Double screw pumps: efficiency and reliability for viscous fluids
Twin screw pumps: a revolutionary technology
In the modern industrial landscape, viscous fluid handling represents a technical challenge of primary importance. Twin screw pumps have established themselves as the most advanced and efficient solution for complex fluid transport, overcoming the limitations of traditional technologies and setting new performance standards in the positive displacement pumps sector.
Nova Rotors has developed cutting-edge technology that redefines the concept of efficiency in viscous fluid transport, offering innovative solutions that combine superior performance, operational reliability, and environmental sustainability.
Operating principles of twin screw pumps and innovative design
Twin screw architecture
Nova Rotors twin screw pumps are based on an operating principle that utilizes two counter-rotating helical screws, perfectly synchronized, which create variable volume chambers for fluid transport. This innovative design eliminates metallic contact between the screws, ensuring silent operation and exceptional operational durability.
The optimized geometry of the screws allows handling of fluids with viscosities up to 500,000 cSt, maintaining constant flow and pulsation-free operation even in the most demanding operating conditions. The advanced helical profile ensures gradual and uniform compression, minimizing mechanical and thermal stress on the transported fluids.
Patented advanced synchronization technology
The patented Nova Rotors synchronization system uses precision gears made with high-resistance materials, ensuring perfect screw alignment even after thousands of operating hours. This technology eliminates the backflow phenomenon, maximizing volumetric efficiency and significantly reducing energy consumption.
Competitive advantages over alternative technologies
Superiority over centrifugal pumps
While centrifugal pumps drastically lose efficiency as fluid viscosity increases, twin screw positive displacement pumps maintain constant performance regardless of the rheological characteristics of the transported liquid. This characteristic makes them ideal for applications where viscosity can vary during the process.
Key advantages:
- Constant efficiency regardless of viscosity variation
- Self-priming capability
- Uniform flow without pulsations
- Possibility of dry running for short periods
Comparison with gear pumps
Compared to traditional gear pumps, twin screw technology offers:
- Lower wear: The absence of metallic contact between screws drastically reduces wear, extending maintenance intervals and reducing operational costs.
- Greater energy efficiency: The optimized design of compression chambers minimizes internal losses, resulting in energy savings of up to 25% compared to traditional solutions.
- Operational versatility: Ability to handle fluids containing solid particles without damage, thanks to the wide tolerances between screws.
Industrial applications of twin-screw pumps and areas of excellence
Food industry
In food production, where hygiene and product delicacy are fundamental, twin screw pumps excel in transporting honey, syrups, concentrated pastes, tomatoes, chunky fruit, and dairy products. The sanitary design and ability to maintain intact organoleptic properties of products make them the preferred choice of the most demanding food manufacturers.
Chemical and pharmaceutical sector
For transporting active ingredients, molten polymers, and viscous chemical compounds, dosing precision and performance repeatability are crucial. Nova Rotors pumps guarantee constant flow rate with deviations of less than 2%, an essential requirement for chemical synthesis processes and pharmaceutical production.
Plastics industry
In handling molten polymers, plasticizing additives, and thermoplastic compounds, the ability to operate at high temperatures (up to 170°C) without compromising fluid integrity represents a decisive advantage.
Energy efficiency and environmental sustainability
Consumption optimization
Nova Rotors viscous fluid transport pumps incorporate advanced technologies for energy consumption reduction:
- High-efficiency motors: Integration with IE4 motors and variable speed control inverter systems to optimize consumption based on actual process requirements.
- Advanced fluid dynamic design: CFD (Computational Fluid Dynamics) optimized geometries to minimize pressure losses and reduce absorbed power.
- Energy recovery systems: Possibility to integrate heat recovery systems for processes requiring fluid heating.
Reduced environmental impact
The long operational life and reduced maintenance requirements contribute significantly to environmental sustainability. The possibility of completely reconditioning pumps at the end of their operational life reduces environmental impact and disposal costs.
Scheduled maintenance and operational reliability
Predictive maintenance strategy
The design of Nova Rotors twin screw pumps allows easy access to critical components, supporting predictive maintenance strategies through targeted controls and external instrumentation.
- Vibration monitoring: changes in vibrations can indicate wear or misalignments.
- Oil analysis: Integrated systems for lubricant quality control and contaminant identification.
- Targeted periodic inspections: to verify wear of screws, mechanical seals, and bearings.
Ease of maintenance
The modular design greatly facilitates routine and extraordinary maintenance operations. The possibility of replacing critical components without completely dismantling the pump significantly reduces plant downtime.
Extended maintenance intervals: Thanks to superior construction quality, routine maintenance intervals can extend up to 8,000 operating hours.
Technological innovations and future developments
Digitalization and Industry 4.0
Nova Rotors is developing integrated solutions for Industry 4.0, with "intelligent" pumps capable of self-diagnosing their health status and automatically optimizing performance based on operating conditions.
- Digital twin: Virtual models that simulate pump behavior to optimize maintenance and performance.
- Use of motors with predictive technology: Collaboration with partners capable of providing motorizations with devices that allow parameter control through cloud systems and send alerts in case of discrepancies in preset detected data
- IoT connectivity: Integration with distributed control systems for remote monitoring and centralized management of pump fleets.
Innovative materials
Ongoing research on advanced materials promises further improvements in terms of corrosion resistance, operational durability, and energy efficiency. The use of ceramic coatings and special alloys opens new application possibilities in particularly aggressive environments.
Economic analysis and return on investment
Total Cost of Ownership (TCO)
Total cost of ownership analysis highlights the economic advantages of twin screw pumps:
- Acquisition costs: Competitive initial investment considering superior performance.
- Operating costs: Significant reduction in energy consumption and maintenance costs.
- Plant downtime costs: Minimization of downtime thanks to high reliability.
The typical payback period ranges between 18 and 36 months, depending on the application and operating conditions.
Documented success cases
Chemical sector: A major bioethanol producer recorded an improvement in terms of performance and lack of machine downtime by replacing existing lobe and centrifugal pumps with Nova Rotors technology.
Food industry: A multinational fruit concentrate company achieved a 25% improvement in production efficiency and a 40% reduction in maintenance costs.
Optimal selection and sizing
Selection criteria
The choice of the optimal twin screw pump depends on several critical factors:
- Fluid characteristics: Viscosity, temperature, presence of suspended solids, chemical compatibility.
- Operating parameters: Required flow rate, head, operating temperature, type of operation.
- Specific requirements: Required certifications, acceptable noise level, available space.
Technical support services
Nova Rotors offers a specialized consulting service to optimize selection and sizing, ensuring the most effective solution for each specific application.
Nova Rotors twin screw pumps represent the natural evolution of pumping technology for viscous fluids. The combination of superior energy efficiency, exceptional operational reliability, and application versatility positions them as the strategic solution for industries that want to optimize their production processes.
Investment in this advanced technology guarantees not only superior performance in the short term, but also the flexibility needed to face future challenges in the industrial market. The ability to adapt to fluids with different characteristics and the ease of integration with modern control systems ensure a future-proof solution.
Choosing Nova Rotors twin screw pumps means choosing technological excellence, environmental sustainability, and economic competitiveness in a single strategic investment that will continue to generate value for years. Contact us for more information!
