This Pump Will Reduce Your Kaolin Slurry Pumping Costs
How to pump kaolin slurry quickly and reliably directly from the train
"White gold" - the fact that this name for porcelain also applied to paper goes back a long time: Both are based on kaolin. This unique clay gives the materials luminous whiteness. Kaolin is used in paper production not only as a coating but also as a filler.
No matter how vital kaolin slurry is for paper production, the challenge of pumping it efficiently is equally huge. As a global specialist in handling complex media, NETZSCH Pumps & Systems offers an innovative pump solution for pumping kaolin slurry. We will show you how to make your paper production more efficient.
Paper production: Cost reduction thanks to delivery by train?
While porcelain and paper used to be called "white gold" and were considered a great treasure, today, paper companies worldwide are asking themselves how to make their production more efficient and thus withstand competitive pressure in the future. If you are faced with this question, we have the answer. As in many other areas, one factor is to increase the output of the kaolin slurry pumps and thus increase the production rate. For this reason, a paper company changed its production processes to delivery by train. In contrast to the transport by truck used until then, the rail route allowed larger quantities and, thus, cheaper procurement. However, the downtimes of the private railway company had to be kept as short as possible. At the same time, only a few square metres of space were available in the pump cellar; the previously used progressing cavity pumps could not have been accommodated there in the necessary number.
These are the challenges to overcome when pumping kaolin slurry
In addition, there were the unique characteristics of the medium. The starting material for the white porcelain clay is feldspar. During its weathering, kaolinite forms the actual kaolin and smaller portions of undecomposed feldspar and quartz. The individual particles have a layered structure and are usually only a few micrometres in size. Kaolinite itself is relatively soft, with a Mohs hardness of about 2.5. However, the other feldspar and quartz components lend abrasive properties to the clay, usually softened into a slurry for processing. Therefore, the pump used to convey the kaolin slurry must be designed to withstand higher loads in everyday use and provide consistent performance. While progressing cavity pumps require too much space, centrifugal pumps are unsuitable due to the expected vacuum. That's where NETZSCH came in as a specialist for pumping complex media.
How to pump kaolin slurry efficiently in confined spaces
In close consultation with those responsible for the paper mill, the experts from NETZSCH found the right solution for pumping the kaolin slurry. The decision was finally made in favour of a TORNADO® T1 rotary lobe pump, which is characterised by its small footprint and excellent flexibility, among other things. A total of five pumps were installed at the paper manufacturer's site, pumping around 70 m³ of kaolin slurry per hour with a viscosity of 100 to 500 mPas. Thanks to the choice of materials, the TORNADO® offers particularly long service lives. All pumps are made of a highly corrosion-resistant CrNiMo steel alloy. In addition, axially and radially abrasion-resistant wear protection plates are fitted, which you can easily replace if necessary. Furthermore, the multi-bladed lobes are made of resistant butadiene-sodium rubber with low shore hardness, which is especially suitable for abrasive products. However, in case cleaning or maintenance work becomes necessary, you can remove the front of the pump chamber in a few easy steps. This makes the entire pumping area easily accessible so that the individual components can be serviced or replaced without dismantling the housing from the system. This saves you time and, consequently, money during maintenance and servicing.
Another key factor for the robustness of the TORNADO® is the globally unique Gearbox Security System (GSS). The spatial separation of the pump chamber and gear chamber prevents the medium from getting into the synchronising gear and the gear oil from getting into the pump chamber. This and the insensitivity to dry running preventively counteracts possible operational stops and the associated downtime costs. In addition, the springs of the mechanical seal are encapsulated on the shaft to prevent damage to the components. To cope with the confined space conditions, the pumps, which conventionally pump horizontally, were turned 90° to the right. Each rotary lobe pump thus occupies only one square metre of the small pump chamber. The entire unloading process takes only a few hours, despite the large quantities delivered, and the rental times for train transport are significantly shorter. What are you waiting for? Replace your existing kaolin slurry pumps and increase your efficiency in paper production.