Tag Archive for: corrosive

,

Leach Feed and Tank Transfer Between Stages

What it is:
Leaching dissolves valuable metals using chemical solutions in a series of tanks. Reliable transfer between stages ensures consistent residence time and extraction efficiency.

Challenges:
Leach solutions are corrosive and often contain suspended solids that can cause erosion and chemical attack. Pump failures disrupt recovery and increase reagent costs.

Solution:
Hevvy/Toyo pumps in stainless or elastomer-lined materials resist corrosion and abrasion, maintaining steady flow between leach tanks. Their recessed impellers handle solids without plugging, ensuring uninterrupted leaching performance.

Digester Cleanout

Digesters are vital to wastewater treatment, converting organic waste into biogas and biosolids. Over time, dense grit, rags, and inert solids accumulate at the bottom, reducing capacity and efficiency. Periodic cleanouts are required to restore volume and performance.

Challenges:
Digester sludge is thick, corrosive, and often contains stringy or fibrous material that clogs conventional pumps. Cleaning operations are complex and must be completed quickly to minimize downtime. The combination of gas buildup, solids stratification, and confined-space conditions makes reliability and solids-handling ability critical.

Solution:
Hevvy/Toyo pumps provide safe and efficient digester cleanout with powerful agitation to break up settled sludge. Their robust wet-end design and open or recessed impellers pass fibrous material without clogging. Built with corrosion-resistant alloys and heavy-duty seals, they deliver dependable performance under the toughest anaerobic conditions — reducing labor and downtime.

Hog Waste Lagoons

Hog waste lagoons store liquid manure and wastewater from livestock operations before treatment or land application. These lagoons contain a thick slurry of solids, fats, and organic matter that must be agitated and transferred regularly to prevent buildup and environmental hazards.

Challenges:
Hog waste is dense, corrosive, and prone to stratification, forming thick sludge layers at the bottom that are difficult to mobilize. Gas generation and solids accumulation can lead to odor, safety, and compliance issues. Pumps must operate reliably in abrasive, corrosive, and biologically active conditions.

Solution:
Hevvy/Toyo’s heavy-duty agitator pumps are ideal for lagoon agitation and transfer. Their high-chrome wet ends, mechanical seal protection, and robust motors handle corrosive, high-solid waste with ease. The powerful agitator keeps sludge suspended for full lagoon turnover, enabling efficient pumping and reducing the need for manual or mechanical dredging.

Black Liquor

Black liquor is a by-product of the kraft pulping process, containing lignin, chemicals, and dissolved wood materials. It is a highly alkaline, viscous fluid that is concentrated and burned in recovery boilers to reclaim energy and chemicals for reuse in the mill.

Challenges:
Black liquor is both corrosive and sticky, with high viscosity that increases as it cools. It can cause scaling, crystallization, and deposits that clog standard pumps and piping. The chemical composition also leads to corrosion and mechanical seal wear, making reliability difficult to maintain in high-temperature service.

Solution:
Hevvy/Toyo’s pumps for black liquor service feature corrosion-resistant alloys, mechanical seal protection, and high-temperature capability. Their open and recessed impellers handle viscous fluids without clogging, and optional heating jackets or material upgrades ensure steady, reliable operation. These features extend equipment life and reduce unplanned maintenance in harsh liquor handling circuits.

TPA Production

Purified terephthalic acid (TPA) is produced by oxidizing paraxylene with air in an acetic acid medium — a critical step in manufacturing PET plastics and polyester fibers. The process generates hot, corrosive, and particle-laden slurries that must be transferred between reactors, crystallizers, and filtration units.

Challenges:
TPA slurries are chemically aggressive, hot, and contain fine solids that can crystallize and cause blockages. Pumps in this service face severe corrosion, erosion, and seal degradation from the combination of heat, acids, and abrasive particulates. Consistent, leak-free operation is crucial to prevent contamination or safety risks.

 Solution:
Hevvy/Toyo offers corrosion- and temperature-resistant pumps designed for the oxidative and acidic environment of TPA production. Using stainless, duplex, or special alloy materials, these pumps deliver durability and reliability in harsh chemical service. Their recessed impellers minimize crystal buildup, while seal protection and modular construction simplify maintenance and extend service life.

Wet Scrubbers

Wet scrubbers remove particulates and gases from steel plant exhaust systems by washing them with water or chemical solutions. The collected slurry, containing dust, metal oxides, and chemical residues, settles in sumps or collection tanks that must be regularly emptied to maintain scrubber performance.

Challenges:
Scrubber slurries are abrasive, corrosive, and often have high solids concentrations that lead to rapid erosion of impellers and volutes. Chemical additives can attack seals and metallic components, while variable slurry densities challenge consistent pumping.

Solution:
Hevvy/Toyo’s corrosion- and abrasion-resistant pumps handle aggressive scrubber slurry with ease. Available in high-chrome, stainless steel, or elastomer-lined configurations, they resist both chemical and mechanical attack. Their recessed impeller and agitator systems ensure consistent flow and minimal downtime, making them ideal for continuous scrubber sump operation.

Coke Ovens

Coke ovens convert coal into coke, a critical fuel and reducing agent in steelmaking. The process produces large volumes of wastewater laden with tar, oils, and suspended solids that collect in sumps and require removal or recirculation for treatment.

Challenges:
Coke oven wastewater is highly contaminated with viscous hydrocarbons, fine solids, and corrosive chemicals. Conventional pumps struggle with sticky residues that cause blockages, seal failures, and motor overloads. High temperature and chemical content further accelerate corrosion and wear.

Solution:
Hevvy/Toyo’s heavy-duty submersible and cantilever pumps excel in handling viscous, contaminated fluids. Their open impellers, optional elastomer linings, and agitator technology prevent buildup and maintain smooth flow. With corrosion-resistant materials and mechanical seal protection, these pumps offer reliable operation in the harsh, hot, and chemical-laden environment of coke oven systems.

FGD Washdown Sumps

Flue Gas Desulfurization (FGD) systems scrub sulfur dioxide from exhaust gases in coal-fired plants. Washdown sumps collect slurry containing lime, gypsum, and residual solids from these systems. Efficient sump pumping is essential to maintain clean, safe, and compliant operations.

Challenges:
FGD slurries are chemically aggressive and highly abrasive, causing corrosion and erosion in conventional pump materials. pH fluctuations and dense solids often lead to clogging and seal damage. Downtime for cleaning or repair directly impacts environmental compliance and plant uptime.

Solution:
Hevvy/Toyo pumps designed for FGD service use corrosion- and abrasion-resistant alloys and elastomers. Their recessed impellers minimize contact with solids, and agitators keep materials in suspension for complete sump cleaning. The result is reliable, chemical-resistant performance that maintains sump integrity and minimizes manual intervention.

Subsea Drilling

Subsea drilling involves extracting oil and gas from beneath the ocean floor, often at great depths. Pumping systems are vital for managing drilling fluids, cuttings, and seawater mixtures under high pressure and variable flow conditions.

Challenges:
Subsea environments expose equipment to immense pressure, corrosion from saltwater, and abrasive drilling muds. Pumps must operate reliably in remote, difficult-to-access locations where failures are costly and repairs require specialized intervention.

Solution:
Hevvy/Toyo offers rugged, corrosion-resistant submersible pumps engineered for deepwater and offshore use. Constructed from marine-grade alloys and sealed for subsea conditions, they handle abrasive muds and solids with ease. Their proven hydraulic efficiency and long-life components reduce intervention frequency, ensuring dependable operation in mission-critical drilling systems.