New Year’s Newsletter (No. 37)

New Year’s Greetings

Dear Readers, dear Friends of Rheinhütte Pumpen,

2017 is still young, and we hope it began happily and free of cares for you.

As you are already aware, the business activities of Division Rheinhütte Pumpen were transferred from FRIATEC AG to RHEINHÜTTE Pumpen GmbH last year in the context of a spin-off. Greater consideration is now given to our business model within the Aliaxis Group, and decision-making processes are now shorter and more flexible.

December 2016 saw us successfully achieve certification for the implementation of an environmental and energy management system pursuant to ISO 14001 and ISO 50001.

In business terms, 2016 was a difficult year for Rheinhütte, as we did not achieve the sales targets we had set ourselves.

However, what is optimistic about 2017 is the development of incoming orders. We already received an order from Saipem (Italy) in March 2016 for the supply of 28 GVSO and RCE liquid sulphur pumps for the operator Saudi Aramco’s Jazan project. This was followed in June by an order from Petrofac (UAE), also for liquid sulphur. In the coming months, we will supply 44 GVSO and RCE units for the Fadhili gas field project (also from Saudi Aramco). Other interesting orders followed in the last quarter, including Grasim in India, OCP in Morocco and from some European plant manufacturers. There will be other major projects in the next few weeks ready for awarding where we have a good chance of success.

The picture in the regions continues to differ greatly. The MENA region shows very gratifying development. Despite continuing sanctions and the weakness of the rouble, there are promising projects in Russia and the CIS countries. Hardly any new plants are being built in Germany, and there are currently few Projects for our applications in the German plant construction sector. By relocating the Service Center from Duisburg (the Thyssen premises) to Essen, we have laid the foundation for a special focus on service and the individual pump business in Germany. There are promising projects ready for awarding in some European countries (e.g. Italy and the Netherlands), and we expect short-term decisions here on the part of our customers. Asia continues to be difficult with, among other things, the Korean plant construction sector which had been so successful up until now hardly awarding any contracts for our applications. Local competition continues to grow in India and China. In China, however, we expect our prospects to be good in some solar projects.

Brazil shows the first cautious signs of an improving economic situation. In the US, it remains to be seen how the newly elected president will exercise his office as of January. We see further potential for 2017 in Iran, although things were still rather slow here in 2016. There are enough projects, but financing and the flow of money are still very sluggish.

At the moment, we are working on additions to our range of materials such as Polymercarbid, PE 1000R and various ceramics, while also adapting pump designs (e.g. FNC standardised chemical pump made of Frikorund® ) to meet the increased demand for niche applications equipped for high temperatures and / or wear resistance. The area of numerical simulation (including CFD and FEM) will be further expanded in 2017 in order to create an option for complete virtual prototype testing.

We are looking forward to facing exciting challenges together and, as regards 2017, we would like to wish you at this point the very best, professional success and, above all, good health.

Klaus Wolf and Jürgen Weinerth
Klaus Wolf and Dr. Jürgen Weinerth

Innovative Processes And Applications
New Application Areas For RHEINHÜTTE PUMPEN

RCFKU 125-80-250 CST Test Pump For The Preparation Of Hydrochloric Acid In Pickling Plants

About 6 years ago, SMS Siemag started to develop a new process for the treatment of hydrochloric acid in pickling plants. The process is called hydrothermal hydrochloric acid regeneration technology and is far superior to previous processes when it comes to energy use, efficiency, space requirements and investment costs. The critical pump positions are located on the oxidizer and hydrolyzer, with high requirements in terms of temperature and wear.

RCFKu 125-80-250 CST
RCFKu 125-80-250 CST

The first real plant was built at Thyssen Krupp Steel in Alabama (USA). However, this new acid treatment process was discontinued, due to the sale of the steelworks at the end of 2012. Many technical problems proved insolvable. Among other things, RCFKu pumps made of PTFE supplied by us had service lives of less than 3 months. A test pump was therefore developed together with FRIATEC AG – Division Keramik, the business division for ceramics in Mannheim using zirconium and aluminium oxide ceramic, but this could not be tested because of the closure. Now SMS is resuming development of the process. The RCFKu 125-80-250 CST test pump was delivered to a test facility in September 2016 for further tests.

