SHAFT SLIDING SCREW PRESS DEHYDRATOR

This dehydrator, developed by integrating a  shaft sliding mechanism with a screen type thickener and a traditional dewatering screw press.

DIAPHRAGM PUMPS

Types of conveyor systems

           Coming to types of conveyors, there are many alternative varieties of conveyors we are able to notice. First of all companies those who want to use conveyors should be able to notice their wants. Some of the foremost common things ought to be considered before installation are mentioned below.

Product type being handled: Unit load or Bulk load
Product dimension: Length, breadth and height
Product Variability
Surrounding environment i.e., It's location : Overhead, on-floor, or in-floor
Whether or not lots will accumulate on the conveyor
Type of path: Horizontal, Declined or Inclined manner

Different types of conveyors:

          The verity of conveyors is infinite, but the two major classifications used in typical plants are Pneumatic and Mechanical.

Note: The power requirement of a Pneumatic conveyor system are much greater than for a mechanical conveyor of equal capacity. 

Mechanical Conveyors:

1. Chute conveyor

2. Wheel conveyor

3. Rollor conveyor

                 a. Gravity Roller conveyor

                 b. Live powered roller conveyor

4. Chain conveyor

5. Slat conveyor

6. Belt conveyor

                 a. Magnetic belt conveyor

                 b. Troughed belt conveyor

                 c. Slider bed

                 d. Roller bed

                 e. Horizontal belt conveyor

                 f. Inclined and declined conveyor

                 g. Brake and meter conveyor

                 h. Wire mesh belt conveyor

                 i. Portable conveyor

                 j. Metal piano hinge conveyor

7. Bucket conveyor

8. Vibrating conveyor

9. Screw conveyor

10. Tow conveyor

11. Trolley conveyor

12. Monorail conveyor

Pneumatic Conveyors:

WATER TREATMENT

          Water occurs in nature "pure" and what ever be the source always contains impurities either in solution or in suspension. The determination of these impurities makes analysis of water necessary and removal and control of these impurities make water treatment essential.

Water sources:

The various sources of water can be broadly classified as:

          a) Rain water

          b) Surface water (River, Streams, Ponds, Lakes and Reservoirs)

          c) Ground water (Springs, Shallow wells and Deep wells)

of the above, logically rain water is the purest but even this collects and dissolves atmospheric gasses and impurities in air. Further, once in contact with the earth's crust, the rain water will gradually dissolve various materials.

Various (Majour) impurities:

The major impurities of water can be classified in three main groups:

          1) Non-ionic and undissolved

          2) Ionic and Dissolved

          3) Gaseous

          In this article we discusses briefly about the water treatment processes indicating the various impurities present in the water and the different types of treatment processes such as 'Filtration' and 'Demineralization', for treating the water for eliminating the suspended and dissolved impurities.

Table of contents

1) Water treatment -- Basic water chemistry

2) Importance of removal of impurities

3) Water softening process
4) Standard Operation Procedure (SOP) of Water treatment plant (for example purpose)

WATER TREATMENT - BASIC WATER CHEMISTRY

          Water occurs in nature "pure" and what ever be the source always contains impurities either in solution or in suspension. The determination of these impurities makes analysis of water necessary and removal and control of these impurities make water treatment essential.

Water sources:

The various sources of water can be broadly classified as:

          a) Rain water

          b) Surface water (River, Streams, Ponds, Lakes and Reservoirs)

          c) Ground water (Springs, Shallow wells and Deep wells)

of the above, logically rain water is the purest but even this collects and dissolves atmospheric gasses and impurities in air. Further, once in contact with the earth's crust, the rain water will gradually dissolve various materials.

Various (Majour) impurities:

The major impurities of water can be classified in three main groups:

          1) Non-ionic and undissolved

          2) Ionic and Dissolved

          3) Gaseous

1) Non-ionic Impurities:  These are mainly, salt, mud, dirt and other suspended matter, micro-organisms, bactiria and other organic matter, oil and corrosion products. It goes without saying that drinking water and most industrial water supplied should be clear and organic-free.

