This challenging task required a customised solution considering the medium‘s sensitivity. Using an innovative, customer specific solution from NETZSCH Pumps & Systems, the manufacturing process was optimised regarding quality, duration, and costs. Today, the chemical plant benefits from a high degree of flexibility in production and can offer a wide range of highquality gels.
As an expert in producing inorganic speciality chemicals, the company manufactures high-quality materials for users in various industries, including hydrogel. It is used to produce silica gel, typically used in the protein stabilisation of beer, as a matting agent in paints and varnishes, or as a coating for inkjet paper.
Tension between homogenisation and destruction
This requires the hydrogel lumps, up to 30 mm in size, to be crushed in a defined manner so that a Steady flow of uniform particle size can be realised. Like in any process in the chemical industry, efficiency and product quality take centre stage.
The material must be handled precisely and gently to achieve the desired particle size without damaging the product. Because the hydrogel is shear-sensitive, the manufacturing process is characterised by a tension between optimal results and the destruction of the product through shear forces. To counterbalance this, the shear rate must be controlled and homogenisation monitored. Consistent and uniformly sized particles, essential for the downstream decanter process, can only be produced with suitable technology.
Experienced partner for conveying complex media: NETZSCH on board
This process was initially based on an energyintensive thermal drying method at the chemical plant. In addition to the high operating costs, this led to unsatisfactory particle consistency and quality results.
Therefore, it was decided to work with NETZSCH to realise an innovative pump system tailored to the application‘s requirements. As a global specialist in conveying complex media with more than seven decades of experience, NETZSCH offers customised and sophisticated pump solutions for every individual application. NETZSCH‘s quality and performance standards are high – not only in the development and production of pumps but also in maintenance, repair and modernisation. The Focus always lies on providing customers with expert advice. Ultimately, the aim is to use a wide range of technologies in a targeted manner to solve specific challenges to maximise customer satisfaction.
This also includes the opportunity to test Solutions and, if necessary, adapt them until they fit the specific application. “We really appreciate the fact that we had the opportunity to test the system in advance. This was a deciding factor for us when selecting the supplier”, reports a project manager from the chemical plant. Short communicationchannels and fast response times from all Stakeholders meant a suitable approach could be designed within three months.
Customised system solution: NETZSCH combines NEMO and TORNADO
As a result, a system was developed for the industrial company combining two types of positive displacement pumps: The NEMO progressing cavity pump and a specially adapted TORNADO rotary lobe pump. The NEMO pump draws the hydrogel from the storage containers, ensures a continuous flow and transports the medium to the TORNADO. There, homogenisation is done by two counterrotating circular rotors, which reduce the medium to smaller pieces. The rotors are set to a defined gap and thus significantly determine the particle size. Afterwards, the gel is dried in a chamber filter press.
This combination is unique because the rotary lobe pump has been precisely optimised for this application. It functions as a shearing unit and macerator, where the material is homogenised. Special toothed pistons with a machined surface and customised gap spacing ensure minimal pressure loss.
Uniformity combined with flexibility: Advantages of the new System
The synergy between the upstream NEMO pump and the TORNADO ensures an optimised process guaranteeing a uniform particle size and even conveying of the shear-sensitive medium. All materials and Technologies are used to provide high chemical resistance. CIP and SIP processes are considered, dead spaces are eliminated, and food-compliant surface quality and finish are guaranteed.
But that‘s not all: Using the new technology, the chemical plant can adapt the operation of the machine depending on the product characteristics. Both the direction of rotation and the speed can be selected manually – an entirely new level of control and flexibility in process management. This opens up additional possibilities in the product portfolio, as the entire range of silica gels with different product properties can be covered.
“Proven Excellence” for complex industrial requirements
The combined use of the two NETZSCH pumps has proven to be a win-win situation for the mediumsized family business. “The throughput and Quality meet our expectations, and we were also impressed by the support and advice we received from NETZSCH”, explains the project manager.
The project is a vivid example of customised pump solutions for Stefan Baudner, Area Sales Manager at NETZSCH Pumps & Systems. “It shows how important customised and flexible process solutions are in modern industry to meet our customers specific requirements”, he explains. “With “Proven Excellence”, which is recognised in the industry, we at NETZSCH are once again demonstrating our ability to solve even the most complex industrial requirements with innovative concepts.”
Source: NETZSCH Pumpen & Systeme GmbH
