clean and economical solutions for conveying … ip 1318-12 gb content applications mining /...

IP 1318-12 GB 1

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Clean and economical solutions for conveying different types of materials

IP 1318-12 GB2

Content

Applications

Mining / Backfilling 5

Fly Ash / Bottom Ash 7

Sludge Removal 8

Tunnel Construction 10

Oil & Gas Industry 12

Biomass 15

Sewage Treatment Plants 18

Co-Incineration 20

Coal Sludge 22

Cement Industry 23

Special Waste 25

Inorganic Materials

Organic Materials

Pump Technology

IP 1318-12 GB 3

Piston Pump with S-Transfer Tube KOS 27

Piston Pump with Seat-Valves HSP 28

Piston Pump with Ball Valves KOV 29

Single-Piston Pump EKO 30

Power Pack Units 31

Products

Silos 32

Sliding Frames 33

Discharge Augers 33

Silo Technology

System Components 34Accessories

Range of Services 38Service

IP 1318-12 GB4

Inorganic Materials5

IP 1318-12 GB 5

Mining / BackfillingInorganic Materials

Two tailings pumps of type HSP 25100 at the Bulyanhulu Goldmine in Tansania

Safe “Backfilling”High production costs, safety concerns,environmental aspects and so on areforc ing mine operators to undertakeextensive restructuring. Backfilling ofresidues from mines and power stationsplays an important role. The core components of such installa -tions are S-transfer tube pumps (KOS),seat valve pumps (HSP) and ZX pipingsystems from Putzmeister:

Conveying distances up to 11 kmfrom the mixing facility located onthe surface to the backfill locationunderground and with no pumpsinstalled on this route

Up to 200 m3/h conveying capacities Up to 120 bar operating pressure in

the material Permissible pressure of up to 250 bar

in the 200 mm internal diameterpipeline due to high static pressurecomponents encountered

Suitable for abrasive material

Advantages of the system

Closed loop of washery tailings:minepit – treatment – minepit

Increased stability of the miningstructures

Better exploitation of deposits Safe and clean transport in pipelines High operational safety and reliability Low wear costs Lower specific energy consumption Little water circulating

Creating tunnellinings for targeted mine ventilation withthe BSM 1002 (Elefantino)

Mining companies are constantly search -ing for ways to ensure that workingunderground is economical and safe.This is particularly true of coal miningcompanies.

Potential application sites for the BSM 1002

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Creating linings for the roadways

Securing roadways with"concrete" packing

Concreting dam constructions

With the BSM 1002, it is possible to mixand pump building materials on site, e.g.concrete or other mineral substancesmixed with cement.

These materials are for example bestsuit ed for building tunnel linings in acoal mine.

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IP 1318-12 GB6

KOS HSP KOV BSM

Upward conveyanceof sludge with high-performance„Mine dewatering“In “mine dewatering”, mine slurries filledwith sand must be conveyed up to thesurface.The Putzmeister HSP seat valve pumpoffers a particularly efficient and inex-pensive solution to this problem.

The following case study on a miningcompany in Lorraine demonstrates someof the economic and technical advan -tages of this process: The French miningcompany Houillères de Bassin deLorraine (HBL) was looking for a betterway of pumping its mine slurries with720 g/litre sand up to the surface from adepth of 1250 m. The 43 centrifugalpumps which they were currently usingwere reaching their limits as the depth

HBL slurry pumping system. Before: 43 centrifugal pumps – Now: Only two HSP 3080 solids pumps.The HSP 3080 at work in an underground site

increased. Moreover, their linkage into acascade meant a fivefold dilution ofconcen tration over the distance to thesurface.

To solve this problem Putzmeister plantspecialists decided to use two doublepiston pumps with seat valves (modelHSP 3080 with a 320 kW hydraulic drive.This system brought the followingresults.

Mining / BackfillingInorganic Materials

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Increased capacity – 90 m³/h ispumped at a flow rate of 2.7 m/s at apressure of 100 bar

Constant solids concentration Energy requirements are reduced to ¼ The size of the 3 m stroke guarantees

low wear and quiet running The reliable technology increases

availability and considerably reducesmaintenance costs

IP 1318-12 GB 7

Fly Ash / Bottom Ash

Economical fly and bottom ashtransport as high-density slurriesAfter incinerating coal in coal fuelledpower stations, the resulting waste suchas fly ash from the electofilters or thebottom ash from the boiler have to bedisposed of.

The most economic way to convey thesedifferent types of ashes is by usingPutzmeister KOS double-piston pumps.A mixture of fly and bottom ash can besuccesfully transported without opera -tion al disturbances. Since PutzmeisterKOS piston pumps do not have any val-ves between the inlet and outlet of the

Fly ash landfill siteA KOS 25100 pump installation (Kogan Creek, Australia) for fly and bottom ash

Inorganic Materials

KOS HSP

Solutions from asingle sourceIn order to ensure the efficiency in powerstations, Putzmeister offers completesolutions for the conveyance of fly andbottom ash in landfills. The turn-keysupply consist of silos, piston pumps,pipework, including all necessary acces-sories and services.

In order to ensure that its systems can befully integrated in power stations,Putzmeister works closely with the lead -ing suppliers of power station equipmentworldwide. Pumping of fly ash, bed ashand sulphurization gypsum are furtherimportant areas of application forPutzmeister solids pumps in power sta -tion.

pump, even coarse particles can passthrough the pump without interruptingthe flow process.

