Maintenance Matters Problem Solver 18 | Plant & Works Engineering www.pwemag.co.uk February/March 2025 The Lyckeby potato starch plant in Mjällby, Southern Sweden, produces native and specialty starches, along with valuable by-products such as fibres, proteins, and biofertilisers for the global food and paper industries. In 2022, the factory underwent modernisation, expanding production to 40,000 tonnes of commercial starch annually, with a strong focus on energy efficiency and sustainability. Each stage of the process involved selecting high-performance, reliable, and cost-effective equipment from leading technology suppliers. Sulzer was chosen for the most demanding liquid pumping applications, with twenty-eight new AHLSTAR and SNS pump units now operating efficiently on-site, complementing the older Sulzer pumps that have delivered excellent service for decades. Mattias Åkesson, Process Technician at Lyckeby, commented: “We trust Sulzer not only for their top-quality equipment but above all for their people.” The Challenge: Managing high air content in starch processing Producing potato starch presents several technical challenges at each stage, from raw material washing and rasping to fibre and fruit juice separation, followed by final starch washing and drying. A significant challenge is pumping liquids prone to foaming, which arises due to the protein content of the liquid and the mechanical separation of raw material components. The fibre pulp separation stage is particularly critical, as the liquids being pumped can contain over 40% air. Conventional centrifugal pumps struggle in such conditions, as their capacity is drastically reduced, leading to unstable and inefficient pumping. The Solution: Advanced pump technology After rasping, the slurry mixture of pulp, starch, and potato juice passes through rotating conical sieves for fibre separation. In collaboration with Lyckeby and the sieve supplier, Sulzer provided seven AHLSTAR A-LM Pumping solution resolves foaming challenges in starch production Lyckeby’s potato starch plant in Sweden has modernised production with highperformance Sulzer pumps, optimising efficiency, handling foamy liquids, reducing energy use, and ensuring reliable, cost-effective operation for long-term sustainability. PWE reports. pumping units for transferring or recirculating starch, fruit juice, fibres, and water. The AHLSTAR A pumps, equipped with LM integrated liquid ring pump degassing units, are specifically designed to handle foamy suspensions efficiently and reliably. This ensures stable operation and a consistent process flow. Even for viscous slurries, the built-in vacuum system within the A-LM pumps effectively separates most of the air from the liquid, maintaining a constant and reliable pumping capacity. Due to Sulzer’s global network of design and manufacturing facilities, offshore platform operators and industrial clients benefit from a rapid response from initial enquiry to equipment delivery. The AHLSTAR A-LM pump units have enhanced process stability, optimising the performance of both upstream and downstream equipment. Improved Pump Efficiency – The internal degassing system removes air bubbles from the impeller eye, significantly increasing pump efficiency, reducing energy consumption, and lowering environmental impact. Reduced System Air Content – By removing excess air, the efficiency of other process equipment is improved, and the need for expensive antifoaming agents is greatly reduced. Project data The new full starch processing line includes 28 Sulzer single-stage overhung process pumps made from duplex materials with double mechanical seals: 7 AHLSTAR A pumps with LM integrated liquid ring pump degassing units and open impellers 21 SNS pumps with open impellers Most pump units are equipped with variable frequency drives (VFDs), providing greater flexibility and energy efficiency. This case study highlights the importance of selecting the right pumping solutions for challenging industrial applications, ensuring process reliability, cost savings, and long-term sustainability. For further information please visit: https://www.sulzer.com
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