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1 Module 1 – Basics of Bioprocess Technology

PUMPS
Simply stated, a pump is a machine used to move liquid through a piping system and to raise the pressure of the liquid or
to move a liquid form one place to another. A pump can be further defined as a machine that uses several energy
transformations to increase the pressure of a liquid. The energy input into the pump is typically the energy source used to
power the driver. Most commonly, this is electricity used to power an electric motor. Alternative forms of energy used to
power the driver include high-pressure steam to drive a steam turbine, fuel oil to power a diesel engine, high-pressure
hydraulic fluid to power a hydraulic motor, and compressed air to drive an air motor. The power transmitted from the
driver to the pump is a function of the rotating speed times the torque.
The remaining energy transformations take place inside the pump itself. The rotating pump shaft is attached to the pump
impeller. The rotating impeller causes the liquid that has entered the pump to increase in velocity. This is the second
energy transformation in the pump, where the input power is used to raise the kinetic energy of the liquid. Kinetic energy
is a function of mass and velocity. Raising a liquid’s velocity increases its kinetic energy.
After the liquid leaves the impeller, but before exiting the pump, the final transformation of energy occurs in a diffusion
process. An expansion of the flow area causes the liquid’s velocity to decrease to more than when it entered the pump, but
well below its maximum velocity at the impeller tip. This diffusion transforms some of the velocity energy to pressure
energy.

There are actually three distinct reasons for raising the pressure of a liquid with a pump, plus another related factor:
1. Static elevation: A liquid’s pressure must be increased to raise the liquid from one elevation to a higher elevation.
This might be necessary, for example, to move liquid from one floor of a building to a higher floor, or to pump liquid
up a hill.
2. Friction: It is necessary to increase the pressure of a liquid to move the liquid through a piping system and overcome
frictional losses. Liquid moving through a system of pipes, valves, and fittings experiences frictional losses along the
way. These losses vary with the geometry and material of the pipe, valves, and fittings, with the viscosity and density
of the liquid, and with the flow rate.
3. Pressure: In some systems, it is necessary to increase the pressure of the liquid for process reasons. In addition to
moving the liquid over changes in elevation and through a piping system, the pressure of a liquid must often be
increased to move the liquid into a pressurized vessel, such as a boiler or fractionating tower, or into a pressurized
pipeline, or it may be necessary to overcome a vacuum in the supply vessel.
4. Velocity: There is another factor to be considered here, namely that not all of the velocity energy in a pump is
converted to potential or pressure energy. The outlet or discharge connection of most pumps is smaller than the inlet
or suction connection. Because liquids are, practically speaking, incompressible, the velocity of the liquid leaving the
pump is higher than that entering the pump. This velocity head may need to be taken into account (depending on the
point of reference) when computing pump total head to meet system requirements.

Classification of Pumps
Pumps can be classified into two general types:

PUMPS

Rotadynamic
Rotadynamic Positive
Positive
/Dynamic/
/Dynamic/ displacement/
displacement/
Kinetic
Kinetic Displacement
Displacement

Centrifugal
Centrifugal Special
Special Reciprocating Rotatory
Reciprocating Rotatory

Split Case
Split Case Jet
Jet Vortex
Vortex Piston
Piston
Vertical
Vertical
Turbine
Turbine
End
End Suction
Suction Regenerative
Regenerative Diaphragm
Diaphragm
Turbine
Turbine
1) Positive displacement.
In positive displacement pumping energy is transferred to the liquid by trapping a fixed volume and forcing the trapped
volume to the pump discharge in arrangements such as reciprocating pistons, or rotary motion of gears, screws or vanes.
Positive displacement pumps deliver a definite quantity for each stroke or partial rotation of the device. They are used
when the liquid has a high viscosity, low flow rate, or a combination of the two. They are used to obtain a more precise
flow rate.
Energy is periodically added to the liquid by the direct application of a force to one or more movable volumes of liquid.
This causes an increase in pressure up to the value required to move the liquid through ports in the discharge line. The
important points here are that the energy addition is periodic (i.e., not continuous) and that there is a direct application of
force to the liquid. This is most easily visualized through the example of a reciprocating piston or plunger pump. As the
piston or plunger moves back and forth in the cylinder, it exerts a force directly on the liquid, which causes an increase in
the liquid pressure.

2) Dynamic.
They are used in conditions where high volume of liquid is required to be transported and flow rate specificity is not seen
or is ignored. In dynamic pumps energy is transferred to the liquid by means of vanes mounted on a rotating shaft. The
liquid enters a long or near the rotating shaft and is accelerated by the rotation of the vanes. This imparts kinetic energy to
the liquid, which is transformed to pressure energy. When the liquid velocity is subsequently reduced, this produces a
pressure increase. The liquid is not contained in a set volume. Although there are several special types of pumps that fall
into this classification, for the most part this classification consists of centrifugal pumps.

1. CENTRIFUGAL PUMP
Centrifugal pumps are used to transport fluids by the conversion of rotational kinetic energy to the hydrodynamic energy
of the fluid flow. The rotational energy typically comes from an engine or electric motor. Generally, a centrifugal pump is
based around a casing filled with fluid, usually water. A special unit within the casing exerts fast rotary motion that
causes the water to spin, generating centrifugal force that channels it through a discharge outlet. Discharged water creates
a vacuum for atmospheric pressure to force more water out of the casing. It is a continuous process, dependent mostly on
continued rotary motion and a constant supply of water. Most centrifugal pumps rely on rotating impellers or vanes to
provide rotary motion.