2) Ionic and dissolved Impurities:  Any salt which dissolves in water disassociates into positively charged ions called "Cations" and negetively charged ions called "Anions". Since these permit the water to conduct electricity, these salts are called electrolytes.
          Some of the most common Cations in water are:
      Calcium, Magnesium, Sodium and Iron, and rarely Ammonium, Potassium and Manganese. These cations are associated with Anions like Bicarbonates, Carbonates, Hydroxides (the sum of which is termed as Alkalinity), Sulfates and Chlorides. Presence of Nitrites and Phosphates is normally not very common. In the water treatment field, the preferred method of expression of these dissolved impurities is in terms of Equivalent Calcium Carbonate, abbrevated to as "CaCO3". This is because Calcium Carbonate is a good common denominator as it has a molecular weight of 100, which facilitates calculations.
          Moreover, in this form of analysis, the sum of Cations or total Cation always equals the total Anions. Quantitatively, these are expressed in parts per million or milligram/ltr. One part per million equals one ten thousandth of one percent (0.0001%). One part per million means one part in a million parts, for example, one liter in a million liters of water or one Kg in a million Kgs of water.
          Of all the dissolved impurities, hardness is perhaps the most troublesome. Hardness is due to compounds of Calcium and Magnesium. On heating water caontaining these salts, Carbon Dioxide is released from solution and the Bicarbonates are converted into Carbonates which are insoluble and form scales and deposites. Other salts of Calcium and Magnesium like Sulfates and Chlorides have lower solubility than Sodium salts and participated out at high temperatures. Bicarbonates of Calcium and Magnesium are known as the "Alkaline hardness" or "Temporary hardness" and chlorides, sulfates, nitrates etc., of Calcium and Magnesium are known as "Neutral" or "Permanent hardness". Sodium salts are highly soluble but can be corrosive if present in large quantities such as Sodium Chloride or Sodium Bicarbonate.
          Dissolved Silica is another troublesome impurity, especially in water fed to Boilers of very high temperatures and pressures. Even in lower pressure boilers, it could form a very hard type of scale by acting as a binding agent.
          The natural water contains solid, liquid and gaseous impurities and therefore, this water cannot be used for the generation od steam in the boilers. The impurities present in the water should be removed before it'suse in steam generation. The necessity for reducing the corrosive nature & quantity of dissolved and suspended solids in feed water has become increasingly important with the advent of high pressure, critical & supercritical boilers.

Impurities in water:
The impurities present in the feed water are classified as given below -

-- Undissolved and suspended solid materials.
-- Dissolved salts and minerals.
-- Dissolved gases.
-- Other materials (as Oil, Acid) either in mixed or unmixed forms.

A. Undissolved and suspended materials: Turbidity and sediments:

          Turbidity in the water is suspended insoluble matter including coarse particles (mud, sediment, sand etc.,) that settle rapidly on standing. Amounts range from almost zero in most ground waters and 60,000 ppm in muddy and turbulent river water. The turbidity of feed water should not exceed 5 ppm. These materials can be removed by settling, coagulation and filtration. Their presence is undesirable because heating or evaporation produces hard stony scale deposits on the heating surface and clog the fluid system. Both are objectionable as they cause damage to the boiler system.

B. Dissolved salts and minerals:

a) Calcium and Magnesium salts: The calcium and Magnesium salts present in the water in the form of carbonates, bicarbonates, sulfates and chlorides. The presence of these salts is recognized by the hardness of water (Hardness of water is tested by soap test). The hardness of water is classified as temporary and permanent hardness. The temporary hardness is caused by the bicarbonates of calcium and magnesium and can be removed by boiling. The boiling converts the soluble bicarbonates into less soluble carbonates which can be removed by simple blow down method. The permanent hardness of the water is caused by the presence of chlorides, sulfates and nitraes of calcium and magnesium and they cannot be removed just by boiling because they form a hard scale on heating surfaces.
          A standard amount of measurement of hardness is taken as being the amount of Calcium Carbonate (CaCO3) in th water and is referred to in part per million (ppm) or grains per gallon (grains/gallon*17.1=ppm).

