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Magnetically driven pump development
For many years, the conventional sealed pump has been a staple in the petrochemical industry. These pumps come with various types of seals, ranging from simple packing seals to more complex double mechanical seals. The main advantage of sealed pumps is their relatively low cost and versatile design, which makes them easy for users to maintain using familiar methods. However, one major downside is that the seal must allow some leakage to lubricate the sealing surface. Packing seals typically leak between 3 to 80 mL/h, while well-made mechanical seals may only leak a few milliliters per hour—between 0.01 to 3 mL/h. If a seal fails, the transported medium can escape into the atmosphere, posing serious risks to both personnel and the environment.
Moreover, as mechanical seals and their supporting systems have become increasingly complex, the improvements in extending their service life have not always met expectations. This has led to a growing interest in an alternative: the sealless centrifugal pump, also known as a magnetic drive pump. Unlike traditional sealed pumps, these units eliminate the need for a shaft seal, significantly reducing the risk of catastrophic leaks and greatly extending the pump’s lifespan.
Magnetic drive pumps operate with only static seals and no dynamic ones, ensuring a leak-proof operation when handling liquids. The concept was first developed in 1947 by British company HMD, and later refined by German engineer Franz Klaus. Early adopters included companies like Imperial Chemical Industries (UK) and Bayer (Germany), primarily to enhance safety in hazardous environments such as chemical, nuclear, and defense industries.
Since the 1970s, advancements in rare earth magnets and silicon carbide bearings have dramatically improved the performance of magnetic drive pumps. Today, they can handle flow rates up to 1150 m³/h, head up to 500 meters, and temperatures ranging from -120°C to 450°C. They are capable of transporting media with viscosities up to 200 cP, and even solids up to 1.5% by weight with particle sizes of 100 microns. Special designs allow them to handle up to 20% insoluble solids with particles as large as 20 mm. They can operate under pressures of up to 450 bar and are suitable for high vacuum conditions where mechanical seals would fail.
Studies show that magnetically driven pumps have significantly lower failure rates compared to sealed pumps. For example, while a mechanical seal on a hydrothermal pump at 400°C might last only six months, a magnetic drive pump can run for years with minimal maintenance—mainly just ensuring proper lubrication of external bearings and the motor.
The chemical industry has widely adopted magnetic drive pumps due to their reliability and cost-effectiveness. Their use has grown not only for environmental protection but also because of reduced operational and maintenance costs. These pumps are now used in a wide range of applications—from handling dangerous or expensive liquids to general industrial uses requiring long service life and low maintenance.
For instance, offshore vessels often use magnetic pumps to circulate cold water in air conditioning systems, where maintenance costs are high. Over the past decade, the adoption of magnetic drive pumps has become widespread, covering nearly 90% of all sealless pump applications.
In summary, magnetic drive pumps offer a reliable, safe, and efficient solution for many industrial processes. While they do have some limitations—such as lower efficiency compared to standard centrifugal pumps and restrictions on operating temperature and pressure—they remain a preferred choice in many critical applications. Their ability to eliminate shaft seal leakage and reduce maintenance makes them an essential part of modern fluid handling systems.