Horizontal axial flow pumps play an indispensable role in many industrial fields such as flood control projects, irrigation systems and water treatment. Faced with increasingly severe environmental challenges and rising energy costs, improving the energy efficiency of these pumps and achieving low energy consumption has become a top priority.

Improve Flow Channel Design

Optimizing the flow path design helps improve the energy efficiency of horizontal axial flow pumps. The flow path, that is, the path of the fluid flowing inside the pump, has a decisive influence on the overall performance of the pump and the energy consumption.In order to significantly improve efficiency, friction losses in the flow path must be minimized. When the fluid encounters obstacles in the pump, friction losses are generated, which not only consumes energy, but also increases heat and reduces the efficiency of the pump. Therefore, engineers are committed to making the flow path surface smoother and optimizing its geometry to reduce this loss. Using CFD (Computational Fluid Dynamics) technology to study and improve the flow pattern of the fluid can ensure that the fluid passes through the pump body with minimal resistance and turbulence.

In runner design, it is equally important to optimize the shapes of the inlets and outlets. Especially the inlet design, which is directly related to whether the fluid can enter the pump smoothly. Cavitation, the formation and collapse of gas bubbles, can damage pumps and reduce efficiency. A well-designed inlet can effectively reduce the probability of cavitation. By adjusting the inlet shape, the fluid can be guided to flow smoothly to the impeller, reducing turbulence and thus improving the overall efficiency of the pump.

Likewise, optimizing the outlet shape is critical to reducing energy losses as the fluid leaves the pump. Excellent outlet design ensures that the kinetic energy of the fluid is effectively converted into pressure energy, thus giving full play to the performance potential of the pump. This usually requires a gradual widening of the outlet, smoothly reducing the fluid velocity to reduce turbulence and energy losses.

Use high-efficiency motors

As the core component of the pump system, the performance of the motor has a decisive influence on the efficiency of the pump. Therefore, the use of high-performance motors is an important means to improve the energy efficiency of horizontal axial flow pumps. In recent years, variable frequency motors and high-efficiency permanent magnet synchronous motors have attracted much attention. Compared with traditional induction motors, permanent magnet synchronous motors have many advantages, such as higher power density, providing the same power output in a smaller space, and maintaining high efficiency over a wide operating speed range. It is suitable for application scenarios where the pump speed needs to be flexibly adjusted according to actual needs. Because of the use of permanent magnets, rotor windings are no longer required, which not only reduces electrical losses but also further improves overall efficiency.

Variable frequency motors are able to precisely control pump speed and are usually used with a variable frequency drive (VFD). This feature is especially important in systems with variable traffic demands. When demand is lower, the VFD effectively saves energy by adjusting the motor speed to match the actual flow rate. At the same time, the soft start and soft stop functions of VFD can significantly reduce the mechanical stress of the pump, extend its service life, and reduce maintenance costs.

In order to maximize energy utilization, matching the motor to the pump is crucial. A motor that is too large will result in low efficiency and waste of energy; a motor that is too small may not be able to meet the power requirements of the pump and may even cause failure. Therefore, to achieve optimal energy efficiency, the motor size must be carefully selected based on the specific characteristics of the pump and the system requirements.

The energy efficiency of a pump is greatly affected by the surface condition of its internal components. Polishing and applying special coatings are key measures to improve surface properties. Polishing the blades and the inner surface of the pump body can significantly reduce the friction between the fluid and the pump components. The smoother surface helps to reduce flow resistance and thus reduce energy consumption. Electrolytic polishing and mechanical polishing with fine abrasives are advanced technologies for creating ultra-smooth surfaces and reducing friction losses.

In addition to polishing, applying special coatings can further increase the efficiency and durability of horizontal axial flow pumps.These coatings offer a number of benefits. First and foremost, they create an extremely smooth surface, further reducing frictional drag. Second, coatings create hydrophobic or oleophobic properties, effectively repelling water or grease, which reduces friction and improves fluid flow.

In addition, these coatings offer excellent resistance to erosion and corrosion, which is critical for pump systems that handle corrosive fluids. The coatings’ superior resistance to erosion and corrosion allows pumps to operate efficiently for longer periods of time. Once a surface has eroded or corroded, it becomes rough, increasing friction and reducing efficiency. Therefore, protective coatings not only maintain the initial high efficiency of the pump, but also continue to improve its performance over time.

Finally, some specialized coatings can also prevent the buildup of scale or biofouling, both of which can seriously affect pump performance over time. These coatings ensure that pumps continue to operate at peak efficiency because they keep internal surfaces clean and smooth.

Optimize Pump Size

Choosing the right size for a horizontal axial flow pump can help improve energy efficiency. In addition to wasting energy, an oversized pump can cause operational problems such as increased wear, noise and vibration. A pump that is too small can have trouble meeting system requirements, resulting in low flow or even system failure.

In order to optimally select a pump type, a comprehensive review of system requirements is necessary. This includes the precise calculation of the flow and head required under different operating conditions. During the planning phase, peak demand, daily operating environment and its long-term changes need to be taken into consideration.

The key to pump selection is to avoid design redundancy. Although large pumps seem to be safe when dealing with peak loads, they are often inefficient in daily operation. A wiser approach is to use multiple small pumps in parallel, so that they can both handle peak loads together and operate independently and efficiently when demand is lower.

Variable speed pumps are highly regarded for their high flexibility. They can adjust the operating speed in time according to changes in system requirements, and can ensure efficient operation under various working conditions without increasing the size.

In addition, the pump system should be inspected and maintained regularly. Over time, system requirements may change, and the originally adapted pump may gradually no longer match. Therefore, regularly evaluate the matching degree of pump performance with system requirements and look for optimization space, such as timely replacement of pumps or adjustment of system layout to ensure efficient operation of the system.

Horizontal Axial Flow Pump Manufacturer

Tianjin Kairun Pump Industry is a professional manufacturer that provides you with high-quality horizontal axial flow pumps and provides comprehensive installation and commissioning services. Welcome to contact us, catherine@kairunpump.com.

References

1. Gülich, J.F. (2020). Centrifugal Pumps. Springer, Heidelberg.

2. Karassik, I.J., et al. (2008). Pump Handbook. McGraw-Hill Education.

3. Tuzson, J. (2000). Centrifugal Pump Design. John Wiley & Sons.

4. Hydraulic Institute. (2021). Pump Systems Matter: Energy Efficiency.

5. U.S. Department of Energy. (2019). Improving Pumping System Performance.