How a Top Non-Ferrous Metal Manufacturer Enhanced Efficiency with Cognito EODD Pumps

In this case study, learn how a top non-ferrous metal manufacturer in China enhanced energy efficiency and ensured a seamless production line with minimal unplanned maintenance by implementing Cognito EODD pumps.

In the non-ferrous metal industry, lime slurry transfer application is vital for moving thick, abrasive slurries. This process neutralizes acidic solutions, removes heavy metals from wastewater, and stabilizes waste materials. Efficient slurry transfer is crucial for product quality and environmental protection, with pumps playing a key role in ensuring reliable movement and operational efficiency.

The Need

One of the leading non-ferrous metal manufacturers encountered difficulties with traditional AODD pumps in this demanding application. These challenges were successfully addressed with the implementation of Cognito’s EODD pump. Let’s delve into the specifics of how this solution made a difference.

Customer Challenges

Higher Energy Consumption:

The customer was not using any pumping technology due to a lack of confidence in positive displacement pumps.

High Operational Time:

Significant safety hazards and operational disruptions due to undetected leakages from diaphragm ruptures.

Elevated Maintenance Costs:

Frequent diaphragm ruptures and wear of the ball and valve seats due to the abrasive nature of the liquid, along with potential air valve assembly failures, led to high maintenance costs and increased downtime.

Process Details

Fluid: Lime Slurry (High abrasive in nature)
Flow Rate: 350 LPM
Discharge Pressure: 350 LPM
Viscosity: 500 Cp
Specific Gravity: 1.3 - 1.5

The Right Solution

EODD pumps offer greater efficiency and lower energy consumption than AODD pumps. Their electric operation and advanced safety features reduce energy use, quickly detect leaks, and ensure reliable performance. Additional features further lower maintenance costs and extend pump longevity in challenging conditions.

  • Unique patented diaphragm: Engineered for exceptional durability, especially in abrasive conditions. Their unique design and optimized balance of diameter and stroke length ensure effective performance and increased longevity under negative suction.
  • Seal-less design: Eliminates the need for seals, reducing maintenance requirements and minimizing potential failure points.
  • The unique "Stopper Cage Design": Extends manifold life by protecting seats from abrasion, ensuring trouble-free operation, and increasing the life of the manifold, check valves, and seats by 2 to 3 times.
  • Leak detection mechanism: Prevents leakages by promptly identifying them, allowing for immediate corrective action to minimize downtime, ensuring reliable pump performance.

The Cognito team successfully convinced the customer to replace 2" AODD pumps with 3" EODD pumps by showcasing the above benefits along with the ROI calculations. These features promised to cut maintenance needs, extend the lifespan of critical components by 3 times, reduce energy consumption by 60–70%, and improve the total cost of ownership. These significant benefits made a strong case for the replacement.

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Customer Experience

The switch to Cognito’s EODD pumps has been transformative for the customer. They reported a substantial reduction in energy cost, maintenance costs, and downtime.

Post-implementation, the customer observed significant improvements:

  • Phenomenal energy savings
  • Reduced maintenance cost
  • Improved safety mechanism
  • Achieved ROI within 0.8 year
  • Improved total cost of ownership

Energy Consumption Comparison: AODD Pumps vs. Cognito EODD Pump

AODD Pump
Cognito EODD Pump
Working Hours Per Day
20 hrs/day
20 hrs/day
Energy Consumption at Duty Point (Estimated)
15.1 kW
2.2 kW
Electricity Consumption Per Month
6647 kWh
968 kWh
Total Electricity Consumption Per Year
79,762 kWh
11,616 kWh

Maintenance Comparison: AODD Pumps vs. Cognito EODD Pump

AODD Pump
Cognito EODD Pump
Total Maintenance Cost Per Year Per Pump
Consumption of minimum 2 set Diaphragm & Air valve assembly in a year
Operated smoothly very minimum maintenance and zero downtime, resulting in efficient operations

The customer conveyed their immense satisfaction with the reliability and efficiency of their new system, noting that the decision to replace the AODD pumps with EODD pumps enhanced their operational efficiency and overall cost savings.

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