Knowledge of Harsh Operating Conditions for API Pumps
Common Industrial Environments Requiring Trustworthy Pumps
In petrochemical, coal chemical, and refining processes, pumps need to be able to handle aggressive media under severe conditions. Longgang Pump provides mature technological solutions to petrochemical equipment pumps and provides large pumps for oil refining facilities of tens of millions of tons and ethylene of millions of tons. Such installations are normally operated at elevated temperatures, high pressures, and erosive or corrosive liquids—condition that necessitates robust and reliable API pumps.
Issues Faced by API Pumps in Aggressive Applications
API pumps in such conditions must withstand flash temperature fluctuations, cavitation risk, chemical corrosion by acids or hydrocarbons, and mechanical stress due to high-pressure heads or flow rates. The confirmed hydraulic optimum operating point of Longgang’s BB2 centrifugal pump is 90.5%, 3.5% higher than the national first-level energy efficiency, which is a testament to its capability to operate optimally even in tough conditions.
Significant Material Properties Required for Severe Applications
Chemical Compatibility and Corrosion Resistance
Corrosion resistance is of utmost importance while working with acidic or alkaline media. The materials should be able to withstand degradation over time to be safe and reduce downtime.
Resistance to High Pressure and Temperature
Refinery or power plant pumps usually work above 200°C at pressures over 25 MPa. The material needs to be able to withstand such thermal and mechanical stresses.
Mechanical Strength and Wear Resistance
Fluids with trace particles or highly viscous fluids require materials that are wear and erosion-resistant but maintain dimensional stability under long-term service.
Commonly Used Materials in Longgang API Pumps
Duplex Stainless Steel for Corrosive Media
Longgang has developed special alloy material pumps such as anti-dilute sulfuric acid, hydrochloric acid, concentrated sulfuric acid, caustic soda, and other highly corrosive super-low carbon duplex stainless steel pumps. This material offers excellent corrosion resistance combined with high strength—ideal for seawater desalination or chemical processing.
Hastelloy C276 for Extreme Chemical Resistance
For applications involving strong oxidizers or chlorinated compounds, Hastelloy C276 is chosen due to its superior corrosion resistance across a broad pH range.
Alloy 20 for Sulfuric Acid Handling
Alloy 20 is particularly effective against sulfuric acid corrosion. Longgang’s customization capabilities allow them to tailor pump materials like Alloy 20 based on the specific concentration levels of acids in the process stream.
Longgang Pump Models Designed for Harsh Environments
LAD(BB1)-Axial Split Double Suction Centrifugal Pump
The LAD(BB1) series conforms to API610 standards and features a double-suction impeller structure that self-balances axial force. It is suitable for transporting clean or slightly contaminated liquids in petrochemical processes.
LZE(OH2)-Single Stage Cantilever Centrifugal Pump
LZE(OH2) adopts a center-supported volute casing with a balanced hole and throat bushing design for axial force management. It handles neutral or highly corrosive liquids at both low and high temperatures efficiently.
Design Features That Enhance Durability in Longgang Pumps
Reinforced Shaft Seals and Bearing Systems
Longgang integrates bearing systems designed for harsh operating conditions using deep groove ball bearings on the drive end and angular contact ball bearings on the non-drive end, ensuring long service life even under vibration-heavy operations.
Optimized Impeller Design to Reduce Erosion
Impellers are designed using advanced CFD simulation tools to ensure efficient hydraulic performance while minimizing cavitation risks—critical when handling abrasive slurries or volatile hydrocarbons.
Modular Construction for Easy Maintenance
Many models feature an integrated bearing bracket design, allowing bearings and seals to be replaced without moving the pump case, reducing downtime during maintenance cycles.
Industry Applications of Longgang Harsh-Duty API Pumps
Petrochemical and Refinery Installations
Longgang supplies BB2(LBD) heavy-duty process pumps widely used as raw oil feed pumps, quenching circulation units, ethylene separator return systems, etc.
Acid Manufacturing and Handling Plants
With customized materials like super duplex stainless steel or Alloy 20, Longgang’s OH1(LZA) series effectively handles sulfuric acid streams used in fertilizer production or battery manufacturing.
Pharmaceutical and Specialty Chemical Facilities
In environments requiring stringent contamination control, Longgang’s LZE series offers reliable performance with compatibility across a wide range of solvents used in active pharmaceutical ingredient (API) synthesis.
How to Select the Right Material Based on Application Needs
Matching Media Type with Compatible Pump Material
For hydrochloric acid applications, choose Hastelloy-based configurations; for seawater desalination, use duplex stainless steel; while Alloy 20 suits sulfuric acid transport best.
Considering Operating Temperature and Pressure Ranges
LTD (BB5) double-shell multistage pumps operate up to +450°C at pressures up to 30 MPa, making them ideal for high-pressure steam injection systems or thermal cracking units.
Maintenance Considerations to Maximize Pump Lifespan
Routine Inspection of Critical Components
Bearings, seals, shafts, and impellers should be inspected periodically using vibration analysis tools provided by Longgang’s after-sales service team.
Importance of Using OEM Spare Parts from Longgang
We provide qualified spare parts according to customers’ needs. Using OEM components ensures compatibility with original tolerances and extends operational reliability significantly.
FAQ
Q: What materials are best suited for pumping sulfuric acid?
A: Alloy 20 is commonly used due to its excellent resistance against sulfuric acid corrosion across various concentrations.
Q: Can I customize pump materials based on my process fluid?
A: Yes, Yantai Longgang offers customized solutions tailored to your specific media requirements, including acid-resistant alloys like Hastelloy C276 or duplex stainless steel.
Q: How do I ensure my API pump can handle high temperatures?
A: Select models like LTD (BB5), which support temperatures up to +450°C thanks to their double-casing structure made from forged components.
Q: Why should I choose OEM parts over generic ones?
A: OEM parts from Longgang match original specifications exactly, ensuring proper fitment and preserving warranty terms while enhancing longevity.
