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KSB's "Jumbo" Sets Sail | Building a Solid Ecological Barrier for the Upper Yangtze   Recently, amidst much anticipation, the core equipment of the fourth phase expansion project of the Chongqing Jiguanshi Wastewater Treatment Plant—the KSB SPN 1200 vertical volute wastewater pump—held a grand delivery ceremony at Shanghai KSB Pump Co., Ltd. This not only marks the successful delivery of another crucial piece of equipment from KSB, but also signifies that a major environmental protection project safeguarding the Yangtze River is about to be equipped with a powerful "domestic heart"!   The fourth phase expansion project of the Chongqing Jiguanshi Wastewater Treatment Plant carries the dual mission of addressing the central environmental protection inspection rectification and the ecological problems of the Yangtze River Economic Belt, making it a highly anticipated key project in Chongqing.     Upon completion, the total treatment capacity of the Jiguanshi Wastewater Treatment Plant will reach 1.2 million m³/d (cubic meters/day), making it the largest wastewater treatment plant in western China and one of the top five in the country. This surging purification power will greatly enhance the wastewater treatment capacity of Chongqing's central urban area, providing solid support for building a vital ecological barrier in the upper reaches of the Yangtze River.   A 12-Meter-High "Giant" Heart   Participating in such a significant project is an honor, but also a heavy responsibility: as the "heart" of the entire wastewater lifting system, the pump sets provided by KSB face unprecedented challenges.   ⏺︎ Giant Size: The SPN 1200 pump sets shipped this time exceed 12 meters in height from the bottom of the inlet bend to the top of the motor, resembling a steel giant.   ⏺︎ Enormous Energy Capacity: To achieve the project's massive leap in processing capacity from 800,000 tons to 1.2 million tons per day, KSB has revolutionized the inlet pump house. By converting six of the original seven main pump units to 12,000 m³/h SPN1200 pumps and adding three additional SPN series pumps with capacities of 8,750 m³/h, 5,370 m³/h, and 2,100 m³/h, KSB Shanghai's newly configured pump unit not only achieved a qualitative leap in total delivery capacity but also brought unprecedented operational flexibility and reliability.   ⏺︎ Challenging the "Giant": The enormous size and energy of the units placed extremely stringent demands on vibration, flow patterns, and energy efficiency. Every step of transportation, installation, and commissioning was an ultimate test of technology and experience.     Facing these challenges, the KSB technical team showcased its core strengths:   ⏺︎ Advanced Hydraulic Modeling: Leveraging KSB's technological DNA to ensure excellent design from the outset.   ⏺︎ CFD Flow Simulation: Digital twin analysis of the entire pump house to predict and optimize water flow patterns.   ⏺︎ CAE Vibration Analysis: "Diagnosing" each pump unit to ensure rock-solid stability under high-speed operation.   Furthermore, KSB provided over 100 key process equipment units for this project, including submersible sewage pumps, impellers, and agitators, ensuring smooth project operation with a comprehensive product portfolio.   Precise Contract Fulfillment, Living Up to Expectations   "High standards and strict requirements for project quality control, comprehensive coordination of construction progress across multiple stages"—this was the project's commitment and a test for all suppliers.   As a key equipment supplier for the project, KSB Shanghai deeply understood the weight of its responsibility. Facing the dual challenges of tight project deadlines and high technical requirements, the KSB team rose to the challenge, demonstrating outstanding professionalism and strong execution capabilities. All departments worked together seamlessly, with meticulous coordination at every stage from design and production to delivery, strictly controlling quality.   As expected, KSB ultimately delivered the first batch of 6 vertical volute sewage pumps and over 100 submersible agitator pumps in the first half of the year, strictly adhering to the project schedule requirements.   This precise fulfillment of contractual obligations effectively ensured the smooth progress of the entire project. On June 30th of this year, the project successfully achieved initial water supply operation. All installed KSB products operated stably and performed excellently, laying a solid foundation for the project's phased success.   Behind this success lies KSB's commitment to its customers, its dedication to social responsibility, and proof of the strength of "German technology, made in China."     With the successful delivery of the SPN 1200 pump, we will continue our efforts to fully complete the delivery of the subsequent retrofit pumps for this project.   Every shipment is a fulfillment of a promise; every departure is a journey towards the mission of protecting our green mountains and clear waters. KSB will continue to contribute to China's environmental protection cause with its superior technology, reliable products, and professional services, working together with all partners to build a green future.

On October 15th, Dr. Stephan Bross, Executive Director and Chief Technology Officer of KSB Group, attended the opening ceremony of the intelligent test bench at the Shanghai Chemical Engineering Pump Plant. In a media interview, he stated, "China has evolved from KSB's 'production base' to a 'global innovation hub.'"     China Speed, German Quality, Bright Future   At the ribbon-cutting ceremony, Dr. Bross summarized KSB's 31 years of development in China with three key words:   China Speed ​​- The CEP plant, with a total investment of 130 million yuan and a construction area of ​​10,000 square meters, began production in July last year and has an annual production capacity of 2,500 sets of high-end chemical pumps.   German Quality - The intelligent test bench has a maximum power of 4,000 kW and a maximum flow rate of 4,300 m³/h, increasing testing efficiency by 300%.   Bright Future - The Chinese market has become the Group's second-largest globally, and the North Asia region has achieved five consecutive years of growth in orders, sales, and profits.   From "Localization" to "Global Standards"   Dr. Bross emphasized the innovative value of KSB's China team:   “ In the past, people might have viewed Europe and the United States as centers of technology development, but the situation is completely different now. The intelligent diagnostic algorithms and digital twin technologies developed by the China team have evolved from "localized achievements" to "standard features" across the Group's global factories, and are even being exported to the European and American markets. ”   He further noted, "KSB's global standards have never been 'set by headquarters, implemented locally,' but rather 'where there are good innovations, we transform their experience into standards.'"   The newly commissioned intelligent test bench is KSB's largest closed-loop test bench in Shanghai and one of the Group's most advanced. Dr. Bross stated that this is more than just a hardware upgrade; it also carries the strategic mission of "intelligent testing, empowering the chemical industry," strengthening KSB's brand recognition as an industry technology leader.   KSB Global Operations Conference to be Held in Shanghai   The KSB Global Operations Conference will soon be held in Shanghai. Over 100 operations leaders from various countries will gather in Shanghai to learn from the Shanghai team's experience in digitalization and AI applications.   “ We aim to combine China's speed of innovation with German quality standards to serve global customers. ”     The chemical engineering pump factory of KSB Pump Co., Ltd. in Shanghai, completed and put into operation in July 2024, is a model chemical pump production facility featuring green, intelligent manufacturing, and digitalization. It further enhances KSB's chemical pump production capacity and quality in Shanghai. The factory covers an area of ​​10,000 square meters and has a total investment of approximately 130 million yuan, including approximately 65 million yuan in equipment. It covers the entire chemical pump production process, including warehousing, machining, assembly, performance testing, pipe welding and assembly, painting, and packaging. The company manufactures dozens of products, including API and ISO series chemical process pumps, heat transfer pumps, magnetic drive pumps, and polyethylene medium pumps for special applications. The standard production capacity is 2,500 units/year, with a maximum capacity expandable to 4,000 units/year.

