph ite part ismod eled using finite ele ment anal y sis to check me-chan i cal stress es.
Ther mal expan sion is close ly cal cu lat ed to ensureoptimal performance.
Selec tion step dur ing quo ta tionSpaix Clas sic, our pump dimen sion ing soft ware,guar an tees that our cus tom ers receive a tech ni caland com mer cial offer per fect ly suit ed to their re-quire ments.It ena bles us to prompt ly respond to your inquir ies– thanks to our con tin u al ly updat ed data base.
Per form ance testOur pump pro duc tion cen ters in Europe and Amer -i ca are equipped with test benches for test ingpumps of any design. This ena bles the prop er tiesof indi vid u al pumps – flow, dis charge head, effi -cien cy, power and NPSH – to be spe cif i cal lymatched to the cus tom er’s require ments. The abil i -ty to sim u late all appli ca tions ensures our pumps’excel lent reli a bil i ty.
SolidWorks screenshot
Spaix screenshot
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Quality Management
Continuous quality assurance is an integral part of the SGL Group corporate philosophy. Our quality management system is certified in accordance with ISO 9001:2008. In order to guarantee consis tently high quality to our customers, we work according to a key performance indicator orientated quality management system.
Depending on specifications we are able to meet specific requirements like the Pressure Equipment Directive 97/23/EC Annex III, Module H/H1, AD 2000 Merkblatt N2 as well as ASME “U” Stamp, Section VIII, Part UIG.
Quality Management and After Sales Service
After Sales Services – Anytime and Everywhere
We take care of our products during the entire operational lifetime. We aim to provide the best customer service anytime and everywhere.
E Maintenance – genuine spare parts supply, failure analysis, repair, field service
E Fast emergency supportE Start-up assistanceE Consulting for continuous improvement
Our service specialists as well as our service centers work in a global network to support you best.
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System SolutionsE Syntheses E Distillation and concentrationE PurificationE DilutionE AbsorptionE DesorptionE Thermal destruction and recyclingE Reactors and convertersE Heat storageE ...
After Sales ServicesE MaintenanceE Emergency supportE Start-up assistanceE ConsultingE ...
Equipment SolutionsE Graphite and SiC heat exchangers –
shell & tube, block and plate typeE Columns and internals E VesselsE QuenchersE PumpsE Rupture discsE PTFE piping and bellowsE PTFE hoses E ...
Process Technology Our Products
Regional Sales & Service Center
Central and East Europe
SGL CARBON GmbHWerner-von-Siemens-Strasse 1886405 Meitingen/GermanyPhone +49 8271 83-1564Fax +49 8271 [email protected]
South Europe, Middle East, Africa
SGL CARBON Technic S.A.S.18, Avenue Marcel Cachin38407 Saint Martin d‘Heres/FrancePhone +33 4 7625 9600Fax +33 4 7625 [email protected]
Americas
SGL CARBON Technic, LLC 21945 Drake Road44149 Strongsville, Ohio/USAPhone +1 440 572-3600Fax +1 440 [email protected]
® registered trademarks of SGL CARBON SE 11 2014/0 4NÄ Printed in Germany
The data contained herein represent the current state of our product knowledge and are intended to provide general information on our products and their application spectra. In view of the variety and large number of application possibilities, these data should be regarded merely as general information that gives no guarantee of any specific properties and/or suitability of those products for any particular application. Consequently, when ordering a product, please contact us for specific information on the properties required for the application concerned. On request, our technical service will supply a profile of characteristics for your specific application requirements without delay.
Process Technology
SGL CARBON GmbH
Söhnleinstrasse 865201 Wiesbaden/Germanywww.sgl-processtechnology.com
www.sglgroup.com
Asia, Oceania
SGL CARBON Far East Ltd. Shanghai 1208, Shanghai Oriental Plaza31 Wujiang Road/ChinaPhone +86 21 5211 0333Fax +86 21 5211 0085 [email protected]
India
SGL CARBON India Pvt. Ltd.Plot No. E-100, MIDC RanjangaonVillage: Karegaon, Taluka: ShirurDist. Pune - 412 220/IndiaPhone +91 21 386 [email protected]
