How to Manage Pumping of Stock,

Liquors, and Other Liquids with

a High Air or Gas Content?
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E00544 en (2) article 10.2002 (2000), Copyright © Sulzer Pumps Finland Oy

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products. Directions for use and safety will be given separately. All information herein is subject to change without notice.
Sulzer Pumps' Solutions Illustrated by
Practical Examples
1. General on air and gas
content
The liquids pumped always contain
some gas, usually air, unless this gas
has been specifically removed, for in-
stance by boiling. The gases can be
present in the liquid in three different
states:
• Dissolved in the liquid.
• Bound on the particles contained in
the liquid.
• As free gas in the form of bubbles.
1.1. The amount of gas dissolved in
the liquid depends on the gas, liquid,
temperature, pressure etc. This gas
dissolved in the liquid does not sepa-
rate from the liquid unless the liquid
pressure is decreased or the liquid
temperature is raised. The separation
of this dissolved gas is best seen as
bubbling just before the liquid begins
to boil. This dissolved gas does not
usually separate from the liquid, and
its content is not considered when the
amounts of gas are given.
1.2. The gas bound on the surface of
particles contained in the liquid has
very small bubbles. Stock fibers which
have been dried once contain air in
their hollow lumen, even after pulping.
Under normal conditions, this gas
does not disturb pumping, either. How-
ever, this air may cause problems in
other process equipment such as
washers and the wire section of a pa-
per machine.
1.3. Air contained in a liquid such as
fiber suspension in the form of bubbles
disturbs pumping. Bubble-form air is
attached to the fibers or it is present
between them. The higher the stock
consistency, the higher the air content.
The air content depends on the stock
type, stock characteristics etc.
Typical values for the air content in
stock have been given in Fig. 1.
This air in bubble form enters the
pumped liquid from several sources
such as:
• The cooking process produces car-
bon dioxide, formic acid, mercaptans,
dimethyl sulphide etc. The oxygen
bleaching reaction also produces car-
bon dioxide.
• In certain processes, air or gas is
added into the liquid so as to achieve
the desired result. Ink particles are re-
moved from recycled fiber by means
of the flotation method, where air is
introduced into the stock.
• The process industry commonly
uses equipment whose structure al-
lows the mixing of air into the liquid.
This is particularly problematic in pro-
cess stages following the cooking pro-
cess where soap contributes to foam-
ing and mixing of air.
- In the pulp and paper industry, stock
drops several meters from almost all
filters to a tank situated beneath. Air is
efficiently mixed into the stock during
this free fall.
- Stock is often fed into a storage tower
through the top of the tower, through
its center section. The resulting free fall
may be dozens of meters, causing air
to be mixed with the stock.
• Inadequately designed or imple-
mented pumping solutions cause un-
desirable mixing of gases or air with
liquids (Fig. 2, 3 and 4).
• Leaking seals in valves and pumps
and other leaks in the vacuum system
may also cause air to be mixed into
the liquid pumped.
All of the above causes can lead to a
situation where pumping with conven-
tional centrifugal pumps is no longer
possible.
TMP
Maple
Spruce
Softwood
Kraft samples
Fig. 1. Air content in the stock.
Up until now, the most reliable means
to lead away the separated water from
the water separators has been to use
barometric legs, i.e. pipes led into a
seal pit. The necessary vacuum of up
to 0.7 bar (70 kPa) requires a seal pit
depth of approx. 10 meters, which is
relatively expensive to make. More-
over, the length of the vertical pumps
required in seal pit service, approx. 10
meters, means that the pumps are dif-
ficult to service. The pumps also need
a level control system because of the
risk of running the pumps dry.
Fig. 22. a) A typical piping arrangement for liquid
ring pumps.
Fig. 22. b) ARP Pumps connected to water
separators.
Experience has shown that by install-
ing an air and gas separating
AHLSTAR™ ARP Pump immediately
below the water separator, water sepa-
ration is at least as reliable as with the
use of barometric legs.
Advantages given by the use ARP
Pump:
• Simple location of water separators.
• Water separated at the various suc-
tion locations can be easily led to the
desired applications.
• No need for level control equipment
in the water separators.
• No need for deep seal pits, long
barometric legs, or vertical pumps.
Fig. 23. AHLSTAR™ ARP Air Separating Pump.
6. Summary
Features and benefits of air and gas
removal AHLSTAR™ ARP and ASP
Pumps in pulp and paper applications:
• Difficult and even to date unsolved
pumping problems have been solved.
• Trouble free process operation de-
spite high air content.
• The efficiency of other process
equipment is improved due to gas and
air removal.
• The need for expensive antifoam
agents is reduced.
• The need for chemicals which bur-
den the environment is consequently
reduced.
• Overall pumping efficiency is im-
proved.
• Most of the spare parts are inter-
changeable with the other AHLSTAR™
Pumps.
• An APP Pump can be later converted
into an ARP Pump and vice versa.
5.3 TMP plant processes
Case 1 (Fig. 20): Pumping TMP
reject from refiners to refined
reject tank.
The reject handling system at the TMP
department of a paper mill was mod-
ernized. In this conjunction, the mill
wanted to replace the existing trans-
fer system where five screws trans-
ferred the 25% refined reject to a re-
ject tank. In the reject tank, the stock
was diluted to 2 to 3%. From the reject
tank, the stock was pumped further to
screening.
In the new solution, an inlet tank was
installed under the refiners on the floor
below, where the stock was diluted di-
rectly to 2 to 3%. It was also assumed
that the stock contains a lot of air and
that the tank has a low level. The pump
selection process concluded in the gas
and air removing AHLSTAR™ ASP
Pump with a built-in degassing sys-
tem. The degassing return pipe was
led back into the inlet tank.
The gas and air removing ASP Pump
has operated well in this application
since spring 1997. The ASP Pump fea-
tures the following benefits:
• Simple transfer system,
• low maintenance costs,
• additional reliability at the mill.
Fig. 20. Reject screening in a TMP plant.
5.4 Paper mill processes
Case 1 (Fig. 21): Deflaking and
pumping of broke stock to ma-
chine chest.
At the stock preparation department of
a paper mill, broke stock is pulped at a
consistency of 5 to 7%. After pulping,
the stock is pumped into two alternate
tanks using an AHLSTAR™ NPP
Pump. In order to guarantee good stock
quality, stock is recirculated 2 to 3 times
through a deflaker using a conven-
tional stock pump situated between the
tanks. After this, the stock is pumped
from the tank into a mixing chest. The
inlet head in the tank varies between
4.5 and 0 meters. At the end of the
emptying stage, at a small inlet head,
the air contained in the stock began to
separate in front of the impeller, and
the pump was not able to empty the
tank completely. The mill carries out
several color changes due to a cer-
tain production program. It is very im-
portant to empty the tank completely
in order to minimize the proportion of
waste stock.
Fig. 21. A part of a broke stock line.
An AHLSTAR™ ARP air removal pump
without a vacuum pump was installed
as the recirculation and emptying
pump. The ARP Pump features an air
separating expeller behind the impel-
ler, separating from the stock any air
which disturbs pumping. The stock is
returned to the suction side of the
pump, and the degassing pipe is led
to the top part of the tank. With this con-
figuration, the AHLSTAR™ ARP Pump
empties the tank completely, eliminat-
ing the amount of waste stock.
Case 2 (Fig. 22): Separating and
pumping white water from water
separators in the vacuum system
of a paper machine or pulp drying