Principle
The centrifugal pump works in the same way as sucking on the straw. As the engine
starts, the impeller turns which forces the water around it out of the pump's
discharge port. The partial vacuum created, allows the earth's air pressure to force
water up the suction hose (straw), and into the suction (inlet) side of the pump to
replace the displaced water. When the water hits the rotating impeller, energy of the
impeller is transferred to the water, forcing the water out (centrifugal force). The
water is displaced outward, and more water can now enter the suction side of the
pump to replace the displaced water. Pumps DO NOT SUCK liquid into the pump.
Rather, atmospheric pressure pushes water into the pump keeping the liquid in its natural state

Centrifugal Force
In Newtonian mechanics, the centrifugal force is an inertial force directed away from the axis of rotation that appears to
act on all objects when viewed in a rotating frame of reference. The centrifugal force is an outward force apparent in a
rotating reference frame; it does not exist when a system is described relative to an inertial frame of reference. All
measurements of position and velocity must be made relative to some frame of reference. Some engineering texts ignore
centrifugal force and do not mention it. Others define it as a body force; that is, it acts on a mass that is in circular motion.

When the circular motion is uniform with constant angular speed at a fixed radius,
then the magnitude of this force is defined by the equation:
Fc = mrω2
Where: Fc = centrifugal force
m = mass
r = radius
ω = circular frequency of rotation
This is nothing less than Newton’s second law (F = ma) applied to rotation. The term
rω2 is defined as the radial acceleration, and the term mr is the unbalance. This
equation is a relationship. It does not tell us what centrifugal force really is, but only
how it relates to other known quantities. It does provide some insight, though. It is a force associated with motion,
specifically, rotating motion.
If not restrained, then this rotation would cause the mass to fly off on a tangent to an observer viewing from an external
inertial frame of reference. To an observer on the wheel, and rotating with it, the outward motion would appear to be
directed outward along a radius. The restraining force is centripetal force, which is defined by the angular acceleration:
m v2
Centripetal Force =
r
Where v²/r = Radial acceleration (same as rω2)
With these two mathematical definitions, the magnitude of centrifugal force and centripetal force are exactly equal, only
differing in sign. Centrifugal force = mrw2 = –mv²/r. Centripetal is the force that constantly pulls inward on the body,
keeping it at a constant radius in circular motion. The dimensional units of both centrifugal and centripetal force, kg⋅m/s2,
computes correctly to a force by Newton’s second law: F

= ma.

Working of the pump

PARTS OF A CENTRIFUGAL PUMP

1. Impellers
 Open impellers: Vanes are attached to the central hub,
without any form, sidewall, or shroud, and are mounted
directly onto a shaft. Open impellers are structurally weak
and require higher NPSHR values. They are typically used
in small-diameter, inexpensive pumps and pumps handling
suspended solids. They are more sensitive to wear than
closed impellers, thus their efficiency deteriorates rapidly
in erosive service. No shrouds are present. Used for high
density liquids, for low heads, suspended solids
applications, and provides very small flows.
 Partially open or semi closed impellers: This type of impeller incorporates a back wall (shroud) that serves to stiffen the
vanes and adds mechanical strength. They are used in medium-diameter pumps and with liquids containing small amounts
of suspended solids. They offer higher efficiencies and lower NPSHR than open impellers. It is important that a small
clearance or gap exists between the impeller vanes and the housing. If the clearance is too large, slippage and recirculation
will occur, which in turn results in reduced efficiency and positive heat buildup. Shroud is present on the backside of the
impeller blades or vanes. Used for general purpose applications, has open vane tips at entrance to break up suspended
particles and prevent clogging.
 Closed impellers: The closed impeller has both a back and front wall for maximum strength. They are used in large pumps
with high efficiencies and low NPSHR. They can operate in suspended-solids service without clogging but will exhibit high
 wear rates. The closed-impeller type is the most widely used type of impeller for centrifugal pumps handling clear liquids.
They rely on close-clearance wear rings on the impeller and on the pump housing. The wear rings separate the inlet pressure
from the pressure within the pump, reduce axial loads, and help maintain pump efficiency. The impeller blades or vanes are
covered from both front as well as backside by the shrouds. Used for low density liquids, high head high pressure
applications.
 Shroud – A baseplate on which the impeller blade is perpendicularly fixed or fitted.

2. Casing
 Volutes
Simply, a volute is a spiral shaped case surrounding the impeller that collects the liquid
discharged by the impeller. Volutes are designed to capture the velocity of liquid as it
enters the outermost diameter of an impeller and convert the velocity of the liquid into
pressure. The portion of the volute that extends closest to the impeller is called the
cutwater. Starting from the cutwater and proceeding in a counter-clockwise fashion, the
distance between the volute and the impeller increases gradually. This has the effect of
causing pressure to build within the volute as the distance increases. Once the point of
greatest separation is reached – directly next to the cutwater moving in clockwise
direction – the pressure is at its greatest, and water is forced out the casing when it encounters the cutwater. The
single volute casing has a single cutwater where the flow is separated. As the flow leaves the impeller and moves
around the volute casing, the pressure increases. This increasing pressure as the liquid moves around the casing
typically produces an increasing radial force at each point on the periphery of the impeller, due to the pres sure acting
on the projected area of the impeller. Summing all of these radial forces produces a net radial force that must be
carried by the shaft and radial bearing system in the pump. The radial bearing must also support the load created by
the weight of the shaft and impeller.

