Enhancing Efficiency & Sustainability with Chemitek NM Series
In the complex realm of chemical manufacturing, a pivotal entity, recognized for its production of ethyl chloride, assumes prominence. This case study embarks on a journey to uncover significant operational enhancements achieved through the integration of the CHEMITEK NM Series Centrifugal PFA Pump into its production process. It outlines the challenges encountered and explores how the innovative design and material selection of the NM series pump acted as a catalyst for substantial improvements. By unravelling this narrative, we shed light on how these advancements not only bolstered efficiency but also strengthened sustainability and safety within its operations.
- Operational hurdles due to the existing pump handing Recirculating Hydroch(onc acid (HCL) and Ethanol solution at 142”C.
- Excessive noise generation (approximately 90 dB) creating an unfavorable work environment.
- High energy consumption (50 amps) leading to increased operational costs.
- Risks of accelerated wear and tear from harsh chemicals and high operating temperatures.
- Potential impacts on production uptime and equipmenL safety due to wear- related concerns.
- Search for a solution to effectively transfer chemicals while addressing noise, energy, and wear and tear related challenges.
Chemitek NM Series Centrifugal PFA pump emerged as the optimal solution due to its
Advanced Material of Construction
The NM series utilizes a robust PFA (Perftuoroalkoxy) construction molded with Strong Metal Armor, offering exceptional chemical resistance to HCL & ethanol even at elevated temperatures(142"C). This material selection ensure process compatibility & extended pump life.
Pioneering Trapezoidal Volute Design
This innovative design optimizes flow efficiency within the pump, leading to reduced energy consumption and improved overall operational costs.
Twisted Van Support Impeller
The NM series incorporates a unique twisted van support impeller that enhances mechanical strength and prevents deformation during operation. This translates to smoother pump operation, minimized vibration, and extended equipment lifespan.
Specialized Internal Double Mechanical Seal
The NM series features a heavy-duty double mechanical sel with thick and sturdy faces, specifically engineered to withstand the demanding chemical environment and high operating temperatures encountered in process.
Reinforced Bearing Housing and Shaft
The NM series boasts a robust bearing housing and shaft design that minimizes vibration and ensures reliable operation under demanding loads.
The implementation of the Chemitek NM Series PFA Pump delivered quantifiable improvements across various facets of the production process.
Enhanced Energy Saving & Reduced Carbon Footprint
The NM series pump's lower current draw (26 amps) translates to a potential power saving of approximately 15 kW per hour. Considering a power unit rate of INR 11/unit and continuous operation for 24 hours a day, 300 days a year, the annual estimated cost saving is: (15 kW/ hr * 24 hr / day * 300 days/year * INR 11/unit ) = INR 11,88,000 Additionally, the lower energy consumption reduces the company's carbon footprint and environmental impact through lower greenhouse gas emissions.
Minimized Wear and Tear
The NM series pump's design features, including its PFA construction and lower vibration levels (0.77 mm/sec compared to 4.77 mm/sec), significantly reduce wear and tear on the pump components. This leads to:
- Extended pump life, reducing overall equipment replacement costs.
- Reduced maintenance requirements, minimizing downtime and enhancing operational efficiency.
- Lower risk of unexpected equipment failures that can disrupt production.
Reduced Noise Levels
The NM series operates at a significantly lower noise level (76 dB) compared to the previous pump (90 dB). This reduction creates a safer and more comfortable work environment for employees, ultimately boosting productivity and promoting employee well-being.
Improved Durability and Reliability
The NM series boasts a longer bearing life, superior mechanical seal life, and a robust overall design, ensuring reliable performance and minimizing the risk of unexpected failures that can disrupt production
Conclusion!The Chemitek NM Series Centrifugal PFA Pump proved to be a strategfc investment for the company. By addressing noise levels, operational costs, environmental impact, and safety concerns, the N/ñ series pump has demonstrably enhanced efficiency, sustainability, and safety within the ethyl chloride production process. This case study exemplifies how innovative pump technology can contribute to significant improvements in the chemical manufacturing industry.