Pumps for high-temperature technology

STERLING FLUID SYSTEMS GROUP

 HOT WATER
Most of the processes in industrial pro-
cess engineering take place where energy
is absorbed or released simultaneously.
Only a defined temperature level enables
the required reactions or working pro-
cesses in plants to take place. For precise
control of the process the indirect heat
input using heat carrier liquids is adventa-
geous. In this case a heat transfer medium
is circulated between the heater and heat
consumer. The working temperatures in
these heat carrier circuits are mainly bet-
ween 100 C and 400 C. Different heat
carrier liquids can be used for the transfer
of energy to the heat consumer.
In the temperature range up to approxi-
mately 200 C, water is the preferred
medium as it is non-polluting and has a
high specific thermal capacity. In the tem-
perature range from 200 C to 400 C,
organic heat transfer liquids are prefera-
ble because the vapour pressure also
rises considerably when the temperature
increases. For handling these heat transfer
media, volute casing pumps have been
specially developed. Because of the
different physical properties of the heat
transfer liquids the hot water pumps are
different in design to the heat transfer oil
pump.
Technical data:
Output: 200 m 3/h
Delivery head: 60 m
Temperature : max. 160 C uncooled
Casing pressure: PN 16
Material: GGG 40.3 (Ductile iron)
ZLN
100 -160 C uncooled
100
80
p
bar
60
water ZLI
40 Inline hot water pump
range of organic The economical inline design is becom-
20 heat transfer oil ming more acceptable where hot water is
used, as it can be directly mounted into
any pipework system. The ZLI uses a stub
shaft connection which makes it possible
to use a standard motor, giving the pump
100 200 300 400 500
t a compact design. The max. pumping
C temperature for the uncooled ZLI in the
hot water design is limited to 150 C. The
Comparison between the vapour pressure of back pull out design allows the disassem-
water and of organic heat transfer liquids bly of the complete pump unit without
removing the pump casing from the
pipework.
ZLN
Standard hot water pump
Up to temperatures of 160 C, the ZLN, a Technical data
standard water pump in accordance with Output: 150 m 3/h
EN 733/ DIN 24255 , can be used with an Delivery head: 90 m
uncooled, balanced mechanical seal. Temperature : max. 150 C uncooled
Product circulation ensures that the Casing pressure: PN 25
mechanical seal is permanently surroun- Material: GGG 40.3 (Ductile iron)
ded by the medium thus preventing dry
running. In plants where the necessary
vapour pressure cannot be maintained,
the ZLN with a throttling device is used.
The throttling device maintains a suffi-
cient pressure level in the mechanical seal
chamber to prevent evaporation.
ZLI
 160 - 230 C uncooled

The design of conventional single-stage

hot water pumps is based mainly on
standard pumps to EN 733/DIN 24255 and
EN 22858/DIN 24256. Modification to the
seals makes these pumps suitable for
specific requirements.

230 C
205 C
180 C
155 C
130 C
105 C
80 C
55 C
mechanical seal
30 C

The pumping of hot water makes high

demands on the pump design. Safe ope-
ration is influenced, to a high degree, by
the mechanical seal. Therefore the para-
meters of pressure, temperature and
sliding speed at the mechanical seal are Thermo-photograph of a ZEN hot water pump
optimised so that the service life is con-
siderably increased.

ZEN / ZDN
The hot water pumps

Many other manufacturers of pumps and

mechanical seals allow standard pumps
with uncooled shaft seals to be operated
at temperatures up to 180 C. However,
high thermal stresses, friction, insufficient
margin from the vapour pressure as well
as deformation of the seal surfaces may
lead to a short service life and an unfa-
vourable cost/benefit ratio.
Therefore, operation at temperatures of
more than 180 C is only feasible using
expensive cooling measures. Althrough
these measures will reduce the operating
temperature at the mechanical seal, they
will, at the same time, increase the instal-
lation and operating costs.