 Diffusers
What a cutwater is to a volute, vanes are to a diffuser. While volutes only have one (or
sometimes two) points where the edge of the casing approaches the edge of the
impeller in order to begin building pressure, diffusers often have many vanes. In the
case of the assembly drawing shown the diffuser contains 10 vanes as compared the
volute casing which only has one. Also, while an impeller is placed in the center of a
volute, an impeller generally sits directly adjacent to a diffuser and pushes water into
the diffuser vanes. The basic function of a diffuser is similar to that of a volute.
Diffuser vanes are positioned such that they begin close to the outer edge of the
impeller and then gradually extend away from the impeller periphery.
A diffuser is a more complex casing arrangement, consisting of multiple flow paths around the periphery of the
impeller. The liquid that leaves the impeller vanes, rather than having to move completely around the casing
periphery as it does with the single volute casing, merely enters the nearest flow channel in the diffuser casing. The
diffuser casing has multiple cutwaters, evenly spaced around the impeller, as opposed to the one cutwater found in a
single volute casing. The main advantage of the diffuser casing design is that this results in a near balancing of radial
forces, thus reducing shaft deflection and eliminating the need for a heavy-duty radial bearing system. The dead
weight of the rotating element must still be carried by the radial bearing, but overall the diffuser design minimizes
radial bearing
loads compared
with other casing
types.
Types of Centrifugal Pumps Based on Configuration

 End-Suction Centrifugal Pumps- The most common style of

centrifugal pump.  The center of the suction line is centered on the
impeller eye.  End suction centrifugal pumps are further classified as
either frame-mounted or close-coupled.
 Split-case Centrifugal Pumps- A centrifugal pump design so that the
volute case is split horizontally.  The case divides on a plane that cuts
through the eye of the impeller
 Vertical Turbine Pumps- A classification of centrifugal pumps
designed to be mounted with the shaft in a vertical position; the motor
is commonly mounted above the pump.  Vertical turbine pumps are
either mixed or axial flow devices.

Types of End Suction Centrifugal Pump

Cavitation in centrifugal pump
Cavitation, is a phenomenon that occurs when vapour bubbles form and move along the vane of an impeller. As these
vapour bubbles move along the impeller vane, the pressure around the
bubbles begins to increase. It is a phenomenon that has both hydraulic and
sometimes destructive mechanical effects on pumps. The phenomenon of the
formation and subsequent collapse of these vapour bubbles, known as
cavitation, has several effects on a centrifugal pump.
1. First, the collapsing bubbles make a distinctive noise that has been
described as a cracking or popping or rattling sound, or a sound like
the pump is pumping gravel. This can be a nuisance in an extreme
situation where a cavitating pump is operating where people are working.
This physical symptom is usually the area of least concerns with
cavitation, however. Of far greater concern is the effect of cavitation on
the hydraulic performance and the mechanical integrity of the pump.
2. The hydraulic effect of a cavitating pump is that the pump performance
drops off of its expected performance curve, referred to as break away, as illustrated by Figure 2.13, producing a
lower than expected head and flow.
3. An even more serious effect of cavitation is the mechanical damage that can occur due to excessive vibration in
the pump. This vibration is due to the uneven loading of the impeller as the mixture of vapor and liquid passes
through it, and to the local shock wave that occurs as each bubble collapses. The shock waves can physically damage
the impeller, causing the removal of material from the surface of the impeller. The amount of material removed
varies, depending on the extent of the cavitation and the impeller material. If the impeller is made of ferrous-based
material such as ductile iron, material is removed from the impeller due to a combination of corrosion of the ferrous
material from the water being pumped and the erosive effect of the cavitation shock waves.

Priming of Centrifugal Pump

Most centrifugal pumps are not self-priming. In other words, the pump casing must be filled with liquid before the pump
is started, or the pump will not be able to function. If the pump casing becomes filled with vapors or gases, the pump
impeller becomes gas-bound and incapable of pumping. To ensure that a centrifugal pump remains primed and does not
become gas-bound, most centrifugal pumps are located below the level of the source from which the pump is to take its
suction. The same effect can be gained by supplying liquid to the pump suction under pressure supplied by another pump
placed in the suction line. If the pipeline leading to the pump inlet contains a non-condensable gas such as air, then the
pressure reduction at the impeller inlet merely causes the gas to expand, and suction pressure does not force liquid into
the impeller inlet. Consequently, no pumping action can occur unless this non-condensable gas is first eliminated, a
process known as priming the pump.
End Suction and Split Case Piping Systems

Parts of Suction Lift System

2. GEAR PUMP
Gear pumps are the most common type of positive displacement pump. They are ideal for transferring high viscosity
fluids such as automotive oils, plastics, paint, adhesives, and soaps with a steady and pulseless flow and offer self-priming
capabilities. This pump type cannot run dry or handle abrasive-laden fluids, and places high shear on the fluid. They
operate by creating suction at the inlet with a rotating assembly of two gears –a drive gear and an idler. Pump flow is
determined by the size of the cavity (volume) between gear teeth, the amount of slippage (reverse flow), and the speed of
rotation (rpm) of the gears. They operate by an unchanging volume of fluid passing between the teeth of two meshing
gears and their casing at a constant rate (not between the gears themselves). As the gears rotate and the meshed teeth
separate, a partial vacuum is formed that fills with fluid. As the gears continue to rotate, they trap the liquid and move it
around the casing from the suction to the discharge point. There are 2 types of gear pumps-

A. External Gear Pump

External gear pumps have two meshing gears, which may be of the spur, helical, or
herringbone type. Liquid is carried between the gear teeth and displaced as the teeth mesh.
Close clearances between the gear teeth and between the teeth and the casing walls minimize
slippage of liquid from the high-pressure side to the low-pressure side. Large-capacity external
gear pumps typically use helical or herringbone gears. Small external gear pumps usually
operate at 1750 or 3450 rpm and larger models operate at speeds up to 640 rpm. External gear
pumps have close tolerances and shaft support on both sides of the gears.  This allows them to
run to pressures beyond 3,000 PSI / 200 BAR, making them well suited for use in hydraulics. 
With four bearings in the liquid and tight tolerances, they are not well suited to handling
abrasive or extreme high temperature applications.
Tighter internal clearances provide for a more reliable measure of liquid passing through a pump and for greater flow
control. Because of this, external gear pumps are popular for precise transfer and metering applications involving
polymers, fuels, and chemical additives.

