Improving pump efficiency with protective coatings

With energy prices continuing to rise in recent years, companies in various industries are actively seeking ways to reduce their energy costs. This emphasis on cost reduction is driven by the significant impact that rising expenses have on production costs and overall business competitiveness. Moreover, it is important to emphasize that with the increasing threat of climate change, sustainability is no longer a choice but a necessity to secure a better future for future generations. It has become essential for industries to prioritize reducing their carbon footprint and cutting CO2 emissions. Pumps, known for their significant energy consumption, offer companies a significant opportunity to improve their operational efficiency, leading to a reduction in energy expenditure and a consequent reduction in their carbon footprint.

Pumps play a crucial role in any industrial plant and can be considered the heart of the entire operation, but also contribute significantly to energy consumption and greenhouse gas emissions. Pumping systems account for more than 20% of total global electrical energy requirements, and the percentage of electric motor energy used by centrifugal pumps in a plant can vary depending on the industry, ranging from 25 to 60%. To reduce energy costs and contribute to a sustainable future, it is essential to improve pump efficiency and reduce CO2 emissions. By implementing energy-efficient practices on pumps, companies can reduce operating costs, meet their environmental responsibilities and contribute to a greener future.

Understanding energy losses in pumps

Pumps suffer energy losses when converting mechanical energy into fluid energy. There are three main types of energy losses that pumps encounter: mechanical, volumetric and hydraulic losses:

1) Mechanical losses are caused by friction from rotating components such as bearings, valves and seals.

2) Volumetric leakage losses occur due to leakage through various seal openings in the wet end of the pump, including areas such as the pump wear rings.

3) Hydraulic losses are caused by friction of the fluid wall in the pump housing, impeller and piping system.

These losses have a significant impact on overall efficiency and performance. LOCTITE Protective Coatings provide a solution to reduce hydraulic losses by creating a smooth and frictionless surface on pump components where transported fluid is in contact.

Hydraulic energy loss is directly linked to surface roughness along the flow path. Surface roughness can significantly affect the behavior of fluids in convective flows by causing perturbations in the velocity profile, thus affecting surface resistance. When the surface is rougher, it causes more frictional energy loss and increases turbulence in the flow.

Role of coating in reducing hydraulic losses

By applying appropriate coatings to the casing and impeller, a low surface energy surface can be achieved. Coatings with low surface energy and high contact angle play a crucial role in minimizing friction losses in pump systems. Coating the casing and impeller with a low surface energy coating helps reduce the energy loss caused by friction in the flow path, leading to improved efficiency. In addition, a high contact angle surface allows fluids to move effortlessly across the coated surface, resulting in minimal drag and reduced friction losses. In addition, continuous operation of the pump results in the surface of the pump being degraded by abrasive and corrosive pumped media, leading to a reduction in efficiency. Applying protective coatings can prevent this deterioration and ensure long-term efficiency. The coating acts as a protective barrier and ensures smooth and efficient pump operation.

However, improved efficiency can be achieved through the use of the coating method, which applies not only to pumps in need of repair, but also to new units and units operating without problems. LOCTITE protective coatings can help improve pump efficiency.

LOCTITE has a variety of advanced products designed to improve pump efficiency and reduce energy consumption, as well as protect the surface of the pump from wear and corrosion. These include products such as LOCTITE PC 7255, LOCTITE PC 7337 and LOCTITE PC 7227, all of which are specifically made to meet different needs. One notable example is LOCTITE PC 7337, which stands out as a new-generation hybrid protective coating. This product is a combination of epoxy and silicone. LOCTITE PC 7337 has a special formula that results in impressive qualities such as a low surface energy of 23 mN/m, a high surface contact angle of 1060 (according to ASTM D 7334) and exceptional resistance to abrasion compared to ceramic-filled epoxy coatings. This unique formula provides a surface that is hydrophobic, glossy, smooth and low friction. This results in less energy loss due to friction in the pumping system.

By using LOCTITE Protective Coatings, companies can achieve significant gains in pump efficiency, which translates into reduced energy consumption and cost savings. These coatings enable companies to optimize pump performance, minimize hydraulic losses and improve overall operational effectiveness. Case studies conducted at leading companies in the water, refinery, chemical and steel industries show that with coatings, an increase of 6-25% can be achieved in used pumps, depending on the condition of the pump. An increase of 3-7% in efficiency can be achieved with a new pump.

Smooth, low-friction surfaces 

As companies face the challenges of rising electricity costs and environmental sustainability, optimizing pump efficiency becomes paramount. LOCTITE Protective Coatings offer a reliable and effective solution to improve pump performance by reducing hydraulic losses and reducing friction. With products such as LOCTITE PC 7337, characterized by its low surface energy and high contact angle, LOCTITE enables companies to achieve smooth, low-friction surfaces, resulting in improved pumping efficiency, lower costs and a more sustainable future for all.

This pump efficiency solution perfectly illustrates that Henkel, with its LOCTITE brand, is much more than just a supplier of adhesives, sealants and coatings. Henkel wants to be a reliable partner with LOCTITE. With all the expertise gained over all these years worldwide, Henkel can sit down with the customer and together go deeper into challenges such as increasing efficiency, sustainability and cost savings and propose professional and innovative solutions, help implement them and provide support in the further process. Telephone support, customized training courses, analyses of customer processes, the digital learning platform LOCTITE(R) XPLORE, etc. are just a few examples of the comprehensive service LOCTITE offers. With the new slogan 'Beyond the Bond', LOCTITE wants to make clear its concrete commitment to think along with the customer as a full partner.