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Feature Report

Mechanical Pumps for


Vacuum Processing
Phil Vibert
Tuthill Vacuum & Blower Systems Liquid ring and dry pumps are best-suited for
ike water, power, and compressed applications in the chemical process industries
L air, vacuum is a standard utility
in many chemical process plants.
Commonly used, for instance, to
remove gases or vapors that other-
wise would interfere with a reaction,
modate larger pumping capacities.
The main building block for any
vacuum system is a primary-stage or
• Process various solvent vapors with-
out harm
• Avoid pollution of the process and
vacuum enhances reaction efficiency atmospheric-stage vacuum pump, the environment
and yield and the recovery of essen- which exhausts directly to the atmos- • Keep waste generation to a mini-
tial compounds. phere. Primary pumping devices are mum
Under vacuum, the boiling point of categorized based on the method by • Resist corrosion
liquids is reduced, which is useful for which they pump gas: • Handle flammable gases or vapors
the processing of temperature-sensi- • Mechanically trap gas and transport • Ingest some liquid without harm
tive materials and the separation of it from suction to discharge. Positive-
liquids. Heat transfer through liquids displacement pumps are the best ex- Oil-sealed pumps
is more efficient without the presence ample of this method of operation Of the primary positive-displacement
of air bubbles, while solid end-prod- • Transfer momentum through a mo- pumps, oil-sealed rotary piston and
ucts produced under vacuum from a tive fluid. Steam or vapor ejectors vane pumps are most similar in range
liquid phase are more homogeneous, and air ejectors employ this method in terms of pumping capacity and ulti-
and are virtually free of voids caused of operation mate pressures (vacuum levels). Both
by unwanted gas bubbles. Also, ag- • Capture gas on extended surfaces rely on oil for three main functions:
gressive compounds that must be con- using porous media at cryogenic • Sealing the internal clearances be-
tained can be better and more safely temperatures. Sorption pumps tween rotary components and hous-
handled and transferred using vac- work on this principle ing to reduce gas slippage
uum. In particular, vacuum is used to: The first two categories are most • Transferring the heat of gas com-
• Remove air and its constituents, widely used the chemical process in- pression
such as oxygen and water vapor, dustries (CPI). Steam ejectors, long • Lubricating the rotary internals
which, if they are combined with a considered the workhorses of vacuum This dependency upon the oil for in-
process constituent, could alter a processing, are easy to use and oper- ternal lubrication is a limiting factor
chemical reaction ate (CE, March 1999, pp. 96–100). in the use of these type pumps in the
• Remove excess reactants or un- However, concerns about energy con- CPI. The integrity of the oil must be
wanted byproducts that can com- sumption and environmental pollu- maintained to avoid internal damage
promise efficiency and yield tion associated with them have slowed that could cause contaminant buildup.
• Reduce the boiling point for distilla- the demand for these types of pumps. Particulates in the oil must be filtered
tion of mixtures Preferable for a growing number of out ahead of the pump, and water or
• Dry solute material by removing the applications are hybrid systems that solvent vapors must be either knocked
solvent incorporate a steam-ejector stage out ahead of the pump by precon-
• Create a pressure differential for backed by a mechanical pump stage — densers, or prevented from condens-
initiating transport of material for instance, a steam ejector stage/in- ing within the pump by gas ballasting
from one section to another or terstage condenser/liquid-ring pump (air stripping) or oil distillation.
through filtration media stage, all in series — or systems con- Rotary piston. The rotary piston
Vacuum is generated by vacuum sisting entirely of mechanical pumps. pump is extremely robust and stands
pumps. The spectrum of vacuum up well to adverse process conditions.
pumps is large, and it can include PUMP MECHANICS Typically constructed of cast iron, this
multiple stages of pumps in combina- AND OPERATION pump has four basic rotary compo-
tion to provide systems that either A pump used in CPI applications nents: a shaft, eccentric cam, piston,
operate at lower pressures or accom- should have the capability to: and slide pin. The cam is eccentrically

