HYDRAULIC POWER RECOVERY TURBINE

Maximum energy efficiency with HPRT in industrial processes

Apollo Gößnitz GmbH is expanding its portfolio to include a hydraulic power recovery turbine (HPRT), an efficient solution for recovering hydraulic energy in industrial processes. The HPRT utilises the pressure potential within a process to convert potential energy into mechanical energy. This technology can significantly reduce energy consumption and optimise pump systems.

Product Features

Technical features of an HPRT skid in fertilizer production

The HPRT is a reverse-running, axially split, single-stage process pump of the ZMK type (BB1 according to API 610). It uses the existing static system pressure to generate drive power and thereby relieve the motor of torque. This reduces energy consumption.

The automatic over running clutch is used to achieve precise speed control. It automatically disconnects as soon as the HPRT starts to rotate more slowly than the pump. This ensures that torque is only transmitted once the two components are moving at the same speed. This guarantees efficient and smooth operation.

The Apollo ZMK is an axially split, single-stage BB1 process pump that complies with the API 610 standard. In this application, the pump delivers 1,500 m³/h of semi-lean Amdea solution, with a delivery head of 350 metres and power consumption of approximately 1.8 MW. The material complies with API Class A-8, ensuring a robust and corrosion-resistant design.

The motor is classified according to IP-55 and has a drive power of around 2.2 MW. Once the over running clutch has been engaged, the motor is almost fully relieved. It features a special design that provides additional protection against external influences.

Designed in accordance with API 614, the Apollo lubricating oil system ensures a reliable and continuous oil supply for the bearings of centrifugal pumps, HPRTs and electric motors, as well as the antifriction bearings of the clutch. Thanks to its precise design, the system minimises wear and significantly increases operational reliability. Its modular design allows it to be adapted flexibly to individual plant situations, ensuring optimal integration into the application.

Typical applications for HPRT

Apollo's Hydraulic Power Recovery Turbine (HPRT) is used in a variety of demanding industrial applications. An HPRT can be used wherever the system pressure needs to be reduced to meet the requirements of subsequent processes or to relieve excess pressure. Unlike a conventional throttling device, an HPRT recovers energy rather than dissipating it as heat. Typical areas of application for HPRTs include:

  • refineries and petrochemical plants
  • natural gas processing
  • fertilizer factories
  • power plant technology
  • pump systems with high pressure loss

 

  • View of the hydraulic power recovery turbine (HPRT) unit with a BB1 pump in the foreground, followed by piping and cabling with switch boxes and then a reverse-running, axially split, single-stage process pump of the ZMK type (BB1 according to API 610).

    HPRT 1

  • Complete HPRT skid on the Apollo test field during piping and preparation for the test run.

    HPRT 2

  • View of the completed Apollo Hydraulic Power Recovery Turbine (HPRT) package with motor and all piping insulation and acoustic insulation mats of Apollo axially split, single-stage process pump type ZMK (BB1 according to API 610).

    HPRT 3

Centrifugal pumps compatible with HPRT

The selection and design of an HPRT essentially follows the same principles as the dimensioning of pumps. Although they are referred to as turbines, HPRTs are based on the design of centrifugal pumps, with the flow of the medium reversed. Regardless of their specific speed, design (horizontal or vertical) or whether they are single-stage or multi-stage, numerous centrifugal pumps can be operated in reverse. Therefore, they can be used as HPRTs.

The common types of pumps that are often used in combination with HPRT require special design modifications to their construction and hydraulic components. These pumps include:

3D representation of a horizontal, axially split, single-stage, double-flow intermediate storage process pump, API 610 Type BB1.

ZMK (BB1)

Apollo ZMK (BB1) is a single-stage, axially split process pump with between-bearings, designed for easy installation and low maintenance times.

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3D rendering of a ZPR, BB2 process pump with bearings on both sides in accordance with API 610.

ZPR (BB2)

The Apollo ZPR (BB2) is a single-stage, double-flow process pump with a radially split casing and bearings on both sides with a flexible casing design.

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Axially split pump AMG (BB3)

Robust, multi-stage, axially split pumps (BB3) to API 610, ideal for pipeline and high-pressure applications in industry, energy and oil & gas.

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3D representation of an HP Apollo pump according to API 610, BB4 type.

HP (BB4)

The Apollo high-pressure pump HP (BB4) inline ring-section pump with bearings on both sides for diverse industrial applications.

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TG (BB5)

The TG (BB5) high-pressure barrel pump back-to-back version, to API 610, is the most reliable option when operating under extreme conditions.

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3D view of a TL API 610 BB5 pump from Apollo Gößnitz.

TL (BB5)

The Apollo TL (BB5) high-pressure barrel pump inline version, which complies with API 610, ensures maximum reliability under extreme conditions.

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