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IP 1318-12 GB 1
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der: A1
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Clean and economical solutions for conveying different types of materials
IP 1318-12 GB2
Content
Applications
Mining / Backfilling 5
Fly Ash / Bottom Ash 7
Sludge Removal 8
Tunnel Construction 10
Oil & Gas Industry 12
Biomass 15
Sewage Treatment Plants 18
Co-Incineration 20
Coal Sludge 22
Cement Industry 23
Special Waste 25
Inorganic Materials
Organic Materials
Pump Technology
IP 1318-12 GB 3
Piston Pump with S-Transfer Tube KOS 27
Piston Pump with Seat-Valves HSP 28
Piston Pump with Ball Valves KOV 29
Single-Piston Pump EKO 30
Power Pack Units 31
Products
Silos 32
Sliding Frames 33
Discharge Augers 33
Silo Technology
System Components 34Accessories
Range of Services 38Service
IP 1318-12 GB 5
Mining / BackfillingInorganic Materials
Two tailings pumps of type HSP 25100 at the Bulyanhulu Goldmine in Tansania
Safe “Backfilling”High production costs, safety concerns,environmental aspects and so on areforc ing mine operators to undertakeextensive restructuring. Backfilling ofresidues from mines and power stationsplays an important role. The core components of such installa -tions are S-transfer tube pumps (KOS),seat valve pumps (HSP) and ZX pipingsystems from Putzmeister:
Conveying distances up to 11 kmfrom the mixing facility located onthe surface to the backfill locationunderground and with no pumpsinstalled on this route
Up to 200 m3/h conveying capacities Up to 120 bar operating pressure in
the material Permissible pressure of up to 250 bar
in the 200 mm internal diameterpipeline due to high static pressurecomponents encountered
Suitable for abrasive material
Advantages of the system
Closed loop of washery tailings:minepit – treatment – minepit
Increased stability of the miningstructures
Better exploitation of deposits Safe and clean transport in pipelines High operational safety and reliability Low wear costs Lower specific energy consumption Little water circulating
Creating tunnellinings for targeted mine ventilation withthe BSM 1002 (Elefantino)
Mining companies are constantly search -ing for ways to ensure that workingunderground is economical and safe.This is particularly true of coal miningcompanies.
Potential application sites for the BSM 1002
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Creating linings for the roadways
Securing roadways with"concrete" packing
Concreting dam constructions
With the BSM 1002, it is possible to mixand pump building materials on site, e.g.concrete or other mineral substancesmixed with cement.
These materials are for example bestsuit ed for building tunnel linings in acoal mine.
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IP 1318-12 GB6
KOS HSP KOV BSM
Upward conveyanceof sludge with high-performance„Mine dewatering“In “mine dewatering”, mine slurries filledwith sand must be conveyed up to thesurface.The Putzmeister HSP seat valve pumpoffers a particularly efficient and inex-pensive solution to this problem.
The following case study on a miningcompany in Lorraine demonstrates someof the economic and technical advan -tages of this process: The French miningcompany Houillères de Bassin deLorraine (HBL) was looking for a betterway of pumping its mine slurries with720 g/litre sand up to the surface from adepth of 1250 m. The 43 centrifugalpumps which they were currently usingwere reaching their limits as the depth
HBL slurry pumping system. Before: 43 centrifugal pumps – Now: Only two HSP 3080 solids pumps.The HSP 3080 at work in an underground site
increased. Moreover, their linkage into acascade meant a fivefold dilution ofconcen tration over the distance to thesurface.
To solve this problem Putzmeister plantspecialists decided to use two doublepiston pumps with seat valves (modelHSP 3080 with a 320 kW hydraulic drive.This system brought the followingresults.
Mining / BackfillingInorganic Materials
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Advantages of the system
Increased capacity – 90 m³/h ispumped at a flow rate of 2.7 m/s at apressure of 100 bar
Constant solids concentration Energy requirements are reduced to ¼ The size of the 3 m stroke guarantees
low wear and quiet running The reliable technology increases
availability and considerably reducesmaintenance costs
IP 1318-12 GB 7
Fly Ash / Bottom Ash
Economical fly and bottom ashtransport as high-density slurriesAfter incinerating coal in coal fuelledpower stations, the resulting waste suchas fly ash from the electofilters or thebottom ash from the boiler have to bedisposed of.
The most economic way to convey thesedifferent types of ashes is by usingPutzmeister KOS double-piston pumps.A mixture of fly and bottom ash can besuccesfully transported without opera -tion al disturbances. Since PutzmeisterKOS piston pumps do not have any val-ves between the inlet and outlet of the
Fly ash landfill siteA KOS 25100 pump installation (Kogan Creek, Australia) for fly and bottom ash
Inorganic Materials
KOS HSP
Solutions from asingle sourceIn order to ensure the efficiency in powerstations, Putzmeister offers completesolutions for the conveyance of fly andbottom ash in landfills. The turn-keysupply consist of silos, piston pumps,pipework, including all necessary acces-sories and services.
In order to ensure that its systems can befully integrated in power stations,Putzmeister works closely with the lead -ing suppliers of power station equipmentworldwide. Pumping of fly ash, bed ashand sulphurization gypsum are furtherimportant areas of application forPutzmeister solids pumps in power sta -tion.
pump, even coarse particles can passthrough the pump without interruptingthe flow process.
Another important aspect for usingPutzmeister piston pumps is the lowwater consumption. The pumps operatereliably even high dry solids contents upto 85 %.This translates in an extended lifetime ofthe disposal site and/or its size can bereduced. The main advantage is howeveran ecological one: large amounts of con-taminated water can be reduced to aminimum.
