Contexte du projet
In the pyrite-based sulfuric acid production project of Inner Mongolia Energy Company, the waste gas dust removal and purification process in the sulfuric acid workshop operates under the following actual working conditions:
- Ambient Temperature & Climate: Due to the dry climate and large diurnal temperature variations in Inner Mongolia, the medium’s properties vary readily with changes in ambient temperature.
- Medium Composition: The pyrite raw material contains complex impurities. Consequently, the circulating scrubbing liquid contains high concentrations of fluoride and chloride ions, along with a large volume of solid particles.
- Previous Equipment Status: Previously, the pumps originally used by the customer failed to adapt to these working conditions. The replacement cycle for wear parts was only 10 days. Frequent maintenance downtime increased labor and spare parts costs, disrupting the continuous production schedule and limiting overall output capacity.
Pyrite Acid-Making Process Flow
Depending on the production scale, an entire pyrite-to-acid project requires approximately 30 to 100 industrial pumps of various types. The core process flow and key pumping nodes are outlined below:
Pyrite (FeS₂)
│
▼
Crushing & Grinding
│
▼
Fluidized Bed Roasting (approx. 850°C) ──► Generates SO₂ Gas + Fe₂O₃ Cinder
│
▼
Waste Heat Boiler Cooling
│
▼
Purification System (Scrubbing, Cooling, Mist Eliminators) [scrubbing tower circulation pump – UHB-ZKD Pump Position]
│
▼
SO₂ Conversion to SO₃
│
▼
Absorption Tower
│
▼
98% Concentrated Sulfuric Acid
Major Pumping Technical Problems & Changyu Pump Solutions
High Concentration Sulfuric Acid Corrosion
Actual Medium Condition: 93% sulfuric acid, 98% sulfuric acid, oleum, and dilute sulfuric acid.
Common Equipment Failure: Standard 304 and 316 stainless steel pump bodies fail rapidly, resulting in pump casing corrosion, mechanical seal leakage, flange leakage, and corrosive perforation.
Solution de pompage Changyu : Fluoroplastic-lined pumps are utilized, where the wetted parts are lined with ETFE, PFA, or F46 materials. Critical areas are configured with Hastelloy and magnetic seal structures to achieve leak-free operation, making them suitable for long-term transmission of 98% concentrated sulfuric acid. (This is the corrosion and wear-resistant pump solution.)
Calcined Cinder Slurry Wear
Actual Medium Condition: Iron oxide cinder slurry generated after pyrite roasting (FeS₂ → Fe₂O₃). This slurry has a solid content of 20% to 60%, with high particle hardness and high concentration.
Common Equipment Failure: When standard chemical pumps handle this type of slurry, the impeller and volute usually suffer severe mechanical wear within a few months, leading to a decline in pump efficiency.
Pompe Changyu Solution : The pump features a wide flow channel design. The impeller and inner lining are made of high-chromium wear-resistant alloy or duplex steel, supplemented by wear-resistant liners. This configuration reduces the mechanical wear of solid particles on the impeller and volute, lowers the risk of clogging, and extends maintenance intervals. (Another corrosion and wear-resistant pump application.)
Dual Conditions: Abrasion + Corrosion
Actual Medium Condition: Low-concentration sulfuric acid slurry formed in the scrubbing tower circulation pump (SO₂ + water + ore powder + acid solution).
Common Equipment Failure: Corrosion and wear act simultaneously on the pump body, reducing standard pump life to a few months.
Pompe Changyu Solution : UHMWPE or fluoroplastics paired with high-chromium alloy are used, with SiC mechanical seals and corrosion-resistant shaft sleeves, ensuring stable operation under dual-destructive conditions.
Clogging in Washing Tower
Actual Medium Condition: The scrubbing tower circulating liquid contains high volumes of gypsum, iron mud, dust, and other solids.
Common Equipment Failure: Solid materials accumulate in impeller, pipelines, and seal chamber, causing blockage, flow drop, vibration, and motor overload.
Pompe Changyu Solution : Open or semi-open impeller design with wide flow channels reduces solid deposition and unscheduled shutdowns.