This is not the case with the ZEN, a volute

casing pump to EN 22858, where the
mechanical seal has been placed at the
cold end/drive end, of the pump. By
means of a double heat barrier, a favoura-
ble drop in temperature at the drive end
of the shaft is obtained. Even at inlet
temperatures up to 230 C, the use of an
uncooled mechanical seal does not cause
ZEN any problems as the temperature will not
exceed 100 C in the seal area.
 HOT WATER 160 - 230 C uncooled

When pumping hot water it is not merely This programme includes a multistage
sufficient to place the seal at the cold end, centrifugal pump to cover the range up to
because this particular medium tends to 12 m3/h.
vaporise during heating. Due to centrifu-
gal forces, gas bubbles will be deposited The hydraulic parts of the ZEN 31 are
on the smallest rotating parts, these being enclosed by a barrel. Dimensions of the
generally the sliding surfaces of the pipe connection remain unchanged, even
mechanical seal. The ZEN counters these when the duty parameters are altered, be-
physical effects by using patented gas sepa- cause of the adaptibility of the hydraulic
rator in the mechanical seal chamber. At parts. Apart from the hydraulics, this
the highest point is a collecting chamber pump is identical with the volute casing
for the resulting gases, which can be ven- Additional design and consequently can be operated
annual ex-
tilated by a valve both during standstill pediture of uncooled up to 230 C.
cooling
and start up of the plant. Vaporisation in water,
the mechanical seal chamber can also approx. 50% The series ZDN is based on the same
be avoided as the chamber is technology as the ZEN; the maximum
connected through the flushing Installation operating temperature is 185 C.
cost for
bore of the sleeve bearing so that cooling
the consequential low temperature water
supply 30%
maintains the liquid above its
vapour pressure.

Cost for Cost for

Shaft deflection also contributes to pump with pump with
excessive wear of the shaft seal and uncooled cooled shaft
shaft seal seal 70%
to overcome this, deflection has been 100 %
minimized in the ZEN by maintai-
ning a short distance from the ball
bearing to the mechanical seal. The
sleeve bearing at pump end is hydro- Comparison of cost of ownership
dynamically balanced and is lubricated by
the medium; it has a special geometry in
order to promote the proper flow of lubri-
cant. The internal bearing is of wear-resi-
stant tungsten carbide. This combination
has optimum properties for the handling
of hot water. The slotted pump feet com-
pensate for thermal expansion and thus
prevent additional tension in the pipe
system.

above: Conventional hot water pump

below: The new generation of hot water
pumps ZEN

Technical data:
Output: 600 m 3/h
Delivery head: 90 m
Temperature : max. 230 C uncooled
Casing pressure: PN 40
Material: GGG 40.3 (Ductile iron)

ZEN 31
 100 - 350 C uncooled HEAT TRANSFER OIL

Organic or synthetic heat transfer liquids

offer the possibility to heat or cool without
high system pressures.

350
300

200
In the course of the development of heat
transfer installations and their liquids, the
100
standard DIN 4754 has been compiled.
This standard determines, among other
C
things, safety requirements for the opera-
tion of pumps in hot oil circuits. Volute
pumps in accordance with EN 733/DIN
24255 are also generally accepted for this
specification. ZTK/ ZTI
Compact design thermal oil pumps

The ZTK and ZTI have been specially de-
veloped for installation in compact machi-
nery. The series only differ from each other
in the shape of the pump casing.
The ZTK has a volute casing with axial
inlet and radial discharge branches, whe-
reas the ZTI has an inline casing which
can be installed directly in the pipe
system. Both pumps are designed as
monobloc units and are fitted with a stub
shaft which makes it possible to use stan-
dard motors. Furthermore the stub shaft
principle is able to compensate for heat
stresses between the pump and motor.
The back pull out design allows the disas-
sembly of the complete pump unit with-
out removing the pump casing from the
pipe work system.
By means of the double acting heat barri-
er and a ventilation fan, a favourable drop
in temperature is obtained at the drive
end. Heat losses at the product end are
effectively prevented and the use of an
uncooled standard mechanical seal be-
comes possible. In order to prevent the
medium leaking from the pump in the
case of sudden failure of the mechanical
seal, a radial shaft seal ring has been
installed as additional protection.
Technical data:
Output: 200 m 3/h
Delivery head: 60 m
Temperature : max. 350 C ungekhlt
Casing pressure: PN 16
Material: GGG 40.3

