KENFLO Assists Kaiyang Chemical with Circulating Water Pump Energy-Saving Retrofit, Achieving 30% Power Savings
Against the backdrop of the nation's push for industrial equipment renewal and dual-carbon emission reduction, circulating water systems in the utilities of chemical enterprises—major energy consumers—have made pump energy-efficiency optimization an important lever for cost reduction and efficiency gains. Guangdong KENFLO has been deeply engaged in pump R&D and manufacturing for more than seventy years, focusing on providing pump equipment and customized system energy-saving retrofit solutions for the chemical, petrochemical and other industries. In the circulating water pump energy-saving retrofit project at its key customer Kaiyang Chemical, on-site measurements and verification delivered impressive energy-saving results.
Project pain point: deeply tapping the energy-saving potential of the circulating water system. Circulating water pumps are core equipment in the utilities of chemical plants, running continuously and uninterrupted over long periods, with a high share of electricity consumption. Kaiyang Chemical's original circulating water pumps, after long service, had degraded matching between hydraulic conditions and actual production loads, resulting in high energy consumption per ton of water and significant room for energy-saving improvement. Upon receiving the customer's request, KENFLO's technical service team went deep into the production site, conducting systematic condition surveys and data collection and analysis. Combined with the plant's actual water demand, they customized an exclusive pump energy-saving retrofit plan, upgrading the pumps' hydraulic performance with minimal on-site modifications and without interrupting continuous production, balancing water supply capacity, operational stability, and electricity savings.
Pre-retrofit baseline testing (August 16–19, 72 hours of continuous measurement): The technical team, together with the customer, used data genuinely collected from electrical meter readings and on-site flow meters as the assessment baseline for the retrofit: total daily electricity consumption of the two pumps: 71,280 kW·h; daily circulating water delivery volume: 723,300 tons; electricity consumption per ton of water: 0.0985 kW·h/t.
Retrofit completed: on-site measurement and verification of the retrofit results (September 24–25, 24 hours of measurement). After the retrofit was implemented, in order to objectively verify the actual results and avoid condition fluctuations, both parties jointly conducted a full-load performance calibration test. After the retrofit, not only was the water supply assurance capability not reduced, but the circulating water delivery volume increased, better meeting the production units' water demand, while electricity consumption dropped sharply: total daily electricity consumption of the two pumps: 52,820 kW·h; daily circulating water delivery volume: 770,500 tons; electricity consumption per ton of water: 0.0685 kW·h/t.
Solid results: overall electricity savings rate of 30.45%. Through a comparative calculation of electricity consumption per ton of water before and after the retrofit, the measured electricity savings rate of the circulating water pump retrofit project reached 30.45%. Increased flow and reduced unit electricity consumption not only ensure the safe and stable operation of the circulating water system, but also directly reduce the enterprise's production electricity costs, truly achieving the multiple values of "safeguarding production, increasing flow, and reducing energy consumption," and confirming the technical strength of KENFLO's energy-saving retrofit solutions with real operational data.
KENFLO: not just selling pumps, but providing full-process fluid system solutions. This Kaiyang Chemical retrofit project is one of KENFLO's many implemented industrial pump energy-saving retrofit cases. Backed by years of fluid CFD simulation R&D experience and a high-efficiency hydraulic model library, we can provide customers with a full-chain service covering preliminary condition diagnosis, customized retrofit plans, on-site implementation, effect measurement and acceptance, and operation and maintenance services. We support both complete unit replacement and retrofits of old pumps such as impeller hydraulic optimization, helping customers in energy-intensive industries such as chemical, petrochemical, power, and water services tap into system energy-saving potential and supporting green, low-carbon, high-quality enterprise development.
Service Support Domestic Sales Network Service Guide Product Installation and User Manual Downloads