The differences between self-priming pumps and centrifugal pumps are mainly reflected in the following aspects:   1. Working Principle:   Self-priming pumps: Before starting the pump, the pump casing is filled with water (or water itself is present in the pump casing). After starting, the impeller rotates at high speed, causing water in the impeller grooves to flow toward the volute. This creates a vacuum at the inlet, opening the water inlet check valve. Air in the suction pipe enters the pump and flows through the impeller grooves to the outer edge. Centrifugal pumps: These pumps operate by centrifugal motion of water caused by the rotation of the impeller. Before starting the pump, the pump casing and suction pipe must be filled with water. Then, the motor is started, causing the pump shaft to rotate the impeller and water at high speed. This centrifugal motion causes the water to be thrown toward the outer edge of the impeller and flow through the flow channel of the volute casing into the pump's pressure water line.   2. Applications:   Centrifugal pumps: Used in liquid transportation, cooling systems, industrial cleaning systems, aquaculture, fertilization systems, metering systems, and industrial equipment. They are also widely used in industries such as power, metallurgy, coal, and building materials to transport slurries containing solid particles. Self-priming pumps: They disperse water into fine droplets for spraying, making them ideal for farms, nurseries, orchards, and vegetable gardens. They are suitable for handling clean water, seawater, chemical media with acidic or alkaline content, and generally pasty slurries. They can be used with filter presses of any model and specification, making them an ideal companion pump for filtering slurries while feeding them.     3. Components:   Centrifugal pumps: Consists of six components: impeller, pump body, pump shaft, bearings, sealing rings, and stuffing box. Self-priming pumps: Consists of a suction chamber, liquid storage chamber, scroll chamber, liquid return port, and gas-liquid separation chamber.   4. Starting Method:   Centrifugal pumps: To start, both the inlet pipe and the pump body must be filled with water, or an auxiliary device must be used to evacuate the inlet pipe. Self-priming pumps: To start, a certain amount of starting circulating water must be injected into the pump body.   5. Different Devices:   Centrifugal Pumps: Must be equipped with a foot valve at the bottom of the inlet pipe or an air extraction device at the outlet. Self-Priming Pumps: Only a filter is installed at the bottom of the inlet pipe, without a foot valve.     6. Advantages:   Centrifugal Pumps: Compact structure, wide flow and head range, suitable for mildly corrosive liquids, uniform flow, smooth operation, low vibration, no need for special shock-absorbing foundations or equipment installation, and low maintenance costs. Self-Priming Pumps: Compact structure, easy operation, stable operation, easy maintenance, high efficiency, long service life, and strong self-priming capacity.   7. Characteristic Curve:   Centrifugal pump: The characteristic curve will not show the abnormal phenomenon of the self-priming pump mentioned above, and the efficiency is relatively high. Self-priming pumps: The characteristic curve is generally flatter than that of centrifugal pumps, meaning that the flow rate changes less for the same head change. With strong self-priming capacity, they can be started with no fluid in the suction pipe. However, when the flow rate is low, the characteristic curve of a self-priming pump will exhibit anomalies, meaning that the head increases as the flow rate decreases, resulting in generally lower efficiency.  

I recently visited the Dalian plant of Leo Pump, a well-known pump manufacturer. The Dalian plant is a key base for Leo Pump in the petrochemical and chemical industries.   Let me introduce the Dalian base   LEO Dalian, a wholly-owned subsidiary of the LEO Group, is located in Dalian and specializes in the research, development, and manufacturing of pump products for the petrochemical industry. The base covers an area of ​​100,000 square meters. The Dalian base specializes in the research, development, and production of pumps for upstream oil and gas applications such as oilfield water injection, pipeline transportation, and storage, as well as downstream applications such as crude oil refining, heavy chemicals, fine chemicals, and coal chemical processing. The base possesses proprietary technologies for liquid transportation under harsh and extreme conditions, including ultra-low temperature, high temperature, high pressure, low cavitation, high corrosion, and energy recovery. The base is a qualified supplier to CNPC, Sinopec, CNOOC, and China Shenhua.   What are the characteristics of Leo Pump's independently developed hydraulic turbine equipment?   As we all know, the hydrocracking unit's hydroprocessing feed pumps and hydraulic turbines are among the most advanced in the chemical pump industry, representing cutting-edge design, manufacturing, and application requirements for harsh operating conditions. These include high temperatures, high pressures, flammable and explosive media, and harsh and complex gas-liquid-solid three-phase flows. The successful application of this equipment in this field demonstrates mastery of the industry's core design, manufacturing, and application technologies. As early as 2015, we achieved localization of a 1.7 million tons/year residue oil hydroprocessing hydraulic turbine for Sinopec Changling Refining and Chemical. This equipment was fully independently developed and manufactured, and has passed on-site evaluation by industry equipment experts. To date, this equipment has been in stable operation for 11 years, exceeding all performance indicators of existing equipment and reaching the internationally advanced level of similar products.   Faced with such demanding operating conditions, how does Leo Dalian prioritize pump quality to ensure long-term, reliable operation? This brings us to the core process of the factory—quality management.   As a design and manufacturing company focused on the customized market, the base builds its core business processes around customer needs. Across design and development, material procurement, production execution, quality planning, financial oversight, and safety assurance, the base continuously identifies blind spots and bottlenecks at all levels of the process, deepens optimization concepts like IPD and LTC, and continuously iterates and restructures processes. This management model maximizes the ability to meet personalized market demands, avoid excess inventory, and improve capital turnover, enabling the base to respond quickly in a rapidly changing market environment and enhance market competitiveness. Before raw materials enter storage, advanced equipment such as handheld spectrometers, portable hardness testers, and roughness testers conduct a comprehensive inspection of key indicators such as chemical composition, hardness, and roughness. Only raw materials that perfectly meet standards are assigned traceability identification, including WBS numbers, batch numbers, and material codes, before entering the production process. During the component assembly phase, each pump receives its own unique assembly quality tracking sheet, permanently recording the operators, assembly parameters, and inspection results for each process within the entire assembly process. During testing, the pump's flow rate, head, efficiency, NPSH, and other operating parameters are all subjected to performance testing under comprehensive digital instrumentation. Even the slightest deviation in any indicator will result in corrections and retesting until the product fully meets customer operating requirements. In 2024, the CNAS Testing Center at the LEO Dalian base successfully passed the review of the China National Accreditation Service for Conformity Assessment and received CNAS National Accredited Laboratory certification. The center has a maximum test flow rate of 12,000 m³/h and a test head of 3,500 m.   It is precisely through such rigorous, standardized, and orderly quality process management that the Dalian factory is able to continuously provide the market with high-quality domestically produced equipment, ensuring the reliable operation of industrial processes. At the same time, product delivery times are also of concern.   "LEO Dalian ensures product delivery cycles through three key approaches: First, standardized management: a division of labor and collaboration between project managers and product managers, and the division of products into standardized and customized categories. Projects are clearly defined with milestones and component precision is strictly controlled, ensuring a 99.5% first-pass pass rate." Second, digital empowerment: the SAP system is used to automatically convert production orders, monitor materials in real time, and track progress. A digital procurement platform is established to enable online supplier management, automated matching, and delivery tracking. Using an intelligent selection system, operating conditions are automatically input to generate performance curves and quotations, reducing quote response times from three days to two hours. Third, supply chain optimization: supplier grading and monthly KPI assessments are implemented to eliminate those that fail to meet standards, resulting in an increase in the arrival rate of key raw materials from 85% to 95%. A quality-focused approach is adopted: procurement requests material reports and critical parts undergo re-inspection upon arrival. During production, parts precision is strictly controlled to ensure a 99.5% first-pass pass rate.   The Leo Dalian Technical Center is a petrochemical research branch affiliated with the Leo Group's national-level technical center. What achievements has it achieved so far?   The Leo Dalian Technical Center possesses Leo's independently developed core technology for energy recovery in gas-liquid two-phase flow conditions, which is leading both domestically and internationally. This technology has been used in a 1.1 million tons/year low-temperature methanol washing plant at Inner Mongolia Huineng, achieving energy savings of over 1,300 kWh per unit. Through the promotion of this core technology, the energy-saving equipment independently developed and manufactured in this field saves over 500 million kWh per hour, equivalent to reducing annual coal consumption by 140,000 tons and CO2 emissions by 220,000 tons. In the coal chemical industry, Leo's independently developed and innovative low-temperature methanol washing integrated turbine technology, with an installed capacity exceeding 40,000 kW/h, is an industry leader. The relevant technical specifications drafted by Leo also fill gaps in the industry. In addition, as the basic theoretical research institution of the Leo Group, it not only provides comprehensive technical support for petrochemical pump products for Leo Pump Industry, but also provides technical support in hydraulics, strength, vibration analysis and other aspects to each member unit within the group.  

