Hydra Cell Polyurethane Processing - Monitor Pumps

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Accurate Metering and Superior Handling of Abrasivesand Particulates for Polyurethane ProcessingPolyurethane Processing

Hydra-Cell Pumps for Polyurethane ProcessingPressure Injecting and Mixing Transfer Spraying Metering and DosingRigid Foam(High-pressure requirements from 2175 to 3480 psi)Typical end products:Panel insulation, packaging, and frame insulation for buildingproductsIsocyanates & Polyols:Hydra-Cell can pump Isocyanates and Polyols from large tanks andsilos to smaller tanks and day tanks, and then into the productionprocess. If the pressure requirement does not exceed 2500 psi, oneHydra-Cell pump can handle the job of two pumps by eliminatingthe need for a feeder pump. Costs are also reduced becauseHydra-Cell has no dynamic seals to wear or replace.Blowing agents:Hydra-Cell metering pumps can meet the same pressure and flowrequirements in a much smaller footprint than traditional meteringpumps. This lowers acquisition costs and facilitates maintenance.Soft Polyurethane(Medium-pressure requirements from 870 to 2175 psi)Typical end products:Insulation, car dashboards, life-saving equipment, and foam for beds,car seats, household furniture, cushions, and pillowsIsocyanates & Polyols:Hydra-Cell Pumps Selection and ApplicationsHydra-Cell positive displacement pumps are available in 14pump models covering a widerange of flows and pressures.Nine (9) Hydra-Cell Seal-lessmodels are ideal for transfer,spraying, and pressure injecting and mixing.Six (6) metering pump models are ideal for metering anddosing, spraying, and pressureinjecting and mixing.Hydra-Cell pumps are usedin many industries manufacturing products made withpolyurethane plastic and foam.AppliancesAutomotiveHydra-Cell can pump Isocyanates and Polyols from large tanks tosmaller tanks and day tanks without damage to the pump if crystalsform in Isocyanates due to exposure to air.C.A.S.E.(Coatings, Adhesives, Sealants& Elastomers)Catalysts & Additives:Cast Elastomer WheelsHydra-Cell pumps are also used to pump catalysts and additivesinto the production process.FootwearFurnitureHard or Dense Polyurethane(Low-pressure requirements up to 875 psi)Typical end products:Agricultural tires, shoe soles, simulated wood and laminates, and asa replacement for fiber glass and silicon sealsIsocyanates & Polyols:Seal-less Hydra-Cell pumps are ideal for pumping Polyols andIsocyanates from large tanks into smaller tanks and day tankswithout the constant need to replace worn seals used in otherpumps.Insulation(Thermal & Sound)PackagingPaddingRIM Solid Plastics(Enclosures for BusinessMachines, Medical &Electronic Equipment)Isocyanates, Polyols & Additives:SlabstockWhen pumping Polyols, Isocyanates, or additives into theproduction process, accurate dosing is often required, as is alow-speed, low-flow rate with minimal pulsations. Hydra-Cellexceeds API 675 performance standards for accuracy, linearity andrepeatability with virtually pulse-free flow - including low-speed,low-flow performance. As a result, Hydra-Cell can eliminate theneed for expensive pulsation dampeners.Sporting Goods & Facilities2 www.Hydra-Cell.comStructural Foam & SimulatedWood