44 CHEMICAL ENGINEERING WWW.CHE.COM OCTOBER 2004


FIGURE 1a–b. In a rotary piston pump, positioning of the eccentric cam on the shaft results in
an imbalance. To compensate, two or more such stages of rotary components are positioned on
the shaft 180 deg out of phase from each other. These stages are normally arranged in parallel
(common inlet and outlet) for single-stage pumps or in series for compound pumps (inlet and outlet in series)

mounted to the shaft and the piston is tion of the lubricant or ingestion of Hg absolute for rough industrial ap-
concentric to the cam. This arrange- process liquid. plications, while others are capable of
ment allows the piston to ride on the This pump employs a rotor concen- ultimate pressures from 0.1 to 0.0002
cam and rotate around the periphery tric with the shaft, with slots for ac- mm Hg abs for use in applications
of the pump housing (cylinder), form- ceptance of two or more vanes, provid- with higher vacuum requirements.
ing a void between the piston and ing the inherently balanced design. A vane pump that uses a once-
housing that alternates from maxi- The rotor-shaft assemblage is through oiling system is an alternative
mum to zero at top dead center. mounted eccentrically in the stator to those that recirculate oil. In the
The positioning of the eccentric cam cylinder to provide the necessary cres- once-through approach, oil flow is me-
on the shaft results in an imbalance. To cent-shaped volume for expansion and tered out in amounts just sufficient to
compensate, two or more such stages of compression, with the critical dimen- seal and lubricate the vanes to the
rotary components are placed on the sion being the rotor-to-stator clear- housing. Instead of being recycled, the
shaft, with each 180 deg out of phase ance between the suction and dis- oil is collected for disposal. The advan-
with the stage next to it. These stages charge porting at top dead center. The tage of this design is that any contam-
are normally arranged in parallel for clearance must be kept as small as ination of the oil by the process vapor
single-stage pumps or in series for com- possible to reduce gas slippage where is passed out of the pump and not al-
pound pumps (Figure 1). Single-stage the pressure differential is greatest. lowed to build up and cause additional
rotary piston pumps can provide pres- The use of multiple vanes in the problems. This design also avoids any
sures down to 0.005 mm Hg abs and ca- rotor allows the pumping volume to be increases in the operating pressure
pacities to 850 cfm; compound pumps, swept the same number of times in one due to the vapor pressure of residual
0.0002 mm Hg abs and 200 cfm. shaft rotation, providing a compact de- process vapors. The drawback is the
The geometric positioning of the pis- sign. The vanes can be spring-loaded, need for waste oil disposal, which is an
ton-cam-shaft assembly prevents the or more commonly, can rely on cen- environmental and cost issue.
piston from touching the cylinder trifugal force to make contact with the
wall, allowing a constant clearance to cylinder and seal off the gas pocket. Liquid ring pumps
be maintained at all times. Oil is used Contact pressure between the vane Liquid ring pumps employ one or two
to seal this gap between the piston and housing is high, resulting in signif- multiblade impellers concentrically
and cylinder, provide lubrication and icant frictional effects that increase in- mounted to the drive shaft. The im-
transfer heat throughout the rest of ternal localized temperatures, even in peller shaft assembly is eccentrically
the pump. the presence of oil, which provides lu- mounted in the pump housing, in such
Rotary vane. The advantage of the brication, sealing and cooling. a way that at top dead center the clear-
rotary vane pump is its inherently Various designs of vane pumps are ance between impeller blade tip and
well-balanced design. Its disadvan- available, typically with capacities to housing is at a minimum, and at bot-
tage is the sensitivity of its vanes to 1,000 cfm. Some are capable only of tom dead center the clearance is at a
sticking or breaking from deteriora- ultimate pressures from 15 to 0.5 mm maximum, resulting in a relatively