machine; replacing the barometric
leg.
Water removed from the web of a pa-
per machine by means of vacuum is
separated in water separators situated
between the paper machine and the
vacuum system. It is important that this
water is separated as completely as
possible so that only moist air goes
into the vacuum pumps.
Fig. 2. If the end of the inlet pipe going
into a tank is situated above the liquid
level, the inlet flow of the liquid mixes air
efficiently into the liquid.
The situation is aggravated by factors
such as:
• Additives contained in the liquid
such as soap, emulsifying agents, de-
tergents, dispersion agents, lignin
compounds, and alum.
• Characteristics of the liquid such as
stock consistency (the higher the con-
sistency, the higher the air content) and
production method used (various types
of stocks contain different amounts of
air under identical conditions), refin-
ing degree (refining increases the air
content), fillers, viscosity of the liquid,
and temperature of the liquid.
Fig. 6. If the liquid contains approx. 4 % of free gas or air, a conventional centrifugal pump can generally still pump it.
However, the flow rate, head, and efficiency of the pump decrease as the gas or air content increases.
Fig. 3. If the liquid level in the tank is
kept so low that the blades of the
agitator break the liquid surface, the
agitator mixes air into the liquid.
2. How does the air prob-
lem appear in pumping?
When a conventional centrifugal pump
(Fig. 5) pumps a liquid containing a lot
of gas or air, such as stock, filtrate wa-
ter etc., the free gas or air contained in
the liquid begins to gather in front of
the impeller. The lighter gas or air is
separated at the point of the lowest
pressure, which is often in front of the
impeller. Hence, an air or gas bubble
is formed here. That section of the
vanes of the impeller which is inside
the bubble loses some of its pumping
efficiency. This way, the output of the
pump decreases (Fig. 6). As the bubble
Fig. 4. If the level in the suction tank of
the pump is too low, a so-called vortex
phenomenon will be created above the
suction pipe, causing air to enter the
pump.
grows big enough, it begins to disturb
pumping and the operation of the en-
tire process. Pumping may also cease
completely. The air or gas bubble re-
mains in front of the impeller for as long
as the pump rotates. If the pump is
stopped for a while, the bubble will
disappear. After restarting, the pump
will run normally until a new bubble
starts to form. In general, stopping and
restarting pumps this way is unaccept-
able.
Fig. 5. The free gas or air begins to
accumulate in front of the impeller.
3. What are the traditional stance, a displacement pump. How- moving this disturbing gas or air in the 5.2 Pulp mill processes • The lobe rotor pump is an expen- Case 2 (Fig. 19): Feeding brown
means for eliminating ever, this solution is not always eco- pump, the pump operation becomes sive and complicated special pump. stock to washer.
nomical. If the liquid pumped contains stable. This also enhances the opera- Case 1 (Fig. 18): Pumping soap • The pump maintenance is difficult
disturbances caused by
solids, which is often the case, screw tion of the entire process and other from the washing department to and also its spare parts are expensive. At a pulp mill, brown stock is pumped
air and gas?
pumps, lobe rotor pumps etc. wear rap- process equipment. the evaporation plant. from a blow tank into an intermediate
idly. As the capacities of mills just keep The AHLSTAR™ ARP Pump with a tank. From the intermediate tank, an
Since stable pumping is imperative in
increasing, the size of displacement 4.1 Sulzer Pumps' pump The cooking process produces a lot of degassing system was installed for the APP Pump pumped this stock with a
view of the operation of the entire pro-
pumps also imposes limitations. solutions for liquids con- various gases. In conjunction with first time at a pulp mill in 1991 to pump consistency of 3 to 5% via knot sepa-
cess, factors enabling trouble-free
taining gas or air: stock washing, these gases enter the the soap mixture from the washing ration to a washer. The brown stock
pumping have been studied in the past.
4. New pump solutions filtrate tank with the wash liquor. Since department to the evaporation plant, temperature was approx. 90°C, and it
The means discovered include,
4.1.1. The AHLSTAR™ APP pump soap contained in the black liquor where the actual soap separation from contained a lot of gas, air, and foam.
among others, the following:
Sulzer Pumps has developed pump range includes the ARP Pumps (Fig. makes up very stable foam together black liquor takes place. The inlet head The problem was that the entrained
types which through their operating 7), which are used to pump stocks con- with the gases, soap separates on top in the soap tank varies between 0 and air caused fluctuations in the display
3.1 Optimizing the conditions on the
principle remove disturbing gas or air taining considerable amounts of gas of the black liquor, from where it is led 1 meters. of the feed flow rate measurement. This
suction side of the pump
contained in the liquid so as to main- and air at a consistency range of up to into a separate soap tank. From the in turn resulted in control problems.
• Size of suction pipe.
tain proper pumping and to prevent 8%, plus other process liquids. A sepa- soap tank, soap is pumped to a soap The ARP Pump has been working well
• Shape of suction pipe.
any pumping disturbances resulting rate vacuum pump is used in conjunc- collecting tank situated at the evapo- here. After this, several other ARP In June 1997, a gas and air removal
• Correct location of suction pipe in
from the gas or air. In these pumps, tion with the ARP Pump if the inlet head ration plant. The density of soap com- Pumps and more recently also ASP AHLSTAR™ ARP Pump with a sepa-
the tank.
gas or air is removed by creating a on the suction side is low. The ARP ing from the washing department can Pumps with a built-in vacuum pump rate degassing system was installed
certain pressure difference between Pump is also self priming when a be as low as 300 kg/m because of the have been installed in various appli- in this service. After the installation,
3.2 Overdimensioning instructions for
the suction side of the pump and the vacuum pump is used with it. gases contained in it. cations both at the cooking plant and there have been no problems in flow
pumps have been provided on account
degassing chamber, situated behind This difficult mixture has earlier been at the washing department. rate measurement.
of the gas content. These are partly
the impeller. This pressure difference Based on long-term experiences, the pumped from the soap tank to the
practicable even today.
is achieved for instance through suffi- ARP Pump operates trouble-free with evaporation plant using a lobe rotor Benefits brought by the AHLSTAR™ In this application, the ARP Pump gives
cient inlet head prevailing in front of liquids which contain up to 70% of air pump. ARP and ASP Pump: the following advantages:
3.3 It has also been studied which
the pump. If sufficient inlet head can- or gas. The degassing system removes The following problems have been • The disadvantages of lobe rotor • Better runnability at the washing
types of impellers, clearances, and
not be achieved, the pressure differ- that proportion of the gases or air con- encountered in the use of the lobe ro- pumps are eliminated. department, since the feed flow rate is
other potential structures best tolerate
ence can be created either with a sepa- tained in the liquid which disturbs tor pump: • Improved soap separation. under control.
liquids containing gas or air. The effect
rate or built-in vacuum pump. By re- pumping. • The soap mixture pumped has • Better, fiber-free soap quality • Improved drainage at the washer.
of turbulence for instance in the impel-
foamed from the tank onto the floor, (pumping through fiber filter). • More opportunities to optimize
ler has also been examined.
causing additional need for cleaning. brown stock washing.

