Introduction: The Criticality of Seamless Fluid Transfer

In the demanding realm of industrial processes, particularly those involving aggressive slurries and high-pressure filtration, the reliability of fluid transfer equipment is paramount. Conventional pumping solutions often falter under such arduous conditions, leading to operational inefficiencies, escalated maintenance costs, and compromised product quality.

This case study explores a significant challenge faced by a processing facility in New Zealand, which struggled with the inefficient transfer of a dense solid-liquid mixture into a filter press.

The Objective: High Discharge Pressure Fluid Transfer

The client aims to achieve higher discharge pressures to enhance dewatering, resulting in drier filter cakes and superior end-product quality while minimising operational and maintenance costs.

The Challenge: Sub-Optimal Slurry Filtration

The New Zealand facility, involved in the extraction and processing of minerals, encountered persistent difficulties with its solid-liquid separation stage. A crucial part of their operation involved feeding a highly concentrated, abrasive slurry—a mixture of mineral solids suspended in process water—into a filter press. The performance of their existing pumps, which were standard diaphragm transfer pump models, proved inadequate. While effective for general fluid movement, they lacked the necessary high-pressure capabilities to efficiently force water out of the solid material within the filter press.

This limitation manifested in several critical operational drawbacks:‍

• ‍Wet Filter Cakes: The inability to achieve sufficiently high pressures meant the filter cakes produced were excessively wet. This not only increased the volume of material requiring further drying (a high-energy process) but also led to higher disposal costs for waste cakes.‍
• Reduced Throughput: The inefficient dewatering prolonged the filtration cycles, significantly reducing the overall throughput of the filter press and, consequently, the entire production line.‍
• Compromised Product Quality: For specific applications, the moisture content in the final solid product was too high, necessitating additional, costly drying steps or impacting the material’s downstream processability and market value.‍
• Premature Wear and Maintenance: While air operated diaphragm pumps are generally robust, pushing them beyond their designed pressure limits or using inadequate models for high-solids applications could still lead to increased wear on diaphragms and valve components, resulting in more frequent maintenance than desired. The facility was caught in a cycle of marginal performance and elevated operational expenditure.

The core of the problem was the mismatch between the pressure requirements of the filter press and the capabilities of standard industrial pumps. Achieving consistent, high-pressure delivery of an abrasive slurry without incurring excessive wear or sacrificing pump life presented a substantial engineering hurdle.

The Solution: Ovell's High-Pressure Pneumatic Booster Pump Innovation

Recognising the urgent need for a more robust and efficient solution, the New Zealand facility engaged with various diaphragm pump manufacturers. Their search eventually led them to Ovell Pump, whose unique approach to high-pressure air-operated diaphragm technology stood out.

Ovell developed and offered a specialised 2-inch high-pressure air-operated pneumatic diaphragm booster pump (Model: HA20SAGGG), featuring a durable stainless-steel casing designed for resilience in demanding industrial environments. It has pressure up to 17Bar and has a flow rate of 680 l/m and can also be available in 1.5 and 3-inch inlet and outlet sizes.

The key differentiator of Ovell's solution lay in its innovative design, which addressed a fundamental flaw in many other high-pressure diaphragm air pump designs. Traditionally, some high-pressure diaphragm pumps achieve elevated discharge pressures by reducing the working volume of one of the fluid chambers, which often results in unstable pressure output and a shortened operational lifespan. Ovell, however, circumvented this limitation by adopting an independent pressure converter within their pump's design.

This design ensures that the increased pressure is generated without compromising the flow rate or the stability of pressure across both fluid chambers. Critically, it maintains the same projected lifespan as a standard air powered diaphragm pump of its size. This independent pressure amplification not only provides stable, consistent high pressure but also significantly reduces the overall operational costs associated with pump replacements and maintenance.

The pump's robust construction and clever engineering made it an ideal diaphragm pump for handling the abrasive solid-liquid mixture, protecting internal components from premature wear while delivering unprecedented discharge pressure.

Implementation and Technical Synergy

The integration of Ovell's HA20SAGGG into the facility's existing filtration line was a meticulously planned process. The 2-inch diaphragm pump was positioned strategically upstream of the filter press, replacing the underperforming units. Its stainless-steel casing provided excellent corrosion resistance against the chemical slurry, a vital characteristic for long-term reliability.