CHEMICAL ENGINEERING WWW.CHE.COM OCTOBER 2004 45


LIQUID RING VERSUS DRY PUMP SYSTEMS
COMPARISON OF OPERATING AND MAINTENANCE COSTS
Feature Report Liquid Ring Pump Dry Pump
two-stage variable pitch
System stainless steel rotary screw
Capacity (acfm) 100 400 100 400
large void (Figure 2). Steam usage (lb/h) 0 0 0 0
The sealant liquid, typically
Cost of steam ($/1,000 lb) 6 6 6 6
water (but see further discus-
Annual cost of steam ($) 0 0 0 0
sion below), is used to seal be-
tween the impeller blade tips Motor hp 7.5 40 5 20
and housing. The sealant liq- Total bhp 7 33 4.4 15
uid is thrown by the impeller Power consumption kWh/yr 46,418 218,827 29,177 99,467
against the inside walls of the Unit cost of power ($/kWh) 0.06 0.06 0.06 0.06cot
pump housing, where it forms Annual cost of power ($/yr) 2,785.07 13,129.60 1,750.61 5,968
a rotating ring of liquid. Cooling water usage (gal/min) 9 27 1 5
At top dead center, the ring of Cost of cooling water ($/1,000 gal) 0.5 0.5 0.5 0.5
sealant liquid completely fills Annual cooling water cost ($/yr) 2,160 6,480 240 1,200
the voids between the blades of Wastewater to be treated (gal/min) 0.25 0.5 0 0
the impeller. Because of the ec-
Wastewater treatment cost ($/1,000 gal) 2.5 2.5 2.5 2.5
centric position of the impeller
Annual cost of wastewater treatment ($/yr) 300 600 0 0
with respect to the housing as it
rotates around the ring of liq- Total quantity of oil (gal) 0 0 0.3 0.3
uid, the sealant is peeled away Cost of oil ($/55-gal drum) 400 400 400 400
from the spaces between the Changeout intervals (h) 1,000 1,000 1,000 1,000
blades, creating voids where Annual cost of oil ($/yr) 0 0 17.45 17.45
gas can enter and be trapped. Cost of oil disposal ($/55-gal drum) 100 100 100 100
At bottom dead center, voids Cost of oil waste disposal ($/yr) 0 0 4.36 4.36
between the impeller blades Cost for oil filter element ($) 0 0 0 0
and ring liquid are at a maxi- Recommended filter changeout interval (h) 1,000 1,000 1,000 1,000
mum, while the blade tips re- Annual cost of exhaust filters 0 0 0 0
main immersed in the liquid
Annual cost of pump overhaul 340 780 2,550 4,930
ring for sealing. As the impeller
Annual total cost per pump ($/yr) 5,585.07 20,99.60 4,562.43 12,119.82
continues to rotate back up
from bottom dead center to top Annual savings per system ($) None None 1,022.64 8869.78
dead center, the sealant begins Capital costs ($) 14,800 40,000 23,000 48,000
to refill the volume between the Higher capacity (%) None None None None
blades, creating an essentially First-year total cost/cfm ($) 203.85 152.47 275.62 150.30
isothermal compression of the Second-year total cost/cfm ($) 55.85 52.47 45.62 30.30
gas trapped within. Higher second-year cost/cfm (%) 22.4 73.2 0 0
Inlet-outlet porting are posi- Payback time (yr) – – 8.0 0.9
tioned either in an endplate or a
port cone positioned at the axial end of where then
the impeller. In the endplate arrange- A = unit area in in.2 rpmmin = [900GDp/(rVp2R)]1/2 (2)
ment, two ports for entering and exit- G = gravitational acceleration of 32.16
ing of gas normally straddle an imagi- ft/s2 at sea level As shown, ring pressure for sealing
nary line connecting top dead center to r = sealant liquid density in (lb/in.3) is dependent on both the impeller rpm
bottom dead center, but the ports (nor- Dp = gas differential pressure across and radius, as well as the density of
mally triangular) can vary in shape the pump for single-stage pumps and the sealant liquid.
and exact location depending upon the the pressure differential for two-stage Liquid ring pumps are available as
vendor. With this kind of arrangement, pumps in (lb/in.2) single-stage (one or two impellers in
the sealant liquid acts as a liquid pis- P = ring pressure due to the impeller parallel) or two-stage (two impellers
ton, alternately creating expansion and in (lb/in.2 A) in series). Using 60°F sealant water,
compression for the gas trapped in the V = hA is the volume of sealant in single-stage pumps are capable of
spaces between the impeller blades. (in.3) achieving 100 mm Hg abs, while two-
Because ring energy is derived from h = impeller blade height or sealant stage or compound pumps can achieve
the impeller rotational speed, the ring thickness in inches 30 mm Hg abs. Pumping capacities up
minimum number of rotations per R = effective impeller radius in ft to and over 20,000 cfm are available.
minute (rpm) that a given liquid ring rpm = rotations per minute Liquid ring pumps are well de-
pump can operate can be estimated. Then, for a unit surface area, A, signed for the CPI. They do not re-
Since pressure = force/area, where the ring is sealing against a quire internal lubrication of the im-
maximum differential pressure, Dp, pellers, which do not contact the
P = F/A = rVw 2R/A = rV for the gas being pumped across each housing. The sealant liquid, used for
(2p(rpm)/60)2R/A = impeller stage, the minimum ring both sealing and cooling, can be any
rVp2(rpm)2R/(900A) (1) pressure, P must be greater than Dp liquid that is compatible with the

