As part of a R & D project, a KD PUMP was used in a multi-year trial in a prototype plant for the production of biodegradable fertiliser to continuously circulate the manure substrate in continuous operation. The customer opted for a KORTHAUS pump due to the contact-free operation of its pumping elements. Thanks to the low solids content of <5%, the KD PUMP ran for >17,500 hours in the pumping chamber without any wear.

At an existing digester site, a customer was looking for a redundant pump system to circulate the slurry between two digesters. The aim was to find a solution that was as low-maintenance and low-wear as possible. 

The customer opted for a KD PUMP from KORTHAUS due to its integrated cutting mechanism. This mechanism shreds solids (stones and grass) present in the medium and protects other components in the pump chamber from wear. After several years of using the pump in their plant, the service life has been extended by a factor of eight compared with existing systems. 

A local municipal wastewater treatment plant required a universal unit for draining of sedimentation and clarification tanks and for emergency management. Due to the integrated KORTHAUS hammer plate-system and the excellent suction performance of up to –0.8 bar on the suction side, the costumer opted for a KORTHAUS mobile unit. A control cabinet with integrated flow monitoring allows the unit to be regulated to the required flow rate. Thanks to plug-in systems, the unit can be used both as a mobile unit and in stationary continuous operation. Additional sedimentation tanks improve suction performance and protect the pump chamber from solid contaminants. 

A costumers' municipal water treatment plant required a new pump for the digested sludge transfer pumping station. The replacement was for older equipment, in this case eccentric screw pumps. Due to the existing pipework layout, which resulted in difficult suction conditions, the pumps previously in use had suffered frequent breakdowns caused by dry running. Thanks to the contact-free operation of the rotors and KD PUMPS' separator design, 100% protection against dry running is guaranteed.

Due to the greater ease of maintenance and the excellent suction conditions, the customer opted for a pump from KORTHAUS. Following commissioning, the pump initially operated under cavitation for several weeks. Despite this, the pump has been operating without wear or damage, having clocked up over 2,750 operating hours. 

A municipal sewage treatment plant which is located in an industrial area was experiencing increased wear and tear on the components of the pumps that come into contact with the pumping medium. In addition to this confronted with irregular downtime caused by contaminants, the plant was faced with increased wear on components due to chemical residues in the industrial effluent. Furthermore, the pump regularly became blocked due to the swelling of elastomer-coated components.

It was decided to conduct a trial lasting several months with a pump from KORTHAUS. The key to success was the integrated cutting mechanism, which shredded contaminants before they entered the pumping chamber. Pump blockages caused by swelling were counteracted by a rotor with an additional cutting edge. The wear and tear rate could be reduced by 500%, irregular downtime of the pump was reduced to zero.

As part of efforts to optimise the energy efficiency of the process technology in use, a municipal sewage treatment plant was seeking alternative pump technology. Thanks to KORTHAUS’s efficiency-optimised pumping elements, the decision was made to install a KD PUMP. The contact-free operation of the patented pumping geometries results in an optimized efficiency rate.

Despite a high percentage of sand residues, the pump is in continuous operation at the customer’s site without any loss of flow rate. Its use at the customer’s site over several years thus demonstrates that, in addition to the increase in efficiency, the replacement interval for spare parts has also been reduced to zero.

When redesigning a sewage treatment plant, the costumer faced the challenge to feed a centrifuge with dewatered sewage sludge having a dry matter content of > 30 per cent. The technical challenge was to find a low-maintenance yet cost-effective solution that could be installed within the confined space available. 

The customer opted for a solution from KORTHAUS: a KH PUMP, designed as  a single-cylinder plunger pump with an upstream twin-screw feeder type DS. The twin-screw feeder ensures the reliable feed of the medium into the pump. Thanks to its vertical design, the KH PUMP is very space-saving. The system has been in maintenance-free operation at the customer’s site for many years.

As part of a new construction project, a municipal sewage treatment plant was planning to install a low-maintenance high-pressure pump to feed a chamber filter press. Contaminants  of waste disposal in the dewatered sewage sludge posed an additional challenge.

The customer opted for a KH PUMP from KORTHAUS, which combines high delivery pressures with high flow rates. The hydraulic plate valves are used to cut off contaminants via a forced-switch mechanism and guarantee trouble-free operation of the pumping process. The pump has been in operation for decades without requiring any maintenance.