b) Sodium and Potassium salts:  These are extremly soluble in water and do not deposit unless highly concentrated. Their presence is troublesome as they are alkaline in nature and accelerated the corrosion.

c) Chlorides:  Majority of the chlorides cause increased corrosive action of water.

d) Iron:  Most common soluble iron in water is ferrous bicarbonate. The water cantaining ferrous bicarbonate deposits become yellowish and reddish sediments of ferric hydroxide if exposed to air. Majority of ground surface water contains less than 5 ppm but even 0.3 ppm can create trouble in feed water system by soft scale formation and accelerating the corrosion.

e) Manganese:  It also occurs in similar form and it is also equally troublesome.

f) Silica:  Most natural water contains silica from 1 to 100 ppm. Its presence is highly objectionable as it forms very hard scale in Boilers and forms insoluble deposits in turbine blades. In modern high pressure boilers its presence is reduced as low as 10-50 ppb.

g) Microbiological Growth:  Various growth occur in surface water (lake & river). The micro-organisms include diatoms, molds, bacterial slimes, algae, manganese & sulphate reducing bacteria and many others. These can cause coating on Heat Exchanger and clog the flow passages and reduce the heat transfer rates.

h) Colour:  Surface waters from swampy areas become highly colored due to decaying vegetation. Colour of feed water is objectionable as it causes foaming in Boilers and may interfere with treatment processes. It is generally removed by chlorination and absorption by activated carbon.

C. Dissolved Gases:

a) Oxygen:  It presents in surface water in dissolved form with variable percentage depending upon the water temperature and other solid contents in water. Its presence is highly objectionable as it corrosive to iron, zinc, brass and other minerals. It causes corrosion and pitting of water lines, boiler tubes. Its effect is furthur accelerated at high temperatures.

b) Carbon Dioxide:  The river water contains 50 ppm and well water contains 2 to 50 ppm of C02. It also causes the corrosion of stream, water and condensate lines, It also helps to accelerate the corrosive action of oxygen.
          wThe other gases are H2S, CH4, N2, and many others but their percentages are negligible, therefore, their effects are not discussed here.

D. Other minerals:
a) Free Mineral Acid:   Usually present as Sulphuric or hydrochloric acid and causes corrosion. The presence is reduced by neutralization with alkalis.

b) Oil:  Generally, the lubricating oil is carried with steam into the condenser and through the feed system to the Boiler. It causes sludge, scale and foaming in Boilers. It is generally removed by strainers and baffle seperators.
          The effects of all the impurities present in the water are the scale formation on the different parts of the boiler system and corrosion. The scale formation reduces the heat transfer rates and clog the flow passage and endager the life of the equipments by increasing the temperature above safe limit. The corrosion phenomenon reduces the life of the plant rapidity. Therefore, it is absolutely necessary to reduce the impurities below a safe limit for the proper working of the power plant.

C. Dissolved Gases:
The atmosphereic gases found in naturally occuring waters, only two Carbon Dioxide and Oxygen, are the main causes of many corrosion related problems.

WATER TREATMENT - IMPORTANCE OF REMOVAL OF IMPURITIES

          The major concern in industrial water treatment, where thw water used directly or indirectly in an industrial process, is to treat the water to be suitable for that particular application/process. The use of water in boiler for steam generation is an obvious industrial use. Depending on the process, varying degrees of purity of treated water are required. For example, a textile processing unit will require soft and clea water for process use; a chemical plant will require pure water for process not exceeding 1.0 mg/ltr of dissolved impurities or electronic components manufacturing unit require ultra pure water containing total dissolved impurities not exceeding 0.5 mg/ltr or less. So depending upon the requirement, various water treatment processes are adopted to ttreat the water, to make the water suitable for that particular application. The details of the process are as follows:

FILTRATION

          Filtration is the process of passing a liquid containing suspended matter through a suitable porous material (filtering medium) to efficiently remove the suspended matter in the liquid. This is basically a physical treatment of water.

