Six Steps to a Tailor-Made Vacuum Solution

By Fabian Falbusch, Head of Content Marketing, Busch Vacuum Solutions
04/25/2023

The Port of Gothenburg, Sweden, required a tailor-made vacuum solution to minimize the amount of hydrocarbon vapors that can be released into the atmosphere during the loading and unloading of tanker vessels. Photo Source: Mikael-stock.adobe.com

Vacuum has the ability to significantly improve manufacturing. Using a vacuum system solution in the right context and for the right reason can dramatically change costs, effectiveness, and sustainability as they relate to manufacturing – because using one vacuum pump alone is often not enough.

Tailor-made vacuum systems and modular systems can provide the right solution for individual process requirements – from initial analysis to design, from installation to subsequent top-quality service.

Building a vacuum system solution is always a joint undertaking. Each solution aims to be compliant with location regulations, as well as to be reliable, energy-saving, sustainable and economical. An essential part of the process is including the customer and their requests during the planning process. There are six steps to find the optimum vacuum solution for the respective application.

A tailor-made vacuum system for use in the chemical industry.

Step 1: Consultation and Analysis

This important initial step is to examine and understand the customer’s challenges and expectations. A vacuum expert collaborates with the customer on site to discover the best solution for the customer’s individual needs. The most important questions are clarified first: What will the vacuum solution be used for? Which vacuum technology is most suitable? What improvements should be made regarding efficiency, energy consumption or the work environment?

Step 2: Design and Quotation

After discussions with the customer, the local technicians draft an initial overall concept. This concept creates the framework for designing and building the future vacuum system. The process takes many factors into consideration, among other things, the local conditions, compliance, safety, performance, and easy operability. A clear and comprehensive quotation for the tailor-made vacuum solution is then drawn up based on this concept.

A modular centralized vacuum system solution makes it possible to generate significant savings when it comes to energy and maintenance costs.

Step 3: Manufacture and Installation

The vacuum system solution will be built in one of Busch’s local systems building centers. The global network of experts provides support during this stage. Once the system has been built, it is then installed. This means not only delivering it, but also having local service engineers integrate it into the customer’s ongoing
production processes and connecting it to the piping system. Once installed, we will verify tightness, proper functionality, and conformity. We also perform necessary test runs and final start-up.

Step 4: Training

Training is a vital component. The vacuum experts will fully train staff on site to guarantee safe and reliable operation of the new vacuum system. They will learn how to maintain maximum performance.

Standard vacuum systems are the perfect choice if a cost-effective vacuum generation concept is needed for a production process.

Step 5: Service

The new vacuum system solution is now fully operational and can be run by the trained staff. Service ensures that things will stay that way in the long term, too – with preventive maintenance. This is handled on site or with remote support via digital services. Customer service always supports customers and with all potential issues or errors.

Step 6: Customer Satisfaction

A fully functional vacuum system ensures seamless production processes and customer satisfaction. Premium customer service provides process reliability and planning security. A tailor-made vacuum system solution is sustainable and will also continue to adapt to future process requirements.

The tailor-made DOLPHIN liquid ring vacuum system solution installed in the vapor recovery unit at the Port of Gothenburg, Sweden. Source: Busch Sweden.

Port of Gothenburg Deploys Safe and Environmentally-Friendly Tanker Loading/Unloading

With 130 direct services to destinations in Europe, Asia, the Middle East, Africa and North America, the Port of Gothenburg is the biggest in Scandinavia and the gateway to the world for a large part of Swedish industry. More than 11,000 ships call at the port every year, including many tankers. The aim during the loading and unloading of tankers is to prevent hydrocarbon vapors from escaping. This is where a tailor-made vacuum solution comes into play: in a vapor recovery unit that captures hydrocarbons.

The Port of Gothenburg is classified as one of the world’s greenest ports. It is actively working to minimize the impact of maritime operations on the environment and to contribute to sustainable transportation. For this reason, the Port of Gothenburg takes extra precautions to minimize the amount of hydrocarbon vapors that could be released into the atmosphere during the loading and unloading of tankers. This is achieved through vapor recovery.

Vapor recovery is the adsorption of hydrocarbon vapors using activated carbon regenerated under vacuum. The vacuum unit collects the vapors that would otherwise be released into the atmosphere. The vapor is turned into liquid and returned to the transport tank of the ship. In addition to the main objective of avoiding emissions, vapor recovery is also used for safety reasons and to prevent major fuel losses.

The vacuum pump previously used in the vapor recovery unit at the Port of Gothenburg was very old and needed maintenance. However, spare parts were no longer available, and the port's managers were looking for a better solution for vapor recovery during the loading and unloading of the tankers. Since the unit is in permanent and daily use, a replacement had to be found as soon as possible. The vacuum experts from Busch recommended a DOLPHIN liquid ring vacuum pump. Thanks to their preparation and support, the old vacuum pump was removed, and the DOLPHIN was installed in the vacuum unit. The changeover took place within two days from stop to restart.

The new vacuum solution has a larger capacity. Therefore, it ensures better recovery of hydrocarbon vapors and, thus, better protection of the environment. The process is highly reliable for the Port of Gothenburg and the loaded and unloaded tankers. The new DOLPHIN liquid ring vacuum pump even showed another benefit when in operation. It is significantly quieter than the previous solution. This makes working close to the vapor recovery unit much more comfortable for the employees. The customer is very satisfied with the new vacuum solutions and informed that it works perfectly and is more efficient than the previous one. The tankers can now be loaded and unloaded in a safe and environmentally friendly manner.

About Busch Vacuum Pumps and Systems

Busch Vacuum Pumps and Systems is one of the largest manufacturers of vacuum pumps, blowers and compressors in the world. Our products are at the forefront of vacuum and low-pressure technology. For more information visit www.buschvacuum.com. All images courtesy of Busch Vacuum Pumps and Systems.

For similar articles on Industrial Vacuum System Assessments, visit https://www.blowervacuumbestpractices.com/system-assessments/vacuum-systems.

Visit our Webinar Archives to listen to expert presentations on Industrial Vacuum Technology at https://www.blowervacuumbestpractices.com/magazine/webinars.