Another important aspect for usingPutzmeister piston pumps is the lowwater consumption. The pumps operatereliably even high dry solids contents upto 85 %.This translates in an extended lifetime ofthe disposal site and/or its size can bereduced. The main advantage is howeveran ecological one: large amounts of con-taminated water can be reduced to aminimum.


High availability Long service life Low maintenance and operating

costs Lower water requirements Service-friendly

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IP 1318-12 GB8

On the Japanese coast line, three huge KOS 25100 and 25200 piston pumps are pumping silt out of the sea for land reclamation. The Nagoya is now located on this new artificial island.

Sludge Removal

Top figures withsolids pumps Outputs up to 450 m³/h Delivery pressures up to 130 bar Conveying distances of more

than 2000 m

Putzmeister solids pumps for economicsolutions without damaging or dirtyingthe road.

System components Solids pumps Mixing devices Vibrating screens Pontons Floats Pipelines Quick-action couplings and fittings

Efficient solutionsfor sludge removaland transportThe sludge is removed by shovel excava-tors and Putzmeister solids pumps.These pumps can operate even withextremely high solids content and thereis no need for dilution with water.

Particular emphasis is placed here onenvironmental friendliness and econo-mic efficiency. Experienced engineerscome up with the right solution tailoredto individual requirements, which is thenimplemented technically. The rated per-formance of the PM solids pumps is ofdecisive importance here.

Inorganic Materials

Sludge handling system operating in a canal in France with an S-tube pump and diesel-driven power pack mounted on a ponton

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IP 1318-12 GB 9

Desludging – Simple and environmentally friendly

60 m3/h effectivedischarge flow

Dump inquarry

Height difference50 m (165 ft)

Pipeline lengthapprox. 1540 m (5000 ft)

Lake 22000 m3 (28380 yd3)

Front endloader

Dam

KOS

Desludging of a tar dump using a remote-controlled Dredgemaster dredge vessel

Mobile dewatering and pumping station

River sludge with high dry solids content has short drying times


In practice, solids contents up to 68 % and more have been pumpedwithout the need to add water. Thismeans no flushing- or waste water.

This environmentally-friendly andclean transportation solution meansthat less space is required at thedump site.

Thanks to its gentle conveyance andthe material’s solid consistency, thesludge dries out extremely rapidlyand no dams are therefore required.

Efficient disposal and processing Conveyance of large foreign bodies Quick laying of pipeline systems

Since many components are offered froma single source, we are able to offer effi-cient and environment-friendly solu tions.

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IP 1318-12 GB10

Tunnel Construction

Auger conveyor with two muck pumps of type KOS 1480 (Botlek tunnel, Netherlands)

MPT 40: the compact and powerful muck remo-val pump for extremely small cross-sections

The fact that Putzmeister has masteredthe conveying engineering for high den-sity solids and has gained experiencefrom more than 100 tunnel constructionprojects, makes the company the rightpartner for complete solutions when con-veying muck out of tunnels.

In addition to the comprehensive con-sult ing service offered, machines suchas the drive units, crushing and sortingplants, conveying belts, screens, mixing

troughs, high performance pumps, silosabove ground, etc. are all within the scopeof supply.

Double piston pumps provide a perform -ance of up to 250 m3/h per pump unit.Tunnel machines with up to 14 metersdiameter can be equipped with our high-density solids pumps.

Numerous projects in Asia as well as inEurope (e.g. Botlek Tunnel in the Nether -

lands) demonstrate the strengths of thismethod compared to ground transport bycentrifugal pumps or via conveyor belts.

Pipeline deliverywith high-perform ance piston pumpsAdvantages of the system

Space-saving, e.g. for drivingpipelines in a small tunnel

Clean and safe conveyance ofexcavated muck over long distances

High output Addition of water is rarely or not

necessary at all Simple logistics – no muck cars

needed Operational safety Continuous conveyance is guaran-

teed, even with pressure locks

Inorganic Materials

Clean and safe conveyance of largeamounts of excava-tion residues

“Closed system” muck removal

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IP 1318-12 GB 11

TRIA – continuous annular space filling for tubbing behind the tunnelling machine

Efficient annularspace backfilling for tubbing

Depending on rock properties, con -struct ion method and time frame, differ-ent machines are used in tunnel con-struction for the injection of mortar.Putzmeister’s product portfolio includeseverything from the smallest stand-alonemachine to fill anchor holes, spiralpumps for low pressures, to pistonpumps for pressures up to 100 bar.

In combination with important accesso-ries such as turbo mixers, high pressurevalves, high pressure rotor distributors,special delivery lines, auger conveyors,flow meters, pressure gauges, etc.,plants can be individually arranged forthe most advanced methods.

TRIA, i.e. continuous annular space fil-ling for tubbing, is often used behind thetunnelling machine.

KOV double-pistonpumps for free-flowing materialcontaining up to 70 % solidsInexpensive double-piston pumps withball valves for the economically efficientconveying of fine-grained mortar andlow-consistency slurries containing for-eign bodies up to 20 mm in size.

High performance ranging up to 60 m3/hand 130 bar mean large safety reservesfor the pumping process and allows eco-nomic, clean and safe conveyance bypipeline over several kilometres.

KOS KOV

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Space-saving installation with two KOV 550 Duo underneath a 6m³ agitating trough

A KOV 1050 pumps the injection mortar behind the ring segment

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IP 1318-12 GB12

Oil & Gas Industries

Innovative SystemsPumping with Putzmeister hydraulic dri-ven solids pumps is the most efficientmethod for conveyance of very stiff mate-rial with high viscosity and high share ofcoarse grain over long conveying dis -tances.

