Desulfurization Pump Slurry Pump Repair

Pump Volute Casing Repair damage caused by erosion/corrosion Restore casings with sand holes and cracks Reshape end covers, protect wear plates Reduce friction loss, improve efficiency Enhance efficiency by using hydrophobic coatings Impeller www.qdyuke.com Restore impeller wear ring clearance Reshape blade profiles Provide protection against erosion and chemical attack Bushings, Seal Tubes, and Wear Rings www.qdyuke.com Adjust bearing bushes Reshape steam seal bodies Recast water-lubricated bearings Shaft www.qdyuke.com Repair and protect dented support shafts Rebuild shaft sleeves/bearing areas New Technology for Desulfurization Slurry Circulation Pump Repair, Wear Protection, and Corrosion Resistance www.qdyuke.com In response to the requirements of national environmental protection departments, enterprises such as thermal power plants and chemical plants that fail to meet emission standards must install desulfurization systems to address emission issues. A critical component in these systems is the slurry circulation pump, whose operational condition directly affects the entire system's performance. Additionally, slurry circulation pumps are major energy consumers; for instance, a 500KW slurry pump running uninterrupted year-round can consume over 4 million kWh annually. During prolonged operation, the impeller surface suffers from wear, corrosion, and cavitation damage, gradually thinning the blades, causing pitting (corrosion), and even leading to gaps. These pits and gaps slowly expand, causing structural damage and eventually rendering the impeller unusable, while also significantly reducing pump efficiency. Pits and roughness on the impeller surface increase flow resistance. Blade gaps generate substantial vortices, reducing flow rate and wasting energy. The additional energy consumption due to these factors can be as high as 6–7%. Taking a 500KW pump as an example, this results in over 300,000 kWh of extra electricity consumption per year. Given the extremely harsh working conditions of slurry pumps, impellers typically need replacement or repair after one to two years of operation. Impeller materials are specialized and costly; replacing an impeller for an imported pump can cost over 200,000 RMB, while domestically produced ones cost around 100,000 RMB. Traditional repair methods, such as overlay welding (which can easily cause cracking), are outdated. In today’s era of building an energy-saving society, improving the efficiency of circulation pumps and advancing repair technologies offer significant economic benefits and social value for power plants, petrochemical industries, and other enterprises by reducing plant electricity consumption and maintenance costs. Therefore, these operational slurry circulation pump impellers require timely repair and energy-saving upgrades. II. Original Solution www.qdyuke.com Purchase replacement impellers from the original manufacturer. This approach is straightforward but costly, and it also involves considering spare parts capital costs. III. New Solution To address the working environment of slurry circulation pumps, applying brushed ceramics can effectively resolve issues of mechanical wear, chemical corrosion, and cavitation. This restores the impeller surface quality, extends service life, improves pump operation, and enhances pump efficiency. Implementation Plan: 1. Surface treatment: Sandblast the impeller to expose the metal base, achieving a roughness of 75u, and clean thoroughly. 2. Use EG to repair severely damaged areas (deep grooves), restoring the original profile. 3. Apply CR as a primer to wet the surface. After two hours, use EG to repair thinned areas. Allow full curing for 8 hours. 4. Turn on a lathe to restore original dimensions, then use EG to level the surface. After 8 hours of curing, polish smooth. 5. Perform dynamic balancing. 6. Apply EG and CR alternately twice. Allow curing for 6 hours before completion. 7. With adequate preparation, the entire repair process can be completed within 5–9 days. This technical solution can be used for both old pump repairs and new pumps, providing wear and corrosion prevention, extending impeller service life, and reducing energy consumption. Energy-saving principles of this solution: 1. Seal perforations on the impeller to prevent communication between high and low-pressure zones, reducing energy loss. 2. Fill pits on the flow surface to decrease flow resistance. 3. The extremely smooth brushed ceramic surface significantly reduces vortex formation and minimizes vortex resistance. Based on practical experience, this solution can reduce energy consumption by 6% in old pump retrofits. This technology is applicable to pumps of any brand and model, thereby reducing inventory and saving on spare parts costs.