How External Gear Pumps Work

External gear pumps are similar in pumping action to internal gear pumps in that two gears come into and out of mesh to
produce flow.  However, the external gear pump uses two identical gears rotating against each other -- one gear is driven
by a motor and it in turn drives the other gear.  Each gear is supported by a shaft with bearings on both sides of the gear.
1. As the gears come out of mesh, they create expanding volume on the inlet side of the pump. Liquid flows into the
cavity and is trapped by the gear teeth as they rotate.
2. Liquid travels around the interior of the casing in the pockets between the teeth and the casing -- it does not pass
between the gears. 
3. Finally, the meshing of the gears forces liquid through the outlet port under pressure.
Because the gears are supported on both sides, external gear pumps are quiet-running and are routinely used for high-
pressure applications such as hydraulic applications. With no overhung bearing loads, the rotor shaft can't deflect and
cause premature wear.

The 3 major types of gears used in this type of pump are-

1. Spur gears are simple, and generally cost less to manufacture than helical or herringbone gears. They have good
characteristics but can be noisy and inefficient. The trapped liquid between the teeth where the teeth mesh has no
place to exit. As the trapped liquid squeezes by the tight clearances, it can make a loud screaming sound. Some
manufactures provide a relief slot in this area to give the fluid a place to escape. This minimizes noise and increases
efficiency, especially with viscous liquids. Spur gears have the added advantage of minimal axial thrust.
2. Helical gears are another means of giving the trapped liquid a path to escape. The helix shape gives the liquid a
place to exit. Helical gear pumps are generally efficient and quiet. They do have one disadvantage: they are forced
axially against the pump thrust bushing. Axial wearing a gear pump decreases performance much faster than radial
wear, so it is important to maintain tight clearances in the axial direction.
3. Herringbone gears are the most expensive to manufacture, but they are quiet, efficient, and do not exhibit axial
thrust. They are very difficult to machine, so sometimes they are made up with two helical gears butted together with
the helix of the two gears oriented opposite to each other.
Most external gear pumps have the first gear (which is coupled to the driver) driving the second gear. An alternative
design uses timing gears, which are a separate set of gears, normally isolated from the pumped liquid, which cause the
two main gears to remain in mesh without requiring direct contact. This use of timing gears, common on many types of
double-rotor rotary pumps, allows larger clearances between the pumping gears, which means that the pump can more
easily accommodate some abrasives without doing damage to the gears.
Advantages Disadvantages
High speed Four bushings in liquid area
High pressure No solids allowed
No overhung bearing loads Fixed End Clearances
Relatively quiet operation
Design accommodates wide variety of materials
Applications
Common external gear pump applications include, but are not limited to:
 Various fuel oils and lube oils
 Chemical additive and polymer metering
 Chemical mixing and blending (double pump)
 Industrial and mobile hydraulic applications (log splitters, lifts, etc.)
 Acids and caustic (stainless steel or composite construction)
 Low volume transfer or application
 
Materials of Construction / Configuration Options
As the following list indicates, rotary pumps can be constructed in a wide variety of materials. By precisely matching the
materials of construction with the liquid, superior life cycle performance will result. External gear pumps in particular can
be engineered to handle even the most aggressive corrosive liquids.  While external gear pumps are commonly found in
cast iron, newer materials are allowing these pumps to handle liquids such as sulfuric acid, sodium hypochlorite, ferric
chloride, sodium hydroxide, and hundreds of other corrosive liquids.
 Externals (head, casing, bracket) - Iron, ductile iron, steel, stainless steel, high alloys, composites (PPS, ETFE)
 Internals (shafts) - Steel, stainless steel, high alloys, alumina ceramic
 Internals (gears) - Steel, stainless steel, PTFE, composite (PPS)
 Bushing - Carbon, bronze, silicon carbide, needle bearings
 Shaft Seal - Packing, lip seal, component mechanical seal, magnetically-driven pump

B. Internal Gear Pump

Internal gear pumps, like external gear pumps, move and pressurize liquid by the meshing and unmeshing of gear teeth.
With an internal gear pump, a rotor having internally cut teeth meshes with and drives an idler gear having externally cut
teeth. Pumps of this type usually have a crescent-shaped partition that moves the liquid through the pump with minimal
slip. Internal gear pumps are exceptionally versatile.  While they are often used on thin liquids such as solvents and fuel
oil, they excel at efficiently pumping thick liquids such as asphalt, chocolate, and adhesives.  The useful viscosity range
of an internal gear pump is from 1cPs to over 1,000,000cP. In addition to their wide viscosity range, the pump has a wide
temperature range as well, handling liquids up to 750 0F / 4000C.  This is due to the single point of end clearance (the
distance between the ends of the rotor gear teeth and the head of the pump).  This
clearance is adjustable to accommodate high temperature, maximize efficiency for
handling high viscosity liquids, and to accommodate for wear.
The internal gear pump is non-pulsing, self-priming, and can run dry for short periods. 
They're also bi-rotational, meaning that the same pump can be used to load and unload
vessels.  Because internal gear pumps have only two moving parts, they are reliable,
simple to operate, and easy to maintain.
 
How Internal Gear Pumps Work
1. Liquid enters the suction port between the rotor (large exterior gear) and idler (small
interior gear) teeth. The arrows indicate the direction of the pump and liquid.
2. Liquid travels through the pump between the teeth of the "gear-within-a-gear"
principle. The crescent shape divides the liquid and acts as a seal between the suction and discharge ports.
3. The pump head is now nearly flooded, just prior to forcing the liquid out of the discharge port.  Intermeshing gears of
the idler and rotor form locked pockets for the liquid which assures volume control.
4. Rotor and idler teeth mesh completely to form a seal equidistant from the discharge and suction ports. This seal forces
the liquid out of the discharge port.