The “S-transfer tube” system used in thispump type even allows the pumping ofmaterial with poor liquid content.

If the material has poor flow character-istics a special double auger feeder isused to fill the piston pump type KOS.

Inorganic Materials

Typical OffshoreApplications for the PutzmeisterPumping System Pumping drill cuttings from shaker to

buffer tanks or containers Pumping drill cuttings from buffer

tanks to the supply vessel

Putzmeister high density solidspumps also operate on supplyvessels

On -shore for conveying treated drillcuttings to an environmentally friend-ly storage area and processing plant

Kompact design for applications onoffshore platforms

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Putzmeister KOS high density solids pump with feeding device

IP 1318-12 GB 13

KOS HSP KOV

Hydraulic power pack HA 90 S with(Pressure Constant Flow) forpulsation free transportation

Re-Injection Pumpsthe Perfect Fit HSPOil-hydraulically driven piston pumpwith hydraulically actuated seat valves for treated drill cuttings.

KOVOil-hydraulically driven double pistonpump with ball valves for drip water anddrain liquids.

The Putzmeister delivery program for in -dustrial applications includes also:

Auger feeder units Power packs Delivery pipelines Silos and tanks Silo discharge systems


Due to low piston speeds inside the delivery cylinders, the wear isreduced to a minimum

Due to low wear, the maintenancecosts, effort & down times arereduced

Due to low down times, maintenancestaff can be protected from beingexposed to hazardous media

The Putzmeister pump is a well de signed solution, based onPutzmeister’s long experience for different applications, mainly inpumping of abrasive media

The module design allows Putzmeister to find a suitable solution for almost every pumpingtask, for every output rate and highest pressure levels

Putzmeister KOV 1075 – special equipped for the operation on rough sea

On the rig From rig to ship From ship to shore

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IP 1318-12 GB14

Organic Materials31

IP 1318-12 GB 15

The appropriatepumps for differenttypes of biomassesPutzmeister industrial engineering hasexperience with the conveyance of bio-mass since the end 80’s. The uniquedesign of the pumps enables to conveyvarious types of biomasses, even whencontaining foreign bodies such as knives,spoons, bottle caps or glass, which candramatically disturb the fermentationprocess.

Opposed to other conveying systems, thetreatment of biomass with reduced life-cycle costs is guaranteed when usinghydraulically-driven piston pumps. Fur-ther more, together with the Germanengineering company FinsterwalderUmwelttechnick, Putzmeister also de vel -op ed a process to separate out foreignparticles during the pump process.

A fault-free and and non-stalling con-struction of the pump and feed lines isnecessary when pumping biomass, bio-waste and foodwaste from households,supermarkets, restaurants or other sources. Everything that disturbs theflow can lead to clogging or blockages.

Shredder

Sieve drum

Feeding belt

Piston pump Fermentation tankRecirculationpump

Bio vertilizer

Electric energy

and heat

Feeding screw

Manure or recirculation

Piston pump withmixing screw

Dry-anaerobic fermentation of biomass

Biomasse power plant

Biomass from food remains and wrapped food

Schredder

Piston pump

Single pistonpump EKO

Fermentation tank

Container

Shredder

Heat exchanger

Biomass from animal carcasses

Piston pump withmixing screw

Piston pump

Waste material / inorganic material

Bio vertilizer

Electric energy

and heat

Suspensio

n

KOS 25100 with hydraulic power pack and twin-screw feeding device, transporting biomass

to the fermentation tank

BiomassOrganic Materials

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IP 1318-12 GB16

The alternative option for producing electricity and heat out of biomass

Biowaste recycling plant in Varenne-Jarcy, France: KOS 2180 pumping biomass into a fermentation plant

The KOV twin-cylinder piston pump canconvey liquid and wet material. Due tohaving a large inlet and outlet opening,this pump type can also digest large par-ticles without disturbing the pumpingprocess.

KOV twin-cylinder piston pumpshave been pumping more than100000 hours without any majorinterruptions.

Biogas from waste –for a cleaner environmentIn accordance with EU 1774, using left-over foods as animal food is no longerallowed in Europe. These are now con-verted in electrical energy and heat inbiogas pants.

The KOS twin-cylinder piston pump canpump bulky, wet and pasty material withimportant grain size.

KOS twin-cylinder piston pumpshave been pumping more than160000 hours without any majorinterruptions.

BiomassOrganic Materials

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Green household waste or NaWaRo

IP 1318-12 GB 17

An EKO 1060 PP in a biomethanisation plant (Kössen, Austria) for unwrapping and transporting foodspast expiry date

Remaining packaging and foreign bodiesLeftovers and expired foods before processing Substrate of the biomass after the pressing process of the EKO 1060 PP

Efficiency throughthe separation offoreign particlesDuring the methanisation of biomass(leftover and/or expired foods or otherorganic waste), inert foreign bodies suchas wrappings/packagings, plastic trays,glass, cans, or metal can disturb the bio-gas process since those foreign bodiesreduce the active volume in the fermen-ters.

With the EKO single cylinder pistonpump, in order to improve the fermenta-tion process, it is possible to reliablyseparate foreign bodies before feedingthe organic waste into the fermenter. TheEKO can deal with wet material, as wellas sludges containing large foreignbodies.

EKO single-piston pumps have beenpumping more than 60000 hourswithout any major interruptions.