Among many types of water pumps, self-priming pumps have attracted considerable attention for their unique performance. Today, let's delve deeper into the working principles and significant advantages of self-priming pumps.   Working Principle:   First, let's understand the working principle of a self-priming pump. The key to a self-priming pump's ability to self-prime liquid lies in its unique structural design. When the pump starts, a portion of the liquid stored in the pump body rotates with the impeller, forming a liquid ring. Centrifugal force propels the liquid around the impeller toward the outer edge, creating a low-pressure area. Simultaneously, a vacuum is created at the center of the impeller as the liquid is ejected. Atmospheric pressure forces the liquid in the suction pipe into the pump, enabling self-priming. As the pump continues to operate, liquid is continuously drawn in and out, creating a steady flow. Self-priming Pump Working Principle Diagram:     Advantages of Self-priming Pumps:   1. Strong self-priming capability: No prior priming is required, enabling quick startup and self-priming, saving time and manpower. 2. Easy operation: Easy startup, no complex preparation required, and suitable for a variety of operating conditions. ⒊ Wide Adaptability: Able to handle liquids containing gas or vapor, with good adaptability to liquids of varying properties. ⒋ Flexible Installation: Unrestricted by mounting location, it can be installed horizontally, vertically, or at an angle to meet various site requirements. ⒌ Low Maintenance Cost: Relatively simple structure and few parts make maintenance and repair relatively easy, reducing long-term operating costs. ⒍ High Energy Efficiency: During operation, it effectively utilizes energy, improving efficiency and reducing energy consumption.   Summary:   With its unique principle and numerous advantages, self-priming pumps play an important role in numerous fields, including agricultural irrigation, industrial drainage, and municipal water supply. We believe that with continuous technological advancement, self-priming pumps will demonstrate even greater performance and a wider range of applications in the future.

Adaptive N impeller helps small sewage pumps solve clogging problems   Clogging is a common problem in wastewater pumping, especially for smaller pumps due to their limited hydraulic space and lower torque. The consequences of clogging include increased energy consumption, additional maintenance, and emergency repairs, all of which lead to higher operating costs. Wastewater pump manufacturers are constantly developing better hydraulic designs to reduce clogging while maintaining high performance.   The Adaptive N Technology hydraulic design, an evolution of the self-cleaning N-type hydraulic design, is designed to address the challenges of anti-clogging in smaller pumps. It provides significant improvements in pump system reliability while reducing energy consumption and unplanned maintenance costs.   The Adaptive N impeller pump can be installed in wastewater pumping stations with or without screens, and is used to pump wastewater from homes, commercial buildings, hospitals, schools, and other locations. It can also be used in industrial wastewater and stormwater applications to transport wastewater that may contain solids, fibers, and other types of impurities.   A Flygt Concertor 6020 pump with Adaptive N technology installed in a municipal wastewater pumping station.     Pumps Designed for Today's Wastewater Conditions   Since the early 20th century, pump designers have focused on reducing clogging by increasing flow rates. In mining, industrial, and raw water pumping applications, hard solids and spherical objects in the pumped medium are the most common clogging problems. Large impeller passages make it easier for these objects to pass through the pump. While conventional wastewater pumps are designed with large flow passages to avoid clogging, this has proven suboptimal for most wastewater applications.   At the same time, the risks posed by soft and fibrous objects—the most common solids in municipal wastewater—have been largely overlooked.   Detailed surveys and studies of modern wastewater indicate that wastewater almost never contains hard, spherical objects with a diameter as large as the internal diameter of the pipe system. Even when such objects enter the wastewater system, they typically settle or accumulate in areas of lower flow velocity, never reaching the pump.   A significant concern: Today's wastewater contains a higher proportion of soft objects. Examples include the growing variety of household and personal hygiene items, including paper towels, wet wipes, rags, dishcloths, and other fibrous objects. While much of this material should be disposed of as trash, many consumers flush it down the toilet. As a result, more fibrous, non-biodegradable material appears in the wastewater, further challenging the pump’s performance.   Figure 1: Likelihood of finding various types of solids in wastewater   Figure 1 is a conceptual illustration of the likelihood of finding different types of solids in wastewater. Hard, nearly spherical objects are on the left, while soft, elongated objects are on the right. As with many systems, the probability of finding very large objects (whether spherical or elongated) is very low. An important feature is that the distribution curve is asymmetric—it favors soft, elongated objects, which are the most common types found in wastewater today.   Soft vs. Hard Blockage   Research has shown that blockage problems are primarily caused by fibrous debris, which tends to become entangled around the leading edges of conventional impellers. The fibers wrap around these leading edges and fold over the sides of the blades. On straight and moderately curved leading edges, debris does not break off; instead, it continues to accumulate. This accumulation forms large clumps of solid material (sometimes called "cloth clumps"), which can lead to blockage.   As debris gradually accumulates around the leading edge of the impeller, the free path for water flow decreases, and pump performance degrades. This phenomenon is called soft blockage because it does not cause the pump to stop. The pump will continue to operate, but performance will be reduced to a certain degree. A typical effect of soft blockage is that the pump needs to run longer to pump a given volume of wastewater. A soft-blocked pump is also less efficient than an unblocked pump. Consequently, soft blockage increases energy consumption. Another consequence of soft blockage is increased vibration levels, which can accelerate wear on seals and bearings.   Small foreign matter can also become lodged between the volute and impeller, causing additional friction. The motor needs to provide greater torque to offset the braking effect, thus requiring higher input power. Once the operating current exceeds the trip current (causing the motor to overload), the pump stops operating. This is called a hard jam. A hard jam can also occur when a soft jam forms a noticeable mass. The primary impact of a hard jam is downtime and the need for unplanned repair services to clear the jam and restart the pump, increasing operating costs.   Dispelling Myths About Throughput Size   Decades of R&D experience, combined with hundreds of thousands of pump installations, have shown that focusing solely on throughput size is incorrect and misleading. Yet, it remains prevalent in wastewater pump purchasing specifications. User feedback and laboratory testing of conventional impellers have yielded the following results:   Channel Hydraulics' Anti-Clogging Performance   Channel impellers are single- or multi-blade, closed-circuit centrifugal impellers with large throughput sizes. They are highly efficient when pumping clear water but are susceptible to clogging when pumping wastewater.   Figure 2: Example of a Single-Blade Impeller   Channel hydraulics are designed to achieve optimal clogging resistance at the pump's best efficiency point (BEP). Therefore, clogging resistance decreases as the operating point moves further from the BEP. The gradual accumulation of fibrous material on the leading edge (Figure 3) will cause pump efficiency to fall far below the factory-tested clear water value—a typical effect of soft clogging.   This design induces significant radial loads over long-term operation, placing greater stress on the shaft and bearings, increasing vibration and noise. Since the impeller can never be perfectly balanced, vibration is further exacerbated.   These problems ultimately lead to increased energy consumption, excessive wear, and shortened pump life.   Figure 3: Clogging in a Channel Impeller   Clog Resistance of Vortex Hydraulics   Vortex impellers are located at a distance from the pump casing, providing ample volute space, but are inefficient when pumping both clean and dirty water.   Pump designers assumed: • The rotating impeller would create a strong vortex within the volute, pumping out the liquid and any debris. • The vortex impeller would operate like a torque converter, transferring energy from the impeller to the pumped medium with little or no fluid exchange. • Because the impeller is outside the fluid flow path, objects never come into contact with the impeller, and the pump would not clog.   Figure 4: Example of a Vortex Impeller   However, vortex impellers function like other centrifugal impellers, meaning energy is transferred to the medium via the impeller blades. Therefore, multi-blade vortex impellers are very sensitive to soft clogging of the hub and leading edge. Its fluid dynamics (flow pattern and pressure distribution) can cause soft materials to accumulate on the impeller surfaces, further reducing the already low hydraulic efficiency.   Furthermore, vortex pumps often experience a large accumulation of solids in the volute, causing additional losses, increased power consumption, and ultimately leading to motor overload and pump shutdown.   Figure 5: Blockage in a vortex impeller   Anti-clogging of Modern Self-Cleaning Hydraulics   Research and investigations have shown that clogging problems are primarily related to the pump's difficulty discharging fibrous debris entangled on the impeller's leading edge. The N-type impeller features a state-of-the-art self-cleaning design developed in response to these findings. With a sharply swept horizontal leading edge and a relief groove, the N-type hydraulic design has proven to be a solution to most clogging issues. Furthermore, without the need for large flow passages, the impeller can be designed with multiple blades, which helps reduce radial forces, improve balance, and increase efficiency.   Figure 6 shows the clogging probability of the N-type impeller, which is significantly lower than that of conventional impellers designed around large flow dimensions.   