When redesigning a sewage treatment plant, the aim was to find a pump solution requiring as little maintenance as possible to transport dewatered sewage sludge downstream of a belt filter press. 

The customer opted for a KH PUMP with a double feeding screw. It feeds the piston pump via an S-tube approximately 2 metres long without any problems. The piston pump conveys the filter cake approximately 30 metres from the plant building to an open container. The KORTHAUS pump concept has been in maintenance-free operation for decades.

At an existing biogas plant, a customer was looking for an alternative to an installed positive displacement pump used for feeding the digester and recirculation of the pumping media. Due to high dry matter content and a large number of contaminants, the existing pump broke down very frequently and at highly irregular intervals. 

The customer opted for a KORTHAUS pump for several reasons: thanks to the contact-free operation of the pumping elements and the KD.PROTECT protection concept, KD PUMPS offer particularly long service life for the wear parts in the pumping chamber. The additional integrated hammer plate cutting mechanism reliably shreds contanminants (such as stones, grasses, fibres), thereby ensuring significantly greater overall process stability and plant availability. 

After several years of operation, the pump has consistently achieved a six- to twelve-fold improvement in service life. Plant productivity has been improved by 15 per cent. 

An international biomethane plant required a mobile unit to deal with incidents in the process plant, to supplement the existing pump units. The plant pumps industrial biomass containing high percentage of fatty acids, which frequently leads to blockages in the pipework. 

A KD PUMP - mobile unit reliably solves the plant’s day-to-day problems. Thanks to the fork lift attachments, the pump can also be installed in a stationary position. Its extremely high cavitation resistance enables it to clear blockages in the pipework. Whilst, after several years of operation, electric motors regularly had to be replaced due to reaching their load limit, the KD PUMP operates undamaged and wear-free despite high technical demands.

At a high-energy biogas plant, a search was undertaken for alternative pump technology as part of the reconception of the feed system. Previous pump systems had suffered from extreme damage and frequent breakdowns. Upstream shredding equipment was even taken out of service in order to maintain plant operations. 

During the redesign, the customer opted for a KORTHAUS KD PUMP, again without an upstream separation and shredding system. The installed pump achieves reliable and trouble-free operation whilst simultaneously improving the service life of wear parts by a factor of three to eight, depending on the specific component in the pumping chamber.

A renewable energy plant incorporating a heat recovery concept required pump technology optimised for continuous operation. The pump technology used to date had suffered from irregular failures of the pumping elements due to unexpected contaminants in the system. An additional challenge was posed by the existing installation layout, which did not allow for the addition of further shredding units. 

KORTHAUS developed a costum-fit unit for the application, featuring a sedimentation and rock trap unit on the suction side which collected the coarsest contaminants and also reduced the wear-inducing solid content in the conveyed medium. KORTHAUS supplied the custom-designed unit via a specially developed modular system at an engineering flat rate. This saved the customer the need for costly pipework modifications and enabled them to retain their old unit as part of their rotational equipment as a fail-safe measure. 

Thanks to the sedimentation and rock trap unit and thepatented KORTHAUS integrated cutting system, the customer has now achieved years of non-stop pump operation with service lives of over 10,000 operating hours for all wear and tear parts. 

A commercial customer in the waste oil disposal sector required a new pump for receiving contaminated waste oil and for removing processed separation residues after the processing of waste oil. The demanding pumping media contains a relatively high proportion of solids: 50 per cent sand and 50 per cent grey water. Aggregates used previously had an insufficient lifetime of wear and tear parts.

The customer opted for a KD PUMP due to its outstanding service life in the pumping chamber. Through the consistent use of steel pistons in a rubber-lined housing, it was possible to extend the service life by a factor of eight to ten after years of continuous operation. 

A producer and manufacturer of sugar beet products required a pump for transporting soil from beet washing. The substrate, with a dry matter content of over 50 per cent, has a slurry-like consistency and an extremely high proportion of abrasive particles. The pump had to be suitable for 24/7 continuous operation throughout the beet processing period (campaign). 