Advantages of the system
High availability Long service life Low maintenance and operating
costs Lower water requirements Service-friendly
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IP 1318-12 GB8
On the Japanese coast line, three huge KOS 25100 and 25200 piston pumps are pumping silt out of the sea for land reclamation. The Nagoya is now located on this new artificial island.
Sludge Removal
Top figures withsolids pumps Outputs up to 450 m³/h Delivery pressures up to 130 bar Conveying distances of more
than 2000 m
Putzmeister solids pumps for economicsolutions without damaging or dirtyingthe road.
System components Solids pumps Mixing devices Vibrating screens Pontons Floats Pipelines Quick-action couplings and fittings
Efficient solutionsfor sludge removaland transportThe sludge is removed by shovel excava-tors and Putzmeister solids pumps.These pumps can operate even withextremely high solids content and thereis no need for dilution with water.
Particular emphasis is placed here onenvironmental friendliness and econo-mic efficiency. Experienced engineerscome up with the right solution tailoredto individual requirements, which is thenimplemented technically. The rated per-formance of the PM solids pumps is ofdecisive importance here.
Inorganic Materials
Sludge handling system operating in a canal in France with an S-tube pump and diesel-driven power pack mounted on a ponton
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IP 1318-12 GB 9
Desludging – Simple and environmentally friendly
60 m3/h effectivedischarge flow
Dump inquarry
Height difference50 m (165 ft)
Pipeline lengthapprox. 1540 m (5000 ft)
Lake 22000 m3 (28380 yd3)
Front endloader
Dam
KOS
Desludging of a tar dump using a remote-controlled Dredgemaster dredge vessel
Mobile dewatering and pumping station
River sludge with high dry solids content has short drying times
Advantages of the system
In practice, solids contents up to 68 % and more have been pumpedwithout the need to add water. Thismeans no flushing- or waste water.
This environmentally-friendly andclean transportation solution meansthat less space is required at thedump site.
Thanks to its gentle conveyance andthe material’s solid consistency, thesludge dries out extremely rapidlyand no dams are therefore required.
Efficient disposal and processing Conveyance of large foreign bodies Quick laying of pipeline systems
Since many components are offered froma single source, we are able to offer effi-cient and environment-friendly solu tions.
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IP 1318-12 GB10
Tunnel Construction
Auger conveyor with two muck pumps of type KOS 1480 (Botlek tunnel, Netherlands)
MPT 40: the compact and powerful muck remo-val pump for extremely small cross-sections
The fact that Putzmeister has masteredthe conveying engineering for high den-sity solids and has gained experiencefrom more than 100 tunnel constructionprojects, makes the company the rightpartner for complete solutions when con-veying muck out of tunnels.
In addition to the comprehensive con-sult ing service offered, machines suchas the drive units, crushing and sortingplants, conveying belts, screens, mixing
troughs, high performance pumps, silosabove ground, etc. are all within the scopeof supply.
Double piston pumps provide a perform -ance of up to 250 m3/h per pump unit.Tunnel machines with up to 14 metersdiameter can be equipped with our high-density solids pumps.
Numerous projects in Asia as well as inEurope (e.g. Botlek Tunnel in the Nether -
lands) demonstrate the strengths of thismethod compared to ground transport bycentrifugal pumps or via conveyor belts.
Pipeline deliverywith high-perform ance piston pumpsAdvantages of the system
Space-saving, e.g. for drivingpipelines in a small tunnel
Clean and safe conveyance ofexcavated muck over long distances
High output Addition of water is rarely or not
necessary at all Simple logistics – no muck cars
needed Operational safety Continuous conveyance is guaran-
teed, even with pressure locks
Inorganic Materials
Clean and safe conveyance of largeamounts of excava-tion residues
“Closed system” muck removal
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IP 1318-12 GB 11
TRIA – continuous annular space filling for tubbing behind the tunnelling machine
Efficient annularspace backfilling for tubbing
Depending on rock properties, con -struct ion method and time frame, differ-ent machines are used in tunnel con-struction for the injection of mortar.Putzmeister’s product portfolio includeseverything from the smallest stand-alonemachine to fill anchor holes, spiralpumps for low pressures, to pistonpumps for pressures up to 100 bar.
In combination with important accesso-ries such as turbo mixers, high pressurevalves, high pressure rotor distributors,special delivery lines, auger conveyors,flow meters, pressure gauges, etc.,plants can be individually arranged forthe most advanced methods.
TRIA, i.e. continuous annular space fil-ling for tubbing, is often used behind thetunnelling machine.
KOV double-pistonpumps for free-flowing materialcontaining up to 70 % solidsInexpensive double-piston pumps withball valves for the economically efficientconveying of fine-grained mortar andlow-consistency slurries containing for-eign bodies up to 20 mm in size.
High performance ranging up to 60 m3/hand 130 bar mean large safety reservesfor the pumping process and allows eco-nomic, clean and safe conveyance bypipeline over several kilometres.
KOS KOV
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Space-saving installation with two KOV 550 Duo underneath a 6m³ agitating trough
A KOV 1050 pumps the injection mortar behind the ring segment
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IP 1318-12 GB12
Oil & Gas Industries
Innovative SystemsPumping with Putzmeister hydraulic dri-ven solids pumps is the most efficientmethod for conveyance of very stiff mate-rial with high viscosity and high share ofcoarse grain over long conveying dis -tances.
The “S-transfer tube” system used in thispump type even allows the pumping ofmaterial with poor liquid content.