ZTI

ZTK
HEAT TRANSFER OIL 100 - 350 C uncooled
ZTN
Thermal oil pump
The new series ZTN has been developed
for handling thermal oil up to 350 C in
the heating prosesses. The increased
demands on operational safety, environ-
mental protection and the reduction in
running expenses have consequently been
considered in this design. This also applies
to the standards DIN 4754 and EN 733.
All pressure loaded components are of
ductile materials, e.g. GGG 40.3 (ductile
iron). The complete field chart for the new
heat transfer pump is covered by 29 sizes
making it an economical selection for your
application. The heat losses of the ZTN
were able to be reduced considerably by
installing a heat barrier arranged behind
the hydraulics. Furthermore the pump is
fitted with a thermally isolated bearing
carrier. A sliding sealing cartridge com-
pensates for possible thermal expansion
and thus prevents distortion between the
pump and coupling. By additional thrott-
ling a favourable drop in temperature in
the shaft seal area is achieved. This allows
the use of single, uncooled shaft seals.
Technical data:
Output: 1000 m 3/h
Delivery head: 90 m
Temperature : max. 350 C uncooled
Casing pressure: PN 16
Material: GGG 40.3
ZTN
Because of increasing environmental con-
sideration, more stringent regulations are
being applied by various Health & Safety
authorities and the legal demands on
greater safety, glandless pumps are in-
creasingly being used, in particular when
handling synthetic heat transfer liquids
which are considered as damaging to a
operators health. For these applications,
pumps with magnetic couplings are be-
coming more and more acceptable. A
leakproof magnetic coupling is the
optimum solution in such cases where
leakage to atmosphere of the heat transfer
medium must be totally prevented,
especially where oxygen is present. After
careful examination a plants requirements
and the required operating conditions not
only can permanent trouble free operation
be expected but also an active contribu-
tion to environmental protection be made.
By moving the magnetic coupling to the
350 cold end of the pump and keeping to the
300 standard dimensions (DIN 24255/56) we
have succeeded in operating thermal oil
200 pumps safely, without cooling, at inlet
temperatures up to 400 C.
100
C
range of the temperature
curve of ZTN
ZTK
As an alternative, a cartridge of several
sealing rings or a mechanical seal can be
magnetic drive
fitted.
The back pull out design allows the disas- Compact magnetic pump up to 300 C
sembly of the complete pump unit with-
uncooled
out removing the pump casing from the The ZTK magnetic drive in monobloc
pipe system. design has proved successful when opera-
ting at temperatures up to 300 C. This
magnetic coupling design is not only com-
pletely leakproof but also practically main-
tenance-free. New higher wear-resistant
sleeve bearings of silicon carbide/tungsten
Technical data ZTK magnetic drive:
carbide give a long service life and the
Output: max. 600 m 3/h
deep drawn isolating shroud, with a wall
Delivery head: 90 m
thickness of 1,6 mm, offers additional
Temperature: max. 300 C uncooled
safety. The magnets are of high quality
Gehusedruck: PN 16
samarium/cobalt (SmCo); their outstanding
Materials: GGG 40.3 (Ductil iron),
stainless steel
ZTK magnetic drive
 100 - 400 C uncooled with magnet coupling
features are: high density magnetic ener-
gy, magnetic size and a high temperature
load limit. Unlike the bearing bracket
design, the alignment of pump and motor
is not necessary. The modular design of
the pump range ensures it is suitable for a
comprehensive range of applications. This
can be combined optionally with volute
casings as per DIN 24255/ 24256 or inline
casings. The robust costruction and the
possibility to mount an external filter for
partial flow also makes these pumps sui-
table for difficult applications.
ZTK
magnetic drive
With a heat barrier up to 400 C 150
uncooled
For temperatures up to 400 C, a design
with a heat barrier where a dead ended
magnetic chamber is used. The heat barri-
er separates the pump thermally from the
magnetic coupling and prevents heat flow
into the magnetic chamber. In order to
prevent the generation of additional heat
by eddy current losses in the metallic isola-
tion shroud, a shroud of industrial cera-
mics (zirconium oxide) is used. This mate-
rial is not conductive and therefore it does
not generate additional heat in the
magnetic chamber. It is possible therefore
to start the pump without venting the
magnetic chamber.
Technical data ZTK magnetic drive
with a heat barrier:
Output: 600 m 3/h
Delivery head: 90 m
Temperature : max. 400 C
Casing pressure: PN 25
Material: GGG 40.3 (Ductile iron),
stainlees steel GS-C25
ZTK magnetic drive with a heat barrier
8
1 2 3 4 5 6 7 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10 11 12 13 14
400
350
325
300
250
200
100
50
C
Pump temperature and temperature measure points
The application of ceramic iso-
lation shrouds is also recommended
if the medium tends to polymeri-
ze, crystallize or solidify in case of
heat input. A throttle bush near
the internal magnet additionally
prevents heat entering during ope-
ration. The sleeve bearing at the
pump side is hydrodynamically
balanced and lubricated by the
medium; it has a special geometry in
order to secure proper flow of the lubri-
cant. The internal bearing is of wear-re-
sistant tungsten carbide, the external bea-
ring of solid silicon carbide. This combina-
tion has optimum properties for the hand-
ling of thermal oils. The casings or the
pressure loaded components, are of GGG
40.3 or stainless steel respectively. Above
350 C, according to DIN 4754 high-tempe-
rature steels are required which means
that cast steel GS-C25 must be used for
casings.
Otherwise the 400 C design corresponds
to the previously mentioned version. At
present the max. temperature limit is
400 C.