EKO KOS KOV

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IP 1318-12 GB18

The economical and reliable solution In sewage treatment plants, Putzmeistersolids pumps will help dispose of thethickest types of sludge. Even solids ashigh as 45% are not an issue.

Especially large-scale plants imposestrict requirements when it comes to run-ning a fault-free continuous operation.This is precisely where Putzmeistersolids pumps have proved themselvesworld-wide, proving their economic effi-ciency in the conveyance of mechanical-ly dewatered sewage sludges.

Conveyancethrough a closedpipeline Odourless No environment pollution Space-saving and can be adjusted

to fit the existing structure of thebuildings

High metering accuracy Pipeline is not subject to wear Low-maintenance and low-wear

technology Maximum availability for continuous

unmanned operation Remote supervision from the control

room Stiff, free-flowing and sticky sludges

can be transported

MS 70328

Plate and bed pressDigestion tower

Sliding frame

Receiving bunker

Precompression screw conveyor

EKO

KOS

Intermediate dumps

Centrifuge

Extractionscrew

Hopper

Mill

Refusepit

Boiler plant

Combustion chamer ash

KOS

Screenings ThickenerSand trap

Belt filter press

KOS

Storagesilo

Storagesilo

Sliding frame

Extraction screw

ConditioningDrying

Compostingdrum

Cement kiln

Incineration

Land fillSludge incineration

Leaders in pump and silo technology The most-favoured features ofPutzmeister piston pumps:

Robust design Flow-optimised suction

characteristics Continuously filled, circular suction

cross section in the S-transfer tube High volumetric efficiency for the

delivery cylinders Long piston strokes


Low life-cycle costs High operational reliability Extremely quiet in operation Can even handle the stiffest sludges

Flow chart of a sewage treatment plant application

Sewage Treatment PlantsOrganic Materials

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IP 1318-12 GB 19

Sewage sludge reception station consisting of reception and storage silos: Incineration of foreign sludge at the main wastewater treatment plant of Stuttgart-Mühlhausen

ScreeningsPumping screenings (Coney Island, New York)

KOS 1050 solids pumps in the ProRheno sewage treatment plant in Basel, Switzerland

Sewage sludge dewatered by a chamber filter press: Solids content > 35% DS

To improve the efficiency, it is possibleextend the Putzmeister piston pumpswith a feeding device which is equippedwith self-cleaning augers and supportsthe optimal filling of the delivery cylin-ders.

Putzmeister’s silotechnologyThe silo technology with sliding framehas been especially developed for dewa-tered sewage sludge. The silo can take upto 1000 m³ sludge and reliably feeds it tothe pumps.

From the various pump models to silosand the corresponding fittings and acces-sories, Putzmeister can provide completesolutions for conveyance tasks in waste-water treatment plants.

EKO KOS HSP

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IP 1318-12 GB20

Co-Incineration

Flow chart: Co-incineration of sewage sludge in a coal fired power plant

Flow chart: Sewage sludge co-incineration in household incineration plant

Receiving building

Sludge receiving silo

KOS

Coal bunker

Receiver container

Coalpulverisers

Boiler

Boiler 4

to boilers3-2-1

Co-incineration of sewage sludge in the coal-fuelled power plant of Zolling (Germany): KOS 2180

Two KOS 1030 with HA 22 for feeding sewage sludge into the refuse incinerator (Dinan, France)

Organic Materials

Energy out of sewage sludge andhousehold waste The disposal of dehydrated sewage sludgein household waste incineration plants isnowadays a very environmental-friendlyand economical procedure.

This process can be integrated in newlyplanned plants, as well as retrofitted inolder plants. The addition of sewagesludge does not affect the reception ofhousehold waste or the discharge andmetering of rubbish into the the combus-tion chambers. Besides the fact that bothmaterials are burnt together, there is nocommon interface between both disposallines.

Putzmeister offers complete turn-key so-lutions for storage, transport and feed ingof refuse in the combustion chambers.

Efficient coal-fuelled power plants The co-incineration of mechanicallydewatered sewage sludge in existingcoal-fuelled power stations with highlyeffective flue gas pollution control is alsoan economic and meaningful alternativethat do pose a threat to the environmentcompared to the previous disposalmethods.

Sludgeacceptance

KOS KOS

Sludgestorage

Refuse bunker Combustion

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IP 1318-12 GB 21

Erzo Oftringen sewage treatment plant (Switzerland): rotary kiln for the incineration of sewage sludge

Flow chart: Reception of foreign sludge and handling one’s own sludge in a swage treatment plant

Two 200 m³ storage silos for sewage sludge storage (Pro Rheno, Switzerland)

KOS

Well-thought-outplanning process of external sludgereceptionRecycling the amounts of received sew agesludge from municipal and industrialplants has become an important issue forsewage treatment companies.

Due to political framework conditions(prohibition of dumping sewage sludge,limitations placed on agricultural use,etc.), the choice of a thermal incinerationto dispose of sewage sludge has becomeinevitable.

To ensure that the multiple hearth fur-naces are used to their full capacity, notonly one’s own only sewage sludge canbe handled but also external sludge fromsurrounding waste-water treatment plantscan be receptioned and treated.

Reception bin

Precompressionscrew conveyor

KOS

KOS

Sliding frame

Slidingframe

Sliding frame

Extractionscrew

Screw conveyors

4 x KOS

4 x centrifuge

4 x precompression screw conveyor4 x agitator container

Storagesilo

Putzmeister Solid Pumps offers com -plete sludge handling systems for suchpurposes.