Figure 6: Clogging in a Self-Cleaning N-Type Impeller Figure 7: Self-Cleaning N-Technology Hydraulic Design   Figure 7 illustrates the N-type hydraulic design, which consists of a semi-open N-type impeller and an insert ring with guide pins.   The self-cleaning technology works as follows: 1. The N-type impeller blades, with their swept horizontal leading edges, achieve self-cleaning by sweeping solids from the center of the insert ring to the outer edge. 2. Unloading grooves in the insert ring work together with the horizontal leading edge to guide solids out of the impeller. 3. In smaller geometries, specially designed guide pins capture any fibers lodged near the impeller hub and allow the blades to push them out of the pump along the unloading grooves.   Thanks to its ability to expel hard objects, self-cleaning technology significantly reduces unscheduled maintenance and improves reliability. By preventing fibrous objects from tangling around the leading edge and causing soft plugging, the N-type impeller ensures sustained high efficiency over the long term, thereby reducing energy consumption.   Unlike channel hydraulics, the self-cleaning N-type hydraulic's anti-plugging properties are mechanically based and unaffected by flow rate variations. Therefore, the pump can operate efficiently at different points along the performance curve and, most importantly, with high reliability at a wide range of frequencies. Pairing the N-type hydraulic design with a variable frequency drive (VFD) enables better process control, energy savings, smoother operation, and reduced maintenance costs.   Development of the Self-Cleaning N-Type Hydraulic Design   Limited Torque in Small Pumps   Submersible pumps are typically driven by an electric motor that is closely coupled to the pump impeller, as shown in Figure 8. When the pump starts, current flows into the stator windings, generating a rotating magnetic field that rotates the rotor via the shaft. Consequently, the motor generates torque proportional to the motor power. Torque is a physical quantity that defines the tendency of a force to rotate an object about an axis or point.   Figure 8: Torque Schematic   As previously mentioned, objects passing through the self-cleaning N pump are pushed along the unloading groove. Because the gap between the impeller blades and the insert ring is very small, only a few tenths of a millimeter, large debris is forced through the unloading groove. When this occurs, additional friction is generated, braking the impeller and slowing it down. The pump must provide additional torque to overcome this additional friction, which means higher motor torque is required. If the maximum motor torque is insufficient, debris will become stuck and the pump will stop. This is known as a hard jam.   Because motors used in submersible wastewater pumps are typically not significantly overrated, the maximum torque available at full power may not be sufficient to dislodge even the toughest debris. This is particularly true for smaller pumps, which often have relatively low torque margins. To further enhance the functionality of smaller N pumps, Flygt has developed Adaptive N technology to reduce the risk of hard jams caused by insufficient torque.   Adaptive N Technology   With Adaptive N technology, the N-type impeller is not completely fixed to the shaft: it can move axially up and down in response to the pressure differential created by large debris trying to pass through the pump. This movement temporarily increases the clearance between the impeller blades and the inlay ring. This allows even the largest pieces of cloth and the toughest debris to pass through the pump without requiring additional motor torque. This advantage is even more pronounced when the pump motor is operating on single-phase power, where available torque is further reduced.   Figure 9: Position of the Adaptive N Impeller During Operation   As shown on the left side of Figure 9, in most conditions, the Adaptive N impeller operates exactly like a conventional N-type impeller. However, when necessary, the impeller moves upward to pass larger debris, as shown on the right side of Figure 9.   The adaptive mechanism operates by exploiting the hydraulic pressure differential across the impeller. The pressure-dependent force is F=PxA, where P is the pressure and A is the area over which the pressure acts. Figure 10 shows how the combined forces determine the impeller's position.   The left side of Figure 10 is a conceptual image of the hydraulic pressure distributed across the impeller in lightly contaminated wastewater. At the base of the impeller, upward pressure increases with radius, so the force increases from the center of the impeller toward the edge. Meanwhile, at the top of the impeller, higher pressure acts evenly across the entire impeller disk. The net force acting on the impeller has a downward net value, maintaining the impeller in its normal operating position.   Figure 10: Force distribution during normal operation (left) and when a large piece of debris enters the pump (right)   When a large piece of debris enters the impeller, the force balance differs from normal operation. As shown on the right side of Figure 10, at the base of the impeller, a gradually increasing upward force is added to the hydraulic force. When the upward force exceeds the downward force, the impeller begins to move upward, and the gap between the impeller and the insert increases. When the gap is sufficiently wide, the debris passes through the impeller. The upward force then decreases, and the impeller returns to its original operating position.   Because this adaptive motion lasts only a fraction of a second, the momentary power increase has no significant impact on the overall efficiency of the pump. This adaptive feature also reduces loads on the shaft, seals, and bearings, thereby extending their service life.   In summary, Adaptive N technology significantly improves the self-cleaning capabilities of small pumps equipped with low-torque motors. Ultimately, reliable operation and consistently high efficiency reduce total cost of ownership.   Note: While there is a spring in the impeller hub, it is not related to the adaptive function. This spring keeps the impeller locked during assembly and shipping, preventing damage that could occur before installation.   Life Cycle Cost (LCC) Analysis for Small Wastewater Pumps   Life Cycle Cost (LCC) analysis is a methodology used to determine the total cost of a system over its lifecycle or to compare investment plans. A complete LCC analysis of any equipment includes all costs associated with the equipment, including initial investment, installation, operation, energy, downtime, environmental, maintenance, and disposal. The most significant components of the calculation will depend on the application, location, labor costs, and energy costs—factors that can vary significantly between markets.   A simplified analysis is often used when evaluating wastewater pump options. In this case, the most relevant factors are initial investment, energy costs, and maintenance costs (especially unplanned maintenance). Other factors can be excluded from the analysis.   Blockage is the most significant factor in unplanned maintenance costs. The number of times a pump blocks in a pumping station can vary significantly. The most common factors are: • Type of pumped medium • Type of pump hydraulic design • Length of pump operating cycle • Pump size • Motor torque and moment of inertia • Performance of routine maintenance   Increased energy costs due to soft clogging   As mentioned above, channel impeller pumps used in wastewater applications can suffer from soft clogging and may trip after a long operating cycle. However, vortex impeller pumps experiencing soft clogging may continue to operate due to the larger volume within the pump casing. This larger volume allows for greater accumulation of solids compared to other impeller types. In either case, soft clogging tends to reduce pump efficiency and induce hard clogging.   Figure 11 shows the impact of soft clogging on the efficiency and energy consumption of a conventional pump (channel or vortex hydraulic design) and a self-cleaning pump (N-type or Adaptive N Technology hydraulic design) over time.   As shown in Figure 11a, when the conventional pump is operated continuously in wastewater, its efficiency decreases and its energy consumption gradually increases. The same trend is observed when the conventional pump is operated intermittently (Figure 11b), even though backwashing can temporarily improve efficiency. In contrast, Figure 11c shows that the self-cleaning pump maintains consistent efficiency and energy consumption during continuous or intermittent operation in wastewater, resulting in the lowest energy consumption over time.   The increased energy costs due to soft clogging are easily measured on-site. However, predicting these additional costs is difficult due to variability in media properties and operating cycles.   Figure 11: Comparison of conventional pump performance and self-cleaning N-technology wastewater pump performance under two different operating scenarios   Simplified LCC Comparison Example   The following example provides a simplified LCC analysis comparing the costs of three pump types under short and long daily operating hours: Application and pumping details   pumping medium Raw sewage for grid   Flow 25 Liters/second   Lift 8 Meters   Years of operation 5 Years   Energy cost* 0.1 EUR/kWh   Unplanned maintenance costs 200 Euros/service   Pump selection Channel type impeller Vortex impeller Adaptive N impeller   Rated power(kW) 3.1 4.7 3.1   Hydraulic efficiency (clean water)** 75% 46% 77%   Total efficiency (clean water)** 63% 38% 65%   Specific energy consumption (kWh/m³)** 0.0346 0.0574 0.0335   Service times/year Run 3 hours/day 4 2 0.5   Run 12 hours/day 16 8 2   *Energy costs can vary significantly by country. **Efficiency and specific energy consumption data are based on Flygt pump performance curves.   In this example, the initial investment for the different hydraulic designs does not vary significantly. Over long operating cycles, the initial investment represents only a small fraction of the LCC. Furthermore, planned maintenance costs will be roughly the same across the various pump options. Meanwhile, unplanned maintenance costs due to hard clogging will have a greater impact on the LCC.   