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Feature Report

AODD Pumps in
Chemical Processes
Advancements in efficiency and the ability to handle a wide array of chemicals combine to make
the air-operated double-diaphragm (AODD) pump a useful choice for chemical processors

T
Edison Brito and he circumstances
Rob Jack surrounding the de-
PSG, A Dover velopment of the
Company air-operated double-
diaphragm (AODD) pumping
IN BRIEF principle six decades ago
involved a ruptured water
THE AIR IN THERE
pipe, a flooded workshop
THROUGH THICK AND and an exclamation that the
THIN idea could make a million
DISCUSSING dollars. In the ensuing 60-
DIAPHRAGMS plus years, those words have
proven to be prophetic, as
CHEMICALLY SPEAKING the AODD pump technology
that was said to be con-
ceived out of necessity, born
in the arms of innovation, and
inspired by sheer will and de-
termination has become a
frequent choice for opera-
tors in heavy-duty industries
that require the pumping of
water, slurries or any finely
divided substance, such
as cement.
AODD pumps (Figure 1)
can obtain dry self-prime,
run dry, maintain suction
lift up to 30 ft, withstand
deadhead pumping condi-
tions, operate while com-
pletely submerged and
pass solids of up to 3 in. in
diameter. However, in many
ways since their invention, FIGURE 1. AODD pumps can handle a wide variety of materials, including very vis-
cous media, and can also pass large solids
AODD pumps have be-
come pigeonholed by many pump users, the unit can now be considered a true
who see them as only usable in utilitar- process pump and has gained accep-
ian, auxiliary or basic liquid-handling and tance as such in the diverse sectors of the
transfer applications. chemical process industries (CPI), includ-
In reality, thanks to a series of notewor- ing paints and coatings, ceramics, ad-
thy refinements that have economized hesives and sealants, foods, beverages,
the AODD pumps method of operation, pharmaceuticals and cosmetics.
74 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM SEPTEMBER 2016
air usage while still maintaining its
operational characteristics.
While air loss has been a constant
concern within the operational win-
dow of AODD pumps, the earliest air
distribution systems were designed
first and foremost to battle another
operational irregularity in the AODD
pumps performance: stalling and
icing. It was only once those perfor-
mance inhibitors were conquered
that designers turned their attention
to developing ways to more efficiently
govern the pumps air consumption.
One of the first air-distribution sys-
tems designed to promote energy
efficiency featured a dial that could
FIGURE 2. The hourglass-shaped air spool (right) within some air-distribution systems decreases overall be used to tune the pumps operat-
air consumption and enables the handling of corrosive or hazardous materials ing speed by restricting the amount
of air that was allowed to enter the
The air in there and added to its bottom-line cost pump. Its a fact of AODD pump life
Despite the fact that AODD pumps of operation. that a slower-running pump is more
have proven their effectiveness in Because of that, AODD pump efficient. For example, a dial-in air dis-
utilitarian liquid-transfer applica- manufacturers must find meth- tribution system running at full throttle
tions, there has always been one ods to decrease or eliminate the air may consume 50 std. ft3/min of air in
annoying glitch in their operation: loss at the end of the pump stroke. order to pump 100 gal/min of fluid.
at the end of every pump stroke, a This led to a series of advance- Using the dial, the incoming com-
small, but still significant, amount ments in the technology behind air pressed air can be dialed back to a
of air was wasted. This kept the distribution systems that have en- 35-std. ft3/min rate, where the pump
pump from operating most efficiently abled the AODD pump to optimize will transfer the liquid at a flowrate of
80 gal/min. This is a 20% reduction
Pressure profile of standard AODD pump equipment in flowrate, accompanied by a 30%
reduction in air consumption, which
Over-filling makes the pump more efficient.
While the dial-in air-distribution
system represented an undoubted
advance in AODD pump operation,
Pressure

there was still more field that needed


to be plowed if pump performance
was to reach true levels of optimized
air consumption. A more recent tech-
Air chamber pressure nology for air-distribution systems
Liquid chamber pressure features an air-control spool (Figure
2), which is shaped, more or less, like
Time an hourglass. This development was
Pressure profile with optimized air distribution system driven by an evaluation of the pres-
sure dynamics that occur within the
AODD pump during its operation.
No over-filling
This evaluation clearly revealed
that air consumption was significantly
impacted by an increase in air pres-
Pressure

sure at the end of each diaphragm


stroke. Specifically, when the shaft
would come to a full stop at the end
of each stroke, a shift signal would
be sent to indicate that the flow of air
should cease. However, there was a
Time
small time lag between the stopping
of the shaft and the sending of the
FIGURE 3. Some AODDs experience wasted air when overfilling occurs at the end of each pump stroke,
but modernized air-distribution systems allow for more optimized air consumption by eliminating overfill signal, meaning that the full force of
76 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM SEPTEMBER 2016
FIGURE 4. An air-control spool can reduce
AODD air consumption by as much as 60%