Isocyanates(TDI 80, PMDI)Polyols(Standard, Filled, HR, Polymer, Melamine,Visco, Polyester)Blowing Agents(Pentane, Freon)Challenges inPumpingThe Hydra-CellAdvantageExposure to air and moisture causes crystalsto form. Crystals can cause premature wearof dynamic seals and other pump componentsthat require a lubricating film. Frequent andexpensive maintenance needed to replaceseals. Seal-less design means no rotary shaftseals to wear or replace, preventing air andmoisture contamination.Abrasive substance that can vary in viscosity;less viscous Polyol often requires low-pulseflow. Handles liquids with viscosities up to 5000cPs (depending on pump model).Very difficult to transfer using pumps thathave dynamic seals. Seal-less design can handle difficult liquidscontaining particles.Abrasive fillers often added that can damagemany pumps. Seal-less design and vertical check valvescan handle fillers up to 9 Mohs hardness.Pressure can vary due to chemicalcomposition. Models can handle a wide range of pressurerequirements.Non-lubricating with low vapor pointsrequiring cooling and high inlet pressures tomaintain in liquid form. The refrigeration unitmust be large enough to accommodate themetering pump. Compact design can provide the same orgreater metering capability with a muchsmaller footprint and up to 30% lowerinitial cost. Seal-less design and spring-loaded,horizontal disk check valves also enableliquids with particulates up to 800 micronsin size (depending on pump model) to bepumped without damage to the pump. Provides virtually pulse-free flow withoutexpensive pulsation dampeners. Can handle 250 - 500 psi inlet pressures(depending on pump model). Smaller refrigeration unit needed,resulting in significant capital equipment,maintenance, and operational savings.Vapors can leak through dynamic seals.Catalysts & Additives(Catalysts - BASF/DOW ProprietaryCatalysts, Amine)(Additives - Silicone 1, Silicone 2, Silicone 3Ester, DEOA, Health Guard, FLE 200, FireRetardant 1, Fire Retardant 2, Coloring Dyesand Pigments) 100% sealed pumping chamber; no leakpaths.Require extremely accurate dosing, typically at Exceeds API 675 performance standardsfor Steady-State Accuracy, Repeatability, andvery low flow rates.Linearity at flow rates as low as 0.15 gph.Need to operate across a wide range of lowto-high pressures. Several models available with maximumpressure ratings from 1000 to 2500 psi.Additives can be difficult to pump and contain Seal-less design and spring-loaded,horizontal disk check valves handleabrasives due to crystallization when additivesabrasives and reduce clogging.come into contact with air or other chemicals. Can run dry without damage to the pump. Variety of materials of construction(metallic and non-metallic) suited for fluidsand additives pumped.Acids(Formic, Sulfonic)Corrosive, abrasive substances that candamage pump. Seal-less design provides no leak path andhandles abrasives. Corrosion-resistant liquid head materialsavailable.De-ionized Water(Pure, Distilled)Crystallization can occur when excessiveair leaks through seals, causing clogging andreduced efficiency. Spring-loaded, horizontal disk check valvesreduce clogging and maintain efficiency.Aggressive against metal surfaces; especially aproblem for any tight tolerances. No tight tolerances in the pump head.Non-lubricating. Pumping action does not need lubrication.www.Hydra-Cell.com 3Hydra-Cell Pumps for Polyurethane ProcessingTypical Chemicals andLiquids Pumped

Hydra-Cell Design & Performance FeaturesLower Initial Investment and Lower Energy CostsLow power consumption - 85% to 90%energy efficiency The lower hp requirement of the Hydra-Cell pump achieves thesame performance but with greater energy efficiency and lesspower consumption. Hydra-Cell positive displacement pumps show significant energysavings when compared to screw pumps and multi-stage centrifugal pumps (notably in transfer applications).Small footprint for savings Compact design can mean up to 30% lower initial cost comparedto other pumps. Space-saving design creates a smaller footprint for more efficientuse of plant space and easier servicing. Pumping blowing agents requires a refrigeration unit. Significantcapital savings are realized because space-saving Hydra-Cell canbe housed in a smaller refrigeration unit compared to othertypes of pumps.The multiple-diaphragm liquid head of Hydra-Cell also allows a lessexpensive, energy-saving motor to be used.Uses lower hp motors Although both pumps have the same pressure rating, thelighter, more compact Hydra-Cell has a higher flow rating whilerequiring a less expensive, lower hp motor. This means HydraCell saves approximately 30% to 55% on initial costs.Pumps Shown to ScaleThe Hydra-Cell and triplex metering pumps both have the same flowcapacity and pressure rating; however, space-saving Hydra-Cell has amuch smaller footprint. Conventional metering pumps can becomeoversized and overpriced at higher flow/pressure requirements.Hydra-Cell metering pumpWeight: 83.5 lbs. (with motor)Conventional metering pumpRated: 2500 psi at 36 gphWeight: 220 lbs. (with motor)Motor: 1-1/2 hpRated: 2500 psi at 29 gphMotor: 5 hp4 www.Hydra-Cell.com