If the material has poor flow character-istics a special double auger feeder isused to fill the piston pump type KOS.
Inorganic Materials
Typical OffshoreApplications for the PutzmeisterPumping System Pumping drill cuttings from shaker to
buffer tanks or containers Pumping drill cuttings from buffer
tanks to the supply vessel
Putzmeister high density solidspumps also operate on supplyvessels
On -shore for conveying treated drillcuttings to an environmentally friend-ly storage area and processing plant
Kompact design for applications onoffshore platforms
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Putzmeister KOS high density solids pump with feeding device
IP 1318-12 GB 13
KOS HSP KOV
Hydraulic power pack HA 90 S with(Pressure Constant Flow) forpulsation free transportation
Re-Injection Pumpsthe Perfect Fit HSPOil-hydraulically driven piston pumpwith hydraulically actuated seat valves for treated drill cuttings.
KOVOil-hydraulically driven double pistonpump with ball valves for drip water anddrain liquids.
The Putzmeister delivery program for in -dustrial applications includes also:
Auger feeder units Power packs Delivery pipelines Silos and tanks Silo discharge systems
Advantages of the system
Due to low piston speeds inside the delivery cylinders, the wear isreduced to a minimum
Due to low wear, the maintenancecosts, effort & down times arereduced
Due to low down times, maintenancestaff can be protected from beingexposed to hazardous media
The Putzmeister pump is a well de signed solution, based onPutzmeister’s long experience for different applications, mainly inpumping of abrasive media
The module design allows Putzmeister to find a suitable solution for almost every pumpingtask, for every output rate and highest pressure levels
Putzmeister KOV 1075 – special equipped for the operation on rough sea
On the rig From rig to ship From ship to shore
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IP 1318-12 GB 15
The appropriatepumps for differenttypes of biomassesPutzmeister industrial engineering hasexperience with the conveyance of bio-mass since the end 80’s. The uniquedesign of the pumps enables to conveyvarious types of biomasses, even whencontaining foreign bodies such as knives,spoons, bottle caps or glass, which candramatically disturb the fermentationprocess.
Opposed to other conveying systems, thetreatment of biomass with reduced life-cycle costs is guaranteed when usinghydraulically-driven piston pumps. Fur-ther more, together with the Germanengineering company FinsterwalderUmwelttechnick, Putzmeister also de vel -op ed a process to separate out foreignparticles during the pump process.
A fault-free and and non-stalling con-struction of the pump and feed lines isnecessary when pumping biomass, bio-waste and foodwaste from households,supermarkets, restaurants or other sources. Everything that disturbs theflow can lead to clogging or blockages.
Shredder
Sieve drum
Feeding belt
Piston pump Fermentation tankRecirculationpump
Bio vertilizer
Electric energy
and heat
Feeding screw
Manure or recirculation
Piston pump withmixing screw
Dry-anaerobic fermentation of biomass
Biomasse power plant
Biomass from food remains and wrapped food
Schredder
Piston pump
Single pistonpump EKO
Fermentation tank
Container
Shredder
Heat exchanger
Biomass from animal carcasses
Piston pump withmixing screw
Piston pump
Waste material / inorganic material
Bio vertilizer
Electric energy
and heat
Suspensio
n
KOS 25100 with hydraulic power pack and twin-screw feeding device, transporting biomass
to the fermentation tank
BiomassOrganic Materials
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IP 1318-12 GB16
The alternative option for producing electricity and heat out of biomass
Biowaste recycling plant in Varenne-Jarcy, France: KOS 2180 pumping biomass into a fermentation plant
The KOV twin-cylinder piston pump canconvey liquid and wet material. Due tohaving a large inlet and outlet opening,this pump type can also digest large par-ticles without disturbing the pumpingprocess.
KOV twin-cylinder piston pumpshave been pumping more than100000 hours without any majorinterruptions.
Biogas from waste –for a cleaner environmentIn accordance with EU 1774, using left-over foods as animal food is no longerallowed in Europe. These are now con-verted in electrical energy and heat inbiogas pants.
The KOS twin-cylinder piston pump canpump bulky, wet and pasty material withimportant grain size.
KOS twin-cylinder piston pumpshave been pumping more than160000 hours without any majorinterruptions.
BiomassOrganic Materials
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Green household waste or NaWaRo
IP 1318-12 GB 17
An EKO 1060 PP in a biomethanisation plant (Kössen, Austria) for unwrapping and transporting foodspast expiry date
Remaining packaging and foreign bodiesLeftovers and expired foods before processing Substrate of the biomass after the pressing process of the EKO 1060 PP
Efficiency throughthe separation offoreign particlesDuring the methanisation of biomass(leftover and/or expired foods or otherorganic waste), inert foreign bodies suchas wrappings/packagings, plastic trays,glass, cans, or metal can disturb the bio-gas process since those foreign bodiesreduce the active volume in the fermen-ters.
With the EKO single cylinder pistonpump, in order to improve the fermenta-tion process, it is possible to reliablyseparate foreign bodies before feedingthe organic waste into the fermenter. TheEKO can deal with wet material, as wellas sludges containing large foreignbodies.
EKO single-piston pumps have beenpumping more than 60000 hourswithout any major interruptions.
EKO KOS KOV
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IP 1318-12 GB18
The economical and reliable solution In sewage treatment plants, Putzmeistersolids pumps will help dispose of thethickest types of sludge. Even solids ashigh as 45% are not an issue.