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the compressor continued to push ances to control slip, which makes
compressed air into the air chamber, them unable to adequately adjust to
but that air was not doing any actual viscosity changes.
work and was lost to the atmosphere When working with a centrifugal
upon exhaust. pump, the fluid viscosity is a design
The function of the air-control spool factor for the pump equipment and
is to decrease the amount of air that its selection for a specific application.
is allowed into the pump at the end of Impeller dimensions and styles are
the stroke, which drastically reduces specifically tailored to be compatible
the amount of wasted energy that with thick or thin fluids. The specificity
had traditionally been force fed into with regard to fluid dynamics makes
the pump, as shown in the charts moving a pump from one application
in Figure 3. This allows the AODD to another less feasible. When work-
pump that is equipped with this type ing with an AODD pump, however,
of air-distribution system (Figure 4) to the viscosity need not be a factor
experience up to 60% savings in air for operation. This is a major bene-
consumption, while delivering more fit of the AODD pump in this realm:
yield per std. ft3/min than AODD its ability to handle multiple or dif-
pump models that feature legacy ferent viscosities without regard for
air-distribution systems. equipment setup.
For example, gear pumps may
Through thick and thin be a suitable choice for very thick
The favorable reputation of AODD oil or viscous liquids, but they are
pumps is built on the technologys poor choices for thinner liquids like
versatility, or ability to handle a wide ethanol or water. The AODD pump,
range of liquids with varying charac- on the other hand, operates consis-
teristics. One of the most important tently whether the fluid is thick, thin,
fluid properties to consider is viscos- particulate-free or laden with particu-
ity, or the thickness of the liquid that is late matter; its design allows it to pull
Your fast lane to
being transferred. A pumps true best in the liquid, no matter its composi-
advanced mixing technology:
operational efficiency is only achieved tion, and drive it downstream. AODD
if the lowest possible volume of air is pump manufacturers do publish vis-
consumed while delivering the high- cosity correction tables, but these are Phone: +1 201 825 4684
est possible flowrate, no matter the simply helpful in predicting pump per- Ext.: 222
viscosity. Specifically, in the opera- formance given specific system dis-
tion of AODD pumps, slip is almost charge and air inlet pressures and a usa@ekato.com
eliminated, regardless of the viscosity known viscosity. In reality, the design
of the fluid, as it is controlled by the of the AODD pump does not need
ball check valves in the pump. Other to change for liquids that have highly www.ekato.com
technologies, such as gear, screw viscous or very thin consistencies.
and lobe pumps, have fixed toler- Pump flow paths are another area
Circle 12 on p. 98 or go to adlinks.chemengonline.com/61499-12

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM SEPTEMBER 2016 77


where recent technological advances the past, with attendant initial cost of extreme suction conditions, the
can make it easier to efficiently trans- of ownership and maintenance cost physical location of the pump rela-
fer highly viscous or particulate-laden reductions smaller pumps equal a tive to the pumped media is a cru-
liquids. In fact, some AODD pump smaller price. cial component of application suc-
models with optimized wetted paths A caveat must be noted, though, cess, meaning that the pump should
deliver flowrates up to 50% higher that AODD pumps do have a few be moved as close to the source of
than legacy models (Figure 5). This performance limitations, most com- the fluid as possible. This will reduce
enhanced flow capability may also monly on the suction side of the the line friction leading to the pump.
allow the operator to use, for ex- pump, since the only pressure that Whenever possible, locate the pump
ample, a 2-in. pump where a 3-in. is available to bring the liquid to below the supply tank this will en-
model may have been the choice in the pump is atmospheric. In cases able gravity to assist the feeding of
the pump. Also, eliminate as many
fittings and elbows on the suction
side of the pump as possible. Op-
erators and system designers may
additionally consider over-sizing the
plumbing leading to the pump, all in
an effort to reduce friction on the suc-
tion side. Note that these are general
recommendations for any pump-
ing system and are not exclusive
for AODD pumps.

