2015 Vortrag D. N?gel Feiberg Conference · Guide bush Cone top Compression i Valve guide ball Ball guide spr ng Rubber ring Valve seat (reversible) Cone ... System DCS Temerature

Customised Gasifier Feed Pumps

Daniel M. NägelFELUWA Pumpen [email protected]

Copyright FELUWA Pumpen GmbH

Hydrostatic displacement Pumps

Oscillating Pumping Characteristic

Piston Pump Diaphragm Piston PumpThe conveyed fluid is in contact Hermetically sealed! The conveyed fluid is in contact with sliding seals

Hermetically sealed! The conveyed fluid is not in contact with sliding seals

1

27 8 9

611

3

3

7 8 9

45

6 412 13 1410VL = Leckagevolumen

1. Pressure air vessel2. Safety valve3 Discharge valve

6. Conveyed fluid7. Piston seal8 Piston

11. Hydraulik oil12. Plunger13 Plunger seal

Copyright FELUWA Pumpen GmbH2 Heinz M Nägel

3. Discharge valve4. Suction valve5. Suction air vessel

8. Piston9. Crank shaft10. Diaphragm

13. Plunger seal14. Crosshead

E 2201190

Traditional hydraulically actuated Process Pumps

Typical diaphragm clamping(risk of sedimentation and damaging in the clamping area)

Hydraulically actuated diaphragm pump

Disadvantage:The utilisation of traditional diaphragm pumps is limited when it comes to the handling of

lid i fl id I th t f di h f il th d fl id ill t tsolids-carrying fluids. In the event of a diaphragm failure the conveyed fluid will penetrateinto the hydraulic drive end and come in contact with sliding seals and the cylinder face,which in turn results in considerable damaging (cost!).

Copyright FELUWA Pumpen GmbH3 Heinz M NägelE 2103037-2

Traditional Double Diaphragm Piston Pump

In order to get rid of the hidden danger in the first generation diaphragm pumps, FELUWA tried to developed a kind of double diaphragm pumps as shown aboveFELUWA tried to developed a kind of double-diaphragm pumps, as shown above.

This design concept ist good, but it can not solve the problem fundamentally. The two diaphragms have the same shape and are installed in the same way. When one

Copyright FELUWA Pumpen GmbH4B-42

p g p yof them is broken, the other one will be worn out soon.

Heinz M Nägel

Stresses of Double Flat Diaphragms

1,00

0,83

0,67

0 500,50

0,33

0,17

0,00

Copyright FELUWA Pumpen GmbH5 Heinz M NägelNo E 2201171-4

Evolution of PumpsMULTISAFE Hose Diaphragm PumpMULTISAFE Hose-Diaphragm Pump

Outlet Outlet

Piston in rear position Piston in front position=

End of suction stroke=

End of discharge stroke

Piston Piston

Inlet Inlet

Copyright FELUWA Pumpen GmbH6No E 2201126-4

MULTISAFE Double Hose Diaphragm PumpBionics in the construction of pumps

Inner Outer

Bionics in the construction of pumps

Inner hose‐diaphragm

Outerhose‐diaphragm Hydraulic load onto

hose-diaphragms

Hydrostatic pressure by means ofsurrouding hydraulic fluidg y

• Identical pressure inside and outside of the hose‐diaphragmo t e ose d ap ag

• The hose‐diaphragm is not subject tophysical load, but to static load only

The conveyed fluid is in contact with thehose‐diaphragm only

Incompressible coupling fluid between both hose‐

Copyright FELUWA Pumpen GmbH7E 2201186-2

Hydraulic fluid diaphragms (compatible to the conveyed fluid)

Stresses of Double Hose-Diaphragms

1 000 830 670 500 330 170 00 1,000,830,670,500,330,170,00



Other significant features of FELUWA double hose diaphragm pumps

Ch k l

double hose-diaphragm pumpsHose failure monitoring

As shown in the photo on the left side, Check valve

Pressure switch

the gap between the inner and the outer

hoses is connected to a pressure switch.

Before the pump is put into operation, switchthe gap is to be filled with liquid to get

rid of air. When the pump is started up,

air and liquid are vented and drained air and liquid are vented and drained

from the air venting valve with the pressure

increase in the pump head. At this time,

th i i th b t th there is no pressure in the gap between the

two hoses. When any of them is broken,

the pressure inside the gap will go up,

Vent valve

then the pressure switch will give out an alarm.

Such a hose failure alarming system is very

sensitive, instant and reliable.

Copyright FELUWA Pumpen GmbH9No E 2140125 Heinz M Nägel


Valves

Necessity of Double Valves

Copyright FELUWA Pumpen GmbH10

Ball Valve vs. Cone Valve

Ball Valve Cone ValveBall Valve Cone ValveGuide bush

Cone top

Compression i

guideValve ball

Ball guide

spring

Rubber ring

Valve seat (reversible) Cone

Cone valve disc

( )Valve seat

Co eguide


Unexpected Particles and Foreign Matters Found in Regular Coal SlurryFound in Regular Coal Slurry


Special Configurations- Double Valves -- Double Valves -

• Double valves are used for critical processes which do not allow interrupted flow.