46 CHEMICAL ENGINEERING WWW.CHE.COM OCTOBER 2004


GHP = (144/33,000)P1Dln(P2/P1) (3)
where
GHP = work done on gas (hP)
P1 = inlet pressure (psia)
D = displacement (cfm)
P2 = discharge pressure (psia)
The low-pressure performance of
single-stage liquid ring pumps is nor-
mally limited by gas slippage from
discharge back to suction, while in
two-stage pumps, a combination of
slippage, sealant vapor pressure and
gas solubility of the sealant limits the
ultimate pressure. When a low-viscos-
ity oil is used as sealant in a two-stage
liquid ring pump, ultimate pressures
of 2–5 mm Hg abs are routinely
achieved. Here the limitation is not
the vapor pressure of the sealant,
which is likely to be less than 10–4 mm
FIGURE 2 a–b. Typically used as a mechanical Hg abs at 100°F, but the air solubility
booster, the rotary lobe pump is used in series with in the oil and slippage between stages.
another vacuum pump — in this case, a liquid ring All liquid ring pumps must cope
— that functions as the primary pump. Another with cavitation when running at low
option is a multistage vacuum pump system that
includes an air ejector inlet pressures. Cavitation is the
rapid formation and collapse of vapor
bubbles within the sealant liquid,
process and falls within the following which can remove minute amounts of
range of physical properties: metal from surfaces. If cavitation is
• Specific gravity 0.5< S.G 1.5 allowed to continue over long periods
• Specific heat 0.35< S.H. 1, relative of time, serious damage can be done to
to that of water the liquid ring pump. Tiny voids
• Viscosity 1 cP n 32 cp within the sealing liquid can be cre-
• Vapor pressure Vp sealant at operat- • Large choice of sealant liquids ated by the pump’s impeller. When
ing temperature Vp water at 60°F • Accommodation of both condensable the ring is exposed to the suction port
Low-viscosity oils, glycols, and many vapors and noncondensables, while at low pressures, some of the sealant
process solvents, such as toluene, xy- operating as both a vacuum pump liquid can vaporize to fill the void with
lene, methanol, ethanol, propanol, bu- and condenser a small vapor bubble, which travels
tanol and ethylbenzene, can be used as • Ability to handle small liquid around from suction to discharge,
sealants. These sealants can be recircu- streams along with the gas flows causing vapor bubbles to collapse.
lated in a full recovery system that in- from the process or precondensers When the bubbles collapse on a metal
cludes a gas-liquid separator tank and • Wide choice of materials of con- surface, the shock force can tear small
a heat exchanger for cooling. Even struction, with all-ferrous, all- amounts of metal away.
higher-vapor-pressure liquids can be bronze, and all-stainless steel being The amount of cavitation can be af-
used if a low-temperature coolant is the most common fected by the sealant liquid, sealant
used in the heat exchanger to reduce The major disadvantage of the liquid temperature, impeller rpm, blade
the sealant temperature. This recovery ring pump is its power consumption, angle, and inlet pressure. For a given
system allows process materials to be compared with that for other types of pump and sealant liquid, cavitation
collected in the pump and either re- mechanical pumps. While frictional can normally be suppressed by bleed-
turned to the process or collected for power due to seals, bearings, and drag ing air into the pump inlet to raise its
disposal, while minimizing contamina- on rotational elements represents total pressure above the vapor pres-
tion of other liquids or the environment. 30–40% of total peak power consump- sure of the sealant at operating tem-
Liquid ring pumps offer many ad- tion in rotary vane and piston pumps, peratures.
vantages, among them: it accounts for 50–75% of total power
• Simplicity of operation (such a pump consumed in liquid ring pumps. The Dry pumps
is essentially a pinwheel on bear- power consumed by liquid ring pumps Dry vacuum pumps do not use any liq-
ings) with minimal moving parts, in pumping gas can be determined uid in the pumping chamber. In the
and no lubricating liquid in the vac- from the isothermal compression of 1980s, semiconductor fabricators real-
uum chamber to be contaminated gas across each stage: ized the potential of dry pumps as an