Especially large-scale plants imposestrict requirements when it comes to run-ning a fault-free continuous operation.This is precisely where Putzmeistersolids pumps have proved themselvesworld-wide, proving their economic effi-ciency in the conveyance of mechanical-ly dewatered sewage sludges.
Conveyancethrough a closedpipeline Odourless No environment pollution Space-saving and can be adjusted
to fit the existing structure of thebuildings
High metering accuracy Pipeline is not subject to wear Low-maintenance and low-wear
technology Maximum availability for continuous
unmanned operation Remote supervision from the control
room Stiff, free-flowing and sticky sludges
can be transported
MS 70328
Plate and bed pressDigestion tower
Sliding frame
Receiving bunker
Precompression screw conveyor
EKO
KOS
Intermediate dumps
Centrifuge
Extractionscrew
Hopper
Mill
Refusepit
Boiler plant
Combustion chamer ash
KOS
Screenings ThickenerSand trap
Belt filter press
KOS
Storagesilo
Storagesilo
Sliding frame
Extraction screw
ConditioningDrying
Compostingdrum
Cement kiln
Incineration
Land fillSludge incineration
Leaders in pump and silo technology The most-favoured features ofPutzmeister piston pumps:
Robust design Flow-optimised suction
characteristics Continuously filled, circular suction
cross section in the S-transfer tube High volumetric efficiency for the
delivery cylinders Long piston strokes
Advantages of the system
Low life-cycle costs High operational reliability Extremely quiet in operation Can even handle the stiffest sludges
Flow chart of a sewage treatment plant application
Sewage Treatment PlantsOrganic Materials
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IP 1318-12 GB 19
Sewage sludge reception station consisting of reception and storage silos: Incineration of foreign sludge at the main wastewater treatment plant of Stuttgart-Mühlhausen
ScreeningsPumping screenings (Coney Island, New York)
KOS 1050 solids pumps in the ProRheno sewage treatment plant in Basel, Switzerland
Sewage sludge dewatered by a chamber filter press: Solids content > 35% DS
To improve the efficiency, it is possibleextend the Putzmeister piston pumpswith a feeding device which is equippedwith self-cleaning augers and supportsthe optimal filling of the delivery cylin-ders.
Putzmeister’s silotechnologyThe silo technology with sliding framehas been especially developed for dewa-tered sewage sludge. The silo can take upto 1000 m³ sludge and reliably feeds it tothe pumps.
From the various pump models to silosand the corresponding fittings and acces-sories, Putzmeister can provide completesolutions for conveyance tasks in waste-water treatment plants.
EKO KOS HSP
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IP 1318-12 GB20
Co-Incineration
Flow chart: Co-incineration of sewage sludge in a coal fired power plant
Flow chart: Sewage sludge co-incineration in household incineration plant
Receiving building
Sludge receiving silo
KOS
Coal bunker
Receiver container
Coalpulverisers
Boiler
Boiler 4
to boilers3-2-1
Co-incineration of sewage sludge in the coal-fuelled power plant of Zolling (Germany): KOS 2180
Two KOS 1030 with HA 22 for feeding sewage sludge into the refuse incinerator (Dinan, France)
Organic Materials
Energy out of sewage sludge andhousehold waste The disposal of dehydrated sewage sludgein household waste incineration plants isnowadays a very environmental-friendlyand economical procedure.
This process can be integrated in newlyplanned plants, as well as retrofitted inolder plants. The addition of sewagesludge does not affect the reception ofhousehold waste or the discharge andmetering of rubbish into the the combus-tion chambers. Besides the fact that bothmaterials are burnt together, there is nocommon interface between both disposallines.
Putzmeister offers complete turn-key so-lutions for storage, transport and feed ingof refuse in the combustion chambers.
Efficient coal-fuelled power plants The co-incineration of mechanicallydewatered sewage sludge in existingcoal-fuelled power stations with highlyeffective flue gas pollution control is alsoan economic and meaningful alternativethat do pose a threat to the environmentcompared to the previous disposalmethods.
Sludgeacceptance
KOS KOS
Sludgestorage
Refuse bunker Combustion
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IP 1318-12 GB 21
Erzo Oftringen sewage treatment plant (Switzerland): rotary kiln for the incineration of sewage sludge
Flow chart: Reception of foreign sludge and handling one’s own sludge in a swage treatment plant
Two 200 m³ storage silos for sewage sludge storage (Pro Rheno, Switzerland)
KOS
Well-thought-outplanning process of external sludgereceptionRecycling the amounts of received sew agesludge from municipal and industrialplants has become an important issue forsewage treatment companies.
Due to political framework conditions(prohibition of dumping sewage sludge,limitations placed on agricultural use,etc.), the choice of a thermal incinerationto dispose of sewage sludge has becomeinevitable.
To ensure that the multiple hearth fur-naces are used to their full capacity, notonly one’s own only sewage sludge canbe handled but also external sludge fromsurrounding waste-water treatment plantscan be receptioned and treated.
Reception bin
Precompressionscrew conveyor
KOS
KOS
Sliding frame
Slidingframe
Sliding frame
Extractionscrew
Screw conveyors
4 x KOS
4 x centrifuge
4 x precompression screw conveyor4 x agitator container
Storagesilo
Putzmeister Solid Pumps offers com -plete sludge handling systems for suchpurposes.
A special advantage of the KOS S-tube pump without valves
Foreign bodies contained in thesludge can be conveyed withoutinterference thanks to the largecross-section opening of the S-tubepump.
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IP 1318-12 GB22
Coal Sludge
Pressurized fluidized-bed incineration – The clean coal technologyThis technology distinguishes itself byits environmental-friendliness and ahigh er degree of efficiency compared toconventional coal-burning processes.