          Filtration is employed in the treatment of industrial water in order to remove or reduce suspended solids and turbidity. This is of special importance in boiler feed water as otherwise there will be formation of sludge and slit deposits. These will restrict flow, causes overheating and consequent failure of water wall tubes. Furthur, in combination with hardness, these sludge and slit deposits will add to the volume and has the insulating effect of scale deposits.

          1. Filtration is employed as a pre-treatment to softening or demineralising plants to protect the resins in them. It is also employed for treating potable water.

          2. The weakly basic anion resins exchanges only the strong acids such as Hydrochloric acid, Sulphuric acid and Nitric acid.

          There are basically two types of Filters - Gravity type, and Pressure type. For industrial applications the latter are preferred; they can be linked into the mains as they work under pressure and used in conjunction with other water treating equipment like softners, demineralisers without recourse to re-pumping. Also, Presure Filters are easier to install and operate, require less space and minimal civil work.

          Filter media commonly employed are graded and washed sand of effective size 0.35 mm to 0.5 mm resting on supporting underbed of crushed gravel and pebble of four varying sizes, with the coarsest size at the bottom of the bed. The sand depth is 500 mm and the underbed depth also 500 mm.

          The major components of a pressure filter are a steel pressure vessel with dished ends (normally vertical and cylindrical, though larger flows horizontal and cylindrical vessels are employed); internals comprising raw water distributor and filtered water collector-cum backwash water distributor; external pipe work and valves; filter media and instruments like pressure gauges, flow indicator etc.,

          Backwashing of the filter bed has to be carried out periodically (normally once in 24 hours, more frequently if the pressure drop across the bed exceeds 0.7 kg/cm and which indicates accumulation of dirt in the bed) with filtered water at a minimum head of 10 MWC. If air agitation facilitates are provided then the backwash rate can be reduced. The normal backwash time is 5-6 minutes and the scour time 2-3 minutes.

          NormallyFilters should not be fed with water carrying suspended matter and turbidity content of more than 30 to 50 NTU. Above these limits the water should be settled and clarified before Filtration. Also to increase the efficiency of Filtration and to ensure that even fine Suspensions are removed, the ususal practice is to dose Coagulant Chemicals like alum, ferrous sulfates or sodium aluminate at the inlet to the filter by means of a effluent. Activated carbon is used as a filtering Medium when oil/chlorine removal, etc, are required. A layer of processes Manganese Dioxide is incorporated in sand filters for iron removal. A layer of anthracite once the sand bed enhances the filtering capasity by providing in-depth filtration. When anthracite is used for filter can handle turbidity of upto 100 NTU.   

WATER SOFTENING PROCESS

          The objective of treatment in a Base Exchange Softner is to convert hardness forming salts of Calcium and Magnesium to soluble Sodium salts. Due to the low solubility of Calcium and Magnesium Salts, they tend to precipitate and form scales when the temperature of water us increased.

          Sodium salts are highly soluble and hence do not form hard scales. The hard water, to be treated, flows through bed of bead type Polystyrene Cation Exchange resins in sodium form, which exchanges sodium ions with Calcium and Magnesium ions present in hard water.

There are two types of hardness present in water.

1. Temporary Hardness: This occurs due to presence of Carbonates and Bicarbonates of Calcium and Magnesium.

2. Permanent Hardness: This occurs due to presence of Sulfates, chlorides and nitrates of Calcium and Magnesium.

          The output capasity of the water softner is inversely proportional to the hardness present in the raw water. The resign has to be regenerated periodically with Sodium Chloride solution of 10-13% concentration.

The ion exchange reaction for the service runcan be presented as follows:

Ca++      +     2 NaR = CaR2       +        2 Na+

Mg++      +    2 NaR = MgR2      +           Na+

(hard water)   (resin in Na form)    (exhausted resin)    (soft water)

where R is the resin.

          From the above reaction, it will be seen that resign retains the Calcium and Magnesium and releases equivalent of sodium to the water leaving the Softner. After the Softner has produced specific quantity of soft water, the softner should be regenerated with Sodium Chloride. The reaction for the regeneration is given below:

CaR2 + 2NaCl       =     2 NaR     +          CaCl2

MgR2 + 2NaCl      =     2 NaR     +          MgCl2

(exhausted resin)  (common salt)   (regenerated Resin)  (waste to drain)

 Where R is the resin.