CHEMICAL ENGINEERING WWW.CHE.COM OCTOBER 2004 47


Feature Report

alternative to the oil-sealed pumps scroll, diaphragm, rotary


that were used to provide pressures of vane, rotary lobe, hook-
0.01–1 mm Hg abs for chemical vapor and-claw, and rotary
deposition and etching of wafers. screw. However, the ro-
In semiconductor manufacture, oil- tary lobe, hook-and-
sealed pumps require lubrication with claw, and rotary screw
inert, fluorine-based fluids for protec- pumps are the ones that
tion from the corrosive gases and dominate the CPI sector,
FIGURE 3. The rotary screw pump
harsh conditions of the fabrication op- particularly in larger-size employs the pockets between
eration. In addition to the expense of pump applications. convolutions of the rotors as separate
the lubricants are the costs of associ- Scroll pump. The scroll pump uses a stages in series to move gas in a flow path
ated materials and maintenance. rotating plate shaped into a spiral (in- that is simple, short and straight
With a dry vacuum pump, not only volute curve), which moves within a years, the rotary lobe pump is typi-
are lubricants eliminated; buildup of second stationary plate, shaped as a cally used as a mechanical booster
process gases within the pump and similar spiral. This rotating motion of (Figure 2). Traditionally it has been
waste disposal are also reduced. But one spiral within another creates cres- used in series with an oil-sealed pis-
eliminating a liquid within the pump- cent-shaped trapped volumes, within ton or vane pump to amplify or boost
ing chamber also eliminates a method which the gas moves from the outside pumping capacity at low pressures, or
of sealing between the pump clear- of the spiral to the center, where the to extend low-pressure capability.
ances, a heat-transfer material for gas is exhausted through a valve. Mul- Today, it continues to be used in this
temperature control, as well as a flush tiple stages can be used to provide capacity, as well as in combination
medium for cleaning the pump inter- lower pressures, down to 0.01 mm Hg with other types of dry pumps that
nals of process material. So, the chal- abs, with pumping capacities limited function as the primary or atmos-
lenges of providing dry-runing pumps to less than 50 cfm. Because its tortu- pheric-stage pump.
were large. ous spiral gas path can act as a trap for The rotary lobe pump consists of two
Early dry pumps consisted of sev- particulates within the pump, this symmetrical two-lobe (figure-eight) ro-
eral pumping stages in series, with type of pump is limited to clean gas ap- tors, each mounted on a separate shaft
either rotary lobes or hook-and-claw plications. in parallel, which rotate in opposite di-
internals that did not make any con- Diaphragm pump. The diaphragm rection to each other at high rotational
tact with the housing and used tim- pump uses a rotating eccentric piston- speeds without making any contact or
ing gears to synchronize the two par- plunger to move an elastomeric di- using any sealing liquid. This pump
allel rotor shafts. While this aphragm back and forth within a uses timing gears to synchronize the
configuration eliminated the need for small cavity, resulting in a rapid re- rotation of the lobes to provide constant
a lubricant within the pumping duction and expansion of volume to clearance between the two.
chamber, the lack of a seal medium provide pumping action for gases. Internal clearances are kept to a
meant that the internal clearances Chemical-resistant diaphragms are minimum — as tight as 0.004 in. — to
had to be kept tight to reduce gas available in polytetrafluoroethylene reduce the back slippage of gas and
slippage. The tight clearances made (PTFE), but the relatively small size still allow for thermal expansion of the
some of the dry pumps sensitive to of this type of pump precludes its use rotors. No internal compression of gas
buildup of process particulate. The in production-scale operations and occurs. The booster traps a pocket of
evolution of these designs saw the in- relegates it to laboratory applications. gas and transports it from low pressure
troduction of various inert gas purges Ultimate pressures vary, with the to high pressure. It is the discharge
to flush process material through the lowest being about 1 torr. pressure conditions at the booster pro-
pump or act as a diluent for flamma- Dry rotary vane. While the dry rotary duced by its backing pump that causes
ble or corrosive gases, or help to con- vane pump is available with self-lubri- the pressure ratio.
trol internal temperatures. cating carbon vanes, the increased gas Typically, the rotary two-lobe is not
The eventual success of dry vacuum slippage compared to that of the oil-lu- an effective pumping device for pres-
pumps in the semiconductor industry bricated vane pump limits the ultimate sures greater than 100 torr, due to its
has inspired pumpmakers to intro- pressure of the dry vane to about 75 increased power consumption. A pres-
duce these pumps into other segments mm Hg abs. These pumps offer capaci- sure switch is often used to energize
of the CPI, where the benefits of a dry ties up to approximately 400 cfm. As the blower only at lower pressures, or a
pumping chamber can lower operat- with most dry pumps, which lack a liq- bypass circuit with valve, either inter-
ing costs and justify the cost of the uid heat-transfer medium in the pump- nal or external, is used to limit the
generally higher-priced pump. ing chamber, it operates at elevated in- pressure differential between suction
For CPI use, considerations for han- ternal temperatures. Air cooling is and discharge, limiting the power re-
dling liquid slugs or higher vapor used. Due to this pump’s sensitivity to quirements and exhaust gas tempera-
loads from the process need to be particulates, inlet filtration is normally ture, while running at higher inlet
weighed. Various types of dry pumps recommended. pressures (>100 torr). The booster does
are currently available, including Rotary lobe. In use for more than 50 not enhance the backing pump capac-