When a channel impeller pump is operated 12 hours per day for five years (Figure 14), its unplanned maintenance costs exceed five times the initial investment. In contrast, the Adaptive N-type impeller pump's maintenance costs are only 60% of its initial investment. While vortex impeller pumps are expected to require fewer services than channel impeller pumps, their lower efficiency than other hydraulic designs will result in higher energy costs. This does not even take into account the additional energy costs caused by soft clogging, which is difficult to predict and therefore not included in the LCC calculation or these charts. Taking this into account, the vortex hydraulic pump will have higher energy consumption than the other two hydraulic designs.   Whether operating 3 or 12 hours per day (Figures 13 and 14), the Adaptive N-type impeller pump has the lowest lifecycle cost in wastewater applications because it minimizes unplanned maintenance. If the additional energy costs caused by soft clogging are taken into account, the savings of the Adaptive N-type impeller pump are even greater than those shown in the LCC analysis. In addition to the economic benefits, the N-type pump provides a worry-free operation experience for the end user.   Figure 12: Example of a wet-well pumping station equipped with two small sewage pumps Figure 13: Simplified LCC analysis based on 3 hours of daily operation for 5 years Figure 14: Simplified LCC analysis based on 12 hours of daily operation for 5 years   Summary   The increasing focus on minimizing operating costs, particularly in sewage applications, has driven the demand for pumps with improved clogging resistance and higher efficiency. Twenty-five years ago, Flygt developed a self-cleaning hydraulic design to address this issue. The semi-open N-type impeller, featuring a swept horizontal leading edge and unloading grooves, significantly reduces the risk of clogging. Compared to traditional hydraulic designs, the N-type pump offers consistently high efficiency and improved reliability. As a result, the self-cleaning N-type pump has become popular worldwide.   Due to the limited size and motor torque of small sewage pumps, implementing N-type technology in the most challenging applications has been challenging. To further enhance the self-cleaning function, particularly to reduce the risk of hard clogging in relatively low-torque pumps, the N-type impeller incorporates adaptive technology. The adaptive N-type hydraulic design allows the impeller to move axially, allowing even the toughest debris to pass through. Extensive laboratory and field testing demonstrates that the Adaptive N technology hydraulic design effectively addresses both soft and hard clogging issues in small pumps.   Furthermore, LCC analysis demonstrates significant cost-saving potential for Adaptive N impeller pumps. In most cases, these savings come from lower energy consumption and reduced unplanned maintenance costs.

From the Wuyue Hydropower Station to the Yarlung Zangbo River, the "pumping power" behind China's pumped storage   1. The largest mega-hydropower project in human history   In recent months, the Yarlung Zangbo River Lower Reaches Hydropower Project, the largest hydropower project in human history, officially commenced. With a total investment exceeding 1.2 trillion yuan, this mega-project plans to build five cascade hydropower stations with a total installed capacity of 60 to 81 million kilowatts, equivalent to more than three times the size of the Three Gorges Dam. The project is expected to generate 300 billion kilowatt-hours of electricity annually, enough to meet the electricity needs of 300 million people.     This is not only a milestone in the history of global hydropower construction, but also a key measure for my country to promote ecological civilization and ensure clean energy security. "Open ditches and canals, return them to the great rivers, and drain stagnant water." The Chinese nation's respect for, compliance with, and protection of water have nurtured an ecological concept of harmony and symbiosis through millennia of water management and use. Today, this concept is quietly revitalizing hydropower construction. In this green and surging energy revolution, water pump equipment is playing an irreplaceable and core role as a key auxiliary system.   2. What is pumped storage? Why is a pump necessary?   A pumped-storage power station is a special form of hydropower station, equivalent to a "super battery" for the power grid. Its operating principle embodies the wisdom of "peak shaving and valley filling, and adapting to changing circumstances."By utilizing surplus electricity during low-demand periods to pump water to the upper reservoir, this system accumulates potential for later use. During peak demand periods, this energy is released to generate power, transforming potential into energy. This ingeniously achieves the temporal and spatial shifting of electrical energy and the stable regulation of the grid frequency.   In this energy storage and discharge cycle, the water pumping equipment becomes the most critical kinetic energy conversion device. Like the human body's "heart system," it performs critical functions such as technical water supply, maintenance drainage, and leak removal. Its performance is directly related to the operational efficiency and safety of the entire power station.   In fact, in addition to super projects such as the Yarlung Zangbo River, pumped-storage power stations, as the "voltage stabilizer" and "regulator" of the power system, are being accelerated across the country and have become an indispensable core component of the new power system.The national target for pumped storage capacity is projected to exceed 62GW by 2025, and to exceed 120GW by 2030. Currently, there are 678 planned pumped storage projects under construction nationwide, with a total investment exceeding 70 trillion yuan. The Henan Wuyue Pumped Storage Power Station, a major, one-million-kilowatt project approved by the National Energy Administration and shared today, is a crucial component of this national strategic plan.   3. Henan Wuyue Pumped Storage Power Station:     Located in the Central Plains, storing energy from the mountains and waters   The Henan Wuyue Pumped Storage Power Station is a key project in Henan Province's "13th Five-Year Plan" energy development plan and power development plan. It is also a key energy project approved by the State Council to revitalize the old revolutionary base area of ​​Dabie Mountains. The total installed capacity is 1 million kilowatts. After the power station is fully put into operation, it can save the system's thermal power coal consumption by 116,800 tons each year, which is equivalent to reducing carbon dioxide emissions by about 291,400 tons each year. It is of great significance to the construction of the power grid regulation capacity in central China.     As of now, three units of Wuyue Pumped Storage Power Station have been put into operation to generate electricity.In this major project, Leo Pump Industry provided technical water supply equipment, maintenance drainage and flow channel water filling systems, leakage drainage systems and other related pump equipment (including GSX high-efficiency single-stage double-suction horizontal centrifugal pumps, NLG vertical pipeline centrifugal pumps, NDX single-stage end-suction cantilever horizontal centrifugal pumps, GLC vertical long-axis pumps, WQ series submersible sewage pumps, and D series horizontal multi-stage centrifugal pumps).     Among them, the GSX250-390 high-efficiency, single-stage, double-suction horizontal centrifugal pump, awarded the China Energy Conservation Certification, features a double-suction design with a flow rate of 1200 m³/h and a head of 40 m. It boasts a wide range of models, excellent hydraulic performance, and a novel structure, offering high efficiency and reliability, low NPSH, and low maintenance. This product, which has been awarded the "Second Prize for National Science and Technology Progress," has demonstrated outstanding performance in major projects such as the Shenhua Guohua Qingyuan Power Generation Project, the Huaneng Dalat Power Plant, and the State Energy Group Yueyang Power Generation Company.   4. Solid Core Capabilities Support Major Projects   The Wuyue Pumped Storage Power Station is a prime example of the localization of China's entire high-end equipment manufacturing industry chain. The vast majority of its core equipment and construction materials, including Leo, are sourced from domestic companies, demonstrating that China's independent R&D, design, and manufacturing capabilities for pumped storage power stations have reached world-leading levels. Harbin Electric Power Group, supplier of the core main equipment, undertook the design, manufacturing, installation, and commissioning of all core components, from the runner, main shaft, and generator rotor. TBEA Shenyang Transformer Co., Ltd., supplier of the 500kV main transformer, undertakes the critical task of boosting the generator's electricity and transmitting it to the grid. Pinggao Group, a leading domestic high-voltage switchgear company, provided a complete set of 500kV GIS equipment. Its high reliability and compact design ensure the safe and stable grid connection of the power station.   In addition to traditional pumping equipment, with the deepening implementation of the national "dual carbon" strategy and the rapid development of the pumped storage industry, smart pump health systems are becoming increasingly important for the safe and stable operation of pumped storage power stations. Examples include Leo Pump's smart pump health monitoring system, Taiji Co., Ltd.'s smart pump cluster system, and Kenfulai's KICS intelligent cloud platform.   In addition to the Wuyue Pumped Storage Power Station, many large-scale, important water conservancy projects for public welfare in China, such as the South-to-North Water Diversion Project, the Yangtze-Huaihe River Diversion Project, the Central Yunnan Water Diversion Project, and projects by the five major energy investment companies, have attracted a group of Chinese manufacturing companies with extensive project experience.   5. Promoting China's Hydropower Development with Flowing Wisdom   "Guiding the river, piling up stones, it reaches the Dragon Gate." Ancient Chinese wisdom in water management transcends time and space, finding new life in hydropower development millennia later. With the deepening of the "Dual Carbon" strategy and the advancement of the Yarlung Zangbo River project, China's pumped storage industry is entering a golden period of development. Amidst this monumental energy transition, a group of domestic manufacturers are injecting powerful momentum into this vital national infrastructure with their exceptional technical prowess and reliable product quality.   Rivers surge, and the times march forward. As the Book of Changes says, "Nothing nourishes all things like water." We have reason to believe that this flowing wisdom will inject inexhaustible impetus into the green development of the Chinese nation and contribute significantly to building a beautiful China.