This process can now also be used in red mud processing. Red mud is a waste product obtained in the Bayer process from ores containing aluminium (particularly bauxite) during the production of aluminium oxide, an intermediate product during the production of aluminium. The characteristic red colour comes from solid particles of iron (III) compounds suspended in sodium hydroxide solution. The amount of red mud produced per tonne of aluminium depends on the composition of the bauxite used which, in turn, depends on its origin. It is estimated that about 1.6 t of damp red mud can be produced from tropical bauxite and about 3.2-3.7 t from European bauxite. Worldwide, red mud is today stored in sometimes exposed landfill sites or routed into rivers (about 120 million tonnes per year).

DLS Reseach Project
High Performance Molten Salt Tower Receiver System (HPMS)

In a first research phase, the German Aerospace Center (DLR) has, together with a consortium, theoretically investigated new receiver concepts for solar tower power plants.

The result of this study indicated that the full potential for cost reduction in salt tower power plants is currently not exhausted by the use of optimised concepts and adapted solar high-temperature circuits. New concepts were developed theoretically. Therefore, an optimised salt circuit with a subreceiver will be set up and tested at the solar institute in Jülich in the context of the HPMS Phase II project. The aim is to test the concept developed in HPMS Phase I under realistic conditions. This step is necessary to enable reliable further development for a receiver system with capacities usual in power stations (700MWth). If the project is approved by the Federal Ministry for Economic Affairs and Energy (BMWi), we will deliver a GVSO 40/250 V in 1.4581 for the test plant.

The project drawing with a description of the planned project was submitted by the German Aerospace Center (DLR) to the BMWi as part of the 6th energy research program in September 2016 and its eligibility for funding confirmed. However, final approval will not be decided until the next round of applications. Other partners are Babcock Borsig Steinmüller, Bilfinger Piping Technology, Solar Institute Jülich at the FH Aachen University of Applied Sciences, TÜV Nord Systems AG, Salzgitter Mannesmann Research, Eugen Arnold GmbH and Rhein Ruhr Power.

Longer Service Life
Polymercarbid And PE 1000R

Innovative Materials for longer Service Life

Corrosion resistance and wear resistance: two material properties which are increasingly required in modern applications for centrifugal pumps, but which cannot always be optimally combined. Metallic materials can be adapted very flexibly in terms of corrosion or wear resistance by means of tempering and alloying adjustments. However, options for the combination of both are often limited. Plastics have a very high resistance to inorganic acids and alkalis, but usually exhibit only low wear resistance. Due to their complex production, extremely corrosion and wear-resistant ceramic pumps made of FRIALIT-F99.7® are only economical viable for unusual applications.

RHEINHÜTTE Pumpen close this gap between plastic and ceramics with two innovative materials. Their exceptional resistance enables the achievement of a longer service life and makes the operation of centrifugal pumps more effective in abrasive media.

Polymercarbid and PE 1000R – Two stable partners

Impeller made of PE 1000R
Impeller made of PE 1000R

The special PE 1000R polyethylene offers up to 30% higher resistance than conventional PE 1000, due to a wear-reducing additive. This means a significant improvement in service life and, consequently, maintenance and repair intervals in wear applications. PE 1000R is available for all PE 1000 pump types from RHEINHÜTTE. The new multi-component material Polymercarbid is significantly more resistant to wear. The secret of this material lies in the combination of an extremely hard silicon carbide as a wear layer with a vinyl ester resin as a binder. The material reaches a Mohs hardness of 9.7, thus almost achieving the hardness level of diamond.

Wear resistant pumps for the most difficult applications

RCFKu made of Frikorund® technical ceramic with an impeller made of polymercarbid.
RCFKu made of Frikorund® technical ceramic with an impeller made of polymercarbid.

Close cooperation between Nomig GmbH and RHEINHÜTTE Pumpen GmbH led to the development of a wear pump made of solid polymercarbid. Tried and tested designs were exploited in a practical manner on the basis of the RHEINHÜTTE CPRF and RCFKu free flow series. The connection dimensions of these series correspond to EN 22858 / ISO 2858 and therefore permit easy replacement of existing standardised chemical pumps with wear problems.