• Double valves provide double safety against smallest leakages.

• Double valves reduce valve wear and increase maintenance intervals.

Copyright FELUWA Pumpen GmbH13E 23100016 Heinz M Nägel


Pump Speed


Wear Related to Speed


Characteristics of displacement Pumps

Single-acting one-cylinderSingle acting one cylinder pump

Double-acting one-cylinder pump

Three-cylinder pump


Unique pulsation dampener- Kinematic Irregularity -

FELUWA PULSORBER +

- Kinematic Irregularity -

FELUWA PULSORBER + (PULSORBER with integrated air vesseland automatic filling

Solenoid valve (v1)

Solenoid valve (v2)g

device)

Provides optimum Air outlet

Hose-diaphragm

Compressed airClient’s compressed

kprotection against water hammer.

Hose-diaphragm condition monitoring

Gas cushion

air network

Bladder type Level indicator

FELUWA hose-diaphragm pulsation dampener

Bladder-type accumulator

pulsation dampener

Double hose-diaphragm

Actuation fluid

Fluctuating hydraulic fluid

Actuation fluidMedium

Discharge pipe


Permanent monitoring of all Permanent monitoring of all components and operating parameters that are relevant to functioningg


Quintuplex MULTISAFE Process PumpsPermanent Operation MonitoringPermanent Operation Monitoring

Operation Monitoring: The detection of inadmissible d f d dd

Option: Automatic behaviouroperating conditions safe guards against sudden failure.

Pre‐Compression

Hydraulic Temperature

under alarm condition

Hydraulic Temperature

Suction Pressure !

LocalMonitoring System

DCSTemerature of Flow of Gearbox Oil

R tSIEMATICFreq enc

Motor Temperature

Temerature and Flow of Intermediate Gearbox Oil

Copyright FELUWA Pumpen GmbH19Foliennr

RemoteService

SIEMATICS7‐300

FrequencyConverter

Quintuplex MULTISAFE Process PumpsPermanent Operation and Condition Monitoring of all Components thatare relevant to Fuctioning

Condition Monitoring: The detection of incipient wear f i l i d i d

Valve Wearof typical wearing parts reduces maintenance cost and increase life span. Option: Automatic

behaviour underalarm condition.alarm condition.

LocalMonitoring System

DCS

Hose‐Diaphragm

R tSIEMATICFreq enc

Hose Diaphragm

Copyright FELUWA Pumpen GmbH20Foliennr

RemoteService

SIEMATICS7‐300

FrequencyConverter


COAL GASIFICATIONHigh Pressure Gasifier FeedingHigh Pressure Gasifier Feeding

Configuration Optionsg p


COAL GASIFICATION - Configuration Options2 Gasifiers - 4 Burner System 2 Gasifiers - 4 Burner System

1 2

Pump Q p PUnits m³/h MPa kW4 31‐63 7.2 250


FELUWA Quadruplex HDP ZGL 300/250 –2 K 180 – 4 SM 460 HD

No E 2201168-5

FELUWA HDP Hose-Diaphragm and MULTISAFE Pumps with FHDP Pulsation Dampener for Coal Gasification FHDP Pulsation Dampener for Coal Gasification

Front: FELUWA Hose Diaphragm Pump ZGL 300/250-2K 180-4SM 460 HD


Rear: FELUWA MULTISAFE Process Pump TGK 400/400 – K 150 – DS 100 HD-U

COAL GASIFICATION - Configuration Options2 Gasifiers - 1 Burner System 2 Gasifiers - 1 Burner System

12

AB

P0201 AP0201 B

Pump Q p PUnits m³/h MPa kW3 15 – 69 7.2 132


Triplex FELUWA MULTISAFE TG 180/200 – K 180 – DS 100 HD

FELUWA MULTISAFE Hose-Diaphragm Pumps with PULSORBER Pulsation Dampener for Coal Gasification PULSORBER Pulsation Dampener for Coal Gasification

T i l FELUWA H Di h P ZGL 300/250 2K 180 4SM 460 HD


Triplex FELUWA Hose Diaphragm Pump ZGL 300/250-2K 180-4SM 460 HD

FELUWA Pumps in Coal Gasification Industry

• In China, a high number of coal gasification plants are used to produce syngas.p y g

• Nowadays, FELUWA’s share of reactor feeding pumps is about 90%.• The coal gasification plants are operated with a total of 361 FELUWA

pumps• With an overall driving power of 70,135 kW, they are pumping a total

volume of 14,491 m³ coal slurry per hour at pressures up to 100 bar

• By means of the FELUWA pumps, 575 million cubic meters of syngas (in terms of CO2 and H) are produced per day ) p p y

The pumps are regarded as the most important item within the plant and none of them has ever caused an

emergency shutdown of the facility.


Thank you for your attention - Questions?

Dipl -Ing Daniel M Naegel

Copyright FELUWA Pumpen GmbH

Dipl. Ing. Daniel M. Naegel [email protected]

Documents

2015 Vortrag D. N?gel Feiberg Conference · Guide bush Cone top Compression i Valve guide ball Ball guide spr ng Rubber ring Valve seat (reversible) Cone ... System DCS Temerature