Sterling SIHI GmbH
Lindenstrasse 170,
D-25524 Itzehoe, Germany.
Telephone: +49 (0)4821 77101
Fax: +49 (0)4821 771274
Sterling Fluid Systems (UK)
Theale Cross, Pincents Lane
Calcot, Reading,
Berkshire RG31 7SP, UK.
Telephone: +44 (0)118 932 3123
Fax: +44 (0)118 932 3302
Sterling Fluid Systems (Netherlands)
Havenstraat 22-28, Postbus 27,
NL 1940 AA Beverwijk, The Netherlands.
Telephone: +31 (0)251 263 232
Fax: +31 (0)251 226 309
Sterling Fluid Systems (Austria)
A-1100 Wien,
Oberlaaer Strasse 228, Austria.
Telephone: +43 (0)1 680 050
Fax: +43 (0)1 680 0521
Sterling Fluid Systems (Hellas)
4, Clisouras Street,
GR-176 72 Kallithea, Athens, Greece.
Telephone: +30 (0)1 9570783
Fax: +30 (0)1 9568121
Sterling SAT
Lindenstrasse 170,
D-25524 Itzehoe/Holstein, Germany.
Telephone: +49 (0)4821 77101
Fax: +49 (0)4821 771501
Sterling Fluid Systems (USA)
2005 Dr M. L. King Jr. Street,
P O Box 7026,
Indianapolis, IN 46207-7026, USA.
Telephone: (1) 317 925 9661
Fax: (1) 317 924 7388
Sterling PCU
2280 West Dorothy Lane,
Dayton 45439-1882 Ohio, USA.
Telephone: (1) 937 299 5594
Fax: (1) 937 299 3843
Sterling Fluid Systems (Asia)
37 Tech Park Crescent,
Tuas South Avenue 4,
Singapore 637851
Telephone: (65) 8630 828
Fax: (65) 8630 868
Sterling Fluid Systems (Philippines)
Suite 404 & 405, Alabang Corporate Centre,
Km. 25 West Service Road,
South Superhighway,
Muntinlupa City, Philippines.
Telephone: (63) 2 809 4908
Fax: (63) 2 807 2013
Sterling Fluid Systems (Middle East/Africa)
www.sterlingfluidsystems.com/middle-east
Sterling Fluid Systems (Middle East)
P O Box 61491, Jebel Ali, Dubai U.A.E.
Telephone: +971 (0)4 8838 733
Fax: +971 (0)4 8838 735
150.22200.53.01 E
1,5-IV.00-14
Sterling Fluid Systems (Europe)
www.sterlingfluidsystems.com/europe
Sterling SIHI GmbH
Halbergstrasse 1
67061 Ludwigshafen, Germany.
Telephone: +49 (0)621 56 12 0
Fax: +49 (0)621 56 12 209
Sterling Fluid Systems (UK)
Mansion House, Manchester Road, Altrincham,
Cheshire, England WA14 4RR.
Telephone: +44 (0)161 9286371
Fax: +44 (0)161 9252129
Sterling Fluid Systems (Belgium)
Zone Gosset, t Hofveld 1,
B-1702 Groot-Bijgaarden, Belgium.
Telephone: +32 (0)2 481 7711
Fax: +32 (0)2 481 7737
Sterling Fluid Systems (Spain)
Avenida Italia No. 2,
E-28224 Pozuelo de Alarcn (Madrid), Spain.
Telephone: +34 (0)91 709 1310
Fax: +34 (0)91 715 97 00
Sterling Fluid Systems (Hungary)
Radnti Ter 2/A,
H-8200 Veszprm. Hungary
Telephone: +36 (0)88 40 63 33
Fax: +36 (0)88 40 66 35
Sterling RWO
Leerkaempe,
28259 Bremen, Germany.
Telephone: +49 (0)421 537050
Fax: +49 (0)421 5370540
Sterling Fluid Systems (Americas)
www.sterlingfluidsystems.com/americas