The customer opted for a KH PUMP from KORTHAUS with an upstream DS twin-screw feeder. This enables the material to be fed into the system, allowing the pump to accept a free-flowing medium and transport it further. The patented KORTHAUS hydraulic plate valves are to used cut out contaminants via a forced-switch mechanism and guarantee trouble-free operation of the conveying process. The pump has been in operation for decades without requiring any maintenance whatsoever.

A replacement for the existing pump systems was sought at an industrial wastewater treatment plant within an associated chemical park. The pumped medium, consisting of chalk milk sludge, caused extreme wear due to its very sharp-edged, abrasive particles, as well as failures caused by dry running. Furthermore, the sludge had to be pumped over a long distance, which ruled out many pump systems. 

The customer opted for a KD PUMP from KORTHAUS. Compared to other rotary positive displacement pumps, KORTHAUS rotary lobe pumps can be used for very high pressures of up to 24 bar without the need for additional systems. The pumps therefore have high pressure reserves and can maintain pressure over long transport systems. Thanks to the contact-free operation of the rotors, the wear parts are protected against dry running. After several years of the pump being in operation at the plant, continuous process stability has been achieved with excellent service life.

At an industrial recycling plant, a customer was looking for a new unit to handle contaminated, untreated thin sludge and various chemical wastes. Until now, pumping the bitumen contained in the sludge had proved problematic.  The KORTHAUS pump installed has been operating for over 10,000 hours as a ‘universal unit’ with absolutely no wear and tear, and is increasingly being used by the customer for difficult media. 

During the planning phase for an industrial slurry injection plant, a customer was looking for new pumps for cavern feeding. The existing pumps had suffered extremely frequent breakdowns every four weeks, prompting the operator to seek a change of system due to high follow-up costs. The high salt and ash content in the pumping media, as well as the presence of steel contaminants, had previously caused significant difficulties.

The customer opted for several units of KH PUMPS. Thanks to their robustness and the use of cutting valves, the pump technology has been reliably handling the extremely demanding slurry for several years now, ensuring process stability in 24/7 operation, in combination with upstream pipe storage systems for pulsation damping.   

At an international coal liquifaction plant, KORTHAUS KH PUMPS have been operating for the pumping of catalyst media successfully since 1980 in 24/7 continuous operation, completely free from any wear for several decades. Pumps used previously required quartely complete maintenance resets. The highly demanding fluid – a highly viscous oil at 200°C – contains extremely abrasive solid particles (iron oxide and tar residues) in quantities and of a quality that are equally extreme. Thanks to the patented sealing system for our KORTHAUS reciprocating pumps, which completely and hermetically separates the hydraulics from the flow circuit of the pumped medium, the system operates without wear.

As part of a plant refurbishment and expansion, the customer placed a further order for additional machines in 2016.

An industrial customer required a pump to extract solvent-contaminated slop tar from a central wastewater treatment plant. The highly viscous, tar-like sedimentation sludge consisted entirely of a mixture of various solvents used in the aromatics industry (tar derivatives: e.g. phenol, methylnaphthalene, bases) and required a wear-free pump capable of suction under vacuum for pumping.

The customer opted for a KORTHAUS KH PUMP of the “Compressor-Pump” design. In addition to its solvent-resistant properties, thanks to the machine’s elastomer-free design, it is capable of suction under vacuum. The pump can run dry indefinitely, meaning the unit has been in wear-free operation at the customer’s site for several decades.

A customer at a refinery required a reliable pump for (highly) viscous sludge residues containing solvents ('oil sludge'). The sludge was fed via a hopper, into which trucks regularly delivered batches of sludge of varying quality. The transport from the intermediate silo to the industrial sludge treatment facility, operating on a continuous basis, was also handled by a KORTHAUS KH unit.

Thanks to the machine’s elastomer-free lining, KORTHAUS KH PUMPS are completely resistant to solvents and solved the costumers pumping challenges.

A customer at an international refinery required a pump to remove sludge from crude oil tanks. The tar-like, highly viscous medium was heavily contaminated with solids and was therefore prone to wear. At the same time, the pump had to be highly resistant to dry running and capable of creating a vacuum. 

The selected KH PUMP possessed all these characteristics, so the customer opted for a solution from KORTHAUS of the Compressor-Design. It is possible to evacuate a tank to a vacuum rate up to 80 per cent whilst the unit operates completey wear-and-tear-free. The pump has been in service for several decades as a permanently installed unit.