48 CHEMICAL ENGINEERING WWW.CHE.COM OCTOBER 2004


ity until its bypass valve starts to close staging is used to reduce the differen- acts similarly to a stage in series with
at inlet pressures below 100 torr. tial pressure across each stage and its the one behind it. A minimum of at
The greatest use of the rotary lobe corresponding gas slip. least three convoluted gas pockets in
booster is as a separate pumping Hook and claw. The hook-and-claw the rotor are required to achieve ac-
stage, connected by piping to another pump makes use of the Northey rotor ceptable vacuum levels. Mechanical
stage that discharges to the atmos- design developed in the 1930s and face seals or lip seals are used to sepa-
phere. This separate atmospheric first used on compressors. This geo- rate the pumping chamber from the
stage can be provided by either an- metrical shape allows for a greater bearings and gears.
other type of dry pump, thus forming compression ratio to be taken across The first generation of rotary screw
an all-dry vacuum pumping system, or the rotors at higher pressures. Two pumps use rotors with a constant
by the more-conventional wet pumps. claw rotors rotate in opposite direc- pitch (number of convolutions per unit
Some dry pumps are manufactured tions of rotation without touching, length). The second generation of
utilizing the rotary lobe design within using timing gears to synchronize the screw rotors utilize a variable pitch
a single housing that can discharge to rotation; two complete rotations are design, which essentially consists of
atmosphere. One such design starts required to pass through the inlet, two individual short rotors, each with
out like a booster, with two counter- compression, and discharge cycle. The a different pitch, connected in series.
rotating shafts in parallel. The design gas enters through an inlet port after The gas at the inlet is first trans-
diverges, however, with a rotary lobe it has been uncovered and fills the ported by the lower pitch (fewer con-
rotor mounted on each shaft as the void space between the rotors and volutions per unit length) portion of
high vacuum stage, in series with two pump housing. On the next rotation, the rotors and then by the higher
or more different-design rotors all that same trapped sample of gas is pitch portion, which results in inter-
mounted in series on the same drive compressed and discharged as the dis- nal compression of the trapped gas.
shaft. Each stage is separated by end- charge port opens. The work for gas compression (as
plates with porting within the same Hook-and-claw rotors perform two measured by the area under a PV dia-
housing. functions: one is to trap, transport and gram) using a variable pitch rotor is
Another such design consists of two compress gas through the pumps, and less than that for the same task ac-
counter-rotating shafts, each driving the other is to automatically open and complished with a constant pitch
three or more three-lobe rotors in se- close the suction and discharge ports rotor. Because less energy is required,
ries within the same housing. This de- like a valve by covering or exposing the motor size of the variable pitch
sign requires interstage cooling by re- the porting to the gas stream at the rotor is smaller and the discharge gas
circulating a portion of the discharged appropriate times. temperature is lower. The third gener-
gas from one stage through a heat ex- A minimum of three stages in series ation uses a continuous variable-pitch
changer before injecting it back into a is required to achieve ultimate pres- design rotor where the trapped gas is
point midway between suction and dis- sures comparable to those of an oil- continuously compressed from inlet to
charge. The three-lobe design rotor sealed mechanical pump. Some de- discharge for greater efficiency with
makes this possible without excessive signs use a mixture of hook-and-claw the lowest energy requirement and
slippage. The problem with this design rotor stages in series with rotary lobe lowest discharge gas temperature.
is the tortuous gas path through a stages, while others use soley hook- The rotary screw pump is unique in
complicated cooling circuit, where and-claw stages. that it uses a singe stage (no inter-
process materials can accumulate or Gas purges are used to avoid partic- stage walls) rather than the multi-
precipitate out. ulate buildup. Discharge gas tempera- stage design of the other dry pumps,
Some modifications to this design ture is controlled by controlling the which are separated by endplates and
have included replacing the external flow of cooling water. seals. Because of this design, its gas
interstage gas coolers with an internal Rotary screw. The rotary screw flow path is simple, short and straight
cooling-jacket design. This configura- pump makes use of two long helical without any volumes in which mater-
tion allows a portion of the discharged rotors in parallel, which rotate in op- ial can accumulate. The symmetrical
gas to be passed through a peripheral posite directions without touching helical design lends itself to a well-
passage that is sandwiched between (Figure 3). Helical timing gears are balanced rotor capable of high rota-
the pumping chamber and cooling used to synchronize the rotation. Gas tional speeds.
jacket. This design allows the gas to be flow moves axially along the screw Various protective coatings such as
cooled before being injected back into without any internal compression PTFE or PFA (a copolymer of tetraflu-
the pumping chamber and reduces the from suction to discharge. Pockets of oroethylene and perfluoroalkoxy
external complications of accessories, gas are trapped within the convolu- resin), or composites of PTFE and
however, it still leaves a tortuous path tions of the rotors and the casing, and nickel, are available for wetted inter-
for the gas where process material can transported to the discharge. Com- nals to provide corrosion resistance to
accumulate. pression occurs at the discharge port, aggressive process streams. Even with
A complete rotary-lobe dry pump where the trapped gas must be dis- these coatings, it is advisable to avoid
that can operates from atmosphere to charged against atmospheric pres- condensing the process corrosives
less than 0.1 torr is possible if multi- sure. Each convolution of the rotor within the pump through the use of