Advantages Disadvantages
 Only two moving parts Medium pressure limitations
Only one stuffing box One bearing runs in the product pumped
Non-pulsating discharge Overhung load on shaft bearing
Excellent for high-viscosity liquids Usually requires moderate speeds
Constant and even discharge regardless of pressure conditions
Operates well in either direction
Can be made to operate with one direction of flow with either
rotation
Low NPSH required
Single adjustable end clearance
Easy to maintain
Flexible design offers application customization
 
Applications
Common internal gear pump applications include, but are not limited to:
 All varieties of fuel oil and lube oil
 Resins and Polymers
 Alcohols and solvents
 Asphalt, Bitumen, and Tar
 Polyurethane foam (Isocyanate and polyol)
 Food products such as corn syrup, chocolate, and peanut butter
 Paint, inks, and pigments
 Soaps and surfactants
 Glycol
 
Materials of Construction / Configuration Options
 Externals (head, casing, bracket) - Cast iron, ductile iron, steel, stainless steel, Alloy 20, and higher alloys.
 Internals (rotor, idler) - Cast iron, ductile iron, steel, stainless steel, Alloy 20, and higher alloys.
 Bushing - Carbon graphite, bronze, silicon carbide, tungsten carbide, ceramic, colomony, and other specials
materials as needed.
 Shaft Seal - Lip seals, component mechanical seals, industry-standard cartridge mechanical seals, gas barrier
seals, magnetically-driven pumps.
 Packing - Impregnated packing, if seal not required.

3. ROTARY LOBE PUMP

A lobe pump is similar to an external gear pump, in that the liquid is carried between the rotor lobe surfaces that
cooperate with each other as they rotate to provide continuous sealing, as do the teeth of a gear pump. Unlike a gear
pump, however, one lobe cannot drive the other, so this type of pump must have timing
gears to allow the lobes to remain in synch with each other. Each rotor may have one
lobe or several, with three lobes being most common. Lobe pumps are used in a variety
of industries including, pulp and paper, chemical, food, beverage, pharmaceutical, and
biotechnology.  They are popular in these diverse industries because they offer superb
sanitary qualities, high efficiency, reliability, corrosion resistance, and good clean-in-
place and sterilize-in-place (CIP/SIP) characteristics.
These pumps offer a variety of lobe options including single, bi-wing, tri-lobe (shown),
and multi-lobe.  Rotary lobe pumps are non-contacting and have large pumping
chambers, allowing them to handle solids such as cherries or olives without damage.  
They are also used to handle slurries, pastes, and a wide variety of other liquids.  If
wetted, they offer self-priming performance.  A gentle pumping action minimizes
product degradation.  They also offer reversible flows and can operate dry for long
periods of time.  Flow is relatively independent of changes in process pressure, so output is constant and continuous.
Rotary lobe pumps range from industrial designs to sanitary designs.  The sanitary designs break down further depending
on the service and specific sanitary requirements.  These requirements include 3-A, EHEDG, and USDA.  The
manufacturer can tell you which certifications, if any, their rotary lobe pump meets. 

How Lobe Pumps Work

Lobe pumps are similar to external gear pumps in operation in that fluid flows around the interior of the casing.   Unlike
external gear pumps, however, the lobes do not make contact.  Lobe contact is prevented by external timing gears located
in the gearbox.  Pump shaft support bearings are located in the gearbox, and since the bearings are out of the pumped
liquid, pressure is limited by bearing location and shaft deflection.

1. As the lobes come out of mesh, they create expanding volume on the inlet side of the pump.   Liquid flows into the
cavity and is trapped by the lobes as they rotate.
2. Liquid travels around the interior of the casing in the pockets between the lobes and the casing -- it does not pass
between the lobes.
3. Finally, the meshing of the lobes forces liquid through the outlet port under pressure.

Lobe pumps are frequently used in food applications because they handle solids without damaging the product.   Particle
size pumped can be much larger in lobe pumps than in other PD types.  Since the lobes do not make contact, and
clearances are not as close as in other PD pumps, this design handles low viscosity liquids with diminished performance.  
Loading characteristics are not as good as other designs, and suction ability is low.  High-viscosity liquids require reduced
speeds to achieve satisfactory performance.  Reductions of 25% of rated speed and lower are common with high-viscosity
liquids.
 
Advantages Disadvantages
Pass medium solids Requires timing gears
No metal-to-metal contact Requires two seals
Superior CIP/SIP capabilities Reduced lift with thin liquids
Long term dry run (with lubrication to seals)
Non-pulsating discharge
 Applications
Common rotary lobe pump applications include, but are not limited to:
 Polymers
 Paper coatings
 Soaps and surfactants
 Paints and dyes
 Rubber and adhesives
 Pharmaceuticals
 Food Process and Bioprocess
Materials of Construction / Configuration Options
 Externals (head, casing) - Typically 316 or 316L stainless steel head and casing
 Externals (gearbox) - Cast iron, stainless steel
 Internals (rotors, shaft) - Typically 316 or 316L stainless steel, non-galling stainless steel
 Shaft Seal - O-rings, component single or double mechanical seals, industry-standard cartridge mechanical seals
Food and cosmetic products capable of being pumped by lobe rotor pumps.
Alcohol Coffee liquor Glycerin Mousse Sorbitol syrup
Apple purée Cordials Gooseberries Mussels Soup
Apricots Corn oil Gravy Mustard Soya sauce
Baby food Corn syrup Hand cream Nail polish Spirits
Batter Cottage cheese Honey Nail varnish Starches
Beans Cotton seed oil Horseradish Offal Stews
Beer Cranberry juice Ice cream Olive oil Strawberries
Beetroot Cream Icings Onions Sugar
Biscuit Cream Cream cheese Iodine ointment Palm oil Syrup
Blackcurrants Custard Jams Pastes Tapioca
Brine Dog food Jelly Peanut butter Tea
Broth Dough Ketchup Pectin Tomato ketchup
Butter fat Eggs - whole Lard Perfumes Tomato paste
Caramel Egg yolk Liquid sugar Piccalilli Tomato purée
Castor Oil Essences Lotions Pie fillings Toothpaste
Cat food Evaporated milk Malt Pizza toppings Vaseline
Cheese curd Fish Maple syrup Plasma Vegetables
Cheese whey Flavorings Margarine Potato salad Vinegar
Cherries Fondants Marmalade Preserves Water
Chicken paste Fruit juice Marshmallow Purées Wines
Chili con carne Fruit pulp Marzipan Quinine Wort
Chocolate Gelatin Mascara Rice pudding Yeast
Chutney Gherkins Mayonnaise Salad dressing Yogurt
Glucose

