Urea and Fertilizer production worldwide rely on Wilfley’s sealing technology for peak operational efficiency
Toughness Where It Counts
Material excellence is central to our value proposition and crucial for urea production. The remarkable WCD4™ duplex stainless steel delivers high value in extreme applications that are both erosive and corrosive. This is achieved through special processing that significantly increases its hardness (345 HBN) while also greatly improving its corrosion resistance. These superior physical properties when combined with Wilfley’s heavy duty design philosophy provide exceptional performance far beyond the competition.
Increased Wear Life
(Sample data based on pin-on-disk testing)
Increased Corrosion Resistance
(Sample data based on testing with 65% nitric acid)
Abuse Tolerant Seals
Pumping water in a controlled environment (such as a manufacturing test lab) is as easy as it gets. But pumping an acidic slurry non-stop, with variable and upset conditions with maximum uptime is another matter – but that is exactly where Wilfley shines.
A common scenario that can trigger a Lost Productivity Failure (LPF) in centrifugal pumps is loss of prime. This can occur in any industrial system, but more often in tanker/rail car off-loading applications. As a constant liquid supply is lost, the pumpage shifts to a two phase fluid (liquid and air) and flow drops to zero. Both conditions subject the rotating assembly of a centrifugal pump to abnormal loads and subsequently high vibration. The mechanical stress can be transmitted to brittle traditional seal faces with almost immediate consequences, even for double mechanical seal systems.
By contrast, Wilfley Sealing Technology separates the faces during operation, isolating detrimental mechanical vibration. Further, the allowable clearances are increased by over 270% when compared to mechanical seal requirements, allowing significantly more tolerance – all with fully isolated, full diameter shafting.
In It for the Long Haul
Commercial grade may suffice for certain automotive products and B2B markets, but urea production requirements rely on equipment designed for continuous, mission critical operation. Moreover, operational demands often subject industrial equipment to rigors well outside a fully constrained design window.
Although the majority (75-90%) of pump ownership costs can be attributed to issues with seals and bearings, the basic design of the pump has a lot to do with its long term success. Wilfley’s philosophy is to produce heavy duty pumps that provide maximum productivity in the harshest of conditions. For instance, our robust ASME B73.1 A9 chemical process pumps are up to 60% heavier than Tier 1 competitors. And a similar trend exists on rotating elements: a common shaft robustness index follows an L3/D4 format and the A9 pump is on average 55% stiffer than others.
|Average Weight||Shaft Stiffness Ratio|
Wilfley’s philosophy is that downtime is unacceptable, so we continue to build robust pumps for continuous, tough and critical services like urea production.