Discussing diaphragms
Theres no question that the improve-
ments in overall AODD pump opera-
tion and air-distribution system ca-
pabilities have been significant over
the years, and the same can be said
for diaphragm materials and design.
As AODD pumps have begun to be
used in more process-type applica-
tions, the advances in diaphragm
performance have kept pace. Cor-
rect diaphragm material selection is
critical to ensure safe AODD pump
operation. The six primary factors
to consider when choosing a dia-
phragm are as follows:
Chemical compatibility
Temperature range
Abrasion resistance
Flex life
Performance
Cost
To help meet these diverse opera-
tional criteria, the number of effective
diaphragm materials has also grown
and now consists of three basic sub-
sets: synthetic rubbers, such as Neo-
prene, Buna-N, ethylene propylene
diene monomer (EPDM) and Viton;
thermoplastic elastomers (TPEs), such
as polyurethane, Santoprene, Hytrel
and Geolast; and polytetrafluoroeth-
ylene (PTFE or Teflon). Manufacturers
have experts on hand to help pump
users select the best diaphragm ma-
terial and design for their applications.
Circle 20 on p. 98 or go to adlinks.chemengonline.com/61499-20
78 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM SEPTEMBER 2016
which means that all product- phragms; this material has the lowest
entrapment areas and leak compression set of any elastomer in
points between the piston use and performs well in sealing the
and diaphragm have been diaphragm at the inner/outer piston
eliminated, resulting in a reduc- interface and the outside diameter
tion in the chance that prod- bead.
uct contamination or leaks
will occur. Chemically speaking
Integral-piston diaphragms So, what does all of this mean for
are also easily cleanable and the CPI? Chemical manufacture fea-
there is no interaction between tures some of the most intricate and
the diaphragm and the outer complex industrial processes in the
piston plate that can lead to world. The complexity of chemical
abrasive diaphragm failure. For manufacture is highlighted by the
the chemical facility operator, vast number of unit operations that
downtime and pump mainte- must be completed during the overall
nance are typically more ex- manufacturing process.
pensive than the spare parts re- One of the most critical of these unit
quired to keep the AODD pump operations is the transfer of liquids
operating. This allows the pump along the production chain. Because
to run twice as long before re- of the importance of the myriad trans-
quiring maintenance and will ferring operations within the entire
translate directly to a healthier chemical-manufacturing process
bottom line. raw materials to storage tanks, raw
FIGURE 5. AODD pumps flow paths can be optimized to
further reduce air consumption
In general, standard AODD materials to blending tanks, finished
pump builds that feature PTFE products into fixed-weight containers
Advances have also been made diaphragms have a Neoprene and so on facility operators must
in diaphragm design that help make backup for reduced-stroke configu- identify the best pumping technology
the AODD pump more hygienic in rations and a Santoprene backup for the job, one that possesses the
its operation, which allows its use in in full-stroke configurations. Santo- versatility to perform reliably and ef-
contamination-sensitive manufactur- prene is actually an excellent backup ficiently at any number of points in the
ing applications like food and bev- choice for both reduced- and full- production hierarchy.
erage, pharmaceutical and personal stroke diaphragm configurations It had almost become an auto-
care. Integral-piston diaphragm de- since it has excellent chemical-re- matic choice among chemical manu-
signs place the shaft-connecting sistance properties and long flex life. facturers that centrifugal pumps were
plates within the diaphragm itself, Another option is Hytrel backup dia- the best technology for transfer op-

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CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM SEPTEMBER 2016 79