3.4 Use of defoamers. If none of the

above means have solved the pump-
ing problem, a common method was
and is to use defoamers. However,
their cost often rises to millions of
marks or more annually, and they load
the environment to a certain degree. It
has also been noticed that some de-
foamers may cause sedimentation in
the process equipment.

3.5 Use of other pump types. If a cen-

trifugal pump has not operated prop-
erly using the above means, it has Fig. 7. AHLSTAR™ ARP Air/Gas Separating Pump.
sometimes been replaced with, for in- Fig. 18. Washing department. Fig. 19. Brown stock washing.
Case 3 (Fig. 15): Pumping re-
cycled fiber to screw presses
A) The following conditions prevailed
in a recycled fiber mill application
where stock enters the dilution tank
from a disc filter:
The consistency of the stock coming
from the disc filter is 14 to 17%. The
stock is diluted in the feed screw and
in the tank to 5.5 to 6%, which was the
desired feed consistency for the
presses. Both presses had their own
feed pumps. Strong turbulence, air, and
foam occurred in the tank.
The APP Pumps which were used
here were able to pump at a consis-
tency of slightly above 4%. First, only
one of the feed pumps was replaced
with an AHLSTAR™ ARP Pump with a
Disc filter
14-17%
AHLSTAR™ ARP
Fig. 15. Pumping deinked stock to screw presses.
Washer
10-12%
AHLSTAR™ APP
Fig. 16. Pumping stock to screw presses.
separate vacuum pump. The consis-
tency objective was achieved, and the
other feed pump was also replaced
with an ARP Pump.
In recycled fiber applications, the air
content can be high, which easily
causes problems in stock pumps.
Is an ARP Pump always required?
B) Stock is pumped in an application
(Fig. 16) resembling the above, with
the stock coming from a washer at a
consistency of approx. 10 to 12%. The
stock is diluted to the desired consis-
tency in a feeding tank situated be-
neath the washer; in this case, the tar-
get consistency was 7 to 7.5%. An or-
dinary AHLSTAR™ APP Stock Pump
managed this application without prob-
lems. The stock flow was distributed to
Fig. 17. Waste water application.
two different presses. Air content in this
particular stock application was low
enough to enable proper operation
with a conventional stock pump.
Case 5 (Fig. 17): Pumping sludge-
containing waste water from the
paper mill to waste water treat-
ment.
From a paper mill, sludge-containing
waste water is pumped to an outdoor
tank with a depth of approx. 5 m. The
consistency of this waste water is 0 to
4%.
A rotary-type displacement pump was
earlier used in this application. How-
ever, its rubber rotor wore rapidly,
since the liquid pumped is also some-
what abrasive. The maintenance costs
of the displacement pump hence were
high.
An AHLSTAR™ ASP Pump with a built-
in vacuum pump was installed for trial
purposes in the fall of 1996, and the
pump worked trouble-free right from
the beginning.
The benefits of the ASP Pump include:
• Easy use of a centrifugal pump,
• low maintenance costs.
Operating principle (Fig. 8.):
In the AHLSTAR™ ARP Pump, air or
gas, which is present in the form of a
bubble in front of the impeller or some
other location with a low pressure, is
led to the back of the impeller through
the channels in the impeller. There is
an expeller on the shaft of the pump,
separating liquid from the air or gas
which enters through the channels. The
liquid is returned along a separate
pipe to the inlet side of the pump, and
the gas or air is led in another pipe out
of the pump.
Fig. 8. Operating principle.
Fig. 9. AHLSTAR™ ASP Self Priming Gas Removal Pump.
If the ARP Pump has a suitable inlet
head, no vacuum pump is needed. The
removed gas or air can be led directly
to a floor channel, for instance.
If no sufficient pressure difference is
achieved, the necessary pressure dif-
ference is created by means of a sepa-
rate, small water ring vacuum pump.
If there is a vacuum in the tank, the
degassing system is connected to the
top part of the tank. No separate
vacuum pump is needed in this case.
Depending on the size and speed of
the ARP Pump, the inlet head in the
liquid tank can be 10 to 15 meters of
water column. In applications requir-
ing the self priming feature, where a
vacuum pump is used, the suction
head of the pump can be even approx.
7 to 8 meters.
In special applications, the ARP Pump
can remove even more air from the liq-
uid by reducing the pressure on the
suction side of the pump. In this case,
the volume of the gas increases, which
means more efficient gas removal from
the liquid.
The ARP Pump is suitable for the fol-
lowing capacities: Q=1800 l/s, H=160
m, temperature 180°C.
4.1.2 The AHLSTAR™ pump range
includes also the ASP self priming gas
removal pumps (Fig. 9). They are highly
suitable for the pumping of liquids con-
taining air or gas when the liquids do
not contain abrasive particles and
when there is a low inlet head or a
vacuum on the inlet side of the pump.