Pumps Abrasives and Runs Dry without DamageHydra-Cell pumps can be installed in-line or as part of aturnkey system with a lower initial investment and loweroperating costs than other types of pumps.Handles abrasives and particulates Seal-less design and spring-loaded, horizontal disk check valvesprovide superior handling of particulates - including abrasivefillers in Polyols and crystals that form in Isocyanates. Can pump liquids containing solid particles up to 800 micronsin size (depending on pump model) and up to 9 hardness on theMohs scale. Reliably pumps acids and caustics which crystallizeRuns dry without damage Hydraulically-balanced diaphragms with patented Kel-Cell technology enable Hydra-Cell pumps to run dry or in a blockedsuction line or valve closure without damage.Pumping blowing agents requires a refrigeration unit. Significantcapital savings are realized because space-saving Hydra-Cellpumps can be housed in a smaller refrigeration unit comparedto pump types with the same flow and pressure ratings.Handles low-to-high viscosity fluids Pumps thin to highly viscous liquids throughout the entirepressure range. Low-shear pumping action makes Hydra-Cell ideal for pumpingand protecting shear-sensitive polymers. Non-lubricating liquids can be pumped reliably.Seal-less design means no harmfulemissions Seal-less, leak-free pumping chamber; no seal maintenancerequired. Liquids are 100% sealed from the atmosphere. No leak path for toxic vapors.Injection of a proprietary catalyst into a high-volumepolyurethane system. Where high flow is needed, Hydra-Cellpump models have maximum flow rates up to 66 gpm.www.Hydra-Cell.com 5Hydra-Cell Design & Performance FeaturesHydra-Cell’s horizontal check valve orientation will handle abrasives andparticulates without clogging or damage to the pump.

Accurate electronic flow control Compared to pumps that rely on manual stroke adjustment orexpensive actuators to change flow, Hydra-Cell metering pumpsutilize speed control for greater accuracy throughoutthe turndown range. Can be equipped with solid-state electronic flow control wherethe volume per every stroke is constant and a known value. Electronic flow also provides easy calibration of the desired feedrate and a near instantaneous rate of change (0 to maximumrpm in 0.3 seconds). Multiple-diaphragm designminimizes pulsations, eliminating the need for expensivepulsation dampeners for mostHydra-Cell models. Reduces pipe strain. Enhances operating safety. Minimizes maintenance. Reduces acceleration/frictionlosses in the suction line. Provides accurate meteringwith linear, constant flow.Hydra-CellSeal-lessModelsHydra-CellP SeriesMetering PumpsSteady StateAccuracy 1% 1% or betterRepeatability 3% 3% or betterLinearity 3% 3% or betterTypical results for recommended speed rangePulsation Graph Comparison150(10.3)Virtually pulse-freeflowPressure: psi (bar)Hydra-Cell Design & Performance FeaturesAccurate Metering and Dosing with Pulse-free,Linear FlowMetering Pumps Operating without Pulsation DampenersFlow Rate: 182 gph (689 lph) Pressure: 100 psi (6.9 bar)100(6.9)ConventionalMetering PumpHydra-CellP40050(3.4) Lowers system acquisitioncosts.000.250.50.75Time: seconds6 www.Hydra-Cell.com11.251.5