  Etanorm sets the standard for all-round performance   Being a model is no easy task. Being a model means maintaining peak performance and continuous improvement, as KSB's Eta series pumps embody. The series' origins date back to 1935/36, and since its launch, over 2.7 million units have been sold worldwide, making it the most successful standardized water pump in the global market.   The Eta series' success is primarily due to its diverse range of variants and applications. The Eta portfolio includes standardized water pumps with conventional seals in a wide variety of designs, including variable-speed models and leak-free variants. The Etanorm series offers ideal solutions for a wide range of applications.   In the mid-1930s, KSB decided to explore a new path. At that time, the young Dr. Fritz Krisam, who later became Head of KSB's Design/Engineering Department, consolidated KSB's then-complex single-stage centrifugal pumps into a single, unified series. He named it after the Greek letter Eta (η), which stands for efficiency in engineering.   Etanorm: “Norm” (derived from the English word norm, meaning “standard”) emphasizes its standardized design (compliant with EN 733) to ensure consistent performance across a wide range of applications.   This new pump series lived up to its reputation and set a benchmark for efficiency. In the early 1950s, the Eta series underwent a technological evolution, again with increased efficiency as its primary goal. The next generation, released in 1968, also maintained this focus.   In the 1970s, the selection chart for this series became the basis for new pump standards and a reference for many international manufacturers. Based on the EN 733 standard for 10 bar pumps, KSB named this successful series Etanorm—"norm" comes from the German/English word for "standard." Since then, Etanorm has become the world's best-selling standardized pump.   Eta Family History     1935   KSB launches the Eta series—energy-efficient single-stage pumps designed for industrial applications.     1968   The standardized Etanorm series is launched, combining standardization, high efficiency, and high reliability.     2017   The first Etanorm equipped with the MyFlowDrive 1 drive system is launched.     2023   The EtaLine Pro series is launched, combining extreme efficiency, unprecedented flexibility, and sustainable production.   The word "standardized" in "standardized pumps" can be somewhat misleading. In fact, the Etanorm series boasts one of the most diverse pump variants. The average order batch size for all pumps sold in this series is approximately 1.4. This wide selection of sizes and materials ensures that customers receive the pump that best suits their specific application. By tailoring the impeller to the operating point, low-wear operation is also guaranteed.   For this classic product that has already demonstrated excellence in energy consumption, reliability, and durability, the challenge facing our R&D team began with a simple question: How can we set a new benchmark again? After repeated discussions, two key factors prompted us to further innovate and optimize the technology of Etanorm.   Hydraulic Modeling is Key to Efficiency   A pump's hydraulic model is central to ensuring high efficiency and low energy consumption. The Etanorm consistently delivers outstanding performance thanks to its optimized hydraulic model. Its extensive selection chart almost always allows users to select a model operating close to its optimal efficiency point. In addition to optimized hydraulics and impeller cutting, variable speed operation combined with a highly efficient drive system significantly contributes to lower energy and operating costs.   1955: The first automated production line for Eta components Opening in Frankenthal   The Etanorm offers 62 sizes. To hydraulically optimize each size, we utilize advanced tools such as the Finite Element Method (FEM) and Computational Fluid Dynamics (CFD) to construct hydraulic profiles, which are then validated through comprehensive testing.   Although the Etanorm is a classic clean water pump and is not typically used for conveying media containing abrasive particles, given the increasing prevalence of solids in these applications, we have designed its shaft seal chamber to be more tolerant of solids-laden media than previous versions. At the same time, in order to make the water pump better adapt to the fluid being transported, users can choose different materials for the pump casing, impeller and mechanical seal.   Virtual Impeller Trimming for Maximum Flexibility   The next evolution of Etanorm is its integration with the Industry 4.0-compatible MyFlowDrive 2 drive system. This "virtual impeller trimming" feature allows users to independently set a desired fixed speed on the motor. The pump's flow rate can be easily increased or decreased at any time, providing users with a high degree of reliability and flexibility. Traditional fixed-speed pumps often have their impellers trimmed during manufacturing to match the design flow rate and head. This model requires significant time and effort to adjust later. Because the synchronous motor's supply voltage is modulated by the motor's integrated frequency converter, it can be connected to virtually any power grid worldwide. This is a significant advantage for global general contractors: they no longer need to consider local grid voltage when selecting a pump.   With its broad selection and extensive material and seal options, Etanorm remains the preferred choice for efficient and economical fluid transport in numerous industries and applications.   Investing in a Modernized Eta Production Line   To ensure the future competitiveness of the Frankenthal site, KSB is comprehensively modernizing its Eta production facilities according to the latest technology and energy standards, with completion scheduled for 2029. Starting in 2026, the Eta production facility at the Frankenthal headquarters will be expanded into a European competence center for the latest generation of electronically controlled pumps. KSB will invest approximately €70 million in this project over the next few years—one of the largest single investments in the company's history.   The new building will provide ample space for the reorganization of machining, assembly, and logistics areas, and the existing production hall will be fully renovated and reused. The energy-efficient production renovation also includes connecting the drying system in the new paint shop to the district heating network of the headquarters' new heating station and installing a photovoltaic system on the roof. KSB already produces the next generation of energy-efficient EtaLine Pro water pumps for the building services sector, manufactured using sustainable methods, at the Eta production site in Frankenthal.   A live view of KSB's Eta production line in Shanghai   This global modernization strategy has also extended to China. Construction is currently underway at KSB's new Eta production line in Shanghai. Installation of the automated high-bay warehouse is nearly halfway complete, and the production line is undergoing final adjustments and construction.     Meanwhile, pre-acceptance of the production line's hardware has been successfully completed, and the equipment is about to be delivered to site, heralding a new level of localized production capacity for KSB in China.     Founded in Frankenthal, Germany in 1871, the KSB Group has grown over 150 years to become a world-leading supplier of pumps, valves, and services. Adhering to its brand philosophy of "Solutions. For Life," the Group employs over 16,000 people worldwide and operates in over 100 countries.