A special advantage of the KOS S-tube pump without valves

Foreign bodies contained in thesludge can be conveyed withoutinterference thanks to the largecross-section opening of the S-tubepump.

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IP 1318-12 GB22

Coal Sludge

Pressurized fluidized-bed incineration – The clean coal technologyThis technology distinguishes itself byits environmental-friendliness and ahigh er degree of efficiency compared toconventional coal-burning processes.

Putzmeister is making a major con tri -bution towards clean power sta tions.Putzmeister KOS pumps feed fuel, inform of a coal-limestone-water mix ture,into the fluidized bed.Depending on the material’s granularstructure, solids content of over 85% arepumpable. The pumps offer a reliable,maintenance-free and continuous modeof operation.

Complete system:from the receptionsilo to the injectionslances into the boiler

Case study:

The installed Putzmeister pumps in thecommercial power plant of Värtan,Stockholm have been running fault-freeand that during the heating period, whichlasts 6500 hours after all in Sweden.

Coal injection with pressurized fluidized-bed combuster. The flow chart shows a combined gas and steam turbine process with pressurized fluidized-bed combustion. (ABB Carbon)

Coal Limestone

Water

Pre-mixer

Ready-mixer

Hydraulicdrive

Economizer

Heat condenser

District heating

Steam turbineGas turbine

Steam

Flue gas

Pressurized combuster

AshFluidized-bed

KOS

HMCS

4 - 20 bar

Air

Compensator

Gate valve

KOS 2180 coal transportation pump for long-distance coal delivery

Coal sludge reception system in a power plant KOS 1070 coal sludge injection pump

Organic Materials

KOS

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IP 1318-12 GB 23

Cement IndustrieOrganic Materials

The volume to be fed into the cement kilnare approx. between 2 and 7 m³/h. In thiscase, Putzmeister high density solidspumps of the KOS series are used.

Co-incineration of alternative fuels in the cement plant of Lafarge in Le Teil, France

The use of substitute fuels forthe production ofcement Substitute fuels offer cost-saving oppor-tunities for energy-intensive industries.With the example of the cement industry,Putzmeister Solid Pumps offers solu-tions comprised of silos and pumps thatsupport the reception and conveyance ofalternative fuels for the production ofcement.

Alternative fuels have to have a highcalorific value in order to be worthy sub-stitute to primary energies. Possiblefuels for such purposes are:

Mechanically dewatered sewagesludge

Tar Paint sludge Slaughterhouse waste

These fuels are receptioned in silos, either individually or mixed together. ThePutzmeister high density solids pumpsthen convey there substitute fuels, eitherto the cold side of the rotary kiln as additives or source of energy; or to thehot side as fuels.

It does not matter wether there are foreign bodies in the material since thePutzmeister S-tube technology is able toconvey those even if they represent 2/3of the size of the pipeline diameter.

However, these alternative fuels have tobe processed before they are pumped,meaning that they have to be madepumpable beforehand.

Paint sludgeSludge from cooling-water treatment

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Cement IndustrieOrganic Materials

KOS HSP

Three types of stations for an efficient sludge-handling systemType 1

The receiving station consists of highdensity solids pumps with a precom-pression screw conveyor and a built-inattachable hopper handling volumes be-tween 6 and 10 m³. The pump is fed witha front-wheel loader.

Type 2

In this option, the attachable hopper isreplaced by a receiving silo with a volu-me of approx. 100 m³.

Different sludges can be receptioned andmixed together by the pump’s rotationfunction.

Type 3

Different alternative fuels can be recep-tioned in one or multiple receiving bun-kers. High density solids pumps thenconvey the material to a 250 m³ storagesilo. Hence, the receiving bunker is readyfor new deliveries of sludge.

In a voluminous storage silo, the substi-tute fuels mix well together, thus guaran-teeing a high calorific value.

Type 1

Ultrasonic sensor

Front wheel loader

Hydraulicpower unit

Installed performanceapprox. 75 kW

Twin screw feeding device, hydr. driven

KOS piston pumpS-tube type;delivery output: 3 – 6 m3/h

Foreign body separator

Polymer injection system

to the cement kiln

Delivery lineDN 150, PN 64

Type 2

Delivery line DN 150, PN 64 to the

cement kiln

Foreign body separatorPolymer injection system

Hydraulicpower unit

Installed performanceapprox. 75 kW

KOS piston pumpS-tube type;delivery output:: 3 – 6 m3/h

Ultrasonic sensor

Silo volume approx. 100 m3

Silo discharge screw,hydr. driven

Gate valve,manually operated

Sliding frame,hydr. driven

Silo, rectangular design

Type 3

Ultrasonic sensor

Silo volume approx. 2 – 3 truck loads

Silo discharge screw, hydr. driven

Gate valve,manually operated

Delivery line,DN 200, PN 64

Hydraulikpower unit

KOS piston pumpS-tube type;delivery output:30 – 40 m3/h


Hydraulic power unit


Silo, rectangular design

Foreign bodyseparator Installierte

Leistung ca. 55 kWPolymer injection system

to thecement kiln

KOS piston pumpS-tube type;delivery output: 3 – 6 m3/h

Delivery lineDN 150, PN 64

Ultrasonic sensor

Silo volume approx. 2 – 3 days operation

Silo discharge screw,hydr. driven

Silo,round design

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Special Waste

Washingapparatus

Mixers

EKO 14100

KTO elevator

Sludge lance

Ash Fly ash

FlueRotary kiln

Oil liquids

N2 lock

EKO 14100 feeding the rotary kiln with shredded barrel waste in a hazardous waste treatment plant

Coarse hazardous waste from the reception bunkers is fed via claw arm to the EKO pistonpump

Flow chart: Incineration plant for hazardous waste

Optimal hazardouswaste treatmentwith specialPutzmeister pumpsWhen conveying hazardous waste, it isimportant that none of these dangeroussubstances get into the environment.Health risks have also to be avoided onthe premises of the plant.

