CASE STUDY: Production Block Removed By Pipeline Lump Breaker

Device prevents plugging, gives low-cost way of upping output to meet rising sales demand.

PROBLEM: Repeated plugging of pipelines and pumping systems forced frequent and costly shutdowns for clean-out in the plant of a major chemical manufacturer. Product lumps in the liquid stream built up in the systems, and their clean-out, a difficult and cumbersome job, brought about a considerable amount of lost production time. This was particularly bad because production could not keep up with an increasing product demand under such conditions. Several systems of this kind were involved.

The company was confronted with the urgent need to increase production. They considered adding extra processing units, but this would have been extremely expensive. Lead time and plant space were also important factors weighing against solution.

SOLUTION: A new device which mechanically breaks up lumps in a flowing liquid stream was installed as a test in one system. On the basis of the excellent results obtained, seven more of the units were installed in the other systems.

In each system, liquids are first pumped to the reactor under pressure through the lump-breaking device, which is flanged right into the line. After reaction, the product is brought back through the same line and breaker, in reverse flow, but under vacuum.

The lump-breaking mechanism is operated by a small motor. A small rpm is used (as in the case cited here) where excessive agitation is undesirable. High-speed units are specified where mixing is wanted. Action tends to make the unit self-cleaning. Pressure drop is said to be usually insignificant (the device develops some pumping action).

The lump breaker is available in pipe sizes from 4 through 24" . Standard units are available for vacuum use and for a pressure of 150 psi; however, the device can be supplied to order for

pressures to 600 psi. Almost any kind of material of construction and packing type can be specified.

Results: The eight breakers have been operating for more than six months without downtime or adjustment. Production has increased to a new high level, to meet sales demand. A side benefit was found: The lump breakers have chopped the solids to a size most desirable for further processing.