Exploring the Working Principle of a Double-Suction Pump The operating principle of a double-suction pump is based on centrifugal force, much like the water in a bucket tethered to a rope spinning rapidly. A double-suction pump primarily consists of an impeller, pump casing, and shaft. When the pump is started, the motor drives the pump shaft and impeller into high-speed rotation. The impeller acts like a high-speed "stirrer," spinning the liquid pre-filled between the blades.   Under the influence of centrifugal force, the liquid is propelled by an invisible force, flowing from the center of the impeller outward. This creates a low-pressure area at the center of the impeller, acting like a "suction trap." The pressure difference between the liquid level and the impeller center causes the liquid in the tank to be drawn into this low-pressure area—the impeller center. Because a double-suction pump has two suction ports, liquid can enter the impeller evenly from both directions, significantly reducing resistance in the inlet piping and improving suction efficiency.   As the impeller rotates continuously, liquid is constantly flung from its center to its periphery. This process seems to energize the liquid, increasing both its static pressure and flow rate. As the liquid leaves the impeller and enters the pump casing, the flow path within the casing gradually widens, slowing the flow rate. Much like a high-speed car entering a wide avenue, its speed slows, and some of the kinetic energy is converted into static pressure, further increasing the liquid pressure. The continuous rotation of the impeller causes the liquid to be continuously drawn in and out, creating a steady flow within the double-suction pump. Ultimately, the high-pressure liquid flows tangentially into the discharge pipe and is delivered to where it's needed.     Advantages of Double-Suction Pumps (1) High Flow: Double efficiency, powerful power (2) Smooth Operation: Symmetrical structure, stable operation (3) Easy Maintenance: Horizontal center opening, easy maintenance (4) High Efficiency and Energy Saving: Optimized design, reduced energy consumption   Disadvantages of Double-Suction Pumps (1) Low NPSH, affecting efficiency (2) Ring leakage, affecting operation (3) Large Footprint: Large size, requiring a lot of space   Double-suction pumps, with their significant advantages such as high flow, stable operation, easy maintenance, and high energy efficiency, play an irreplaceable role in numerous fields, including urban water supply, industrial production, hydraulic engineering, and fire protection systems. However, they also have drawbacks such as low NPSH, prone to ring leakage, and large footprint. In practical applications, it is necessary to comprehensively consider the advantages and disadvantages of double-suction pumps based on specific working conditions and make appropriate selections and use.   With the continuous advancement of technology, double-suction pumps have broad prospects for technological innovation and application expansion. We believe that in the future, double-suction pumps will continue to be optimized and upgraded, providing higher-quality and more efficient services for our production and daily lives.  

  Determining Flow and Head Requirements   When selecting a mixed flow pump, determining flow and head requirements is a critical first step. Flow is like the "volume" of water flowing through a pipe, determining how much water the pump can deliver per unit time; head is like the "height scale" of water being lifted, indicating the vertical height the pump can lift water.   Determining flow requirements depends on the specific application scenario. For example, in agricultural irrigation, the required water volume needs to be estimated based on the irrigated area, crop type, and growth stage. For example, rice fields require a high water demand during the peak growing season, so it's important to accurately calculate the number of cubic meters of water required per hour to ensure healthy growth. For urban drainage, factors such as the city's area, rainfall, and drainage time requirements must be considered. For example, suppose a certain area in a city covers 10 square kilometers. Based on historical rainfall data, rainfall reaches 50 mm per hour during heavy rain. The total hourly rainfall in that area needs to be calculated to determine the required flow rate for the mixed flow pump. Calculating head requirements is equally important. For example, when drawing water from a river to supply a city, the vertical height difference between the water intake point and the city's water supply point, as well as the energy losses in the pipe, must be considered. For example, if the vertical height difference between the water intake point and the city's water supply point is 20 meters, and the pipe is 5 kilometers long, estimate the longitudinal and local resistance losses in the pipe based on the pipe's material and diameter. Assuming the longitudinal resistance loss is 5 meters and the local resistance loss is 3 meters, the total required head is 20 + 5 + 3 = 28 meters.   Inaccurate calculations of flow rate and head can lead to a series of problems. Choosing a too low flow rate is like using a faucet with too little water, failing to meet actual water demand and potentially causing production halts in industrial operations. Choosing a too high flow rate not only wastes energy but also increases equipment costs, like using a large pipe to connect a small bucket, resulting in a waste of resources. If the lift is too low, the water won't be lifted to the required height. For example, in high-rise water supply, insufficient lift won't allow water to reach residents on the upper floors. If the lift is too high, excessive energy consumption will occur and may cause unnecessary stress on the pump and piping, shortening the equipment's lifespan. Therefore, accurately calculating the flow rate and lift requirements is essential for selecting the right mixed flow pump.     Considering Media Characteristics   Media characteristics are like the "opponent characteristics" a mixed flow pump faces during operation, significantly influencing its selection. Different media have varying physical and chemical properties, which determine the pump's material and seal type.   If the medium being transported is clean water, a relatively "mild" medium, a standard cast iron or stainless steel mixed flow pump will suffice. Cast iron is relatively cost-effective and widely used in applications such as agricultural irrigation and urban clean water distribution. Stainless steel, on the other hand, offers greater corrosion resistance and is more suitable for drinking water supply systems with high water quality requirements. In this case, the more common sealing options include a stuffing box or mechanical seal. Packing seals are inexpensive and easy to maintain, making them suitable for applications where leakage requirements are less stringent. Mechanical seals offer better sealing performance, minimize leakage, and can meet more stringent sealing requirements.   When the medium is a corrosive liquid, such as the various acid and alkali solutions used in chemical production, it presents a formidable challenge. Therefore, the pump material must possess excellent corrosion resistance. Materials such as fluoroplastic alloys and titanium alloys can be used to manufacture the flow passage components of mixed-flow pumps to resist erosion by corrosive media. Sealing methods also require upgrading to corrosion-resistant mechanical seals, and specialized flushing and cooling systems may be required to ensure seal reliability. For example, in sulfuric acid production plants, mixed-flow pumps transporting sulfuric acid require fluoroplastic alloys, with double-end mechanical seals and external flushing systems to prevent sulfuric acid leaks.   When the medium contains solid particles, such as sludge in sewage treatment or slurry in mine drainage, it presents a formidable challenge. Therefore, the pump material must be wear-resistant. Wear-resistant cast iron and ceramics are commonly used, and the impeller and pump body design also prioritizes wear resistance. The sealing method must prevent solid particles from entering the sealing surface and causing seal failure. For example, specialized sealing structures can be used, such as a combination of a plenum seal, a packing seal, and a labyrinth seal. In sewage treatment plants, when handling wastewater containing large amounts of solid impurities, the impeller of a mixed flow pump is made of wear-resistant cast iron, and the seal is a plenum seal plus a packing seal.   Therefore, selecting the appropriate mixed flow pump based on the characteristics of the medium is crucial to ensuring stable and efficient operation. If the wrong choice is made, the pump may quickly be corroded and worn by the medium, rendering it inoperable.     Brand and Quality   When choosing a mixed flow pump, brand and quality are crucial factors that cannot be ignored. Well-known brands often represent reliable quality and a good reputation. Just as people trust brands like Apple and Huawei when buying mobile phones, choosing well-known brands like Grundfos and Ebara provides greater peace of mind when purchasing a mixed flow pump. These brands typically possess advanced production technology and strict quality control systems, meticulously overseeing every step from raw material procurement to product production. Their products excel in performance, reliability, and stability, meeting the demands of a variety of complex working conditions.   There are also several methods and suggestions for identifying product quality. First, check the product's certifications, such as ISO 9001 quality management system certification and CE certification. These certifications serve as a testament to product quality. Second, observe the product's appearance. A high-quality mixed-flow pump will have a smooth surface, free of obvious defects, and even, neat welds. You can also research product reviews and reputations online and on industry forums to learn about other users' experiences and feedback. If a majority of users give a particular brand of mixed-flow pump positive reviews, it suggests the product is reliable.     After-sales service is also a key consideration when choosing a mixed-flow pump. High-quality after-sales service can provide timely and effective support in the event of a pump failure. For example, check whether the brand manufacturer has an after-sales service center in your area and whether maintenance personnel can respond quickly and arrive on-site for repairs. After-sales service also includes replacement of wearing parts, technical consultation, and training. If after-sales service is not in place, once a pump fails, it may cause long downtime, causing great losses to production and life. Therefore, when purchasing a mixed flow pump, it is important to understand the brand manufacturer's after-sales service policy and guarantee measures.  

