Cognito's Leak-Free EODD Pump Reduces Energy Use by 81% for Industry-Leading Organic Chemical Manufacturer
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In the organic chemical manufacturing industry, operational efficiency and safety are non-negotiable. An industry-leading chemical manufacturer was grappling with persistent challenges in its filter press feeding process. Frequent seal failures, high energy consumption, and poor cake formation were hampering productivity and increasing operational costs.
Challenges In Filter Press Feeding
The customer was using centrifugal pumps, which led to:
- Frequent seal failures causing hazardous leakages
- Reduced filter press efficiency and improper cake formation
- High energy consumption
- Insufficient safety controls in the pumping system
- Increased downtime and maintenance costs
That's why the customer needed a leak-free, low-maintenance solution that could ensure better cake formation and reduce operational disruptions.
Process Details
The Cognito team studied the customer's process, challenges, and requirements before recommending the best solution.
- Application: Filter press feeding
- Fluid name: Organic slurry
- Flow rate: 234 LPM
- Discharge pressure: 6 bar
- Specific gravity: 1.25
- Viscosity: 300–500 cP
- Solid particle size: Micron level
- Temperature: 25°C
The Right Solution: Cognito's EODD Pump
Cognito proposed its electrically operated double diaphragm (EODD) pump, mounted on a complete skid with integrated safety features. Key benefits included:
- Sealless design: Eliminates leakage risks
- Leakage sensor: Prevents fluid spillage
- Continuous high-pressure feeding: Ensures better cake formation
- Enhanced safety features: Reduces downtime and maintenance
- Environmentally friendly: No emissions or spills
ROI That Speaks For Itself
The transition to Cognito’s EODD pump delivered immediate and measurable benefits. The chemical manufacturer saved 65,448 KWh, significantly reduced maintenance costs, and improved operational uptime, resulting in a full return on investment within the first year.
Customer Benefits
The customer reported transformative improvements across key operational areas:
Leak-free operation:
Better cake formation:
Reduced downtime:
Significant energy savings:
Enhanced safety:
Efficiency, Safety, and Uptime Delivered
Cognito’s EODD pump has transformed filter press feeding at the customer’s facility, delivering leak-free performance, greater energy efficiency, and improved uptime and safety.. The system continues to run reliably with minimal maintenance, reinforcing Cognito's role as a trusted partner for critical chemical processing applications.
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