Precautions for gear oil pump when transporting asphalt

When transporting asphalt with a gear oil pump, special attention should be paid to the following items to ensure safe and efficient operation and extend equipment life:

1.  Temperature control

-Preheating and insulation:

Asphalt has extremely high viscosity at low temperatures, and it is necessary to preheat the pump body, pipeline, and storage tank in advance (usually to 120-180 ℃, depending on the type of asphalt). Continuous insulation is required during operation to prevent asphalt solidification and blockage.

- Avoid overheating :

Excessive temperature (such as>200 ℃) may cause asphalt carbonization or decomposition, resulting in coking and damage to the pump body and seal. Real time monitoring of temperature sensors is required.

- Shutdown processing :

After stopping the operation, it is necessary to thoroughly empty the asphalt in the pump or keep the heating system running to prevent residual asphalt from cooling and hardening.

2.  Pump type and material selection

-High temperature resistant design:

Choose a high-temperature resistant gear oil pump (such as stainless steel or alloy steel material), and the sealing components need to be made of high-temperature resistant materials (such as fluororubber, graphite packing).

-Wear resistant and corrosion-resistant:

If asphalt contains additives (such as SBS modifiers) or particulate matter (such as mineral powder), wear-resistant coated gears or hard alloy materials should be selected.

-Flow and pressure matching:

Select the appropriate pump displacement based on the viscosity of the asphalt and the delivery distance to avoid overloading and overheating or leakage.

3.  Key points of operation and maintenance

- Pre startup check 

-Confirm that the heating system has brought the asphalt to a flowing state.

-Check if the gears are stuck during manual turning to avoid damage during cold start.

- Operation monitoring :

-Monitor the fluctuation of outlet pressure, abnormal increase may indicate blockage, pressure drop may cause leakage or gear wear.

-Monitor the abnormal noise of the pump body (such as dry friction sound) and promptly troubleshoot the problem.

- Cleaning and blockage prevention:

-Immediately flush the pump body and pipelines with diesel or specialized cleaning agents after shutdown to prevent residual asphalt from solidifying.

-Regularly disassemble and inspect the gear clearance, bearing wear, and seal aging.

4.  Pipeline and System Design

- Insulation and heat tracing :

The pipeline needs to be fully insulated and equipped with electric or steam tracing to maintain the fluidity of the asphalt.

- Reduce bends and valves :

Simplify pipeline design to avoid excessive bends that increase resistance. It is recommended to use jacket insulation for valves.

- Filter Configuration :

Install a filter at the pump inlet (the mesh size should be selected based on the asphalt impurities) and regularly clean the filter screen.

5.  Security protection

- Anti scald measures :

High temperature components need to be equipped with heat shields, and operators should wear protective clothing and gloves.

-Explosion proof requirements:

If working in a flammable environment, explosion-proof motors should be selected and electrical grounding should be ensured.

- Emergency Response :

Prepare emergency plans, such as using backup power to maintain heating in case of sudden power outages, or quickly connecting to the cleaning system.

6.  Special case handling

-Modified Asphalt:

Modified asphalt containing polymers has high shear sensitivity and requires control of pump speed to avoid performance degradation caused by excessive shear.

-High solid content asphalt (such as emulsified asphalt):

Pay attention to the tightness of the pump to prevent water evaporation or lotion layering from affecting the delivery.

Suggestion consultation

Based on specific operating conditions (such as asphalt type, delivery volume, ambient temperature, etc.), it is recommended to collaborate with pump manufacturers or fluid engineers to design system solutions and conduct simulation tests if necessary.

Through the above measures, the reliability of the gear oil pump during asphalt transportation can be effectively guaranteed, reducing the risk of failure and shutdown.