4. CIRCUMFERENTIAL PUMP
The circumferential piston and bi-wing lobe pumps are very similar to the traditional lobe pump, both in the way they
operate and in their applications. Instead of traditional lobes, the rotors have arc shaped “pistons,” or rotor wings,
traveling in annular-shaped “cylinders” machined in the pump body. As with traditional lobe pumps, the rotors are not in
direct contact with each other and require the use of timing gears.
Circumferential piston and bi-wing lobe pumps have less slip than do comparably sized traditional lobe pumps. This is
because the rounded lobes of a traditional lobe pump only come in close contact with the casing at a single point on the
outer surface of each lobe, whereas the circumferential piston and bi-wing lobe pumps have a close clearance between the
rotor and the casing over the entire length of the arc. The lower slippage means that these pumps are more energy
efficient than traditional lobe pumps. With liquid viscosities greater than about 2000 SSU, this advantage disappears.
Advantages and disadvantages of circumferential piston and bi-wing lobe pumps are pretty much the same as for
traditional lobe pumps, and again, food processing is the most common application. Circumferential piston and bi-wing
lobe pumps normally do not handle abrasives as well as traditional lobe pumps, and the arc-shaped rotor may make
contact with the casing at times in higher pressure applications.
 When to use CPP technology:
1. High Viscosity: tomato sauce, ketchup, toothpaste, condensed milk etc.
2. High Discharge Pressure: up to 31 bar
3. Vacuum Suction: De-aerator application
Advantages:
• High Pressure Capability, up to 450 psi (31 bar)
• Imparts low shear to the pumped fluid
• Good solids handling capability
• No metal to metal contact between rotors
Disadvantages:
• High Cost due gears

5. DIAPHRAGM PUMP
A diaphragm pump (also known as a Membrane pump) is a positive displacement pump that uses a combination of the
reciprocating action of a rubber, thermoplastic or Teflon diaphragm and suitable valves on either side of the diaphragm
(check valve, butterfly valves, flap valves, or any other form of shut-off valves) to pump a fluid. As with all reciprocating
pumps, diaphragm pumps require check valves at the inlet and outlet ports. The diaphragm can be mechanically attached
to the reciprocating member or it can be separated and actuated by a reservoir of hydraulic fluid, often with a contour
plate to control the travel limits of the
diaphragm.
One very common application for diaphragm
pumps of the type described above is for
metering applications. Metering pumps, or
dosing pumps as they are called in Europe, have
relatively low flow rates, usually measured in
gallons or liters per hour rather than per minute.
These pump types are highly accurate in
measuring flow (usually having an accuracy of
better than ±1%), and the diaphragm makes the
pump leak-free and compatible with a variety of
liquids.
 One of the type of diaphragm pump is the
solenoid metering pump, used in light-duty
metering applications. This style of
diaphragm pump uses an electrical signal to magnetically move the plunger/diaphragm assembly.
 Much larger versions of hydraulically actuated diaphragm pumps are used in process services, where their high
pressure capability and sealless pumping make them an interesting alternative for special services. These pumps, with
metal diaphragms and remote heads, can pump liquids to 900°F.
 Another type of diaphragm pump is the air-operated, double-diaphragm pump. In this pump design, compressed air
enters the air chamber behind one of the diaphragms, flexing the diaphragm and thus forcing the air or liquid on the
other side of the diaphragm out the discharge check valve. Simultaneously, the second diaphragm (Figure 1.26) is
pulled inward by a rod connecting the two diaphragms, creating a suction stroke with that diaphragm, with liquid
coming in through the inlet check valve on that side of the pump. Then a shuttle valve causes the air distribution to
shift, sending air to the other chambers and reversing the stroke of the two diaphragms. Any type of diaphragm pump
has the distinct advantage, compared with piston or plunger pumps, of being sealless, that is, not requiring any pack-
ing assembly or mechanical seal. Air-operated diaphragm pumps offer the additional advantage of being able to
accommodate large solids, abrasives, and corrosives. They are self-priming and can run dry. Their versatility makes
them a good choice for pumping wastewater, acids, and foods. The shortcomings of air-operated diaphragm pumps
are that they require air to operate (this may actually be a benefit if the pump is in an area where compressed air is
available but electricity is not), they have limitations on flow and pressure, they produce fairly large pressure
 pulsations, and they are quite energy inefficient. Some designs also have problems with the air valves stalling or
freezing up, and some air valves require periodic lubrication.
 Another type of diaphragm pump, is known as a wobble plate pump. This pump type has the reciprocating action of
several pistons or diaphragms caused by a rotating plate mounted eccentrically on the shaft. Advantages of this pump
type include quite high pressure capability, sealless pumping, self-priming, and the capability of running dry or with a
blocked inlet line. Disadvantages include relatively low flows and many moving parts.

There are three main types of diaphragm pumps:

 Those in which the diaphragm is sealed with one side in the fluid to be pumped, and the other in air or hydraulic
fluid. The diaphragm is flexed, causing the volume of the pump chamber to increase and decrease. A pair of non-
return check valves prevent reverse flow of the fluid.
 Those employing volumetric positive displacement where the prime mover of the diaphragm is electro-
mechanical, working through a crank or geared motor drive, or purely mechanical, such as with a lever or handle.
This method flexes the diaphragm through simple mechanical action, and one side of the diaphragm is open to
air.
 Those employing one or more unsealed diaphragms with the fluid to be pumped on both sides. The diaphragm(s)
again are flexed, causing the volume to change.