Putzmeister is making a major con tri -bution towards clean power sta tions.Putzmeister KOS pumps feed fuel, inform of a coal-limestone-water mix ture,into the fluidized bed.Depending on the material’s granularstructure, solids content of over 85% arepumpable. The pumps offer a reliable,maintenance-free and continuous modeof operation.
Complete system:from the receptionsilo to the injectionslances into the boiler
Case study:
The installed Putzmeister pumps in thecommercial power plant of Värtan,Stockholm have been running fault-freeand that during the heating period, whichlasts 6500 hours after all in Sweden.
Coal injection with pressurized fluidized-bed combuster. The flow chart shows a combined gas and steam turbine process with pressurized fluidized-bed combustion. (ABB Carbon)
Coal Limestone
Water
Pre-mixer
Ready-mixer
Hydraulicdrive
Economizer
Heat condenser
District heating
Steam turbineGas turbine
Steam
Flue gas
Pressurized combuster
AshFluidized-bed
KOS
HMCS
4 - 20 bar
Air
Compensator
Gate valve
KOS 2180 coal transportation pump for long-distance coal delivery
Coal sludge reception system in a power plant KOS 1070 coal sludge injection pump
Organic Materials
KOS
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IP 1318-12 GB 23
Cement IndustrieOrganic Materials
The volume to be fed into the cement kilnare approx. between 2 and 7 m³/h. In thiscase, Putzmeister high density solidspumps of the KOS series are used.
Co-incineration of alternative fuels in the cement plant of Lafarge in Le Teil, France
The use of substitute fuels forthe production ofcement Substitute fuels offer cost-saving oppor-tunities for energy-intensive industries.With the example of the cement industry,Putzmeister Solid Pumps offers solu-tions comprised of silos and pumps thatsupport the reception and conveyance ofalternative fuels for the production ofcement.
Alternative fuels have to have a highcalorific value in order to be worthy sub-stitute to primary energies. Possiblefuels for such purposes are:
Mechanically dewatered sewagesludge
Tar Paint sludge Slaughterhouse waste
These fuels are receptioned in silos, either individually or mixed together. ThePutzmeister high density solids pumpsthen convey there substitute fuels, eitherto the cold side of the rotary kiln as additives or source of energy; or to thehot side as fuels.
It does not matter wether there are foreign bodies in the material since thePutzmeister S-tube technology is able toconvey those even if they represent 2/3of the size of the pipeline diameter.
However, these alternative fuels have tobe processed before they are pumped,meaning that they have to be madepumpable beforehand.
Paint sludgeSludge from cooling-water treatment
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IP 1318-12 GB24
Cement IndustrieOrganic Materials
KOS HSP
Three types of stations for an efficient sludge-handling systemType 1
The receiving station consists of highdensity solids pumps with a precom-pression screw conveyor and a built-inattachable hopper handling volumes be-tween 6 and 10 m³. The pump is fed witha front-wheel loader.
Type 2
In this option, the attachable hopper isreplaced by a receiving silo with a volu-me of approx. 100 m³.
Different sludges can be receptioned andmixed together by the pump’s rotationfunction.
Type 3
Different alternative fuels can be recep-tioned in one or multiple receiving bun-kers. High density solids pumps thenconvey the material to a 250 m³ storagesilo. Hence, the receiving bunker is readyfor new deliveries of sludge.
In a voluminous storage silo, the substi-tute fuels mix well together, thus guaran-teeing a high calorific value.
Type 1
Ultrasonic sensor
Front wheel loader
Hydraulicpower unit
Installed performanceapprox. 75 kW
Twin screw feeding device, hydr. driven
KOS piston pumpS-tube type;delivery output: 3 – 6 m3/h
Foreign body separator
Polymer injection system
to the cement kiln
Delivery lineDN 150, PN 64
Type 2
Delivery line DN 150, PN 64 to the
cement kiln
Foreign body separatorPolymer injection system
Hydraulicpower unit
Installed performanceapprox. 75 kW
KOS piston pumpS-tube type;delivery output:: 3 – 6 m3/h
Ultrasonic sensor
Silo volume approx. 100 m3
Silo discharge screw,hydr. driven
Gate valve,manually operated
Sliding frame,hydr. driven
Silo, rectangular design
Type 3
Ultrasonic sensor
Silo volume approx. 2 – 3 truck loads
Silo discharge screw, hydr. driven
Gate valve,manually operated
Delivery line,DN 200, PN 64
Hydraulikpower unit
KOS piston pumpS-tube type;delivery output:30 – 40 m3/h
Sliding frame,hydr. driven
Hydraulic power unit
Sliding frame,hydr. driven
Silo, rectangular design
Foreign bodyseparator Installierte
Leistung ca. 55 kWPolymer injection system
to thecement kiln
KOS piston pumpS-tube type;delivery output: 3 – 6 m3/h
Delivery lineDN 150, PN 64
Ultrasonic sensor
Silo volume approx. 2 – 3 days operation
Silo discharge screw,hydr. driven
Silo,round design
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IP 1318-12 GB 25
Special Waste
Washingapparatus
Mixers
EKO 14100
KTO elevator
Sludge lance
Ash Fly ash
FlueRotary kiln
Oil liquids
N2 lock
EKO 14100 feeding the rotary kiln with shredded barrel waste in a hazardous waste treatment plant
Coarse hazardous waste from the reception bunkers is fed via claw arm to the EKO pistonpump
Flow chart: Incineration plant for hazardous waste
Optimal hazardouswaste treatmentwith specialPutzmeister pumpsWhen conveying hazardous waste, it isimportant that none of these dangeroussubstances get into the environment.Health risks have also to be avoided onthe premises of the plant.
