From downtime challenges to reliable flow with Flowrox hose pumps

From raw materials to water treatment chemicals

The production of aluminum based water treatment chemicals begins with aluminum containing feed materials, most commonly aluminum hydroxide Aluminum hydroxide is typically produced from bauxite via the Bayer process, where the ore is refined into alumina, and delivered to downstream chemical production as a consistent, high-purity feed material.

Depending on the final product, aluminum hydroxide is reacted with:

• Sulfuric acid to produce aluminum sulfate (commonly known as alum)
• Hydrochloric acid to produce polyaluminum chloride (PAC)

Process water is used throughout the system for dilution, temperature control, and product formulation.  Water treatment chemicals must meet strict performance and regulatory requirements, the quality and purity of feed materials must be carefully controlled across the supply chain.

Overcoming performance and downtime limitations

A leading manufacturer of aluminum-based chemicals used for the water treatment industry based in Eastern USA, had already trialed several  manufacturers pump types including centrifugal, progressive cavity, hose pumps, and diaphragm pumps. Despite the extensive trialing and testing, the site was still experiencing short hose life, and low flow rates which lead to constant plant shutdowns to keep up with the maintenance of hose and other spare replacements.

After being introduced to the brand and the product, the customer invested in conducting a 90-day trial of the Flowrox LPPT- 2.5” peristaltic pump. Initial results for the trial showed that there was an improvement over the previous performances. However, results were still not up to required expectations with flow rates still below the expected performance levels. The main differentiating factor, however, would be that the Flowrox team continued to work hand in hand with the site maintenance crew through commissioning and early operation. The team jointly discovered several challenges that were not directly related to the pump itself but had impacted the overall system performance including an outdated variable frequency drive that was not compatible with newer pump models which was replaced, undersized suction pipelines that were discharging into a pressurized reactor creating significant flow limitations. As well as other related mounting components which were updated to better fit the assembly.

A Smarter Design for Sustainable Operations

Original Flowrox™ pump before the transition to blue

Despite the initial challenges during the trial, the joint efforts of the teams at Valmet and the customer site, an optimal flowcontrol solution was successfully achieved. Flowrox™ LPP‑T peristaltic pumps feature an advanced single‑roller design that significantly reduces friction and energy consumption. As the cylindrical rotor compresses and rolls along the hose, the process medium is steadily pushed forward. Simultaneously, the hose behind the compression points returns to its original circular shape, creating a suction effect at the pump inlet that refills the hose. Since the hose is fully occluded by the roller, backward flow or slippage is eliminated.

These technical advantages enable Flowrox hose pumps to provide precise, repeatable flow with every revolution. The innovative rolling design maximizes hose life while minimizing wear, maintenance requirements, and energy use. Together, improved energy efficiency, extended hose longevity, and reduced maintenance translate into substantial life‑cycle cost savings. In fact, Flowrox pump hoses typically last three to five times longer than those used in conventional peristaltic pumps.

From trial to trust: Building a long‑term Flowrox partnership

 This successful deployment led the plant to expand its installation to 26 Flowrox pumps of varying sizes to support ongoing operations.

“The initial engagement progressed efficiently, as the customer quickly recognized that our single‑roller design would enhance process performance while reducing downtime,” stated Joshua Baci, Flow Control Technical Business Development Manager, North America.

Valmet continues to support the installation through comprehensive service and spare parts supply, ensuring reliable operation and sustained long‑term performance.