One Versatile, Low-Maintenance Pump Design One Hydra-Cell design with 15 models (9 seal-less; 6 metering)covers a wide range of flows and operating pressures. Can be fitted with ANSI, SAE or DIN flanges, IEC or NEMAmotor mounts, or provided with ATEX certification to adaptto specific applications or meetinternational standards. Proven record of replacing differentpump technologies with improvedabrasives handling, less maintenance,and other benefits (as detailed onpages 8-9). Shaft speeds from 6 rpm to1800/1200 rpm, yielding a 300/200:1turndown ratio. Maximum discharge pressures from1000 to 2500 psi.F20M03D04D10D15200:1Turndown RatioFlow RateExtensive operating rangeH25D35300:1Turndown Ratio Maximum flow rates for seal-lessmodels from 1 to 66 gpm and formetering pumps from 27 to 890 gph. Minimum flow rates less than 0.15gph at approximately 6 rpm.6 rpmSimple pump head design Liquid head materials can be changedreadily, enabling Hydra-Cell to beused for many different chemicalsand liquids pumped. Minimal maintenance required withno special tools needed. Low cost of spare parts.Wide Range of Flow Control1200 rpm1800 rpmMinimumMaximumFlow Rate0.0025 gpm (0.15 gph)37 gpm (2220 gph)Discharge Pressure0 psi2500 psiLow maintenance No mechanical seals, cups or packing to leak, wear, or replace. No tight tolerances that could be susceptible to corrosion ordamaged by solid particles. One design for all applications minimizes the need for standbypumps and spare parts, which optimizes training and serviceexpertise and reduces inventory size and expense. Since there are no dynamic seals to wear or replace, Hydra-Cellpumps need little maintenance and will operate reliably undercontinuous duty at high pressure. Any maintenance or repair can usually be performed on-site. Can operate up to 6,000 hours between lubricating oil changes(compared to 1,500 hours recommended by many piston pumpmanufacturers).www.Hydra-Cell.com 7Hydra-Cell Design & Performance FeaturesAdaptable to many applications

Hydra-Cell Competitive Performance AdvantagesHydra-Cell Performance Advantages Comparedto Other Types of PumpsMagnetic Drive Pump Disadvantages:Hydra-Cell Advantages: Running dry can result in damage to the pump. Seal-less design enables Hydra-Cell to run dry withoutdamage to the pump. Requires monitoring to ensure fluid flow. Ensures proper fluid flow without monitoring. Designed to pump clean, low-viscosity fluids. Low-shear pumping action handles higher viscosity fluids. Higher power requirements and energy costs. More energy efficient. Can have a long horizontal footprint with higheracquisition and replacement costs. Smaller footprint compared to some magnetic drivepumps. More energy efficient. Easier to service. Lower acquisition, operating and replacement costs.Axial Piston Pump Disadvantages:Hydra-Cell Advantages: Tight tolerances prevent use in fluids with particulatesgreater than 7 microns, especially with liquids (e.g.Isocyanates) that react with air and form crystals in theliquid. Tolerances are not an issue because the seal-lessdesign and spring-loaded, horizontal disk check valvesenable Hydra-Cell to pump solids, abrasive fillers andparticulates up to 800 microns in size (depending onpump model). Filter and fluid reservoir necessary to maintain fluidcleanliness. Inherently simple design separates the lubricating filmfrom the pumped liquid. Cylinder barrel can separate from valve plate, causingloss of lubricating film and damage to the barrel or plate. Requires no external filtration of pumped fluids. Back pressure can cause seal failure and mechanicaldamage. No packing and seal-less design, so it will not leak fromseal failure.Internal Gear Pump Disadvantages:Hydra-Cell Advantages: Mechanical seals and packing require maintenance, andreplacement or adjustment. The seal-less design of Hydra-Cell means that there areno mechanical seals or packing to leak or replace. Does not tolerate thin/non-lubricating liquids, and doesnot handle solids, abrasives or particulates well. Seal-less pumping chamber and spring-loaded, horizontaldisk check valves can pump solids, abrasive fillers andparticulates while handling liquids thick or thin. Designed for operating at low speeds and low pressureratings. Low volumetric efficiency. Operates at low-to-high speeds and at higher pressureswith higher volumetric efficiency. Component wear reduces accuracy and efficiency. No internal gears to wear so there is less maintenanceand spare part replacement. Accuracy and efficiency are more stable. One bearing runs in the pumped fluid. No bearings in the pumped fluid. Unbalanced - overhung load on the shaft bearing. Hydraulically balanced design so there is no overhungload.8 www.Hydra-Cell.com