          It should be noted that the same Softner could produce less amount of Soft Water between two regenrations, with increase in raw water hardness. The quality of soft water may also get affected due to this increase/change in composition of raw water.

ION EXCHANGER COLUMN

MECHANICAL SEALS : INTRODUCTION | | What is a Mechanical Seal?

INTRODUCTION:

          In many industries 'Mechanical shaft seals' failures are the major cause of pump's downtime. So we decided to give some information towards mechanical seal basics.

          "Mechanical sealing is a process of preventing leakage and containing fluid within the vessel" (like pumps, Agitators) where the rotating part of the shaft passes through the stationary part of the pump housing or some cases, the housing rotates around the shaft.  

          Years ago, pump shafts are sealed by using Gland packing rope. Gland packing is braided material, rope like material. This type of seal required a skilled worker and these require a small amount of leakage just to lubricate the packing and keep it cool. without this arrangement the packing gland becomes hard. While the shaft rotates friction produces between rope and shaft this causes wear of packing. Packing need to contact the shaft it will wear the shaft too. 

          After facing these kind of problems "Mechanical Seal" development came, which fulfills the task of controlling the leakage produced around the pump shaft with two very flat surfaces (one rotating and one stationary or constant). These mechanical seal faces also require some (very small) leaks across the faces, to form a hydrodynamic film, this leakage is usually evaporating and not identifiable. This fluid comes from processed fluid or from an external source. To achieve a precise gap for this fluid film is a design challenge.

          Now a days most of the pump shafts are sealed by using mechanical seals. However, due to the sensitive parts used in this new sealing system, mechanical seal failure are the biggest cause of pump down time.

Types of mechanical seals

TYPES OF MECHANICAL SEALS

          Mechanical Seals are the devices which arrests leakage of fluids when joined the parts or mechanisms together. Mechanical seals are available in different designs. We have to understand first how they function, it will help us to select the suitable for our application.

Different types of mechanical seals are mentioned below they are:

1. Conventional

2. Pusher

3. Non-Pusher

4. Blanced

5. Unbalanced

6. Cartridge 

7. Cortage

1. Pusher type:

GEAR PUMPS TYPES AND ITS WORKING

          The most common pumping system used in the process of chemicals having high viscocity is the Gear pump. The gear pump was invented around 1600 by Johannes Kepler.
          The Gear Pump is a "Positive displacement pump", which helps us to move fluid with the help of inbuilt gears. This type of pump has two (or) more gears that create vacuum force to drive the fluid within the pump. The pump is built with various components such as shaft, rotors, and casing.   

Design:

          A basic gear pump consists of a rotary housing or casing or stator containing two or more inter-meshing gears (Helical and Herringbone gears) or lobed cams. Tight tolerances are required between the casing & gears and between gears (The fluid being pumped will lubricate this small clearance and help prevent friction and therefore wear of the rotors and casing). Atypical housing will have an inlet and outlet, for suction and discharge respectively. There are two main types of gear pumps: 1) External gear pumps (Exterior bearing type) which use two external gears (Figure 1) and 2) Internal gear pumps (Internal bearing type) which use internal and external gears (Figure 2). The term positive displacement for gear pumps describes, they compel or force a fixed amount of fluid they move for each revolution.

Working:

Ø  In this type of pump, only one of the rotor is driven. The inter-meshing gears rotate the other rotor. As the rotors rotate, the liquid or gas, (this type of mechanism can also be used in compressor), enters from the suction line and fills the space between the teeth of the gears and becomes trapped forming small 'Slugs' of fluid between teeth.

Ø  The slugs are then carried round by the rotation of the teeth to the discharge side of the pump.

Ø At this point, the gears mesh together and, as they do so, the fluid is displaced from each cavity by the inter-meshing teeth.

Ø  Since the fluid cannot pass the points of near contact of the inter-meshed teeth nor between the teeth and casing, it can only pass into the discharge line via the putlet.

