Maximizing Service Life in Harsh Environments: How Electrolysis Plants Reduce Their Maintenance Costs

We found the solution at Colly Flowtech through close collaboration with our supplier, Affetti Pumps. By combining an in-depth needs analysis with customized plastic technology, we were able to deliver the MSP-QT self-priming pumps. For the customer, this means they have been able to standardize their fleet with a flexible pumping solution that is fully protected against corrosion, laying the foundation for a low-maintenance and reliable future.

The Challenge: A tight schedule combined with technical complexity

When the existing electrolysis plant was due for an upgrade to modern standards, the project management team faced a major challenge. But the tight schedule wasn’t the only problem. The process required more than 25 sump pumps, located in a variety of unique positions throughout the facility.

As an operations manager or project manager, this is a familiar nightmare scenario. Each individual pump station has unique parameters for pressure, flow, and temperature, while the fluid in this particular facility is extremely aggressive and corrosive, with very low pH levels. Purchasing 25 unique specialty pumps creates enormous complexity, drives up spare part costs, and complicates future maintenance. The customer needed our help to think strategically and find a flexible pump size that could cover all these different needs.

Our solution: Custom-designed plastic pumps that simplify the process

It is precisely in these kinds of complex projects that our approach makes the biggest difference. Instead of simply offering a standard product from a catalog, we initiated a transparent and close dialogue with both the customer and Affetti Pumps to thoroughly analyze their needs.

The choice fell on that one MSP-QT self-priming pump. The value for the customer lies primarily in the smart choice of materials: since all parts in contact with the fluid are made of durable, chemical-resistant polymers, these plastic pumps can handle aggressive acids without the material breaking down. Thanks to Affetti Pumps’ high flexibility, we were also able to customize the pumps for the specific application. This allowed us to help the customer standardize their machinery and cover the varying operating parameters with a single base model.

Oskar Karlsson, a sales representative at Colly Flowtech, emphasizes the importance of being flexible when conditions are tough:

”This project demonstrates how much can be achieved through close and open collaboration. Together with our supplier, Affetti Pumps, we managed to tailor a solution to the customer’s requirements, despite the enormous time constraints. For us, it’s not just about delivering pump solutions; it’s about ensuring the customer can keep production running without having to keep 25 different spare parts in stock.”

The result: Reliable startup and reduced maintenance costs

Investing in the right equipment ultimately means avoiding unexpected downtime and costly surprises. By choosing high-quality plastic pumps made of durable materials, the smelter has gained three very tangible benefits:

• No more rust or corrosion: Since the liquid only comes into contact with plastic, there is no metal for the acids to corrode. The pumps will last for years to come.

• A spare parts inventory that saves millions: Instead of purchasing unique replacement parts for 25 different pumps, all we need now are a few components on the shelf. In other words, if something breaks, the same part fits everywhere.

• Simpler and faster maintenance: The mechanics on the shop floor only need to learn how to work with one type of pump. This makes service and troubleshooting much faster, which minimizes the risk of costly downtime.

But our work doesn’t end at the delivery gate. To ensure that everything gets up and running exactly as it should, we at Colly Flowtech will be on-site at the factory throughout the entire startup phase. We don’t leave until the system is up and running and the customer feels completely confident. That’s how we build long-term partnerships.

Is your business facing a time-sensitive project or dealing with complex chemicals?

Finding the right pump for aggressive media and fluctuating flow rates requires specialized expertise. At Colly Flowtech, we’re happy to help you navigate the complexity, reduce inventory costs, and ensure reliable, on-time operation with our market-leading plastic pumps. Contact me, Oskar Karlsson, or my colleague Mattias Jansson, and we’ll be happy to assist you!

Oskar Karlsson, Pump specialist: oskar.karlsson@colly.se

Mattias Jansson, Product Manager Pump: mattias.jansson@colly.se