This can only be guaranteed whenconvey ing through a closed pipeworksys tem. Special requirements made bythe legislators, such as ATEX and explo-sion protection are implemented in thePutzmeister systems.
Optimized incineration for abetter environmentThrough a controlled pump feeding, it ispossible to monitor the incineration pro-cess of the substances in order to respectthe echast gas premissible values.
Organic Materials
EKO KOS KOV
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IP 1318-12 GB 27
Oil-hydraulicdouble-pistonpump with S-transfer tubeIn the KOS series, the intake and deliverycylinders are connected by an S-transfertube. This enables a continuous free-flowing conveyance of the material with-out the use of valves. Foreign bodies upto 2/3 of the size of the discharge outletcan be conveyed without any issue.
The KOS pump is particularly suitable forconveying highly viscous sludges andother material with a high proportion ofcoarse solids. The main fields of applica-tion of the KOS are with materials whichpresent the most extreme requirements,such as dewatered sludges containingsolids, oil sludges, high-viscosity solidsand so on.
For extreme applications, a wide range oftask-specific components and functionsare available from Putzmeister.
The pump’s simple design and the fewwear parts offers a very robust, low-maintenance pump with low-operatingcosts.
KOS
For conveying coarse sludges orslurries with a high grain-size content
Low maintenance and wear due tofewer moving parts
Less suction resistance thanks to larger inlet permitting constant free-flow of the material
For further information please refer to our IP 1082 GB brochure
Features and advantages
Performance chart
The hydraulic circuit of the S-tubedoes not come in contact with thematerial being pumped
Delivery rates up to 450 m3/h Delivery pressures up to 150 bar
Products – Pump Technology
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IP 1318-12 GB28
Oil-hydraulic piston pump with seat-valvesThe seat-valve pump is used for heavytasks.
The HSP series is used with paste-likeand highly viscous material with a lowcontent of foreign bodies and small par-ticle sizes (< 15 mm).
Precise sealing of the valves means thatextremely high pumping pressures canbe achieved. The principle behind thedesign of the hydraulic and pumpingpistons is the same as in the PutzmeisterKOS and KOV series. This ensures maxi-mum reliability and availability.
Two special features of the Putzmeisterdesign are that not only is it a simplematter to replace the valves but thedesign also means a long service life forall wearing parts. Valves and valve seat -ings are made of highly wear-resistantsteels and can be used at either end. Thisdoubles their service life. Valves can beeasily replaced easily without dismant-ling the delivery lines.
All of the familiar Putzmeister optionsand variations are available with the HSPseries as well.
A pulsation-free conveyance can beachieved wth the system (PressureConstant Flow)
For conveying fine-grained sludgesor slurries
Switch-over without shorting No backflow at high pressures Easy installation of damping tanks
More effective with materialcontaining a high proportion of air
Outputs up to 350 m3/h Delivery pressures up to 160 bar
For further information please refer to our IP 1971 GB brochure
HSP
Performance chart
Features and advantages
Products – Pump Technology
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IP 1318-12 GB 29
Oil-hydraulic piston pump withball valvesThe KOV series is characterized by itsstraightforward design and high reliabili-ty. The suction and delivery cylinders areconnected by indirectly operated balls.
No elements are actively operated, whichmakes it an inexpensive pump with maxi -mum availability. There are no issues orcomplications when pumping paste-likematerial such as mortar or bentonite,even when they contain foreign bodiesup to 10 mm in size. Pumping pressuresup to 90 bar and an output of as much as60 m3/h apply.
Depending on the specific individualcase, the balls and seat valves can besupplied in different materials and coa-tings. A maintenance aperture allows aneasy and rapid replacement of the ballvalves.
For conveying fine-grained pastes Simple design A minimum of moving parts Very easy to maintain
Outputs up to 60 m3/h Delivery pressures up to 90 bar
For further information please refer to our IP 1027 GB brochure
Features and advantages
KOV
Performance chart
Products – Pump Technology
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IP 1318-12 GB30
For conveying large-sized and coarseforeign bodies
For conveying extremely stiff material Crown version – pumping and
cutting in one stroke Simple design
Delivery pressures up to 60 bar Cutting force up to 80 t Outputs up to 14 m3/h
The oil-hydraulicsingle-piston pumpThe EKO series is designed for the mostextreme pumping tasks. The open hoppersof allow extremely dry material con -taining a high proportion of foreignbodies to be fed to the pump. Materialswhich were unpumpable until now, suchas highly dewatered paper sludges, arethrust by the hydraulically driven pistoninto the delivery line.
The EKO Crown model is equipped witha delivery piston with a hardened toothedcutting crown. This pump is used whenthe material contains large-sized foreignbodies, which would swiftly result inblockages in other systems. The EKOpumps and cuts in one single operation.The most difficult materials, such assewage treatment plant screenings orshredded barrel waste in special wasteincineration plants, can be pumped with-out issue into the delivery line.
A quasi-continuous operation is alsopossible with the double EKO version.
For further information please refer to our IP 2253 GB brochure
EKO
Features and advantages
Products – Pump Technology
Alternative gate valves with the patented blade valve – especially suitable for materialssuch as screenings for example
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The heart of everypiston pumpThese power packs have proved theireffectiveness more than 10000 timeswith concrete pumps and now theypower up industrial pumps that conveythe material.
