A high-pressure twin screw pump achieves differential pressures up to 200 bar by using multiple screw thread starts (2–6 starts), tighter running clearances (0.02–0.08 mm), and hardened screw and liner materials — each additional thread start provides one additional pressure-drop stage across the screw length, distributing the total pressure rise across multiple sealing stages and reducing slip per stage. Processing 0.5–500 m³/h at 1–100,000 cP and 10–200 bar, it replaces high-pressure centrifugal pump stages for viscous fluid and serves as the production standard for polymer melt injection, resin transfer moulding, and pipeline pressure boosting.
High-pressure models use multi-start screw profiles (2–6 starts per screw) with reduced helix pitch — each screw thread start creates a sealed cavity stage, and the total pressure rise is divided equally across all stages in series. Tighter running clearances (0.02–0.08 mm vs. 0.05–0.2 mm standard) minimise slip but require superior bore circularity and screw concentricity (±0.005 mm). The casing is a solid forged block (not split-casing) to resist hoop stress at maximum pressure. A pressure-balanced mechanical seal or cartridge seal rated to 200 bar is standard.
Challenges
Tight Clearance Manufacturing Tolerance (±0.005 mm) at All Operating Temperatures
Multi-start high-pressure screws require screw-to-bore concentricity of ±0.005 mm — difficult to maintain across thermal expansion from 20°C to 200°C.
Screw Seizure Risk at Pressure Overload or Loss of Product Lubrication
Tight clearances with high contact force on thermal expansion or lube-film collapse — seizure within seconds.
Shaft Seal Integrity at 200 bar Continuous Differential Pressure
Standard mechanical seals rated only to 25 bar — high-pressure service requires cartridge balanced seal with 200 bar design rating.
Vibration and Noise at High Speed Under Maximum Pressure
Pressure pulsation from screw mesh at maximum load generates structure-borne vibration — fatigue of casing, pipe, and foundation.
Material Compatibility of Screw and Liner with Process Fluid at Elevated Temperature
High-pressure service at >100°C with aggressive chemical fluid requires careful material pairing.
Solutions
- Pre-Heating Phase on Startup (Gradual Temperature Ramp, ΔT <5°C/min): Controlled heat-up allows thermal expansion to reach steady state before full pressure — prevents clearance closure seizure.
- Thermally Compensated Screw Material Pair (17-4PH + Ni-Resist Liner): Matched thermal expansion coefficient pair — maintains constant clearance over full temperature range.
- Cartridge Balanced Mechanical Seal (API 682, Plan 53B, 200 bar Rated): Pressurised barrier fluid at 110% of process pressure — seal faces under compression, never in tension.
- Damped Foundation Mounts + Pulsation Dampener on Discharge: Anti-vibration mounts isolate pump from structure; gas-charged pulsation dampener reduces pressure ripple >90%.
- Material Test Report Per Screw/Liner Pair (EN 10204 3.2): Full traceability per component — hardness, microstructure, and dimensional certificate before assembly.
Applications
- Polymer Processing: Polymer melt gear pump alternative for extrusion, injection moulding — up to 200 bar, 300°C.
- Chemical: High-pressure resin injection, epoxy and polyurethane RIM systems, pressure reactor feed.
- Petrochemical: Pipeline pressure boosting for heavy oil and bitumen — high viscosity, high pressure, elevated temperature.
- Hydraulics: Hydraulic power unit high-pressure pump — compact, variable speed, reversible.
- Research: High-pressure metering of test fluids, supercritical COâ‚‚ blending, high-pressure extraction feed.
Models & Capacities
Model | Scale | Flow Rate [m³/h] | Screw Ø [mm] | Screw Starts | Speed [RPM] | Max Press. [bar] | Running Clearance [mm] | Max Viscosity [cP] | Max Temp. [°C] | Seal Type | Motor [kW] |
TSP-HP-025 | Lab | 0.05–0.8 | Ø25 | 2 | 200–3,600 VFD | 80 | 0.03–0.08 | 100,000 | 200 | API 682 P53B | 0.37 |
TSP-HP-040 | Pilot | 0.2–3 | Ø40 | 2 | 200–3,600 VFD | 100 | 0.03–0.08 | 100,000 | 200 | API 682 P53B | 0.75 |
TSP-HP-063 | Pilot | 0.5–8 | Ø63 | 3 | 200–3,000 VFD | 120 | 0.02–0.06 | 100,000 | 250 | API 682 P53B | 1.5 |
TSP-HP-080 | Production | 1–18 | Ø80 | 3 | 200–2,500 VFD | 150 | 0.02–0.06 | 100,000 | 250 | API 682 P53B | 3.0 |
TSP-HP-100 | Production | 2–35 | Ø100 | 4 | 200–2,000 VFD | 160 | 0.02–0.05 | 100,000 | 280 | API 682 P53B | 4.0 |
TSP-HP-125 | Production | 4–70 | Ø125 | 4 | 200–1,800 VFD | 180 | 0.02–0.05 | 100,000 | 280 | API 682 P53B | 5.5 |
TSP-HP-160 | Production | 8–140 | Ø160 | 5 | 200–1,500 VFD | 200 | 0.02–0.05 | 100,000 | 300 | API 682 P53B | 11 |
TSP-HP-200 | Large Prod | 15–280 | Ø200 | 5 | 150–1,200 VFD | 200 | 0.02–0.04 | 100,000 | 300 | API 682 P53B | 18.5 |
TSP-HP-250 | Large Prod | 30–500 | Ø250 | 6 | 100–1,000 VFD | 200 | 0.02–0.04 | 100,000 | 300 | API 682 P53B | 30 |