A conceptual diaphragm pump diagram of the HA20SAGGG would illustrate its two primary fluid chambers, each with a flexible diaphragm, driven alternately by compressed air via the independent pressure converter. The air motor is completely isolated from the pumped fluid, eliminating the risk of internal corrosion or contamination. The design allows for the handling of significant solid content without clogging or excessive wear, thanks to its unobstructed flow path and the reciprocating motion of the diaphragms.

Key technical aspects of the implementation included:‍

• ‍Air Supply Management: Ensuring a clean, dry, and consistently regulated compressed air supply was crucial for the optimal performance and longevity of the air operated pneumatic diaphragm booster pumps. Precision air filtration and regulation systems were integrated to protect the sensitive air motor.‍
• Pulsation Dampening: Although Ovell's design promotes stable pressure, the high-pressure nature of the application still warranted the installation of pulsation dampeners on the discharge line. This ensured a smooth, continuous flow into the filter press, preventing hydraulic shock that could damage the press or downstream piping.‍
• Material Compatibility: The HA20SAGGG's flexible diaphragm materials were carefully selected for their chemical resistance and durability against the abrasive solids, further extending the pump's operational life in this harsh environment. The ability to customise wetted materials is a hallmark of leading air diaphragm pump manufacturers, particularly Ovell.‍
• Flow Rate Control: While designed for high pressure, the pump allowed for flow rate adjustments by modulating the air inlet pressure, providing operators with precise control over the filter press feed rate. This adaptability is typical of well-engineered air operated diaphragm pumps.

While this particular application focused on solid-liquid mixtures, the core technology in Ovell's product line often allows for diversification, where similar principles might be adapted for tasks like a diaphragm water pump for high-pressure washdown, or even a diaphragm metering pump for highly accurate chemical dosing in other parts of the facility.

Results and Transformative Benefits

The deployment of Ovell's 2-inch high-pressure pneumatic booster pumps delivered immediate and profound improvements, comprehensively addressing the facility's filtration challenges:

• ‍Accelerated Filtration Process: With a maximum pressure capacity of up to 17 bar, the Ovell pump generated double the pressure of standard diaphragm pump units. This significantly higher force propelled the solid-liquid mixture into the filter press with unprecedented efficiency, radically accelerating the dewatering process.‍
• Drier Filter Cakes: The increased pressure effectively squeezed more water from the material, resulting in substantially drier filter cakes. This outcome directly translated to reduced energy consumption for subsequent drying stages, as less moisture needed to be evaporated.‍
• Improved Product Quality: The drier filter cakes led to a higher-quality solid product, meeting stringent specifications for downstream processing or market sale. This enhanced quality often commanded better prices and reduced rework.‍
• Enhanced Operational Efficiency: The faster filtration cycles meant increased throughput for the entire processing line, boosting overall production capacity without the need for additional filter presses or equipment.‍
• Reduced Operational Costs: The "same lifespan as standard air diaphragm pumps" despite delivering twice the pressure meant that maintenance intervals were maintained or even improved compared to previous underperforming pumps. This, combined with less energy spent on drying and reduced waste volume, led to significant overall cost reductions.‍
• Stable and Predictable Performance: The independent pressure converter design ensured stable pressure delivery, eliminating the fluctuations that plagued prior pumps and contributing to a more predictable and controllable filtration process.

The successful implementation provided compelling evidence of the superior engineering offered by Ovell as a key player among diaphragm pump manufacturers.

Conclusion: A Benchmark for Industrial Pumping Solutions

The case of the New Zealand processing facility exemplifies how purpose-built engineering, such as that offered by leading air operated diaphragm pump manufacturers like Ovell Pump, can resolve complex industrial challenges. The deployment of the 2-inch pneumatic diaphragm booster pump (HA20SAGGG) transformed their solid-liquid separation process, moving from a bottleneck operation to a highly efficient and cost-effective stage.

Ovell's innovative independent pressure converter design stands as a testament to the advancements within the diaphragm pump industry, proving that high pressure can be achieved without compromising pump life or stability. This success story offers a valuable blueprint for other industries grappling with similar abrasive, high-pressure, or viscous fluid transfer requirements.

For businesses seeking to optimise their processes, reduce operational overheads, and enhance product quality, investing in specialised air powered diaphragm pump technology from reputable air diaphragm pump manufacturers like Ovell Pump represents a strategic decision for achieving long-term operational excellence. The ability of these diaphragm pump units to deliver consistent, high-pressure performance in the most demanding environments makes them an indispensable asset in modern industrial applications.

‍

‍