Fig. 10. Operating principle.
Operating principle (Fig. 10):
The AHLSTAR™ ASP Pump has a
small water ring vacuum pump situ-
ated behind the impeller. Gas or air
enters the vacuum pump through the
channels in the impeller. In order to
make gas or air removal possible, a
certain pressure difference is main-
tained between the suction side of the
pump and the vacuum pump by means
of a vacuum relief valve. The removed
gas or air is returned to the suction
tank, to collection, or to a floor chan-
nel. The vacuum pump obtains the liq-
uid it requires during starting for in-
stance from the liquid pumped. Since
the ASP Pump is provided with a me-
chanical seal, it requires sealing wa-
ter during operation. This water is also
used as running water in the vacuum
pump, for instance during starting.
The recommended inlet head in the
liquid tank is generally 0 to 3.5 meters.
In applications requiring self priming,
the suction head of the ASP Pump can
be up to 7 or 8 meters, depending on
the pump size and speed.
When the ASP Pump operates as a
self priming pump, the discharge valve
must be closed upon starting. Once the
pump casing is filled with liquid, the
pump begins to operate in the same
manner as an ordinary centrifugal
pump. However, the difference to other
5. Practical examples and
experiences
In the following practical solutions, we
will concentrate on user experiences
gained from the above AHLSTAR™
ARP and ASP Pumps.
5.1 Processes in recycled fiber
mills
self priming centrifugal pumps is that
Case 1 (Fig. 12): The following
any gas or air disturbing pumping is
example is an indication of the
continuously removed through the
effect of air and gas removal on
vacuum pump.
the operation of the pump:
The ASP Pump is suitable for the fol-
In a recycled fiber line, unsorted re-
lowing maximum capacities: Q=1300
cycled fiber stock is pulped at a con-
l/s, H=160 m, temperature 180°C.
sistency of approx. 15%, diluted to
approx. 6%, pumped into an interme-
4.1.3 Other pumps suitable for liquids
diate tank, and further to a feeding
®
containing gas or air include the MC
tank. The consistency in the feeding
Pumping Systems (Fig. 11). These are
tank is 3.5%. Strong turbulence, air, and
used at consistency ranges of up to
foam occur in the feeding tank, and it
18 %. The air content in medium con-
also contains impurities (plastics, pa-
sistency stocks can be 10 to 40%, de-
per clips, sand), which are separated
pending on the pumping stage, stock
in a high-density cleaner and Spectro
type, temperature, etc. In these pumps,
screen.
air removal is a basic necessity to en-
able pumping over the entire medium
consistency range.
Fig. 12. AHLSTAR™ ARP Pump feeding HD Cleaner
and Spectro Screen.
Fig. 11. MC® Pumping System.
Fig. 13. The behavior of APP and ARP pump.
The APP Pump which was originally
used in this position did not operate in
a stable manner. This is described by
phase A in Fig. 13. The flow rate of the
pump began to decrease gradually,
with simultaneous operational distur-
bances in the process. After a while,
the pump was stopped for a moment
and restarted, which made the pump
run properly for some time, but with a
decreased flow rate. Stopping and re-
starting were repeated.
The APP Pump was replaced with a
gas and air removal AHLSTAR™ ARP
Pump provided with a separate
vacuum pump. The pump operation
became stable as shown by phase B
in Fig. 13.
Fig. 14. Voith flotation cells.
Case 2 (Fig. 14): Application in a
flotation line
There are several applications in flo-
tation lines (Fig. 14), where the liquid
pumped contains considerable
amounts of air or foam.
A) These types of applications include,
for instance, the cyclone tank for stock
entering the deaeration cyclone
through the overflow of primary flota-
tion cells (Fig. 14, A), where the pump
pumps the air-containing stock with a
consistency of approx. 1% to the sec-
ondary flotation cells. The cyclone tank
is normally small, it contains a lot of
foam. Reliable operation here is
achieved with the ARP or ASP Pump.
B) The pump serving the foam collect-
ing tank (Fig. 14, B) following the sec-
ondary flotation cells is another excel-
lent application for the gas removal
pump.
This tank is normally small, the level is
low, and the tank contains a lot of air
and foam. In one application, this po-
sition was originally provided with an
APP Pump where the head was
overdimensioned. Attempts were
made to keep the pump running by
using spray nozzles above the tank to
eliminate foaming. Even this did not
help.
The APP Pump was replaced with an
AHLSTAR™ ARP Pump. The pump
began to operate well with a separate
vacuum pump. A similar AHLSTAR™
ASP Pump can also be used in this
position.
C) In some cases, it is also worthwhile
installing an ARP Pump with degas-
sing for pumping primary flotation cell
accept from the feed chest (Fig. 14, C)
to the cleaners. Depending on the size
of the chest, the stock may contain
considerable amounts of air which in
turn may cause pressure fluctuations.
These may give cause to control prob-
lems in the system and even impair
the separation capacity of cleaners.