it will nonetheless deteriorate the
pumps operational capabilities con-
tinuously, meaning that the pumps
ability to handle any resultant cavita-
tion will be compromised.
By comparison, the fluid-delivery
curve for an AODD pump is very simi-
lar to that of the centrifugal unit, but
without the negative behavior that
occurs when operating away from
BEP. The AODD pump will perform
based on the inlet air pressure sup-
plied to the pump and the system
pressure it encounters. If adequate
suction pressure is available, fluid
will flow into the pump and be dis-
charged based on the relationship
between the air pressure operating
the pump and the system pressure.
FIGURE 6. A major advantage of AODD pumps is the simplicity of their integration into existing The larger this pressure differential
plant footprints is, the faster the pump will operate,
and when the differential is reduced,
erations within the chemical plant, for also with regard to the production the pumps operation will slow. This
several reasons: process and the way the chemical is referred to as infinitely variable
Centrifugal pumps work best with is formulated. speed operation. If the system pres-
thin, water-like fluids, which have Additionally, when a centrifugal sure should increase unexpectedly,
long been a staple in chemical pump operates below its BEP, radial the pump will operate until the inlet
manufacturing loads increase due to the way the air and system pressure are equal, at
A kind of if it aint broke dont fix pump generates pressure along its which time the AODD pump will stop
it attitude has made the centrifu- volute by reducing the fluid velocity. in what is termed a deadhead
gal pump an easy fallback option This method of operation increases condition with no equipment
for operators who have undoubt- shaft deflection at the seal faces, damage. The system remains pres-
edly worked with the technology which results in increased seal wear surized, but no differential pressure
at some point in their careers and a decrease in the pumps life ex- exists to continue driving fluid. The
There was an overriding percep- pectancy. Working to the left of the pump will restart when the system
tion that centrifugal pumps have curve will also increase axial loads that pressure falls below the operating
a lower operating cost when can overload the thrust bearings, es- air pressure, which is particularly im-
compared to the operations of an pecially in open-impeller and diffuser- portant in batch processes.
AODD pump, but this has been type multi-stage centrifugal pumps. In contrast, a closed valve can
shown to not necessarily always Finally, as a centrifugal pump oper- cause damage to or destroy a cen-
be the case ates close to the zero-flow point (zero trifugal pump, and with different
A closer look, though, shows that efficiency), heat will be generated at positive-displacement pump tech-
despite its reputation, the centrifu- levels that can be highly harmful to nologies operating against a closed
gal pump doesnt appear to be the heat-sensitive chemicals or products valve, can create havoc for a system
all-conquering technology that is themselves, which can also adversely by reaching the burst pressure of the
required for efficient and optimized affect safety and the quality of the piping in very short order.
chemical-processing applications. resulting product. If a valve is restricted on the inlet
Specifically, centrifugal pumps At the other end of the spectrum, side of a centrifugal pump, the pump
work best when they are operated when a centrifugal pump works above can cavitate, leading to impeller and
at their best efficiency point (BEP). its BEP, other problems may occur. volute damage. If the inlet were closed
Unfortunately, that BEP is rarely real- Specifically, the level of net positive completely, the operator should ex-
ized for an extended period of time suction head (NPSH) required in- pect bearing and wear-ring failure due
during typical fluid-transfer opera- creases, which may cause efficiency- to heat buildup. If this condition oc-
tions, which can result in flowrates harming cavitation to occur. Since curs when operating an AODD pump,
that may fluctuate constantly. Ad- liquid-transfer processes in the CPI, the pump will slow, and if the inlet
ditionally, consistent operation away particularly when handling specialty were closed completely, the pump
from the BEP can lead to potential chemicals, are managed in batches, would stop, waiting for the inlet line
problems, not only from the equip- an insufficient NPSH condition may to be open once more, when it would
ments operational point of view, but be more complicated to detect, but resume its pumping operations.
80 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM SEPTEMBER 2016
In summation, AODD pumps accessories consist typically of Authors
can match the assumed advan- solenoid operators, pump-cycle Edison Brito is the global sales di-
tages that centrifugal pumps counters and surge-dampener rector for diaphragm equipment at
Wilden Pump & Engineering, LLC
may have while also highlighting assemblies and PSG (1815 S. Meyers Rd, Oak-
some of the centrifugal pumps Operating costs can be similar brook Terrace, IL 60181, USA;
operational disadvantages: when all the maintenance, ac- Phone: (973) 780-7985; Email: edi-
son.brito@psgdover.com). He is re-
AODD pumps are eminently ap- cessories and controllers are sponsible for the sales and business
propriate for use with liquids with evaluated, and in many cases, the development for the following PSG
pump technologies: air-operated
high viscosity and can easily move total cost of ownership is lower double-diaphragm, controlled-volume metering and peri-
fluids that range from water-like over the operational lifespan of an staltic. Brito has 20 years of experience in fluid transferring
liquids to medium and very AODD pump when compared to a applications and equipment, including pumps (AODD,
controlled-volume metering pumps, centrifugal, vane, gear
viscous liquids centrifugal model and vane) and compressors (liquid ring, screw and recipro-
AODD pumps can run dry and From its inception, the industrial cating). He holds mechanical engineering and M.B.A. de-
strip discharge lines without get- pump has faced the same demand grees from Polytechnic National School University of Quito-
Ecuador. Brito has been a member of ASHRAE
ting damaged; if the pressures are from its operators: perform its duties for 14 years.
too high, the pump will just stop reliably and with a limited amount of Rob Jack is a product develop-
running, but will not break. On the downtime and ancillary repair or re- ment engineer for Wilden Pump &
other hand, centrifugal pumps placement costs. The AODD pumps Engineering, LLC and PSG (22069
Van Buren Street, Grand Terrace,
cannot run dry, and when extra operational characteristics dry-run CA 92313; Phone: (909) 422-
pressure is created, their seals, capability, high suction lift, particu- 1784; Email: rob.jack@psgdover.
bearings and piping can break, late-handling, to name a few can com). His work involves material
selection and qualification, as well
which leads to added down- make it suitable for chemical manu- as component design and valida-
time and repair costs, as well as facturers who are searching for a tion. With more than 20 years ex-
perience in air-operated diaphragm pumps, Jack has
increased safety risks for plant pump technology that meshes cost- developed a diverse range of products, including high-
personnel conscious energy consumption with performance air motors, and integral piston diaphragms
AODD pumps are very simple streamlined flow. for sanitary applications. He holds a B.S. degree in me-
chanical engineering from California State Polytechnic
devices (Figure 6), and controlling Edited by Mary Page Bailey University-Pomona and also an M.B.A.

THINI
LONG TERM
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CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM SEPTEMBER 2016 81
Circle 14 on p. 98 or go to adlinks.chemengonline.com/61499-14

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