When the volume of a chamber of either type of pump is increased (the diaphragm moving up), the pressure decreases,
and fluid is drawn into the chamber. When the chamber pressure later increases from decreased volume (the diaphragm
moving down), the fluid previously drawn in is forced out. Finally, the diaphragm moving up once again draws fluid into
the chamber, completing the cycle. This action is similar to that of the cylinder in an internal combustion engine.
Diaphragm Pumps deliver a hermetic seal between the drive mechanism and the compression chamber, allowing the
pump to transfer, compress, and evacuate the medium without a lubricant.
An elastomeric diaphragm can be used as a versatile dynamic seal that removes many of the limitations found with other
sealing methods. They do not leak, offer little friction, and can be constructed for low pressure sensitivity. With the right
material consideration, diaphragms can seal over a wide range of pressures and temperatures without needing lubrication
or maintenance.

Characteristics of Diaphragm pumps

 Have good suction lift characteristics, some are low pressure pumps with low flow rates; others are capable of
higher flow rates, dependent on the effective working diameter of the diaphragm and its stroke length. They can
handle sludges and slurries with a relatively high amount of grit and solid content.
 Suitable for discharge pressure up to 1,200 bar
 Have good dry running characteristics.
 Can be used to make artificial hearts.
 Are used to make air pumps for the filters on small fish tanks.
 Can be up to 97% efficient.
 Have good self-priming capabilities.
 Can handle highly viscous liquids. A viscosity correction chart can be used as a tool to help prevent under-sizing
AOD pumps

6. VANE PUMP
While vane pumps can handle moderate viscosity liquids, they excel at handling low viscosity liquids such as LP gas
(propane), ammonia, solvents, alcohol, fuel oils, gasoline, and refrigerants.  Vane pumps have no internal metal-to-metal
contact and self-compensate for wear, enabling them to maintain peak performance on these non-lubricating liquids. 
Though efficiency drops quickly, they can be used up to 500 cP / 2,300 SSU. Vane pumps are available in a number of
vane configurations including sliding vane (left), flexible vane, swinging vane, rolling vane, and external vane.  Vane
pumps are noted for their dry priming, ease of maintenance, and good suction characteristics over the life of the pump.  
Moreover, vanes can usually handle fluid temperatures from -32 0C / -250F to 2600C / 5000F and differential pressures to
15 BAR / 200 PSI (higher for hydraulic vane pumps). Each type of vane pump offers unique advantages.  For example,
external vane pumps can handle large solids.  Flexible vane pumps, on the other hand, can only handle small solids but
create good vacuum.  Sliding vane pumps can run dry for short periods of time and handle small amounts of vapor.
 
How Vane Pumps Work
Despite the different configurations, most vane pumps operate under the same general principle described below.
1. A slotted rotor is eccentrically supported in a cycloidal cam.  The rotor is located close to the wall of the cam so a
crescent-shaped cavity is formed.  The rotor is sealed into the cam by two side plates.  Vanes or blades fit within the
slots of the impeller.  As the rotor rotates (yellow arrow) and fluid
enters the pump, centrifugal force, hydraulic pressure, and/or
pushrods push the vanes to the walls of the housing.  The tight seal
among the vanes, rotor, cam, and side plate is the key to the good
suction characteristics common to the vane pumping principle.
2. The housing and cam force fluid into the pumping chamber through
holes in the cam.  Fluid enters the pockets created by the vanes,
rotor, cam, and side plate.
3. As the rotor continues around, the vanes sweep the fluid to the opposite side of the crescent where it is squeezed
through discharge holes of the cam as the vane approaches the point of the crescent.  Fluid then exits the discharge
port.
In a sliding vane style of rotary pump, vanes cooperate with a cam to draw liquid into and force it from the pump
chamber. In this pump style, vanes fit into slots cut lengthwise in the rotor, and the rotor turns inside an eccentrically
shaped casing that acts like a cam. When the rotor is turning at operating speed, the vanes are forced by centrifugal force
outward until they come in contact with the casing wall. Some types of vane pumps also rely on springs to force the vanes
outward, so that contact between the vanes and the casing walls is maintained even when the pump is operating at slow
speeds. Other types use liquid pressure from the pump discharge acting beneath the vanes to force the vanes outward.
 
Advantages Disadvantages
 
Handles thin liquids at relatively higher pressures Can have two stuffing boxes
Compensates for wear through vane extension Complex housing and many parts
Sometimes preferred for solvents, LPG Not suitable for high pressures
Can run dry for short periods Not suitable for high viscosity
Can have one seal or stuffing box Not good with abrasives
Develops good vacuum
Applications
 Aerosol and Propellants
 Aviation Service - Fuel Transfer, Deicing
 Auto Industry - Fuels, Lubes, Refrigeration Coolants
 Bulk Transfer of LPG and NH3
 LPG Cylinder Filling
 Alcohols
 Refrigeration - Freons, Ammonia
 Solvents
 Aqueous solutions
Materials of Construction / Configuration Options
 Externals (head, casing) - Cast iron, ductile iron, steel, and stainless steel.
 Vane, Pushrods - Carbon graphite, PEEK.
 End Plates - Carbon graphite
 Shaft Seal - Component mechanical seals, industry-standard cartridge mechanical seals, and magnetically-driven
pumps.
 Packing - Available from some vendors, but not usually recommended for thin liquid service

7. PERISTALTIC PUMP
A peristaltic pump is a type of positive displacement pump used for pumping a variety of fluids. The fluid is contained
within a flexible tube fitted inside a circular pump casing (though linear peristaltic pumps
have been made). A rotor with a number of "rollers", "shoes", "wipers", or "lobes" attached
to the external circumference of the rotor compresses the flexible tube. As the rotor turns,
the part of the tube under compression is pinched closed (or "occludes") thus forcing the
fluid to be pumped to move through the tube. Additionally, as the tube opens to its natural
state after the passing of the cam ("restitution" or "resilience") fluid flow is induced to the
pump. This process is called peristalsis and is used in many biological systems such as the
gastrointestinal tract. Typically, there will be two or more rollers, or wipers, occluding the
tube, trapping between them a body of fluid. The body of fluid is then transported, at
ambient pressure, toward the pump outlet. Peristaltic pumps may run continuously, or they may be indexed through
partial revolutions to deliver smaller amounts of fluid.

