How We Ensured the Operation of the Heating Plant's Flue Gas Treatment System: Without Any Modifications
Fast deliveries, existing piping systems, and zero retrofit costs. When a Swedish heating plant was faced with long delivery times from its pump supplier, the operational reliability of the facility was threatened flue gas cleaning. Ensuring reliable operations without having to rebuild the facility is a challenge that many operations managers and maintenance engineers in the energy and district heating sectors can relate to.
Through close collaboration with our partner Affetti Pumps, we at Colly Flowtech found the perfect solution. We developed a direct replacement pump (1-to-1) of the model Affetti CGI-S. It fits existing motors and base plates perfectly and is delivered in a fraction of the time.
Background: Long delivery times threatened the customer's operational reliability
In the energy and district heating sector, flue gas cleaning a critical process where margins are tight and availability requirements are enormous. For quite some time, our customer had been grappling with major challenges related to its then-current pump supplier. Long delivery times for both spare parts and complete pumps caused constant concern within the maintenance department regarding unforeseen and prolonged downtime.
When the customer contacted us, their primary goal was clear: they needed a new supplier that could guarantee significantly shorter delivery times in order to ensure greater operational reliability in their flue gas cleaning system and throughout the entire facility.
The Challenge: Replacing a Pump in a Corrosive Flue Gas Treatment Process Without Modifying the System
Changing pump suppliers in an existing facility often carries a high risk of unforeseen expenses, something many operations managers want to avoid. The single biggest technical and practical challenge in this project was that the customer was unwilling—or did not have the time—to carry out extensive modifications to the piping systems, base plates, and motors.
A precise “one-to-one” solution was required. The situation was made even more complex by the fact that the pump had to simultaneously meet the extremely stringent performance requirements and withstand the extremely aggressive and corrosive media flowing through a modern flue gas cleaning system. Our mission was to find a solution that would spare the customer the need to invest time, money, and energy in a retrofit.
The Solution: Our close collaboration with our partner, Affetti Pumps
To address the customer’s unique challenge, we at Colly Flowtech began with a thorough needs analysis. We quickly realized that the solution for this flue gas cleaning process lay in building on the technical expertise of our close partner Affetti Pumps.
Together with Affetti Pumps, we sat down and discussed how we could best tailor a solution for this specific application. We decided on the pump model Affetti CGI-S. Thanks to Affetti Pumps’ flexible manufacturing and our joint technical consulting, we were able to develop a pump that met all of the customer’s requirements for reliable flue gas cleaning:
- Optimal choice of materials: Since the pump is made of plastic, it can easily withstand the aggressive media flowing through the flue gas cleaning process.
- Exact capacity and fit: We customized the pump so that it could handle the exact operating conditions in terms of pressure, flow, and temperature, while also fitting perfectly onto the existing base plate connected to the customer’s piping system.
When we presented the quote, the technical solution, and the short delivery time, the customer felt completely confident and satisfied about moving forward with us.
The result: Operational reliability and a long-term partnership
As of this writing, the pump has not yet been commissioned, but the customer has already achieved the most important goal: a more reliable supply chain for its flue gas cleaning system and the elimination of the risk of costly retrofits. We at Colly Flowtech will, of course, also be on site with the customer throughout the entire startup phase and support them in their day-to-day operations.
This project truly demonstrates the strength of our approach. Because we at Colly Flowtech are flexible and committed to meeting our customers’ specific needs—and combine that with the strong product support from our partner, Affetti Pumps—we can work together to create solutions that are completely tailored to each customer. We ensure that Swedish industry can keep moving forward safely, efficiently, and without hassle.
Are you struggling with long delivery times or complex pump replacements?
Please contact me, Oskar Karlsson, or my colleague Mattias Jansson, and we'll help you find a customized replacement solution for your specific facility.
Oskar Karlsson, Pump specialist: oskar.karlsson@colly.se
Mattias Jansson, Product Manager Pump: mattias.jansson@colly.se
About Affetti Pumps
Founded in 1964 in Italy, Affetti Pumps has developed over decades into a global specialist in pumping solutions for corrosive and demanding chemical applications. With in-house development, advanced manufacturing techniques and a strong focus on materials technology, today they deliver high-performance pumps worldwide where accuracy, reliability and safe operation are paramount.
Do you have any questions?
Oskar Karlsson
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