Sterling Fluid Systems (USA)
303 Industrial Boulevard,
P O Box 460.
Grand Island, NY 14072-0460, USA.
Telephone: (1) 716 773 6450
Fax: (1) 716 773 2330
Sterling Fluid Systems (Mexico)
Av. Milimex No. 115, Franco Industrias Milimex
Carr. Miguel Aleman Km. 16.5
Apodaca, Nuevo Leon Mexico CP666000
Mexico
Telephone: (52) 83 693 644
Fax: (52) 83 693 649
Sterling Fluid Systems (Asia)
www.sterlingfluidsystems.com/asia
SIHI (Australia)
820 Mountain Highway,
Bayswater, Victoria 3153,
Australia.
Telephone: (61) 3 9720 1500
Fax: (61) 3 9720 4076
Sterling Fluid Systems (Hong Kong)
Unit 2605, Apec Plaza,
49 Hoi Yuen Road, Kwun Tong,
Kowloon, Hong Kong.
Telephone: (852) 2508 9025
Fax: (852) 2508 9032
www.sterlingfluidsystems.com/africa
Saudi Berkefeld-Filter
P O Box 9419, 11413 Riyadh, Saudi Arabia
Telephone: (966) 14982085
Fax: (966) 14982349
www.sterlingfluidsystems.com
Sterling Berkefeld (Germany)
Lckenweg 5
29227 Celle, Germany.
Telephone: +49 (0) 5141 8030
Fax: +49 (0) 5141 803172
Sterling Fluid Systems (France)
Zone Industrielle de Trappes-Elancourt,
1-3 Avenue Georges Politzer, Boite,
Postale 41, F-78193 Trappes Cedex, France.
Telephone: +33 (0)1 34 82 39 00
Fax: +33 (0)1 34 82 39 61
Sterling Fluid Systems (Italy)
Via degli Orsi e dei Boschi 7,
I-20093 Cologno Monzese (Milano), Italy.
Telephone: +39 (0)2 253 091
Fax: +39 (0)2 253 092 59
Sterling Fluid Systems (Schweiz)
Schweizersbildstrasse 25,
P O Box 110,
8205 Schaffhausen, Switzerland,
Telephone: +41 (0)52 6440606
Fax: +41 (0)52 6440616
Sterling Fluid Systems (Czech Republic)
Kosmonautu 8,
CZ-77211 Olomouc, Czech Republic.
Telephone: +420 (0)68 551 66 51
Fax: +420 (0)68 551 66 53
Sterling Berkefeld (Netherlands)
Cairostraat 55,
NL-3004 AC Rotterdam.
Telephone: +31 (0)10 2622525
Fax: +31 (0)10 2622822
Sterling Fluid Systems (Canada)
225 Speedvale Avenue West,
P O Box 728,
Guelph, Ontario N1H 6L8, Canada.
Telephone: (1) 519 824 4600
Fax: (1) 519 824 7250
Sterling Berkefeld (Canada)
225 Speedvale Avenue West
P O Box 728
Guelph, Ontario, N1H 6L8, Canada
Telephone: (1) 519 824 4600
Fax: (1) 519 824 7250
Sterling Fluid Systems (Malaysia)
No. 2, Jalan TPK 2/2, Taman Perindustrian
Kinrara, Section 2, 47100 Puchong,
Selangor Darul Ehsan, Malaysia.
Telephone: (60) 3 5700198/99
Fax: (60) 3 5700204
Sterling Fluid Systems (Thailand)
1st Floor, Solid Group Building,
104 Thavorn, Patanakarn Road,
Suan-Luang,
Bangkok 10250, Thailand.
Telephone: (66) 2 321 8422/3
Fax: (66) 2 321 8413
Sterling Fluid Systems (South Africa)
8483 Edleen, 1625 Johannesburg, R.S.A.
Telephone: (27) 11 394 3922
Fax: (27) 11 970 2472