Ø  As the rotation continues, the teeth at the suction end are opened up again and the same amount of the fluid will fill the spaces and he process repeated. The liquid at the discharge end is constantly being displaced.

General viscosity range : 2 to 4,00,000 cst (EPW, 2012)

Pump formulas:

· Flow rate in US gal/min = Pump Capacity X rpm

· Power in hp = US gal/min X (lbf/in³)/1714

Types of Gear Pumps:

Based on design these pumps are basically classified into two types they are:
     . External Gear Pump
     . Internal Gear Pump

1) External Gear Pump:

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          In external gear pump two identical external gears (Figure 1) that displace non-lubricating fluids (gears are oil lubricated). The mechanism is usually driven by one of the toothed gears, the intermeshing which inturn dives the other (Driven or Idle gear). The both gears are supported by bush bearing or ball bearing it is based on the application of load. The drive gear driven by motor directly through coupling. Drive shaft leak is controlled by gland rope or by mechanical seal. There are three factors in the regulation of flow; Volume of cavity between the teeth, gears speed, and the amount of fluid that slips back to the inlet (tolerance dependent) via the mechanism. There are three main types of external gears: Spur, Helical and Herringbone gears. Helical and Herringbone gears deliver more flow at higher pressure while also being quieter, but many require a great inlet pressure than spur gear.

2) Internal Gear Pump:

          An internal gear pump uses internal and external gears (Figure 2). The gears themselves are lubricated by the fluid, which is of a lubricating nature. The internal design is reliable, easy to operate and maintain- due to the presence of only two moving parts. Only one drive gear is required for the mechanism to function but it is possible to use two. The pump will usually contain at least one bushing. The design can also be modified to include a cresent shaped portion that improves performance when pumping high viscosity fluids. Internal gear pumps have relatively low speed and inlet pressure requirements. 

Considerations:

          Gear pumps are generally operated at high speed and thus give a fairly pulse-free discharge flow and pressure. Where these pumps are operated at slower speeds, as in pumping viscous liquids, the output tends to pulse due to the meshing of the teeth.

          Any air gap drawn into the pump with the liquid, will be carries through with the liquid and will not cause cavitation. This action of the pump means that it is a 'self priming' pump. The discharge pressure may however, fluctuate.

The output from this type of pump is directly proportional to the speed of operation. If the speed is doubled, the output will be doubled and the pressure will have very little effect. (Due to higher pressures, due to the fine clearences between the teeth and between the casing and the rotors, a small leakage back to the suction side will occur resulting in a very small drop in actual flow rate. The higher the discharge pressure, the more likely that internal leakage will occur).

          Rotory pumps are widely used for viscous liquids and are self-lubricating by the fluid being pumped.

          This means that the external source of lubrication can't be used as it would contaminate the fluid being pumped. Gear pumps are capable of moving small suspended solids but due to the meshing of gears they can be damaged by pumping large solids. However, if a rotory pump is used for dirty liquids or slurries, solid particles may act as abrasives, can get between the small clearences and cause wear of the teeth and casing. This will result in loss of efficiency and expensive repair or replacement of the pump.

          In terms of construction materials, gear pumps can be made form a wide variety of materials, ranging from bronze, iron and stainless steel to cast iron, depending on the application and fluid properties.

OTHER TYPES OF ROTARY PUMPS

The following types of pumps have same characteristics to the gear pump, they are 

a) Lobe pump

b) Sliding vane pump

c) screw pump

Advantages of Rotary Pumps

· They can deliver liquid to high pressures.

· Self - priming.

· Relatively smooth output, (especially at high speed).

· Positive Acting.

· They can pump viscous liquids.

Disadvantages of Rotary Pumps

· Compared to centrifugal pumps these are more expensive.

· Should not be used for fluids containing suspended solids.

· Wear is more if not pumping viscous material.

· Must NEVER be used with the discharge closed.

Areas:

Marine, Chemical, Petrochemical, Food and General industries.

Applications:

Transfer, lubrication, processing and hydraulic.

Fluids/Materials:

High viscosity fluids, fuel oils, lube oils, various chemicals, resins, paints, pulp, acids, etc.,