High Temperature Acid Stability
Actual Medium Condition: Process temperatures range from 80°C to 100°C.
Common Equipment Failure: Standard engineering plastics deform, and conventional rubber seals age faster.
Pompe Changyu Solution : Wetted parts made of PFA, ETFE, PTFE ensure thermal stability and sealing integrity.
Leakage Control
Actual Medium Condition: Sulfuric acid leakage causes severe corrosion and safety hazards.
Pompe Changyu Solution : Magnetic drive or double mechanical seals with external flushing ensure leak-free operation in critical positions.
Sulfuric Acid Plant Pump Positions
| Process Position | Transported Medium | Main Technical Problems | Pompe Changyu Solution |
|---|---|---|---|
| Scrubbing Tower Circulation | Acid slurry | Corrosion + Wear | UHB-ZKD corrosion and wear resistant pump |
| Cooling Tower Circulation | Acid solution | Strong chemical corrosion | UHB-ZKD / Fluoroplastic-lined pump |
| Dilute Acid Transfer | Dilute sulfuric acid | Sulfuric acid corrosion | UHB-ZKD Series |
| Concentrated Acid Transfer | 98% Sulfuric acid | Strong oxidative corrosion | Magnetic drive pump / Fluoroplastic-lined pump |
| Oleum Transfer | Oleum | Extreme corrosiveness | Hastelloy pump / PFA-lined pump |
| Cinder Transfer | Fe₂O₃ slurry | High solid content, high wear | Wide flow channel high-chromium alloy pump / UHB |
| Waste Acid Circulation | Waste acid | Complex component corrosion | UHB-ZKD Corrosion-resistant pump |
| Desulfurization System | Gypsum slurry | Solid crystallization clogging + Wear | Open impeller anti-clogging slurry pump |
| Acid Storage Loading | Finished acid | High sealing requirements, leak prevention | Double mechanical seal pump / Magnetic drive pump |
| Acid Circulation System | Acide sulfurique | High continuous operation requirement | UHB Series long-cycle operation solution |
More products of the same model
Technical Specifications & Reference Parameters
- Corrosion-Resistant Design: UHMWPE lining + PVC/PP support structure, chemically stable against 98% H₂SO₄ and fluoride/chloride ions. (Max acid concentration 98%, medium temp ≤80°C)
- Wear-Resistant Structure: Impeller, volute, and flow channels made of high-wear UHMWPE for mineral slurry with 5%–15% solids, max particle diameter 2 mm
- Thermal Variation Adaptability: UHMWPE stable within ±30°C; ambient -15 to 40°C, medium 10 to 80°C
- Conception anti-clogging : Open or semi-open impeller with wide flow channels; max solids 15%, particle ≤2 mm
- Flow & Head Range: Single-stage / two-stage; flow 5–80 m³/h, head 10–50 m
- Maintenance Configuration: Modular body; wear part replacement cycle 3–6 months
Project Results & Application Effect
Actual Case Operation Results (Inner Mongolia energy company):
- Wear Parts Lifespan: from 10 days → 14 months
- Operational Stability: unscheduled shutdowns reduced >85%
- Running Cost: spare parts & manual maintenance reduced, ensuring production continuity
System Performance Projections:
- Wear parts life: 3–6 months under similar conditions
- Flow/head fluctuation: ≤±5%
- Maintenance cost reduction: ~40%
Conclusion
The UHB-ZKD UHMWPE corrosion and wear-resistant pump meets corrosion, wear, thermal fluctuation, and low maintenance requirements for scrubbing tower circulation pump applications in Sulfuric Acid Plant Acid Transfer Pump System, ensuring long-cycle stable operation and production reliability.
Vous avez besoin d'une réponse rapide ou d'un devis sur mesure ? Notre équipe d'ingénieurs vous répond dans les 24 heures et vous offre un accompagnement personnalisé.
Courriel : [email protected]
WhatsApp : +86-13651913727
For specific product parameters and selection manuals:
Série UHB Pompe résistante à la corrosion en UHMWPE