This can only be guaranteed whenconvey ing through a closed pipeworksys tem. Special requirements made bythe legislators, such as ATEX and explo-sion protection are implemented in thePutzmeister systems.

Optimized incineration for abetter environmentThrough a controlled pump feeding, it ispossible to monitor the incineration pro-cess of the substances in order to respectthe echast gas premissible values.

Organic Materials

EKO KOS KOV

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Products – Pump Technology67

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Oil-hydraulicdouble-pistonpump with S-transfer tubeIn the KOS series, the intake and deliverycylinders are connected by an S-transfertube. This enables a continuous free-flowing conveyance of the material with-out the use of valves. Foreign bodies upto 2/3 of the size of the discharge outletcan be conveyed without any issue.

The KOS pump is particularly suitable forconveying highly viscous sludges andother material with a high proportion ofcoarse solids. The main fields of applica-tion of the KOS are with materials whichpresent the most extreme requirements,such as dewatered sludges containingsolids, oil sludges, high-viscosity solidsand so on.

For extreme applications, a wide range oftask-specific components and functionsare available from Putzmeister.

The pump’s simple design and the fewwear parts offers a very robust, low-maintenance pump with low-operatingcosts.

KOS

For conveying coarse sludges orslurries with a high grain-size content

Low maintenance and wear due tofewer moving parts

Less suction resistance thanks to larger inlet permitting constant free-flow of the material

For further information please refer to our IP 1082 GB brochure

Features and advantages

Performance chart

The hydraulic circuit of the S-tubedoes not come in contact with thematerial being pumped

Delivery rates up to 450 m3/h Delivery pressures up to 150 bar

Products – Pump Technology

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Oil-hydraulic piston pump with seat-valvesThe seat-valve pump is used for heavytasks.

The HSP series is used with paste-likeand highly viscous material with a lowcontent of foreign bodies and small par-ticle sizes (< 15 mm).

Precise sealing of the valves means thatextremely high pumping pressures canbe achieved. The principle behind thedesign of the hydraulic and pumpingpistons is the same as in the PutzmeisterKOS and KOV series. This ensures maxi-mum reliability and availability.

Two special features of the Putzmeisterdesign are that not only is it a simplematter to replace the valves but thedesign also means a long service life forall wearing parts. Valves and valve seat -ings are made of highly wear-resistantsteels and can be used at either end. Thisdoubles their service life. Valves can beeasily replaced easily without dismant-ling the delivery lines.

All of the familiar Putzmeister optionsand variations are available with the HSPseries as well.

A pulsation-free conveyance can beachieved wth the system (PressureConstant Flow)

For conveying fine-grained sludgesor slurries

Switch-over without shorting No backflow at high pressures Easy installation of damping tanks

More effective with materialcontaining a high proportion of air

Outputs up to 350 m3/h Delivery pressures up to 160 bar


HSP

Performance chart



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IP 1318-12 GB 29

Oil-hydraulic piston pump withball valvesThe KOV series is characterized by itsstraightforward design and high reliabili-ty. The suction and delivery cylinders areconnected by indirectly operated balls.

No elements are actively operated, whichmakes it an inexpensive pump with maxi -mum availability. There are no issues orcomplications when pumping paste-likematerial such as mortar or bentonite,even when they contain foreign bodiesup to 10 mm in size. Pumping pressuresup to 90 bar and an output of as much as60 m3/h apply.

Depending on the specific individualcase, the balls and seat valves can besupplied in different materials and coa-tings. A maintenance aperture allows aneasy and rapid replacement of the ballvalves.

For conveying fine-grained pastes Simple design A minimum of moving parts Very easy to maintain

Outputs up to 60 m3/h Delivery pressures up to 90 bar



KOV

Performance chart


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IP 1318-12 GB30

For conveying large-sized and coarseforeign bodies

For conveying extremely stiff material Crown version – pumping and

cutting in one stroke Simple design

Delivery pressures up to 60 bar Cutting force up to 80 t Outputs up to 14 m3/h

The oil-hydraulicsingle-piston pumpThe EKO series is designed for the mostextreme pumping tasks. The open hoppersof allow extremely dry material con -taining a high proportion of foreignbodies to be fed to the pump. Materialswhich were unpumpable until now, suchas highly dewatered paper sludges, arethrust by the hydraulically driven pistoninto the delivery line.

The EKO Crown model is equipped witha delivery piston with a hardened toothedcutting crown. This pump is used whenthe material contains large-sized foreignbodies, which would swiftly result inblockages in other systems. The EKOpumps and cuts in one single operation.The most difficult materials, such assewage treatment plant screenings orshredded barrel waste in special wasteincineration plants, can be pumped with-out issue into the delivery line.

A quasi-continuous operation is alsopossible with the double EKO version.


EKO



Alternative gate valves with the patented blade valve – especially suitable for materialssuch as screenings for example

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The heart of everypiston pumpThese power packs have proved theireffectiveness more than 10000 timeswith concrete pumps and now theypower up industrial pumps that conveythe material.

