Pumps Of The Future Series - Ep 1 Electrification

Electrification: The move to Battery Electric Systems

Electrification represents the transition from fossil-fuel-driven systems to electric-powered alternatives that leverage renewable energy. This shift not only benefits the environment but also enhances on-site efficiency and reliability.

Market Recap: Plug-in Electric and Hybrid Pumps

Prime Fluid Management has already delivered electric and hybrid pump options for clients who want quieter, cleaner sites. For locations with reliable grid access, these models are a proven step toward emissions reduction

We’ve integrated electric and hybrid pump units into our fleet including high-efficiency models supplied by BBA Pumps, a leading global manufacturer:

• The BA150 electric model delivers up to 430 m³/h at a 24-meter head, using 22 kW of power.
• The PT150 electric model provides 90 m³/h at a 20-meter head, using 7.5 kW.

In 2022, Prime Fluid Management added the Plug-in Hybrid Piston Pump (PT), from BBA Pumps to our fleet. They rely on an electric drive as the primary power source, with a diesel engine backup if grid power fails. This hybrid configuration is ideal for sites with unreliable power access but still requires a stable power source for uninterrupted operation.

Gaps in Current Options

Both plug-in electric and hybrid pumps rely on external power sources, which can be problematic on sites without reliable grid access. While generators can supplement power, they introduce noise, emissions, and maintenance challenges.

Introducing Battery Electric Pumps

Battery electric pumps offer a solution to this issue by operating independently of the grid. The latest prototype models from BBA include:

• LiFePO₄ battery packs
• High-efficiency electric motors
• Onboard inverters and control systems
• Integrated solar charging for auxiliary power and control systems
• LinQ telematics for remote monitoring

These pumps are designed to run for up to 10 hours per charge under standard loads, with recharging available via 400V (32A) or 230V (16A) inputs. Maintenance is simplified by the absence of an internal combustion engine and fewer moving parts. The battery packs are internally heated for improved charging efficiency in colder conditions, and the system operates below 110V DC, allowing servicing without high-voltage certification.

Key Advantages:

• High Energy Density: These batteries offer a strong charge-to-weight ratio for optimal performance.
• Low Maintenance: The lack of complex engine components reduces maintenance needs.
• Safety and Reliability: With a lifespan of over 4,000 charging cycles, these pumps are built for long-term use.
• Sustainability: Powered by renewable energy, these pumps help move toward carbon neutrality.

These battery electric pumps are a practical option for industries that require high performance and efficiency without sacrificing environmental goals

Electrification + DPU: Designed for Extended Operation

For sites that require longer operational hours, the Battery Electric + Diesel Power Unit (DPU) setup provides a reliable solution.

This system runs on an electric motor with a built-in speed controller. When grid power is available, the motor is powered through the battery, which charges at the same time. If grid power is unavailable, the pump draws energy from the battery pack. Once the battery is depleted, a 1-cylinder diesel generator automatically starts to recharge it. The generator runs at a consistent load, which helps reduce fuel consumption and emissions.

Benefits:

• 24/7 Operation: Integrated diesel generator (DPU) recharges the battery when grid or stored power is unavailable.
• Automatic Power Switching: Seamless transition between grid, battery, and diesel ensures reliable uptime.
• Fuel Efficient: The DPU runs only when needed and at efficient load levels, minimizing fuel consumption.
• Onboard Fuel Tank: Reduces need for external supply setups.
• Energy Savings: Wellpoint-compatible level switch cuts pump speed by 50% once water levels stabilize, lowering energy use on-site.

Availability Status

The Battery Pumps are now available, following a successful development and trial phase. Selected early units have already entered the market.

Ready for the Future

What does this mean for you? It means cleaner, more reliable, and highly efficient pumping solutions that will help drive your projects into a more sustainable future. As Prime Fluid Management continue to work with BBA Pumps and innovate on the cutting edge of electrification, we’re excited to share even more breakthroughs in the coming weeks.

Stay tuned for next week’s instalment, where we’ll dive deeper into how Methanol Fuel Pumps are already making waves in the field. Follow us to stay ahead of the

Are you ready to power up with the future of pump technology?