The manufacturing of chemical equipment demands precision, reliability, and, critically, an unwavering commitment to safety in fluid transfer. Original Equipment Manufacturers (OEMs) in this sector continuously seek robust pumping solutions that can seamlessly integrate into their diverse range of chemical processing machinery. These solutions must not only handle corrosive and often volatile materials efficiently but also operate with minimal human intervention and maximum safety. This case study explores how Ovell Pump, as a leading diaphragm pump manufacturer, provides essential pumping technology that addresses these complex requirements, supporting OEMs in delivering high-performance chemical equipment globally.

Client: OEM Support Site for Chemical Equipment Manufacturing

This application focuses on an OEM support site specialising in the manufacturing of various chemical processing equipment. These OEMs supply a wide array of machinery, including sand mills, filtration units, finished product filling lines, and diverse storage tanks, to chemical production enterprises worldwide. The consistent performance and safety of these integrated systems are paramount, directly impacting the end-users' operational efficiency and product quality. The client was actively seeking advanced pumping solutions that could enhance the capabilities and reliability of their chemical equipment offerings.

The Problem: Navigating the Challenges of Chemical Fluid Transfer

Chemical equipment manufacturing inherently involves the transfer of a broad spectrum of challenging materials. These fluids often exhibit characteristics that pose significant problems for conventional pumping technologies:

• ‍Corrosivity: Many chemical reagents, solvents, acids, and alkalis are highly corrosive, leading to rapid degradation of metallic pump components. This results in frequent maintenance, premature pump failure, and the risk of costly leaks.‍
• Abrasiveness: Slurries containing fine particles, common in sand mills or filtration processes, can cause abrasive wear on pump internals, reducing efficiency and lifespan.‍
• Viscosity Variations: Chemical processes often involve fluids with wide-ranging viscosities, from thin solvents to thick pastes, requiring pumps that can handle these variations without loss of performance or clogging.‍
• Volatility and Flammability: Numerous chemicals are volatile or flammable, necessitating pumping solutions that eliminate ignition sources and prevent vapour release. Traditional electric diaphragm pump systems can pose inherent risks in such environments due to electrical components.‍
• Process Control and Automation: Manual intervention for pump operation or constant monitoring for pressure fluctuations introduces inefficiencies and human error. OEMs require pumps that can integrate into automated systems, providing consistent and reliable material conveyance without constant oversight.‍
• Maintaining Product Integrity: For sensitive chemical products, shear forces during pumping can alter molecular structures or degrade the material, impacting final product quality.

These challenges highlight the critical need for pumping solutions that are not only durable and chemically compatible but also intrinsically safe and capable of intelligent, automated operation.

The Solution: Ovell Pump's Air-Operated Diaphragm Pumps

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To address these multifaceted challenges, the OEM integrated Ovell Pump's air-operated diaphragm pumps into their chemical equipment. Specifically, 2.1-inch and 1.5-inch aluminium alloy/stainless steel air-operated diaphragm pumps were selected. These particular models are a type of double diaphragm pump, known for their robust construction and versatile performance.

The choice of air-operated diaphragm pump technology is strategic for chemical applications due to several inherent advantages:

• ‍Intrinsic Safety: As pneumatic diaphragm pumps, they operate solely on compressed air, eliminating the need for electricity at the pump head. This makes them intrinsically safe for hazardous and explosive environments, a crucial requirement in chemical manufacturing. There are no electrical sparks or heat generation, a significant advantage over an electric diaphragm pump in such zones.‍
• Chemical Compatibility: The availability of wetted parts in materials like aluminium alloy and stainless steel ensures broad chemical compatibility. Aluminium alloy offers good general resistance for many chemicals, while stainless steel provides enhanced corrosion resistance for a wider range of aggressive media. The flexible pump diaphragm itself is available in various chemically resistant elastomers.‍
• Sealless Design: The pump diaphragm acts as a dynamic seal, completely isolating the fluid from the pump's air motor. This sealless design eliminates potential leak points associated with rotating shaft seals, crucial for containing hazardous chemicals and preventing environmental contamination.‍
• Versatile Fluid Handling: These diaphragm pumps are positive displacement pumps, meaning they can handle a wide array of fluids, including viscous liquids, abrasive slurries, and even some solids, without damage or loss of prime. Their gentle pumping action minimises shear, preserving the integrity of sensitive chemical formulations.‍
• Self-Priming: The inherent self-priming capability of these air diaphragm pumps allows them to draw fluid from below their mounting level, simplifying installation and operation in various tank configurations.

Ovell Pump's air operated double diaphragm pump models are utilised as conveying pumps within the OEM's chemical equipment, finding wide application in sand mills, filters, finished product filling equipment, and various storage tanks. This demonstrates their adaptability across different stages of chemical processing.

Results: Enhanced Performance and Global Adoption

The application of Ovell Pump's diaphragm pumps in OEM chemical equipment has yielded highly effective and demonstrable results, significantly enhancing operational performance and safety for chemical production enterprises.

A key factor in the Ovell pump's success is its explosion-proof performance. This feature is paramount in chemical environments where flammable vapours or combustible dusts are present. The pneumatic operation inherently eliminates ignition sources, providing a safe and compliant solution for transferring hazardous materials, thereby protecting personnel and assets.

Furthermore, the integration of an automatic start-stop function has revolutionised efficiency in critical processes. This intelligent feature operates based on pressure equilibrium:

When the outlet pressure balances with the inlet pressure (indicating, for example, a closed valve, a full tank in filling equipment, or a clogged filter), the pump automatically stops. This prevents over-pressurisation, energy waste from dry running, and potential damage to the pump or system.

When the outlet pressure decreases (indicating, for example, an opening valve, a need for more material in a sand mill, or a filter requiring continuous feed), the pump automatically starts and continues material conveyance.

This automated control has greatly enhanced the Ovell pump's performance in several key applications:

• ‍Filling Equipment: The automatic start-stop function ensures precise and accurate filling of finished products. The pump delivers material only when required, preventing overfills or spills, which minimises waste and ensures consistent product volumes.‍
• Filters: In filtration processes, the pump maintains a consistent flow to the filter, automatically pausing if the filter becomes blocked or the downstream demand ceases. This prevents filter damage from excessive pressure and ensures optimal filtration efficiency.‍
• Sand Mills: For sand mills, which require a continuous and controlled supply of slurry, the pump's automatic operation ensures a steady feed, optimising the milling process and preventing material starvation or overflow.

The proven reliability, safety, and automated functionality of Ovell Pump's solutions have led to widespread industry acceptance. The system has been adopted by thousands of chemical production enterprises globally through OEM chemical equipment suppliers, underscoring the trust placed in Ovell Pump's technology as a preferred chemical diaphragm pump solution for diverse diaphragm pumps applications.

Conclusion

The case study demonstrates the critical role of Ovell Pump's air-operated diaphragm pumps in optimising chemical equipment manufacturing. By providing intrinsically safe, chemically compatible, and intelligently automated pumping solutions, Ovell Pump addresses the complex challenges of transferring hazardous and sensitive chemical materials. The proven explosion-proof performance and automatic start-stop function of their 2.1-inch and 1.5-inch double diaphragm pump models have significantly enhanced efficiency, safety, and reliability across various OEM chemical equipment applications. This widespread adoption by chemical production enterprises globally solidifies Ovell Pump's position as a trusted partner and a leading diaphragm pump manufacturer in the industrial fluid management sector.