PRINCIPLE
Peristalsis
Peristalsis is a radially symmetrical contraction and relaxation of muscles that propagates in a wave down a tube, in an
anterograde direction. In much of a digestive tract such as the human gastrointestinal tract,
smooth muscle tissue contracts in sequence to produce a peristaltic wave, which propels a ball
of food (called a bolus while in the esophagus and upper gastrointestinal tract and chyme in the
stomach) along the tract. Peristaltic movement comprises relaxation of circular smooth muscles,
then their contraction behind the chewed material to keep it from moving backward, then
longitudinal contraction to push it forward. Earthworms use a similar mechanism to drive their
locomotion, and some modern machinery imitates this design.

WORKING OF THE PUMP

 The peristaltic pump rotates and creates a seal at the suction side of the pump. It
also encapsulates the blue section of fluid and starts to push it through the pump.
The red section of fluid is being forced out the discharge end of the pump.
 As the tubing begins to recover, the green section of fluid is sucked into the pump.
 As the pump rotates, it continues to push the blue region of fluid. The green
section of fluid continues to be pulled into the pump.
 As the pump rotates, it continues to push the blue region of fluid.

TYPES OF PERISTALTIC PUMP

TUBE PUMP HOSE PUMP
The tube pumps contain silicon, PVC, fluoropolymer or Hose pumps contain a pump segment, which is a reinforced
other polymer as material of tubing. These are the most tube, called hose. These hoses are harder to be pressed and this
common type of peristaltic pumps tubing and as materials way they need bigger and stronger motors for the same flow;
are improving the difference between hose pumps and tube hence, they are more expensive to operate. The main advantage
pumps are melting. Tube pumps can operate against less of hose pumps is that they can operate against much higher
pressure, but they need smaller motors and force to pressure than tube pumps working up to 16 bars
operate; hence, this way they are space-saving and cheaper
to work with.

Roller design in peristaltic pumps

Fixed occlusion Spring-loaded rollers
 In this kind of pump, the rollers have a fixed locus as it turns, As the name indicates, the rollers in this pump are mounted on
keeping the occlusion constant as it squeezes the tube. This is a spring.
a simple, yet effective design. This design is more elaborate than the fixed occlusion, but
 The only downside to this design is that the occlusion as a helps overcome the variations in the tube wall thickness over
percent on the tube varies with the variation of the tube wall a broader range.
thickness. Regardless of the variations, the roller imparts the same
 Typically, the wall thickness of the extruded tubes vary amount of stress on the tubing that is proportional to the
enough that the % occlusion can vary with the wall spring constant, making this a constant stress operation. The
thickness. Therefore, a section of tube with greater wall spring is selected to overcome not only the hoop strength of
thickness, but within the accepted tolerance, will have higher the tubing, but also the pressure of the pumped fluid.
percent occlusion, which increases the wear on the tubing,
thereby decreasing the tube life.
The operating pressure of these pumps is determined by the tubing and by the motor's ability to overcome the hoop
strength of the tubing and the fluid pressure.
 ADVANTAGES DISADVANTAGES
1. No contamination and tubing can also be autoclaved. 1. Due to deviation caused through the production and the
2. Peristaltic pumps do not need any specific action for replaceable tubing, the pump system must be calibrated to
priming as they are capable of self-priming. reach acceptable accuracy.
3. They are also insensitive to dry running as lubricant and 2. Due to the wear the tubing it needs to be changed and
the tubing does not damage if compressed empty. recalibrated over time. In case of extensive use or in
4. Pumps do not contain any valves, seals or glands; hence absence of exchange the tube may leak.
easy and cheap to maintain and the 3. In some case their chemical inertness can be disadvantage
5. Chance of malfunction is also lower. as well.
6. They can operate reversibly 4. Slight pulsation is inevitable at work. The flow rate is
7. Multi-channel systems can be built easily as well. sensitive to varying differential pressure conditions and
8. Their suction height is excellent and when stopped, no their maximal differential pressure is lower comparison to
siphoning effect will occur. gear and piston pumps.
9. The viscosity of the fluid does not influence the transport;
hence, suspensions and sludges do not influence the
transport.
10. The delivery is gentle due to the low shearing forces;
making them ideal for shear-sensitive fluids such as blood
(due to the blood cells).
11. High repeatability, suitable for auto-analyzers.

APPLICATIONS OF PERISTALTIC PUMPS

Peristaltic pumps can be found in many applications. Below a review can be found with the practical property which is
necessary in the given application.
Testing and Agriculture Food Chemical Engineering and Water and
Medicine research manufacturing handling manufacturing Waste
and sales
 Dialysis  Auto Analyzer 'Sapsucker' pumps  Liquid food Printing, paint  Concrete pump  Chemical
to extract maple tree and pigments
machines  Analytical sap
fountains (ex.  Pulp and paper plants treatment
 Open-heart chemistry cheese sauce Pharmaceutical  Minimum quantity in water
for nachos) production lubrication purification
bypass pump experiments
 Beverage Dosing systems plant
machines  Carbon for dishwasher
 Medical monoxide
dispensing  Sewage
 Food-service and laundry sludge
infusion monitors chemicals
Washing  Aquariums,
pumps  Media Machine fluid
dispensers particularly
pump
calcium
reactors

Materials used for tubing

 High Molecular Weight, Flexible Polyvinyl Chloride (PVC)
 Standard Flexible Polyvinyl Chloride (PVC)
 Peroxide Cured Silicone
 Thermoplastic Vulcanizate (TPV)
 Thermoplastic Elastomer (TPE)
 Viton Rubber
 EPDM
 Hypalon
 NBR (Buna)
 NR (Natural Rubber)