Fig. 10. Operating principle.
Operating principle (Fig. 10):
The AHLSTAR™ ASP Pump has a
small water ring vacuum pump situ-
ated behind the impeller. Gas or air
enters the vacuum pump through the
channels in the impeller. In order to
make gas or air removal possible, a
certain pressure difference is main-
tained between the suction side of the
pump and the vacuum pump by means
of a vacuum relief valve. The removed
gas or air is returned to the suction
tank, to collection, or to a floor chan-
nel. The vacuum pump obtains the liq-
uid it requires during starting for in-
stance from the liquid pumped. Since
the ASP Pump is provided with a me-
chanical seal, it requires sealing wa-
ter during operation. This water is also
used as running water in the vacuum
pump, for instance during starting.
The recommended inlet head in the
liquid tank is generally 0 to 3.5 meters.
In applications requiring self priming,
the suction head of the ASP Pump can
be up to 7 or 8 meters, depending on
the pump size and speed.
When the ASP Pump operates as a
self priming pump, the discharge valve
must be closed upon starting. Once the
pump casing is filled with liquid, the
pump begins to operate in the same
manner as an ordinary centrifugal
pump. However, the difference to other
5. Practical examples and
experiences
In the following practical solutions, we
will concentrate on user experiences
gained from the above AHLSTAR™
ARP and ASP Pumps.
5.1 Processes in recycled fiber
mills
self priming centrifugal pumps is that
Case 1 (Fig. 12): The following
any gas or air disturbing pumping is
example is an indication of the
continuously removed through the
effect of air and gas removal on
vacuum pump.
the operation of the pump:
The ASP Pump is suitable for the fol-
In a recycled fiber line, unsorted re-
lowing maximum capacities: Q=1300
cycled fiber stock is pulped at a con-
l/s, H=160 m, temperature 180°C.
sistency of approx. 15%, diluted to
approx. 6%, pumped into an interme-
4.1.3 Other pumps suitable for liquids
diate tank, and further to a feeding
®
containing gas or air include the MC
tank. The consistency in the feeding
Pumping Systems (Fig. 11). These are
tank is 3.5%. Strong turbulence, air, and
used at consistency ranges of up to
foam occur in the feeding tank, and it
18 %. The air content in medium con-
also contains impurities (plastics, pa-
sistency stocks can be 10 to 40%, de-
per clips, sand), which are separated
pending on the pumping stage, stock
in a high-density cleaner and Spectro
type, temperature, etc. In these pumps,
screen.
air removal is a basic necessity to en-
able pumping over the entire medium
consistency range.
Fig. 12. AHLSTAR™ ARP Pump feeding HD Cleaner
and Spectro Screen.
Fig. 11. MC® Pumping System.
Fig. 13. The behavior of APP and ARP pump.
The APP Pump which was originally
used in this position did not operate in
a stable manner. This is described by
phase A in Fig. 13. The flow rate of the
pump began to decrease gradually,
with simultaneous operational distur-
bances in the process. After a while,
the pump was stopped for a moment
and restarted, which made the pump
run properly for some time, but with a
decreased flow rate. Stopping and re-
starting were repeated.
The APP Pump was replaced with a
gas and air removal AHLSTAR™ ARP
Pump provided with a separate
vacuum pump. The pump operation
became stable as shown by phase B
in Fig. 13.
Fig. 14. Voith flotation cells.
Case 2 (Fig. 14): Application in a
flotation line
There are several applications in flo-
tation lines (Fig. 14), where the liquid
pumped contains considerable
amounts of air or foam.
A) These types of applications include,
for instance, the cyclone tank for stock
entering the deaeration cyclone
through the overflow of primary flota-
tion cells (Fig. 14, A), where the pump
pumps the air-containing stock with a
consistency of approx. 1% to the sec-
ondary flotation cells. The cyclone tank
is normally small, it contains a lot of
foam. Reliable operation here is
achieved with the ARP or ASP Pump.
B) The pump serving the foam collect-
ing tank (Fig. 14, B) following the sec-
ondary flotation cells is another excel-
lent application for the gas removal
pump.
This tank is normally small, the level is
low, and the tank contains a lot of air
and foam. In one application, this po-
sition was originally provided with an
APP Pump where the head was
overdimensioned. Attempts were
made to keep the pump running by
using spray nozzles above the tank to
eliminate foaming. Even this did not
help.
The APP Pump was replaced with an
AHLSTAR™ ARP Pump. The pump
began to operate well with a separate
vacuum pump. A similar AHLSTAR™
ASP Pump can also be used in this
position.
C) In some cases, it is also worthwhile
installing an ARP Pump with degas-
sing for pumping primary flotation cell
accept from the feed chest (Fig. 14, C)
to the cleaners. Depending on the size
of the chest, the stock may contain
considerable amounts of air which in
turn may cause pressure fluctuations.
These may give cause to control prob-
lems in the system and even impair
the separation capacity of cleaners.
Case 3 (Fig. 15): Pumping re-
cycled fiber to screw presses
A) The following conditions prevailed
in a recycled fiber mill application
where stock enters the dilution tank
from a disc filter:
The consistency of the stock coming
from the disc filter is 14 to 17%. The
stock is diluted in the feed screw and
in the tank to 5.5 to 6%, which was the
desired feed consistency for the
presses. Both presses had their own
feed pumps. Strong turbulence, air, and
foam occurred in the tank.
The APP Pumps which were used
here were able to pump at a consis-
tency of slightly above 4%. First, only
one of the feed pumps was replaced
with an AHLSTAR™ ARP Pump with a
Disc filter
14-17%
AHLSTAR™ ARP
Fig. 15. Pumping deinked stock to screw presses.
Washer
10-12%
AHLSTAR™ APP
Fig. 16. Pumping stock to screw presses.
separate vacuum pump. The consis-
tency objective was achieved, and the
other feed pump was also replaced
with an ARP Pump.
In recycled fiber applications, the air
content can be high, which easily
causes problems in stock pumps.
Is an ARP Pump always required?
B) Stock is pumped in an application
(Fig. 16) resembling the above, with
the stock coming from a washer at a
consistency of approx. 10 to 12%. The
stock is diluted to the desired consis-
tency in a feeding tank situated be-
neath the washer; in this case, the tar-
get consistency was 7 to 7.5%. An or-
dinary AHLSTAR™ APP Stock Pump
managed this application without prob-
lems. The stock flow was distributed to
Fig. 17. Waste water application.
two different presses. Air content in this
particular stock application was low
enough to enable proper operation
with a conventional stock pump.
Case 5 (Fig. 17): Pumping sludge-
containing waste water from the
paper mill to waste water treat-
ment.
From a paper mill, sludge-containing
waste water is pumped to an outdoor
tank with a depth of approx. 5 m. The
consistency of this waste water is 0 to
4%.
A rotary-type displacement pump was
earlier used in this application. How-
ever, its rubber rotor wore rapidly,
since the liquid pumped is also some-
what abrasive. The maintenance costs
of the displacement pump hence were
high.
An AHLSTAR™ ASP Pump with a built-
in vacuum pump was installed for trial
purposes in the fall of 1996, and the
pump worked trouble-free right from
the beginning.
The benefits of the ASP Pump include:
• Easy use of a centrifugal pump,
• low maintenance costs.
Operating principle (Fig. 8.):
In the AHLSTAR™ ARP Pump, air or
gas, which is present in the form of a
bubble in front of the impeller or some
other location with a low pressure, is
led to the back of the impeller through
the channels in the impeller. There is
an expeller on the shaft of the pump,
separating liquid from the air or gas
which enters through the channels. The
liquid is returned along a separate
pipe to the inlet side of the pump, and
the gas or air is led in another pipe out
of the pump.
Fig. 8. Operating principle.
Fig. 9. AHLSTAR™ ASP Self Priming Gas Removal Pump.
If the ARP Pump has a suitable inlet
head, no vacuum pump is needed. The
removed gas or air can be led directly
to a floor channel, for instance.
If no sufficient pressure difference is
achieved, the necessary pressure dif-
ference is created by means of a sepa-
rate, small water ring vacuum pump.
If there is a vacuum in the tank, the
degassing system is connected to the
top part of the tank. No separate
vacuum pump is needed in this case.
Depending on the size and speed of
the ARP Pump, the inlet head in the
liquid tank can be 10 to 15 meters of
water column. In applications requir-
ing the self priming feature, where a
vacuum pump is used, the suction
head of the pump can be even approx.
7 to 8 meters.
In special applications, the ARP Pump
can remove even more air from the liq-
uid by reducing the pressure on the
suction side of the pump. In this case,
the volume of the gas increases, which
means more efficient gas removal from
the liquid.
The ARP Pump is suitable for the fol-
lowing capacities: Q=1800 l/s, H=160
m, temperature 180°C.
4.1.2 The AHLSTAR™ pump range
includes also the ASP self priming gas
removal pumps (Fig. 9). They are highly
suitable for the pumping of liquids con-
taining air or gas when the liquids do
not contain abrasive particles and
when there is a low inlet head or a
vacuum on the inlet side of the pump.
3. What are the traditional stance, a displacement pump. How- moving this disturbing gas or air in the 5.2 Pulp mill processes • The lobe rotor pump is an expen- Case 2 (Fig. 19): Feeding brown
means for eliminating ever, this solution is not always eco- pump, the pump operation becomes sive and complicated special pump. stock to washer.
nomical. If the liquid pumped contains stable. This also enhances the opera- Case 1 (Fig. 18): Pumping soap • The pump maintenance is difficult
disturbances caused by
solids, which is often the case, screw tion of the entire process and other from the washing department to and also its spare parts are expensive. At a pulp mill, brown stock is pumped
air and gas?
pumps, lobe rotor pumps etc. wear rap- process equipment. the evaporation plant. from a blow tank into an intermediate
idly. As the capacities of mills just keep The AHLSTAR™ ARP Pump with a tank. From the intermediate tank, an
Since stable pumping is imperative in
increasing, the size of displacement 4.1 Sulzer Pumps' pump The cooking process produces a lot of degassing system was installed for the APP Pump pumped this stock with a
view of the operation of the entire pro-
pumps also imposes limitations. solutions for liquids con- various gases. In conjunction with first time at a pulp mill in 1991 to pump consistency of 3 to 5% via knot sepa-
cess, factors enabling trouble-free
taining gas or air: stock washing, these gases enter the the soap mixture from the washing ration to a washer. The brown stock
pumping have been studied in the past.
4. New pump solutions filtrate tank with the wash liquor. Since department to the evaporation plant, temperature was approx. 90°C, and it
The means discovered include,
4.1.1. The AHLSTAR™ APP pump soap contained in the black liquor where the actual soap separation from contained a lot of gas, air, and foam.
among others, the following:
Sulzer Pumps has developed pump range includes the ARP Pumps (Fig. makes up very stable foam together black liquor takes place. The inlet head The problem was that the entrained
types which through their operating 7), which are used to pump stocks con- with the gases, soap separates on top in the soap tank varies between 0 and air caused fluctuations in the display
3.1 Optimizing the conditions on the
principle remove disturbing gas or air taining considerable amounts of gas of the black liquor, from where it is led 1 meters. of the feed flow rate measurement. This
suction side of the pump
contained in the liquid so as to main- and air at a consistency range of up to into a separate soap tank. From the in turn resulted in control problems.
• Size of suction pipe.
tain proper pumping and to prevent 8%, plus other process liquids. A sepa- soap tank, soap is pumped to a soap The ARP Pump has been working well
• Shape of suction pipe.
any pumping disturbances resulting rate vacuum pump is used in conjunc- collecting tank situated at the evapo- here. After this, several other ARP In June 1997, a gas and air removal
• Correct location of suction pipe in
from the gas or air. In these pumps, tion with the ARP Pump if the inlet head ration plant. The density of soap com- Pumps and more recently also ASP AHLSTAR™ ARP Pump with a sepa-
the tank.
gas or air is removed by creating a on the suction side is low. The ARP ing from the washing department can Pumps with a built-in vacuum pump rate degassing system was installed
certain pressure difference between Pump is also self priming when a be as low as 300 kg/m because of the have been installed in various appli- in this service. After the installation,
3.2 Overdimensioning instructions for
the suction side of the pump and the vacuum pump is used with it. gases contained in it. cations both at the cooking plant and there have been no problems in flow
pumps have been provided on account
degassing chamber, situated behind This difficult mixture has earlier been at the washing department. rate measurement.
of the gas content. These are partly
the impeller. This pressure difference Based on long-term experiences, the pumped from the soap tank to the
practicable even today.
is achieved for instance through suffi- ARP Pump operates trouble-free with evaporation plant using a lobe rotor Benefits brought by the AHLSTAR™ In this application, the ARP Pump gives
cient inlet head prevailing in front of liquids which contain up to 70% of air pump. ARP and ASP Pump: the following advantages:
3.3 It has also been studied which
the pump. If sufficient inlet head can- or gas. The degassing system removes The following problems have been • The disadvantages of lobe rotor • Better runnability at the washing
types of impellers, clearances, and
not be achieved, the pressure differ- that proportion of the gases or air con- encountered in the use of the lobe ro- pumps are eliminated. department, since the feed flow rate is
other potential structures best tolerate
ence can be created either with a sepa- tained in the liquid which disturbs tor pump: • Improved soap separation. under control.
liquids containing gas or air. The effect
rate or built-in vacuum pump. By re- pumping. • The soap mixture pumped has • Better, fiber-free soap quality • Improved drainage at the washer.
of turbulence for instance in the impel-
foamed from the tank onto the floor, (pumping through fiber filter). • More opportunities to optimize
ler has also been examined.
causing additional need for cleaning. brown stock washing.

