Hydraulic Pump: how to optimize efficiency and energy performance.
The hydraulic pump is a device present in many systems and therefore plays a strategic role in meeting the growing demands for energy savings and ecological solutions.
- The adoption of methodologies such as the Extended Product Approach (EPA) and the System Approach, which consider the optimal interaction between pump, motor, and control, to ensure maximum energy savings and reliability.
- Selecting the right hydraulic pump for the specific application and sizing it correctly is essential to avoid energy overloads and excessive costs.
- Advanced impeller design, including materials and blade geometry, is crucial to optimize hydraulic efficiency, reduce friction losses, and prevent phenomena such as cavitation.
The directives guiding electric pump manufacturers increasingly aim to achieve these sustainability goals, which in some cases have already become legal requirements. The philosophy is that of the Extended Product Approach (EPA), a methodology for calculating the Energy Efficiency Index of an "Extended Product" (pump, motor, and any control) by considering the behavior of all components and load profiles.
Another fundamental aspect of the new construction philosophy is the System Approach, which emphasizes that even the most efficient devices are not sufficient if they cannot interact optimally within a system. Only in this way can the most significant results be achieved in terms of energy savings, system reliability, and reduced maintenance costs.
What Makes a Hydraulic Pump Truly Efficient.
There are different types of pumps precisely because there are numerous applications where their presence is required: water extraction and distribution, wastewater treatment, heating and cooling systems, food industry, chemical and mining industry, etc.Choosing the most suitable pump for a specific need is already the first step toward an efficient choice. Similarly, proper sizing is very important to avoid oversized pumping systems, which would necessarily lead to increased costs and energy consumption.
We have mentioned how the different components of a hydraulic pump must work synergistically for optimal operation, each contributing to the final result. The use of a high-efficiency motor undoubtedly makes a difference in pump performance, but it becomes even more significant when paired with a high-performing hydraulic system. When it comes to the hydraulic part, the impeller is the main element, the one that generates the force to circulate the fluid. More precisely, the impeller transforms the mechanical energy of the shaft into kinetic energy of the fluid. The more efficient the energy transfer, the higher the hydraulic efficiency.
Impeller Design Depends on Applications.
Flow rate, pressure, fluid nature, and operating conditions are all aspects that influence impeller characteristics. A first classification distinguishes radial flow impellers from axial flow impellers.In the first case, the impeller blades are arranged radially relative to the axis of rotation. The centrifugal force created pushes the fluid in a direction perpendicular to the impeller axis, ensuring a high-pressure flow relative to the flow rate.
The axial flow impeller, on the other hand, with blades arranged parallel to the impeller's axis of rotation, generates a high-flow, low-pressure flow. There are also mixed flow impellers that ensure a good compromise between pressure and flow rate and are used in many water applications.
A further distinction is between open, closed, or semi-closed impellers. Open impellers allow fluid flow even in the presence of solids and prevent clogging, which is why they are typically used in the mining industry and wastewater treatment. Closed and semi-closed impellers ensure greater efficiency in energy transfer to the fluid and a more stable flow but are suitable only for use with clear water.
In general, the principle is that impellers should be designed so that the geometry and angle of the blades are optimized for the type of fluid being handled and to minimize friction losses and turbulence. This reduces energy consumption and prevents dangerous phenomena such as cavitation.
Finally, the choice of materials affects both efficiency and product durability and must always be linked to the application. Impellers made of stainless steel and technopolymer, such as noryl, for example, can achieve interesting results in terms of efficiency. The smooth surfaces of the blades and precision reduce head losses; moreover, these materials have excellent corrosion resistance and hydrolytic stability, an ideal characteristic when the fluid in question is potable water.