In the industrial field, wear-resistant slurry pumps and mud pumps are both common fluid conveying equipment, but there are some significant differences in their functions, structures, and applications.     In terms of application   Wear-resistant slurry pumps are primarily used to transport slurries containing solid particles, which are typically hard and corrosive, such as ore, sand, gravel, and ash. Their design focuses on resisting the abrasion and impact of solid particles to ensure long-term stable operation under harsh operating conditions. Mud pumps, on the other hand, are primarily used to transport slurry-like media, which typically have finer particles and are relatively less corrosive, such as drilling mud and mud-water mixtures.   Structurally   Wear-resistant slurry pumps typically have more robust flow components, such as the impeller and jacket, made of highly wear-resistant materials to resist abrasion from solid particles. Their pump bodies are also more corrosion-resistant, making them suitable for complex media environments. Mud pumps have a relatively simpler structure, focusing on both suction and discharge capabilities.     Performance   Wear-resistant slurry pumps excel in handling highly concentrated, abrasive slurries, providing high head and flow rates while also exhibiting excellent wear resistance. Mud pumps, on the other hand, focus more on handling viscous slurries and have relatively lower flow and head requirements.   Operating Principles   While the two have similarities, they differ in specific details. Wear-resistant slurry pumps use the rotating impeller to generate centrifugal force to propel the slurry, while also addressing the unique challenges posed by solid particles. Mud pumps focus more on agitating and moving the slurry.   In practical applications   Selecting the appropriate pump depends on the operating conditions and media characteristics. For handling slurries containing a large amount of hard particles and high abrasiveness, wear-resistant slurry pumps are a better choice; for applications primarily handling slurry-like media, mud pumps are more suitable.   In short, both wear-resistant slurry pumps and mud pumps play an important role in industrial production. Understanding their differences can help us select and use them appropriately in various projects and achieve more efficient and reliable fluid transportation.

  Large electric motors are at the heart of industrial operations. They power the pumps that move fluids and the conveyor belts that keep production lines moving. While their mechanical output is readily apparent, what's often overlooked is how efficiently they use energy. Let's explore the importance of energy efficiency in large electric motors. From reducing operating costs to achieving environmental goals, the benefits are clear. Now, we'll take a look inside these devices. What exactly makes large electric motors so energy-efficient? And how can companies ensure each motor is operating at its maximum efficiency?   Understanding Motor Efficiency Motor efficiency measures its ability to convert electrical energy into mechanical energy. No motor is perfect—some energy is always lost as heat, noise, or other effects. Energy-efficient (high-efficiency) motors are designed to minimize these losses. For large electric motors, even small improvements in efficiency can result in significant energy and cost savings. For example, a 1% improvement in the efficiency of a 600-horsepower motor can save thousands of dollars annually.   The Role of Materials One of the primary factors affecting motor efficiency is the quality of the materials used in its construction. High-efficiency motors typically utilize high-quality electrical steel in their stator and rotor cores. This advanced material reduces core losses, such as hysteresis and eddy current losses, by enhancing magnetic flux conductivity. This minimizes heat losses and improves the motor's overall energy efficiency. Furthermore, these motors utilize high-conductivity copper windings and rotor bars, which typically have a larger cross-sectional area and are precision-wound. This design minimizes electrical resistance and reduces I²R losses (heat generated by current flowing through the winding and rotor conductors). While these improvements may increase initial investment costs, they provide long-term benefits through reduced energy consumption, lower operating costs, and extended motor life.   Precision Manufacturing Motor efficiency depends not only on material quality but also on manufacturing precision. By employing tighter mechanical tolerances and precise alignment of internal components, high-efficiency motors effectively reduce mechanical vibration and operating noise, ensuring consistently optimal electromagnetic performance. A key design parameter is the air gap—the tiny gap between the stator and rotor. An excessively large air gap weakens magnetic coupling and reduces efficiency, while an excessively small air gap can lead to physical contact, resulting in mechanical wear and energy loss. Precision manufacturing processes ensure that the air gap is consistently maintained within the optimal range for optimal performance. Thermal management is another crucial factor. High-efficiency motors employ advanced heat dissipation designs, such as enlarged heat sinks and optimized airflow channels, to effectively dissipate heat. This improved heat dissipation not only improves operating efficiency but also extends the motor's lifespan and reliability under continuous operation.   Advanced Motor Design While traditional induction motors remain widely used, new motor designs are pushing the boundaries of efficiency. A typical example is the permanent magnet synchronous motor (PMSM), which incorporates permanent magnets embedded in the rotor. These magnets generate a constant magnetic field, eliminating the need for rotor current and significantly reducing energy losses. PMSMs are particularly well-suited for applications requiring variable speed and/or high torque, such as pumps, fans, HVAC systems, and electric vehicles. While their initial cost is higher, their superior energy efficiency often makes the investment worthwhile.   Variable Frequency Drive Technology The most effective way to improve motor efficiency often lies not in the motor itself, but in how it's controlled. Variable frequency drives (VFDs) enable motors to operate at variable speed, adjusting output power in real time to match load demand. Without a VFD, traditional induction motors maintain a near-constant full speed regardless of load demand, resulting in significant energy waste when operating under partial load conditions. With a VFD, the motor can reduce speed based on actual demand, significantly reducing energy consumption. This feature is particularly beneficial in applications such as pumps and fans, where the power required scales with the cube of the speed.   System-Level Considerations A motor isn't a standalone device; its energy efficiency is influenced by the entire system—from the power supply to the mechanical load. Therefore, a holistic, systems-level approach is essential. Motor selection is crucial: an overpowered motor will operate inefficiently under partial load, while an underpowered motor may overheat and fail prematurely. Performing a load analysis ensures the motor is optimally matched to the application. Regular maintenance is another key factor. Clogged filters, poor shaft alignment, or worn bearings can all reduce motor efficiency. Implementing a preventive maintenance program ensures that motors consistently operate at peak performance. It's important to note that high-efficiency motors typically run at slightly higher speeds than less-efficient motors. When replacing an inefficient motor, it's crucial to thoroughly assess the impact on system performance.   Intelligent Monitoring and Predictive Maintenance Advances in digital technology now make it possible to monitor motor performance in real time. Smart sensors track key parameters such as temperature, vibration, and current draw, providing early warning of potential problems. This data not only enables predictive maintenance, enabling technicians to address issues before they occur, but also helps identify energy inefficiencies, such as motors operating at low loads or outside of their optimal operating range for extended periods. By integrating motor data into broader energy management systems, companies can gain valuable insights and continuously optimize operations.   Building a Smarter Future High-efficiency, large-scale motors are more than just a technological upgrade; they are a strategic investment in sustainability, reliability, and profitability. By focusing on high-quality materials, precision manufacturing processes, advanced design, and intelligent control systems, companies can unlock the significant value of their motor systems.   About the Author: Chris Stockton holds a Bachelor of Science degree in Mechanical Engineering from Clemson University in Clemson, South Carolina. A Fellow of the Institute of Electrical and Electronics Engineers (IEEE) and a Registered Professional Engineer, Stockton currently leads product management and technology for ABB's Large Motors and Generators business in the United States, based in Greenville, South Carolina.