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mixture. Therefore, possible deviations depend on the step Dosing Pumps with Innovative Drive
size.
Concept
The presented group contribution method is a useful tool to
predict limiting oxygen concentrations. The calculated values
achieved by the original method of Subramaniam and By Bernd Eggert*
Cangelosi compared to the experimental values according to
DIN 51649 however show high deviations. Furthermore, these
deviations lie on the ªunsafeº side of the explosion range. 1 Introduction
The purpose of the introduction of new group contribution
values was at least a better representation of the values Displacement pumps and particularly diaphragm pumps are
contained in CHEMSAFE. The predicted values correspond typically used for dosing in the low-pressure range up to
well to the measured values. In order to achieve an extensive approximately 20 bar. However, the design and drive of
validation of the method, more experimental LOC values conventional, mechanically driven diaphragm pumps, results
should be available. in relatively narrow limits to their performance, in terms of
Received: August 22, 2002, [K 2976] dosing and setting accuracy which affects the supply of
chemicals (see Fig. 1). In addition, solenoid-driven dosing
pumps produce ± due to their design ± strong pulsations, which
Symbols used reduce the lifetime of both the pump and adjacent system
components. The integration of the pumps into central process
LOC,
management systems is another aspect that requires improve-
MOC,
ment.
Omax% [mol.-%] limiting oxygen concentration
LAC [mol.-%] limiting air concentration
Os [±] stoichiometric number of oxygen moles
required per mole of combustible gas
NT [±] total nitrogen required per mole of
combustible gas
a [±] number of chlorine atoms in relation
to the number of hydrogen atoms
c [±] number of the carbon atoms
in the fuel gas
d [±] number of the chlorine atoms
in the fuel gas
h [±] number of the hydrogen atoms
in the fuel gas
n [±] number of the nitrogen atoms
in the fuel gas
Figure 1. Unexpected operating cost due to inaccurate dosing.
o [±] number of the oxygen atoms
in the fuel gas
s [±] number of the sulfur atoms
in the fuel gas 2 Design of Dosing Pumps
Chem. Eng. Technol. 26 (2003) 4, Ó 2003 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim 0930-7516/03/0404-0433 $ 17.50+.50/0
0930-7516/03/0404-0433 $ 17.50+.50/0 433
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large dosing quantities and relatively low pressures (approx. 3 Dosing with Constant, Full Piston Stroke
2 m3/h against 5 bar), where accuracy requirements are less
strict, the preferred and most economical choice is a feed Recently developed dosing pumps by Grundfos, Fig. 3, are
pump with a flow meter integrated into the control loop. characterized by their harmonic oscillating actuation via a
Characteristic Q/H curves for centrifugal, diaphragm and crank-cam gear and their constant diaphragm drive. The
piston pumps, Fig. 2, illustrate that piston and piston pumps are driven by a stepper motor with synchronous belt
diaphragm pumps are best suited for accurate dosing, as they transmission, or a synchronous motor with synchronous belt
provide the highest volumetric efficiency together with an transmission. While the typical compact dosing pump used in
almost pressure-stable pump curve, i.e. the flow/dosing low pressure applications has a solenoid drive and a spring-
quantity (Q) is virtually independent of pressure (H). loaded return, the digital dosing concept of these pumps relies
on forced control, i.e. positive diaphragm action throughout
the entire suction and discharge cycle. With forced control, the
diaphragm position and thus the delivered dosing quantity can
be precisely defined at any time. Microprocessor-based
control with plain character display and control panel
provides a clear, easy-to-operate user interface.
434 Ó 2003 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim 0930-7516/03/0404-0434 $ 17.50+.50/0 Chem. Eng. Technol. 26 (2003) 4
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DME 100% Solenoid DME 50% DME anticav intermittent dosing as performed by solenoid-driven dia-
13
phragm pumps, the dosing process is virtually continuous.
Even for extremely small dosing quantities, continuous dosing
results in steady injection of the additive into the starting
11
liquid.
This innovative drive concept has many benefits:
9 l High Dosing Accuracy ± by having virtually constant
volumetric efficiency, the displaced volume is constant.
With highly concentrated and therefore expensive addi-
7 tives, precise dosing combines both cost reduction and
simultaneous environmental protection.
Magnet-P. l Smooth Dosing ± continuous smooth dosing eliminates
5
water hammer load on the diaphragm, which is an important
quality factor in many dosing applications. In the chemical
3 industry, for instance, continuous dosing prevents over-
heating or eliminates the need for static mixers.
l Easy, High-Precision Control ± 'plug & play' with easy
1 calibration, input of dosing quantity in L/h or mL/h and easy
operating mode setting. A multi-voltage, power supply
0 0,2 0,4 0,6 0,8 1 module (100±240 V, 50/60 Hz) is available.
-1
l Reliable and safe operation ± Forced control and operation
at full piston lift optimizes the dosing process even with
degassing and crystallizing liquids, and the optional BUS
connection allows an easy integration into process manage-
ment systems and facilitates validation.
4 Drive Concepts
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The dosing quantity in L/h or mL/h (also Gallons/hr) is set 5.7 Limiting the Maximum Dosing Quantity
via the pump's control panel and remains constantly.
This feature reduces the maximum dosing quantity at
100 %. The new, reduced maximum dosing quantity then
5.2 Pulse applies to all other menu functions, except the quick venting
key. So, the pump size is virtually reduced which, combined
In specific embodiments of the pumps, the dosing quantity with the still valid setting range of 1:1000, offers several
depends on pulses received, e.g., from a water meter. There is advantages:
no direct correlation between the number of received pulses l adjustment of the smooth and constant dosing curve with
and the diaphragm action. The pump's integrated electronic excellent mixing results even for small dosing quantities,
unit automatically determines the optimum stroke velocity for improved dosing in systems with long discharge pipes and
the preset dosing quantity per pulse. The pump adjusts its improved dosing of fluids of higher viscosity;
stroke velocity and frequency according to the following l wider range with only one pump size;
parameters: (a) frequency of the received pulses; (b) preset l adjustment of the pump to 4±20 mA input signal.
dosing quantity/pulse. Consequently, the pump can be used for very small
quantities without changing the input signal. For example: a
DME 48 pump receives an input signal of 12 mA which
5.3 Control via Analogue Input 0/4±20 mA corresponds to a 50 % dosing quantity, that is 24 L/h. Due to a
change in operating conditions, the required quantity is
These pumps dose according to the external analogue signal reduced to only 2 L/h, the input signal still being 12 mA. This
received. The dosing quantity is directly proportional to the 0/ means the maximum dosing quantity limit is to be set to 4 L/h
4±20 mA input signal (0/4 mA = 0 %; 20 mA = 100 %). Signal so that now 20 mA = 4 L/h and 2 L/h = 50 % (Fig. 6). In the
input may also be inversely proportional: 20±0/4 mA. The timer and pulse controlled batch dosing mode or in the
dosing rate depends on the input for the maximum dosing calibrating phase, where the pump is always working at
quantity (see below). 100 % always relates to the value set for maximum dosing quantity, limiting the maximum dosing
the maximum dosing quantity. quantity also has a corresponding effect on the stroke velocity.
436 Ó 2003 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim 0930-7516/03/0404-0436 $ 17.50+.50/0 Chem. Eng. Technol. 26 (2003) 4
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6 Summary
_______________________
Chem. Eng. Technol. 26 (2003) 4, Ó 2003 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim 0930-7516/03/0404-0437 $ 17.50+.50/0 437