External Gear Pump Disadvantages:Hydra-Cell pump used in high-precision Pentane dosing. Hydra-Cellmetering pumps can provide precise dosing at flow rates as low as0.15 gph.Hydra-Cell Advantages: Mechanical seals and packing require maintenance, andreplacement or adjustment. The seal-less design of Hydra-Cell means that there areno mechanical seals or packing to leak or replace. Does not tolerate solids, abrasives, or particulates. Seal-less pumping chamber and spring-loaded, horizontaldisk check valves can pump solids, abrasive fillers andparticulates. Component wear reduces accuracy and efficiency. No internal gears to wear so efficiency is morestable and there is less maintenance and spare partreplacement. Contains four bushings/bearings in the fluid area. No bushings/bearings in the pumped fluid. Fixed end clearances are typical. Design does not rely on clearances. Efficiency drops as outlet pressure increases. Efficiency remains relatively constant over its range ofoperating pressures. Depends on pumped liquid for lubrication. Seal-less design does not require pumped liquid forlubrication.Conventional Metering Pump Disadvantages:Hydra-Cell Advantages: Use manual stroke adjusters or expensive actuators tocontrol flow, which can result in pumping inaccuracies,lost motion, operator error, and a greater chance ofleakage. Hydra-Cell employs optional Variable Frequency Drive(VFD) electronic flow control for greater accuracy andrepeatability, eliminating lost motion, reducing the chanceof operator error, and removing a potential leak path. Require expensive pulsation dampeners to minimizepulsations. Multiple-diaphragm design provides virtually pulse-freeflow, so expensive pulsation dampeners may not berequired. May only offer PTFE diaphragms, requiring frequent Available with a wide choice of cost-effective, elastomericreplacement due to stress and poor elastomeric memory.diaphragm materials. Large footprint to achieve required maximum flow andpressure. Can meet the same flow and pressure requirements witha much smaller footprint, saving space and costs. Different plunger and liquid end sizes needed toaccommodate changes in operating pressures. Operates over a wide range of pressures withoutchanges to the plunger or liquid end size. Integral gearing (necessary to prevent crosscontamination of actuating oil) is difficult and expensiveto maintain. The simplicity of design means lower parts andmaintenance costs. Separate gearbox prevents cross-contamination of theactuating oil.www.Hydra-Cell.com 9Hydra-Cell Competitive Performance AdvantagesCompared to other pumps, Hydra-Cell requires minimal maintenancefor polyurethane processors. Hydra-Cell has no mechanical seals, cups orpacking that leak or need to be replaced and no internal gears to wear.

Hydra-Cell Standard Pump Selection GuideHydra-Cell Positive Displacement DiaphragmPumps are Ideal for HandlingDESIGNED & BUILTIN THE USAAbrasives and ParticulatesSINCE 1973umpsSeal-less P Unmatched versatility for a wide range of pumping applicationsrequired in the production of polyurethane. Variety of models that can operate with very low to very highflow rates and discharge pressures up to 2500 psi. Features a seal-less design and horizontal disk check valves thatenable the pump to handle abrasives and particulates that mightdamage or destroy other types of pumps. Available in a wide range of pump head materials of constructionand diaphragm materials. Variety of options and accessories to optimize performance. Simple, compact design reduces initial investment and lowersmaintenance costs.Flow Capacities and Pressure RatingsMaximumCapacityModel1gpm (l/min)MaximumMaximumDischarge Pressure psi (bar)Operating Temperature F mumInletPressure psi (bar)F201.0 (3.8)350 (24)1500 (103)140 (60 )250 (121 )250 (17)M033.1 (11.7)350 (24)1200 (83)140 (60 )250 (121 )250 (17)D042.9 (11.2)N/A2500 (172)N/A250 (121 )500 (34)D1044.3 (15.1)N/A1500 (103)N/A250 (121 )250 (17)D108.8 (33.4)350 (24)1000 (69)140 (60 )250 (121 )250 (17)D128.8 (33.4)N/A1000 (69)N/A250 (121 )250 (17)D15 & D1715.5 (58.7)N/A2500 (172)N/A250 (121 )500 (34)H2520.0 (75.9)350 (24)1000 (69)140 (60 )250 (121 )250 (17)D3523.1 (87.5)N/A1500 (103)N/A250 (121 )250 (17)D3536.5 (138)N/A1200 (83)N/A250 (121 )500 (34)D6665.7 (248.7)250 (17)700 (48)140 (60 )250 (121 )250 (17)123455Ratings are for cam design with the highest flow rate.350 psi (24 bar) maximum with PVDF liquid end; 250 psi (17 bar) maximum with Polypropylene liquid end.Consult factory for correct component selection for temperatures from 160 F (71 C) to 250 F (121 C).D10 @790 rpm maximum.D35 @700 rpm maximum.For complete specifications and ordering information, consult the Hydra-Cell catalog.10 www.Hydra-Cell.com