They drive the following:
High density solids pumps of typeKOS, HSP, KOV, EKO
Screw conveyors of type THS, SHS Silo sliding-frame of type PDL, PDF,
PDS-L, PDS-F Accessories such as gate valve or
silo-lid, etc.
Performance classes from 5,5 kW up to800 kW and more are available.
Efficiency of thehydraulic systemdesignDepending on the quantity of oil needed,an open or closed oil-circuit can beused. The closed oil-circuit is used whenreaching delivery capacities of 100 m³/hand above, which means considerablecost-savings.
The oil-circuits are designed for hydrau-lic pressures of up to 250 bar. Thisequals delivery capacities of up to 160bar.
Equipment Oil/Air cooler Oil/Water cooler Oil pan Diesel engine Sound insulation
Features andadvantages
Power Pack Units
The power of the hydraulic gives thedelivery cylinder the necessary pressure to pump the material intothe delivery line.
In every speed range, the screw drivecan apply its maximum torque on theconveyed medium.
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IP 1318-12 GB32
Silo-Technology
Storage silo discharging directly into a pump
Storage silo with truck loading
Receiving bunker with rectangular sliding frames and pump feeding
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IP 1318-12 GB 33
Ladder systems /discharge systemsfor round siloDepending on your application, the slid -ing frame can take the form of a laddersystem (PDL) or a cylindrical silo dis -charge system (PDF). The ladder systemwith multiple parallel sliding frames in isparticularly suitable for wide or long re -cei ving bunkers. This ensures an effi-cient transmission of force and in creasesthe availability of the system thanks tothe redundancy.
The delivery range includes silos andbunkers from 10 m3 to 1000 m3 for load-ing trucks and for feeding sludges tosolids pumps and their onward con-veyance.
Material is discharged from the silos bymeans of specially adapted screw con-veyors, with a lateral or central dis -charge. If several end users have to besupplied, multiple discharge augers canbe used.
Common parts are used for pumpand silo, which means fewer spareparts and simplifies maintenance.
No interface clarification necessary,the customer does not have to dealwith sub-suppliers.
Sliding framesystems – tried and testednumerous times,highly reliableThe Putzmeister sliding frame systemhas been designed especially to meet therequirements of harsh three-shift opera-tion. Thanks to modern finite elementanalysis, proven Putzmeister hydrauliccomponents optimize the sliding frame’sdesign, as well as its service life. Onemajor feature is the space-saving designemplacement of the sliding frame’spiston rod which is located on the silofloor. The piston seal used in the high-pressure pumps reliably prevents anysludge leakage.
Pump and silo working in perfectharmonyPutzmeister silos have been designedespecially for highly dewatered andhigh ly viscous sludges.
Since the pump and silo come from thesame manufacturer, the customer enjoysimportant benefits:
The shared silo discharge and pumpfeeding auger reduces costs andincreases availability.
The perfect tuning between pumpand silo leads to an overall optimizedconcept.
PDL rectangular discharge sliding frame
Intermediate silo with double rectangular sliding frames for charging five Putzmeistersolids pumps
Finite element analysis for the sliding frame
Silos, Sliding Frames, Discharge AugersSilo Technology
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Accessories
HCBLCB
LIB
LCBLCB
LIB Low Inline BoosterHCB High Cross BoosterLCB Low Cross Booster
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IP 1318-12 GB 35
Optimal fillingthrough screw conveyorsHighly-viscous sludges have to be fed tothe pump if they cannot flow by them -selves into the pump. This task is bestresolved with twin-screw augers. The latter will generate a pressure in order tobetter fill the pump with the material to beconveyed.
A fur ther positive effect is that the twin-screw augers are self-cleaning since theyare meshingly inter-connected.
They are driven hydraulically.
Foreign body separators enable a continuous flowof materialPutzmeister’s FKA 200 is successfullyused with the conveyance of sludgescontaining foreign bodies. This systemsprotects downstream machines fromdisturbing materials. Thus, when incine-rating sewage sludge in coal-fired powerplants, disturbances can be avoided inthe downstream operating coal mills.
Advantages of the system
In every speed range, the screw conveyor’s drive can exert its maximum torque on the material to be conveyed
Twin-screw auger feeding device with mixing paddles in the supply chute
Twin-screw conveyor SHS 3262 SH
Retained foreign bodies Foreign body separator in a power plant
In the direction of the flow, the foreignbodies will be caught by a grid.
The foreign body separator is equippedwith a quick-release fastener which canbe opened through a single-lever ope-
ration. The quick-release fastener systemensures additional safety during the cleaning operation of the Foreign bodyseparator.
Screw conveyors, foreign body separatorAccessories
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IP 1318-12 GB36
Secure deliverylines in tunnellingand miningDelivery lines for underground con -struct ion cites must be easy to lay, safeand high-pressure resistant.
The Putzmeister Zentrifix® ideally meetsthese requirements. The rigid and abso-lutely leak-proof connections act just likehydraulic connections since the seal istightly pressed into its seat during theassembly. The large wall thickness withthe ZX lines additionally offer a high wearreserve.ZX delivery lines are used for backfilling,mine dewatering and for transportingconcrete over long distances.
Further underground tasks are shot-creting, as well as injection works. Here,The SK quick-action coupling system, aswell as the Ultraflex® PX system areused.
Delivery lines inindustry – a cleanbusinessDelivery lines in industry must especiallybe safe over a long period of operation.The pressure resistance with pulsatingload is one particular criteria when de -signing the delivery line. The Zentrifix®
system was modified for this operationalpurpose. The so-called ZX-IP lines haveproved themselves worthy for abrasiveand non-abrasive materials. ZX-IP linesare used in sewage treatment works, incoal-fired power plants, waters desludg-ing, in mining and other numerous spe-cial applications.