3.4 Use of defoamers. If none of the

above means have solved the pump-
ing problem, a common method was
and is to use defoamers. However,
their cost often rises to millions of
marks or more annually, and they load
the environment to a certain degree. It
has also been noticed that some de-
foamers may cause sedimentation in
the process equipment.

3.5 Use of other pump types. If a cen-

trifugal pump has not operated prop-
erly using the above means, it has Fig. 7. AHLSTAR™ ARP Air/Gas Separating Pump.
sometimes been replaced with, for in- Fig. 18. Washing department. Fig. 19. Brown stock washing.
5.3 TMP plant processes
Case 1 (Fig. 20): Pumping TMP
reject from refiners to refined
reject tank.
The reject handling system at the TMP
department of a paper mill was mod-
ernized. In this conjunction, the mill
wanted to replace the existing trans-
fer system where five screws trans-
ferred the 25% refined reject to a re-
ject tank. In the reject tank, the stock
was diluted to 2 to 3%. From the reject
tank, the stock was pumped further to
screening.
In the new solution, an inlet tank was
installed under the refiners on the floor
below, where the stock was diluted di-
rectly to 2 to 3%. It was also assumed
that the stock contains a lot of air and
that the tank has a low level. The pump
selection process concluded in the gas
and air removing AHLSTAR™ ASP
Pump with a built-in degassing sys-
tem. The degassing return pipe was
led back into the inlet tank.
The gas and air removing ASP Pump
has operated well in this application
since spring 1997. The ASP Pump fea-
tures the following benefits:
• Simple transfer system,
• low maintenance costs,
• additional reliability at the mill.
Fig. 20. Reject screening in a TMP plant.
5.4 Paper mill processes
Case 1 (Fig. 21): Deflaking and
pumping of broke stock to ma-
chine chest.
At the stock preparation department of
a paper mill, broke stock is pulped at a
consistency of 5 to 7%. After pulping,
the stock is pumped into two alternate
tanks using an AHLSTAR™ NPP
Pump. In order to guarantee good stock
quality, stock is recirculated 2 to 3 times
through a deflaker using a conven-
tional stock pump situated between the
tanks. After this, the stock is pumped
from the tank into a mixing chest. The
inlet head in the tank varies between
4.5 and 0 meters. At the end of the
emptying stage, at a small inlet head,
the air contained in the stock began to
separate in front of the impeller, and
the pump was not able to empty the
tank completely. The mill carries out
several color changes due to a cer-
tain production program. It is very im-
portant to empty the tank completely
in order to minimize the proportion of
waste stock.
Fig. 21. A part of a broke stock line.
An AHLSTAR™ ARP air removal pump
without a vacuum pump was installed
as the recirculation and emptying
pump. The ARP Pump features an air
separating expeller behind the impel-
ler, separating from the stock any air
which disturbs pumping. The stock is
returned to the suction side of the
pump, and the degassing pipe is led
to the top part of the tank. With this con-
figuration, the AHLSTAR™ ARP Pump
empties the tank completely, eliminat-
ing the amount of waste stock.
Case 2 (Fig. 22): Separating and
pumping white water from water
separators in the vacuum system
of a paper machine or pulp drying
machine; replacing the barometric
leg.
Water removed from the web of a pa-
per machine by means of vacuum is
separated in water separators situated
between the paper machine and the
vacuum system. It is important that this
water is separated as completely as
possible so that only moist air goes
into the vacuum pumps.
Fig. 2. If the end of the inlet pipe going
into a tank is situated above the liquid
level, the inlet flow of the liquid mixes air
efficiently into the liquid.
The situation is aggravated by factors
such as:
• Additives contained in the liquid
such as soap, emulsifying agents, de-
tergents, dispersion agents, lignin
compounds, and alum.
• Characteristics of the liquid such as
stock consistency (the higher the con-
sistency, the higher the air content) and
production method used (various types
of stocks contain different amounts of
air under identical conditions), refin-
ing degree (refining increases the air
content), fillers, viscosity of the liquid,
and temperature of the liquid.
Fig. 6. If the liquid contains approx. 4 % of free gas or air, a conventional centrifugal pump can generally still pump it.
However, the flow rate, head, and efficiency of the pump decrease as the gas or air content increases.
Fig. 3. If the liquid level in the tank is
kept so low that the blades of the
agitator break the liquid surface, the
agitator mixes air into the liquid.
2. How does the air prob-
lem appear in pumping?
When a conventional centrifugal pump
(Fig. 5) pumps a liquid containing a lot
of gas or air, such as stock, filtrate wa-
ter etc., the free gas or air contained in
the liquid begins to gather in front of
the impeller. The lighter gas or air is
separated at the point of the lowest
pressure, which is often in front of the
impeller. Hence, an air or gas bubble
is formed here. That section of the
vanes of the impeller which is inside
the bubble loses some of its pumping
efficiency. This way, the output of the
pump decreases (Fig. 6). As the bubble
Fig. 4. If the level in the suction tank of
the pump is too low, a so-called vortex
phenomenon will be created above the
suction pipe, causing air to enter the
pump.
grows big enough, it begins to disturb
pumping and the operation of the en-
tire process. Pumping may also cease
completely. The air or gas bubble re-
mains in front of the impeller for as long