Hydra-Cell Metering Pumps Exceed API 675Standards and Provide “Pulse-free” Linear FlowHonorable MentionThe IChemE Awards recognizeinnovation and excellence in makingoutstanding contributions to safety,the environment, and sustainabledevelopment in the chemical andbioprocess industries.IChemE2007Honourable Mention Designed for use with Variable Frequency Drive (VFD) electronicflow control to maintain greater accuracy throughout theturndown range. Multiple-diaphragm design (except the P100) provides virtuallypulse-free flow, eliminating the need to purchase expensivepulsation dampeners. Offers all the features and benefits of standard Hydra-Cellpumps (F/M/D/H Series pumps) including seal-less design,horizontal disk check valves, and space-saving, compact design. Variety of models that can operate with very low to very highflow rates and discharge pressures up to 2500 psi. Available in a wide range of pump head materials of constructionand diaphragm materials. Every model is available with a variety of gear box ratios to meetyour application needs. Variety of options and accessories to optimize performance. P200 models available with Mesamoll oil for use with many typesof polymers and in instances where it will come into contactwith water or an alkali.Flow Capacities and Pressure RatingsModel11234MaximumCapacitygphMaximum DischargePressure psi (bar)Non-metallic2MetallicMaximum OperatingTemperature F (C)3Non-metallic2MetallicMaximumInlet Pressurepsi (bar)P10027.0350 (24)1500 (103)140 (60 )250 (121 )250 (17)P20081.0350 (24)1000 (69)140 (60 )250 (121 )250 (17)P30081.4N/A2500 (172)N/A250 (121 )500 (34)P400242.8350 (24)1000 (69)140 (60 )250 (121 )250 (17)P500425.9N/A2500 (172)N/A250 (121 )500 (34)P600890.3350 (24)1000 (69)140 (60 )250 (121 )250 (17)Ratings are for X-cam design.Consult factory for ratings in liters per hour (lph).350 psi (24 bar) maximum with PVDF liquid end; 250 psi (17 bar) maximum with Polypropylene liquid end.Consult factory for correct component selection for temperatures from 160 F (71 C) to 250 F (121 C).For complete specifications and ordering information, consult the Hydra-Cell metering pumps catalog.www.Hydra-Cell.com 11Hydra-Cell Metering Pump Selection GuideIChemE2007

mpsuSeal-less PWorld Headquarters & ManufacturingWanner Engineering, Inc.1204 Chestnut Avenue,Minneapolis, MN 55403 USAPhone: 612-332-5681 Fax: 612-332-6937Toll-Free Fax (USA): 800-332-6812Email: sales@wannereng.comwww.Hydra-Cell.comRegional Office207 US Highway 281Wichita Falls, TX 76310 USAPhone: 940-322-7111Toll-Free: 800-234-1384Email: sales@wannereng.comwww.Hydra-Cell.comLatin American OfficeR. Álvaro Anes, 150 Bairro CampestreSanto André/São Paulo, Brazil - CEP 09070-030Phone: 55 (11) 4081-7098Email: mmagoni@wannereng.comwww.Hydra-Cell.comWanner International, Ltd.Hampshire - United KingdomPhone: 44 (0) 1252 816847Email: sales@wannerint.comwww.Hydra-Cell.euWanner Pumps Ltd.Wanner Pumps, Ltd.Kowloon - Hong KongPhone: 852 3428 6534Email: sales@wannerpumps.comwww.WannerPumps.comWanner Pumps Ltd.Shanghai - ChinaPhone: 86-21-6876 3700Email: sales@wannerpumps.comwww.WannerPumps.comWanner Pumps Ltd.Printed in USA Wanner Engineering, Inc.HC/PUB 08.16 Rev A

Hydra-Cell pump can handle the job of two pumps by eliminating the need for a feeder pump. Costs are also reduced because Hydra-Cell has no dynamic seals to wear or replace. Blowing agents: Hydra-Cell metering pumps can meet the same pressure and flow . requirements in

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