Depending on the application, thedesign, material and the surface treat-ment can be modified in order to be ideally adapted to the pump and materialto be conveyed.
Flexible throughgate or diversionvalves Gate and diversion valves are essentialwhen multiple delivery lines have to beinstalled. Thus, the material located inthe pipeline after the pump can be diver-ted through a gate valve to other routessuch as a thermal dryer or intermediatestorage.
Gate valves are hydraulically operated.For a faster switch, it is suggested to usea power pack of at least 7,5 kW. The valvehousing is sealed with hardened sealingrings, that are pressed against themoving blade of the valve.
Delivery LinesAccessories
Safe laying of horizontal delivery lines with Zentrifix®
Gate valves for there different delivery linesTunnel concreting with flexible SK pipelines as expansion pipes
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IP 1318-12 GB 37
Reliable and continuous flow ofmaterial thanks toinjection systemsSometimes, for hard-flowing materials,unfavourable material consistency, highinstallations, long conveying distances,there is the need for delivery pressuresthat are higher than what high densitysolids pumps can deliver. High deliverypressures can be reduced through injec-tion and thus an economic conveyanceof specific materials can be guaranteed.
A lubricating film, reducing the deliverypressure, is created when injecting water,oil or lubricant in the delivery line.
A small amount of liquid or lubricant isequally injected via a nozzle ring on theinner-surface of the delivery line. Aboundary layer injection unit with dosingpump is needed for a continuous andautomatic injection of the lubricant.The lubricant dosing pump sucks themixture of high-molecular polymer andwater from a tank and, independentlyfrom the pump’s delivery pressure, in-jects it in the delivery line. The amount oflubricant is reduced or increased accord-ing to the changing delivery pressure ofthe pump which is in turn optimized.
With special lubricants, it is possible toreduce the pressure in the delivery lineby up to 2 % of the initial value.Lubricant amounts between 0,1 and 1 %of the pump’s delivery pressure are injec-ted. However, the lubricant has to bediluted with water to a 1 : 50 ratio.
Injection SystemsAccessories
0
1,2
1,0
0,8
0,6
0,4
0,2
02 4 6 8 10 12 14
Injection site of the lubricant
Boundary layer injection
The injection of water or lubricants significantly reduces the pressure loss in the delivery lineExample: Sewage sludge with 37% and up to47% dry solids content.
Pressure drop p f
[bar/m
]
Flow rate [m3/h]
without injection
water injection (64 l/h)
flocculant(128 l/h)
lubricant(128 l/h)
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IP 1318-12 GB38
Service
Supply of turnkey systems Increased safety and efficiency through modern design processes
Transparency and adherence to deadlines in project management
High quality in production and assembly
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Systems engineering from asingle sourcePutzmeister supplies complete systemsfor the transportation and storage ofsludges and solids. The scope of servicesincludes the planning and engineering ofconveying tasks, consultation servicesregarding the transportation’s processengineering, the supply of pumps, silos,bunkers as well as pipes and fittings,installation and commissioning at custo-mer site and also complete services afterhandover of the system.
Competence andeffectiveness at allstages of the projectModern automation and visualizationsystems are used for controlling theplant unit. These systems control andmonitor the plant from the reception ofthe sludge in the pump up to the me-tering of the sludge into the incinerationfurnace or the final place of use.
Finite elements are used in our designcalculations and state-of-the-art CADsystems for realizing and implementingthe designs. This ensures an effectiveand high-quality solution.
Knowledge TransferWe offer plant-related in-house trainingsas well as on-site seminars.
Experienced projectmanagers processthe contracts onschedule an in atransparent mannerThanks to professional and comprehen-sive documentation, system operatorscan count on a simple operation of theplant and easy trouble-shooting.
ServiceA major factor of Putzmeister’s servicesis an efficient and powerful sales man-age ment. In addition to a telephone hot-line, we supply parts on short notice andalso carry out maintenance works as partof a maintenance contract.
Plant delivery froma general contractorAdvantages of the system
Highest level functional reliability Less time spent with order proces-
sing and interface co-ordination Perfect harmony between all
functional units Less spare parts and storage require-
ments due to the use of versatilecommon parts in the systemcomponents
Simplified servicing and maintenancethanks to standardized control andmaintenance elements
Clear assignment of responsibilitiesmeans rapid solutions to problems inthe event of a malfunction
Technical training at customer premises Rapid response assistance from Putzmeister’s after-sales service
Range of ServicesService
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IP 1318-12 GB
Member of the Putzmeister Group www.pmSolid.com
Putzmeister Solid Pumps GmbHMax-Eyth-Straße 10 · 72631 Aichtal /GermanyP.O.Box 2152 · 72629 Aichtal /GermanyTel. +49 7127 599 500 · Fax +49 7127 599 [email protected] · www.putzmeister-solid-pumps.com
Right to make technical amendments reserved© by Putzmeister Solid Pumps GmbH 2011 All rights reserved Printed in Germany (31106Sc)
Putzmeister is a dynamic company withthe most modern assembly and manu-facturing plants. At the main plant in Aichtal nearStuttgart, the specialists of PutzmeisterSolid Pumps GmbH (PSP) prepare suc-cessful tailor-made system solutions forsolids transportation problems for cus-tom ers throughout the world.
Numerous subsidiary companies world-wide means Putzmeister can offer a highdegree of closeness to the customer.