CHEMICAL ENGINEERING WWW.CHE.COM OCTOBER 2004 49


Feature Report

inert gas purges and elevated gas tem-


perature control. Pumps sizes range
from 50 to 1500 cfm with ultimate
pressures of 0.2 to < 0.01 torr.

Dry service in the CPI


Of this selection of dry pumps, three
types are recommended for general-
purpose use in the CPI: the rotary
lobe, hook-and-claw, and rotary screw
pumps. These three dry pumps share
the following features:
• Rugged rotor design. Whether ro-
tary lobe, hook-and-claw, or rotary
screw all of the rotors are con-
structed of sturdy cast iron, or duc-
tile iron construction without any
flimsy rotating components.
• Noncontact design. Timing gears
are oil lubricated in a sealed-off end
chamber to synchronize the rotors
for proper phasing and noncontact-
ing operation
• High rotational speed. Operation at
high speeds reduces the ratio of gas
slip to displacement, increases net
pumping capacity and reduces ulti-
mate pressure. To accomplish this,
rotors are well balanced
• Multiple staging. Multiple staging
provides inlet pressures below 1 mm
Hg absolute while discharging to at-
mosphere (Figure 4). Being a sepa-
rate stage, the rotary lobe booster is
connected to another separate stage
of dry pump that discharges to at-
mosphere. The rotary lobe and hook-
and-claw pumps use multiple stages
within one housing, with each stage
sealed off from the other with end-
plates, except for the porting that di-
rects the gas along a tortuous path.
The rotary screw uses the pockets
formed by the convolutions in the
helical rotors as separate stages to
transport gas along a straight path
before discharging