When compared to simple coatings or thin-walled plastic inserts, solid volute casings provide a considerably greater material reserve against wear.

The use of free flow pumps is a logical consequence when it comes to conveying highly abrasive media and suspensions. In the case of free flow pumps, the pressure-generating pump impeller is not located directly in the volute casing, but offset from this so that only about 20% of the medium volume comes into contact with the impeller surface. Large flow channels also enable the conveyance of large solid particles.

The right solution. For any fluid.

Even media which encourage wear can be conveyed efficiently through the combination of suitable pump designs and materials. New and innovative materials can significantly reduce operating costs. With its CPRF and RCFKu free flow pumps, RHEINHÜTTE Pumpen provides proven models for the conveyance of media containing solids. Selection of the most economical material by material specialists at RHEINHÜTTE Pumpen depends on the one hand on the quantity, but mainly on the quality of the solids involved. The available spectrum ranges from UHMW-PE, PE 1000R and Polymercarbid to FRIALIT-F99.7®, a highly wear-resistant ceramic from FRIATEC AG. By standardising pump components, combinations of materials or subsequent adaptations can also be realised with modified media data.

As a consequence, these materials have already solved the most difficult application problems to the satisfaction of plant operators.

The next generation of molten salts

In order to further increase the operating temperature and, consequently, the efficiency of molten salts as heat accumulators in power plants, molten salts with a high chloride content are currently being tested in laboratory trials in the USA at temperatures up to 800°C. Chlorides in the molten salt cause very aggressive behaviour in chemical terms, so the standard materials used in our GVSO submersible pump can no longer be used here. Following the successful laboratory tests, the intention now is to construct test plants with pumps in the USA. Corresponding inquiries for pilot projects have been placed. According to the current state of the art, only the new Haynes 230 material, an Inconel material with a nickel-based alloy of 22% chromium, 14% tungsten, 5% cobalt and 3% molybdenum is suitable as pump material. The high tungsten and chromium content in particular results in very good strength values, even at 800°C. The long-term stability of this material is outstanding and surpasses all alloys typically used to date. In laboratory tests, this material has also shown itself to be stable in hot chloride melts.

RHEINHÜTTE Pumpen will design a GVSO submersible pump in Haynes 230 to also test corrosion resistance under flow conditions.

Energy and environmental management
successfully certified

RHEINHÜTTE Pumpen GmbH has successfully passed certification pursuant to DIN 50001 Energy Management and DIN 14001 Environmental Management. The certification audits took place at the end of November 2016 and were conducted by TÜV Süd. The certifications prove that we conserve natural resources and make a sustainable contribution to environmental protection. As a company active on an international level, we also meet the high standards and requirements of our customers and suppliers in this manner.

After sales service
new service center

Our service for you: Fast. Reliable. Individual.

The new RHEINHÜTTE Service Center started operations on 1. September 2016 at Adlerstrasse 28 in Essen. This means that we now have a considerably larger Service center in the region with state-of-the-art technology. Even the repair of larger submersible pumps poses no problems here. Sufficient storage space for spare parts also ensures fast on-site service without long delivery times. The many years of experience gained by our continuously trained personnel in the design and production of pumps of various designs means that we can offer you repairs and maintenance work for RHEINHÜTTE pumps and pumps from other manufacturers.

This ensures maximum operational reliability, minimum downtimes and a long service life for your pumps.

Rheinhütte Pumpen Service-Mitarbeiter

Through the After Sales Service group established on 1 July 2016 in the context of the realignment and which includes the spare parts and service departments, the Service Centers and our worldwide service partners, we aim to provide reliable high-quality services through the rapid supply of spare parts and well-conceived service concepts for our customers.

With the expansion of our global service network with our own Service Centers and service partners, all of which have to meet a defined quality standard, we create the basic prerequisite for acceptance as a partner of planning companies in the project business.

Fast, reliable and individual – our aim is to continue to enhance this service promise.

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