CC-Cut

The powerful pump system

  • Efficient pumping thanks to optimally coordinated pump and cutter
  • Reliable, trouble-free pumping of challenging and highly viscous media
  • Treatment of disruptive matter and separating out of heavy material before the pump
  • Low space requirements thanks to extremely compact design
  • Maintenance and changing of parts can be performed quickly and easily on site

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Biogas

Biogas

CC-Cut - powerful components – perfectly combined and coordinated

Pumping liquid manure, recirculate and organic suspensions is part of the daily work at many biogas plants. However, these media often contain long-fibred solid matter (straw, grass, feed residue), heavy material (metal parts, stones) or disruptive matter (ear tags, branches etc.). This content has a negative impact on the ability to pump the medium, results in increased current consumption in pumps and mixers, and causes malfunctions or even damage, thereby decreasing the cost-effectiveness of a biogas plant.
Vogelsang developed the CC-Cut pump system precisely for these applications. It combines a progressive cavity pump from the CC series with a RotaCut in a compact design. This means that the CC-Cut can be integrated into most biogas plants as the central pump system, without taking up much space. And the CC-Cut also reliably separates heavy material out of highly viscous media, reduces disruptive matter to a manageable size, shreds solid matter and mixes everything intensively. The optimally treated medium is then pumped reliably and trouble-free even against high pressures. In addition, the efficient treatment also reduces the viscosity and the tendency to form a floating crust. Both these advantages can be seen in the lower input energy requirement.
Maintenance and replacing parts are quick and easy with the CC-Cut as they are for the individual components because both retain the full service function: all wear parts can be replaced on site.

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Features

Separation of stones and metal parts is important for ensuring smooth operation of the cutter itself as well as of the downstream pumps and components, and also to prevent damage and blockages they may cause. Each RotaCut therefore has an integrated heavy material separator that can be individually adjusted.
One key feature of the CC series is its swiveling mechanism, which means that the pipe does not need to be disassembled. The rotor and stator are swiveled upwards or to the side as a single unit.
A generously sized cardan shaft with two cardan joints ensures reliable transmission of the drive power in the CC series from the parallel shaft geared motor to the rotor. A sturdy sleeve – which doesn’t even have to be disassembled when changing the rotor – protects the shaft against solid and fibrous matter and against foreign matter in the medium.
The CC series offers many options for replacing parts. If the pump needs to be operational again quickly, the stator and rotor are replaced as a single unit. It is also possible to replace the entire rotating unit. Alternatively, the stator and rotor can be replaced one after the other, as in conventional progressive cavity pumps.
Vogelsang uses its proprietary software to develop cutting screens with optimized geometry for every size-reduction ratio. For operators, this means the best geometry at all times for smooth running, with minimal wear. The cutting screens are produced from wear-resistant special steel and offer twice the performance since they are reversible.
The Automatic Cut Control (ACC) automatically adjusts the RotaCut cutting blades and maintains a constant contact pressure between the cutting screen and blades. In addition, the contact pressure can be adjusted during live operation; as high as necessary and as low as possible. This increases the lifetime of the cutting blades and screen and enables automatic operation.

Options

Depending on the model and application, the rotor and stator of the progressive cavity pumps in the CC series are available either in a single-stage standard geometry (M1) or a two-stage standard geometry (M2) for higher pressures. Long geometries (D1) are available specifically for highly viscous, abrasive media.
The hole pattern of the cutting screens, along with the number of cuts, is decisive for the size-reduction ratio. To meet the requirements of every situation, we offer cutting screens for the RotaCut, depending on the size, with free passage from 4 mm to 50 mm. Stainless steel versions are available for aggressive media.
ACCplus further reduces the cost of maintenance and monitoring of the cutter. It monitors the cutting blade status online and displays it on an external display. This means it's no longer necessary to place the cutter out of service and open it to determine the cutting blade status. Additionally, this information can be processed and displayed by the (central) control and/or remote control.
The Auto-Reverse function detects blockages, such as those caused by coarse disruptive matter, and initiates corrective action. By periodically reversing, the function further ensures that a pair of sharp cutting edges is always used while dull ones are sharpened on the opposite site. This delivers optimal cutting performance with reduced power consumption.

The combination of a progressive cavity pump from the CC series and a special RotaCut make the CC-Cut pump system an efficient solution when it comes to pumping heterogeneous and highly viscous media loaded with heavy material and disruptive matter, cost-effectively and reliably against high pressures. In the first step, harmful foreign matter such as stones and metal parts is separated out in the RotaCut due to size or weight; this matter can later be disposed of through a cleaning port during maintenance.

Light disruptive matter and solid matter, such as wood, fibers etc. are drawn along in the flow of fluid to the cutting screen, where they are shredded and mixed with the fluid. In this way, the CC-Cut pump system converts a heterogeneous, difficult-to-pump medium into a pumpable, homogeneous suspension, which is routed directly into the suction housing of the progressive cavity pump.

The pumping principle of the CC progressive cavity pump

The pumping principle of the rotating, positive displacement pumps is based on two key components: the rotor, and the fixed stator in which it rotates. The rotor is shaped like a feed screw, with a large pitch and flight depth and a small core diameter. In addition, the rotor rotates “eccentrically” in the stator. The stator, in turn, is shaped as a matching but double-threaded internal screw with a double pitch. The interaction between the sophisticated geometry of the pumping elements and the eccentric rotation results in cavities that enclose the medium, which is pumped evenly from the suction side to the discharge side. In addition, the delivery rate is speed-dependent, which means that the progressive cavity pump is very easy to regulate. Furthermore, the progressive cavity pump can generate strong suction, thanks to its underlying principle. The CC-Cut benefits from all these advantages and the CC series ensures reliable and cost-effective pumping of the previously treated medium.

When developing our compact pump systems, we at Vogelsang pay particular attention to day-to-day handling and easy maintainability. In line with this, the design of the CC-Cut ensures that the service functions of the CC series progressive cavity pumps and the RotaCut are not impaired in the overall system. It features the quick opening function that is typical of the RotaCut, giving free access to the cutters. To remove the blade rotor, you simply have to dismount the adjustment unit. Then, you can either turn the cutting screen around or replace it and, if necessary, renew the gasket.

Service and maintenance of the CC-series progressive cavity pump are just as easy. Thanks to the innovative SERVICEplus concept, there is no need to dismount parts from the pipe. The rotor and stator swivel out as a unit and can then either be replaced as a unit or renewed individually.

The two components can both be maintained quickly on site, allowing the CC-Cut pump system to be put back into operation after a very short time. There is no need to dismount the pipe. This reduces downtime to a minimum.


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