LIQUID RING VS DRY PUMPS


When all capabilities are considered,
liquid ring and dry pumps offer the
most advantages for the CPI. Both of
these type pumps have bearings
sealed off from the pumping chamber
and do not require any internal lubri-
cation because the rotors do not con-
tact the housing; therefore, any sol-
vent vapor that condenses within the
pump will not compromise lubrica-
adlinks.che.com/3647-26
50 CHEMICAL ENGINEERING WWW.CHE.COM OCTOBER 2004
FIGURE 4. Combining a booster
with a rotary screw pump pro-
vides an all-dry pumping system
with capacity levels up to 10,000
cfm and ultimate pressures
below 10–3 Hg abs

tion. Both employ a coolant system oxygen into the system through air
that prevents the coolant from con- leakage. In some cases, detonation ar-
tacting the process and causing conta- resters may be used. Liquid ring
mination, and both use mechanical pumps normally operate at low tem-
shaft seals for containment. peratures, well below the auto-igni-
Dry pumps are free of any liquid tion temperature of the materials, and
within the pumping chamber, so that gas compression occurs in a wetted en-
any process carryover is not contami- vironment where sparking or combus-
nated and can be returned to the tion is less likely to occur. Normally,
process. Also the lack of any sealing the sealant liquid can be selected with
liquid means that the dry pump poses this factor in mind.
no danger to contaminating the In many cases, water may be the
process on system upsets. Although preferred sealant. Inert gas or recy-
water is the most commonly used cled gas from discharge is used to pre-
sealant in liquid ring pumps, in many vent cavitation while avoiding the in-
applications, the process fluid can in- troduction of air.
stead serve as the sealant liquid, pro- The liquid ring pump is the pump
vided the vapor pressure is compatible best equipped for handling liquid in-
with the operating pressure. gestion. In fact, in many applications
In other situations, a compatible the condensate from a precondenser is
sealant liquid can be found that meets run directly into the liquid ring pump
the pump sealant requirements and or a liquid spray is used as a contact
will not be a problem for the process. condenser directly upstream of the
The solvent liquid is recirculated in a pump’s suction. Some dry pumps can
full recovery system that includes a handle small amounts of liquid with
gas-liquid separator tank at discharge the rotary screw pump being able to
and a water-cooled heat exchanger handle the most without hydraulically
(normally shell-and-tube) in the recir- locking.
culating line for cooling. In summary, both the liquid ring
For handling corrosive vapors, dry and rotary screw dry pumps offer ad-
pump manufacturers recommend vantages to the CPI. n
passing the vapors through the pump Edited by Deborah Hairston
without condensing, by maintaining
an elevated temperature at discharge References
through control of the cooling water 1. Van Atta, C.M., Vacuum Science and Engi-
neering, McGraw-Hill, New York, N.Y., 1965.
flow, as well as auto start-stop and 2. Vibert, P.D., Dry versus Oil Sealed Vacuum
seal inert gas purges. Some also offer Pumps for Vacuum Coaters, Soc. of Vacuum
Coaters 41st Annual Technical Conference
protective coatings. Makers of liquid Proceedings, ISSN 0737-5921, pp. 7–8, 1998.
ring pumps normally offer all-ferrous 3. Vibert, P.D., Mechanical Booster Vacuum
and all Type 316 stainless steel con- Pumps, Society of Vacuum Coaters 42nd An-
nual Technical Conference Proceedings,
struction as standard options, with ISSN 0737-5921, pp. 11–12, 1999.
some also offering construction in
Alloy 20 or Hastelloy. Author
Dry pumps can handle many flam- Phil Vibert is a senior engineer for Tuthill Vac-
uum & Blower Systems (4840 West Kearney
mable vapors, if the maximum gas Street, Springfield, MO 65801; Phone: 417-865-
8715; Email: pvibert@tuthill.com). His career
temperature is controlled below the with the company, including Kinney Vacuum,
auto-ignition temperature through spans more than 33 years. Involved in the de-
sign, application, operation, and troubleshooting
coolant usage. An inert gas cooling of all types of vacuum pumps and systems, he
stream is added during compression, has sized, selected, and designed thousands of
vacuum systems for the chemical process indus-
or an inert gas stream is added as a tries. Vibert, who holds a B.S. in physics from
diluent to avoid an explosive mixture Northeastern University (Boston, Mass.), has
authored several papers and technical publica-
while limiting the introduction of any tions in the field of vacuum pumps and systems.

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