They drive the following:

High density solids pumps of typeKOS, HSP, KOV, EKO

Screw conveyors of type THS, SHS Silo sliding-frame of type PDL, PDF,

PDS-L, PDS-F Accessories such as gate valve or

silo-lid, etc.

Performance classes from 5,5 kW up to800 kW and more are available.

Efficiency of thehydraulic systemdesignDepending on the quantity of oil needed,an open or closed oil-circuit can beused. The closed oil-circuit is used whenreaching delivery capacities of 100 m³/hand above, which means considerablecost-savings.

The oil-circuits are designed for hydrau-lic pressures of up to 250 bar. Thisequals delivery capacities of up to 160bar.

Equipment Oil/Air cooler Oil/Water cooler Oil pan Diesel engine Sound insulation

Features andadvantages

Power Pack Units

The power of the hydraulic gives thedelivery cylinder the necessary pressure to pump the material intothe delivery line.

In every speed range, the screw drivecan apply its maximum torque on theconveyed medium.

Products – Pump Technology80

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Silo-Technology

Storage silo discharging directly into a pump

Storage silo with truck loading

Receiving bunker with rectangular sliding frames and pump feeding

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Ladder systems /discharge systemsfor round siloDepending on your application, the slid -ing frame can take the form of a laddersystem (PDL) or a cylindrical silo dis -charge system (PDF). The ladder systemwith multiple parallel sliding frames in isparticularly suitable for wide or long re -cei ving bunkers. This ensures an effi-cient transmission of force and in creasesthe availability of the system thanks tothe redundancy.

The delivery range includes silos andbunkers from 10 m3 to 1000 m3 for load-ing trucks and for feeding sludges tosolids pumps and their onward con-veyance.

Material is discharged from the silos bymeans of specially adapted screw con-veyors, with a lateral or central dis -charge. If several end users have to besupplied, multiple discharge augers canbe used.

Common parts are used for pumpand silo, which means fewer spareparts and simplifies maintenance.

No interface clarification necessary,the customer does not have to dealwith sub-suppliers.

Sliding framesystems – tried and testednumerous times,highly reliableThe Putzmeister sliding frame systemhas been designed especially to meet therequirements of harsh three-shift opera-tion. Thanks to modern finite elementanalysis, proven Putzmeister hydrauliccomponents optimize the sliding frame’sdesign, as well as its service life. Onemajor feature is the space-saving designemplacement of the sliding frame’spiston rod which is located on the silofloor. The piston seal used in the high-pressure pumps reliably prevents anysludge leakage.

Pump and silo working in perfectharmonyPutzmeister silos have been designedespecially for highly dewatered andhigh ly viscous sludges.

Since the pump and silo come from thesame manufacturer, the customer enjoysimportant benefits:

The shared silo discharge and pumpfeeding auger reduces costs andincreases availability.

The perfect tuning between pumpand silo leads to an overall optimizedconcept.

PDL rectangular discharge sliding frame

Intermediate silo with double rectangular sliding frames for charging five Putzmeistersolids pumps

Finite element analysis for the sliding frame

Silos, Sliding Frames, Discharge AugersSilo Technology

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Accessories

HCBLCB

LIB

LCBLCB

LIB Low Inline BoosterHCB High Cross BoosterLCB Low Cross Booster

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IP 1318-12 GB 35

Optimal fillingthrough screw conveyorsHighly-viscous sludges have to be fed tothe pump if they cannot flow by them -selves into the pump. This task is bestresolved with twin-screw augers. The latter will generate a pressure in order tobetter fill the pump with the material to beconveyed.

A fur ther positive effect is that the twin-screw augers are self-cleaning since theyare meshingly inter-connected.

They are driven hydraulically.

Foreign body separators enable a continuous flowof materialPutzmeister’s FKA 200 is successfullyused with the conveyance of sludgescontaining foreign bodies. This systemsprotects downstream machines fromdisturbing materials. Thus, when incine-rating sewage sludge in coal-fired powerplants, disturbances can be avoided inthe downstream operating coal mills.


In every speed range, the screw conveyor’s drive can exert its maximum torque on the material to be conveyed

Twin-screw auger feeding device with mixing paddles in the supply chute

Twin-screw conveyor SHS 3262 SH

Retained foreign bodies Foreign body separator in a power plant

In the direction of the flow, the foreignbodies will be caught by a grid.

The foreign body separator is equippedwith a quick-release fastener which canbe opened through a single-lever ope-

ration. The quick-release fastener systemensures additional safety during the cleaning operation of the Foreign bodyseparator.

Screw conveyors, foreign body separatorAccessories

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Secure deliverylines in tunnellingand miningDelivery lines for underground con -struct ion cites must be easy to lay, safeand high-pressure resistant.

The Putzmeister Zentrifix® ideally meetsthese requirements. The rigid and abso-lutely leak-proof connections act just likehydraulic connections since the seal istightly pressed into its seat during theassembly. The large wall thickness withthe ZX lines additionally offer a high wearreserve.ZX delivery lines are used for backfilling,mine dewatering and for transportingconcrete over long distances.

Further underground tasks are shot-creting, as well as injection works. Here,The SK quick-action coupling system, aswell as the Ultraflex® PX system areused.

Delivery lines inindustry – a cleanbusinessDelivery lines in industry must especiallybe safe over a long period of operation.The pressure resistance with pulsatingload is one particular criteria when de -signing the delivery line. The Zentrifix®

system was modified for this operationalpurpose. The so-called ZX-IP lines haveproved themselves worthy for abrasiveand non-abrasive materials. ZX-IP linesare used in sewage treatment works, incoal-fired power plants, waters desludg-ing, in mining and other numerous spe-cial applications.