as the pump rotates. If the pump is
stopped for a while, the bubble will
disappear. After restarting, the pump
will run normally until a new bubble
starts to form. In general, stopping and
restarting pumps this way is unaccept-
able.
Fig. 5. The free gas or air begins to
accumulate in front of the impeller.
Sulzer Pumps' Solutions Illustrated by
Practical Examples
1. General on air and gas
content
The liquids pumped always contain
some gas, usually air, unless this gas
has been specifically removed, for in-
stance by boiling. The gases can be
present in the liquid in three different
states:
• Dissolved in the liquid.
• Bound on the particles contained in
the liquid.
• As free gas in the form of bubbles.
1.1. The amount of gas dissolved in
the liquid depends on the gas, liquid,
temperature, pressure etc. This gas
dissolved in the liquid does not sepa-
rate from the liquid unless the liquid
pressure is decreased or the liquid
temperature is raised. The separation
of this dissolved gas is best seen as
bubbling just before the liquid begins
to boil. This dissolved gas does not
usually separate from the liquid, and
its content is not considered when the
amounts of gas are given.
1.2. The gas bound on the surface of
particles contained in the liquid has
very small bubbles. Stock fibers which
have been dried once contain air in
their hollow lumen, even after pulping.
Under normal conditions, this gas
does not disturb pumping, either. How-
ever, this air may cause problems in
other process equipment such as
washers and the wire section of a pa-
per machine.
1.3. Air contained in a liquid such as
fiber suspension in the form of bubbles
disturbs pumping. Bubble-form air is
attached to the fibers or it is present
between them. The higher the stock
consistency, the higher the air content.
The air content depends on the stock
type, stock characteristics etc.
Typical values for the air content in
stock have been given in Fig. 1.
This air in bubble form enters the
pumped liquid from several sources
such as:
• The cooking process produces car-
bon dioxide, formic acid, mercaptans,
dimethyl sulphide etc. The oxygen
bleaching reaction also produces car-
bon dioxide.
• In certain processes, air or gas is
added into the liquid so as to achieve
the desired result. Ink particles are re-
moved from recycled fiber by means
of the flotation method, where air is
introduced into the stock.
• The process industry commonly
uses equipment whose structure al-
lows the mixing of air into the liquid.
This is particularly problematic in pro-
cess stages following the cooking pro-
cess where soap contributes to foam-
ing and mixing of air.
- In the pulp and paper industry, stock
drops several meters from almost all
filters to a tank situated beneath. Air is
efficiently mixed into the stock during
this free fall.
- Stock is often fed into a storage tower
through the top of the tower, through
its center section. The resulting free fall
may be dozens of meters, causing air
to be mixed with the stock.
• Inadequately designed or imple-
mented pumping solutions cause un-
desirable mixing of gases or air with
liquids (Fig. 2, 3 and 4).
• Leaking seals in valves and pumps
and other leaks in the vacuum system
may also cause air to be mixed into
the liquid pumped.
All of the above causes can lead to a
situation where pumping with conven-
tional centrifugal pumps is no longer
possible.
TMP
Maple
Spruce
Softwood
Kraft samples
Fig. 1. Air content in the stock.
Up until now, the most reliable means
to lead away the separated water from
the water separators has been to use
barometric legs, i.e. pipes led into a
seal pit. The necessary vacuum of up
to 0.7 bar (70 kPa) requires a seal pit
depth of approx. 10 meters, which is
relatively expensive to make. More-
over, the length of the vertical pumps
required in seal pit service, approx. 10
meters, means that the pumps are dif-
ficult to service. The pumps also need
a level control system because of the
risk of running the pumps dry.
Fig. 22. a) A typical piping arrangement for liquid
ring pumps.
Fig. 22. b) ARP Pumps connected to water
separators.
Experience has shown that by install-
ing an air and gas separating
AHLSTAR™ ARP Pump immediately
below the water separator, water sepa-
ration is at least as reliable as with the
use of barometric legs.
Advantages given by the use ARP
Pump:
• Simple location of water separators.
• Water separated at the various suc-
tion locations can be easily led to the
desired applications.
• No need for level control equipment
in the water separators.
• No need for deep seal pits, long
barometric legs, or vertical pumps.
Fig. 23. AHLSTAR™ ARP Air Separating Pump.
6. Summary
Features and benefits of air and gas
removal AHLSTAR™ ARP and ASP
Pumps in pulp and paper applications:
• Difficult and even to date unsolved
pumping problems have been solved.
• Trouble free process operation de-
spite high air content.
• The efficiency of other process
equipment is improved due to gas and
air removal.
• The need for expensive antifoam
agents is reduced.
• The need for chemicals which bur-
den the environment is consequently
reduced.
• Overall pumping efficiency is im-
proved.
• Most of the spare parts are inter-
changeable with the other AHLSTAR™
Pumps.
• An APP Pump can be later converted
into an ARP Pump and vice versa.
 How to Manage Pumping of Stock,
Liquors, and Other Liquids with
a High Air or Gas Content?
Check our worldwide offices at
www.sulzerpumps.com

E00544 en (2) article 10.2002 (2000), Copyright © Sulzer Pumps Finland Oy

This brochure is a general presentation. It does not provide any warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.