High viscosity fluids pose a unique pumping challenge for operations in dozens of industries worldwide. When these fluids constantly cause pump malfunctions, downtime, and high maintenance costs, it can be easy to get discouraged and frustrated. The good news is that there is a solution to pumping high viscosity fluids thanks to the unique science behind our pumps, which are specifically designed for the job.
Let’s take a look at exactly why high viscosity fluids are so difficult to pump.
Viscosity defines a fluid’s resistance to change shape and its opposition to flow. Essentially, fluids with a high viscosity are thicker, heavier, resistant to flow and, thus, difficult to pump. Viscosity also has a direct relationship with shear sensitivity. Shear sensitive fluids easily emulsify, or break into small particles, which can negatively affect the product being pumped. For example, when a highly shear sensitive fluid, like crude oil, is pumped together with water, the liquids are susceptible to emulsification. Separating these emulsions can be difficult, costly, and time consuming
Aside from shear sensitivity, high viscosity fluids tend to be thick and heavy, which poses another challenge for pumps. To pump these thick fluids successfully, a pump needs to be able to handle large amounts of entrained air, since the thicker the fluid, the more likely it is to entrap air. Ideally, a pump handling highly viscous material will have a low minimum stable continuous flow and Net Positive Suction Head - Required (NPSH-R).
The unique challenges of pumping highly viscous fluids call for a unique solution, like Discflo disc pumps. Our pumps are specifically designed for tough pumping jobs like this, and the unique technology behind our pumps make them extremely successful across many applications and industries.
Discflo disc pumps operate on the unique principles of laminar flow, viscous drag, and boundary layer which allows them to effectively, smoothly pump highly viscous materials when other pumps fail.
Our pumps use laminar flow and increase the liquid’s velocity using our patented Discpac technology that transfers energy into the boundary layer. As energy passes into the boundary layer, the liquid’s velocity around the outside of the pipe increases beyond that of the inner liquid. Our parallel, rotating Discpacs combine the power of the boundary layer and viscous drag to create a smooth, pulsation-free laminar flow, even with highly viscous materials.
Another benefit to our superior pump design is how well it can handle delicate materials. Our disc pumps do not use a harsh impeller to generate energy. Thus, rather than violently pushing fluid through the pump, our design creates a gentle pull, making them excellent for shear sensitive fluids.
This also results in a low minimum continuous stable flow and a Net Positive Suction Head - Required (NPSH-R) that is one-third of competitors’. Discflo disc pumps can also handle large amounts of solids and up to 25% air in the line.
Below, we have outlined a few examples of why disc pumps excel at pumping difficult materials.
When it comes to abrasive fluids, disc pumps are suitable for use in:
Disc pumps can handle liquids with up to 80% non-homogenized and non-absorbent solids, which would clog traditional pipes. These solids tend to fall out of the liquid. Thanks to our patented Discpacs and viscous drag technology, the solids fall into the point of lowest velocity. This allows the liquid to continue its smooth, laminar flow without clogs. Disc pumps are an excellent choice for pumping fluids containing high solids.
The science behind Discflo disc pumps make pumping high viscosity, difficult-to-pump liquids easy while increasing efficiency. Using our patented technology, our engineers design our pumps to improve your operational efficiency, reduce your maintenance needs, and decrease your downtime.
For example, when a Florida municipality approached us because they needed to pump sludge with a highly abrasive solids content up to 80%. We installed our pumps in 1993, and to date they are still working hard. That’s 30 years! Our pumps undergo routine maintenance checks and rarely need repair, typically showing almost no signs of wear.
That is just one example of how Discflo disc pumps can fundamentally change an operation by lowering maintenance costs, decreasing downtime, and improving operational efficiency. With Discflo, even the hardest pumping jobs are simplified.
Want to learn exactly how a Discflo pump can improve your operation? Contact our team below.