Depending on the application, thedesign, material and the surface treat-ment can be modified in order to be ideally adapted to the pump and materialto be conveyed.

Flexible throughgate or diversionvalves Gate and diversion valves are essentialwhen multiple delivery lines have to beinstalled. Thus, the material located inthe pipeline after the pump can be diver-ted through a gate valve to other routessuch as a thermal dryer or intermediatestorage.

Gate valves are hydraulically operated.For a faster switch, it is suggested to usea power pack of at least 7,5 kW. The valvehousing is sealed with hardened sealingrings, that are pressed against themoving blade of the valve.

Delivery LinesAccessories

Safe laying of horizontal delivery lines with Zentrifix®

Gate valves for there different delivery linesTunnel concreting with flexible SK pipelines as expansion pipes

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Reliable and continuous flow ofmaterial thanks toinjection systemsSometimes, for hard-flowing materials,unfavourable material consistency, highinstallations, long conveying distances,there is the need for delivery pressuresthat are higher than what high densitysolids pumps can deliver. High deliverypressures can be reduced through injec-tion and thus an economic conveyanceof specific materials can be guaranteed.

A lubricating film, reducing the deliverypressure, is created when injecting water,oil or lubricant in the delivery line.

A small amount of liquid or lubricant isequally injected via a nozzle ring on theinner-surface of the delivery line. Aboundary layer injection unit with dosingpump is needed for a continuous andautomatic injection of the lubricant.The lubricant dosing pump sucks themixture of high-molecular polymer andwater from a tank and, independentlyfrom the pump’s delivery pressure, in-jects it in the delivery line. The amount oflubricant is reduced or increased accord-ing to the changing delivery pressure ofthe pump which is in turn optimized.

With special lubricants, it is possible toreduce the pressure in the delivery lineby up to 2 % of the initial value.Lubricant amounts between 0,1 and 1 %of the pump’s delivery pressure are injec-ted. However, the lubricant has to bediluted with water to a 1 : 50 ratio.

Injection SystemsAccessories

0

1,2

1,0

0,8

0,6

0,4

0,2

02 4 6 8 10 12 14

Injection site of the lubricant

Boundary layer injection

The injection of water or lubricants significantly reduces the pressure loss in the delivery lineExample: Sewage sludge with 37% and up to47% dry solids content.

Pressure drop p f

[bar/m

]

Flow rate [m3/h]

without injection

water injection (64 l/h)

flocculant(128 l/h)

lubricant(128 l/h)

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IP 1318-12 GB38

Service

Supply of turnkey systems Increased safety and efficiency through modern design processes

Transparency and adherence to deadlines in project management

High quality in production and assembly

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Systems engineering from asingle sourcePutzmeister supplies complete systemsfor the transportation and storage ofsludges and solids. The scope of servicesincludes the planning and engineering ofconveying tasks, consultation servicesregarding the transportation’s processengineering, the supply of pumps, silos,bunkers as well as pipes and fittings,installation and commissioning at custo-mer site and also complete services afterhandover of the system.

Competence andeffectiveness at allstages of the projectModern automation and visualizationsystems are used for controlling theplant unit. These systems control andmonitor the plant from the reception ofthe sludge in the pump up to the me-tering of the sludge into the incinerationfurnace or the final place of use.

Finite elements are used in our designcalculations and state-of-the-art CADsystems for realizing and implementingthe designs. This ensures an effectiveand high-quality solution.

Knowledge TransferWe offer plant-related in-house trainingsas well as on-site seminars.

Experienced projectmanagers processthe contracts onschedule an in atransparent mannerThanks to professional and comprehen-sive documentation, system operatorscan count on a simple operation of theplant and easy trouble-shooting.

ServiceA major factor of Putzmeister’s servicesis an efficient and powerful sales man-age ment. In addition to a telephone hot-line, we supply parts on short notice andalso carry out maintenance works as partof a maintenance contract.

Plant delivery froma general contractorAdvantages of the system

Highest level functional reliability Less time spent with order proces-

sing and interface co-ordination Perfect harmony between all

functional units Less spare parts and storage require-

ments due to the use of versatilecommon parts in the systemcomponents

Simplified servicing and maintenancethanks to standardized control andmaintenance elements

Clear assignment of responsibilitiesmeans rapid solutions to problems inthe event of a malfunction

Technical training at customer premises Rapid response assistance from Putzmeister’s after-sales service

Range of ServicesService

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Member of the Putzmeister Group www.pmSolid.com

Putzmeister Solid Pumps GmbHMax-Eyth-Straße 10 · 72631 Aichtal /GermanyP.O.Box 2152 · 72629 Aichtal /GermanyTel. +49 7127 599 500 · Fax +49 7127 599 [email protected] · www.putzmeister-solid-pumps.com

Right to make technical amendments reserved© by Putzmeister Solid Pumps GmbH 2011 All rights reserved Printed in Germany (31106Sc)

Putzmeister is a dynamic company withthe most modern assembly and manu-facturing plants. At the main plant in Aichtal nearStuttgart, the specialists of PutzmeisterSolid Pumps GmbH (PSP) prepare suc-cessful tailor-made system solutions forsolids transportation problems for cus-tom ers throughout the world.

Numerous subsidiary companies world-wide means Putzmeister can offer a highdegree of closeness to the customer.

clean and economical solutions for conveying … ip 1318-12 gb content applications mining /...

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