72150_LM_Vacuum Pump_eBook_JL V2 VACUUM PUMP RESOURCE GUIDE Protecting people, processes, and the environment SAFETY TIPS and features SUSTAINABILITY guide MAINTENANCE checklist VACUUM PUMP SYSTEMS More efficient, more convenient, and safer. The new KNF LABOPORT® vacuum pump systems SC 820 G and SC 840 G are now available. Featuring a new high-precision vacuum controller. Learn more atknf.com/en/us/laboport Table of Contents 3Vacuum Pump Safety and Sustainability inLabs4Vacuum Safety Tips7Vacuum Pump Sustainability: Features and PurchasingQuestions11Vacuum Pump Selection 2 Lab Manager 13Maintenance Matters Introduction Vacuum Pump Safety and Sustainability in Labs Vacuum plays a fundamental role in science, engineering, and manufacturing. Vacuum pumps are ubiquitous in labs-forming critical infrastructure for processes like filtration, drying, distil- lation, and packaging, as well as supporting many analytical and characterization instruments- yet are often overlooked. Given their prevalence and criticality in many applications, vacuum pumps have a substantial impact on lab operations, safety, and sustainability. As such, managers can improve general lab safety and sustainability by following best practices for operation and maintenance and considering key features and specifications when sourcing vacuum pumps. Proper handling, routine maintenance, and adherence to manufacturer guidelines are essential to prevent accidents and ensure operational safety. Integrating vacuum pump safety-including personal protective equipment (PPE), emergency shutoff systems, and ventilation controls-into a lab's overall protocols safeguards personnel, minimizes equipment damage, and maintains a safer work environment. Timely maintenance ensures pumps operate safely and efficiently, mini- mizing risks and downtime. Vacuum pumps present an opportunity for substantial efficiency improvements within the broader lab sustainability movement. By adopting energy-efficient pumps, such as those with variable speed drives (VSDs), oil-free models, and those made with recyclable materials, labs can reduce their carbon footprint, water usage, and hazardous waste. Sustainable vacuum pump technologies that lower emissions, conserve resources, and adopt circular economy principles help labs meet sustainability targets while maintaining high performance and reducing long-term costs. This resource guide reviews core aspects of vacuum pump safety, outlining potential chemical, mechanical, and implosion hazards, key safety features to look for in modern pumps, and maintenance guidelines. It further explores design features and practices that improve sustainability, helping labs make informed choices that contribute to greener lab operations. It also highlights questions labs should ask when selecting pumps to ensure they are balancing performance, safety, and environmental considerations. Vacuum Safety Tips General vacuum pump safety 3 4 Vacuum pumps and systems used in laboratories pose common mechanical and chemical contamination hazards, as well as application- and technology-specific hazards. Vac- uum systems can also pose severe implosion hazards. These hazards include risks of damage or injury to lab staff, equip- ment, processes, and the environment, but can be minimized by following a few best practice guidelines to ensure system safety and effective operation. 1 Read the manual. Always refer to the manu- facturer's manual for specific safety instructions and proper operation of the pump. Use proper power supplies. Ensure that the pump connects to a properly grounded power sup- ply and that the voltage matches the pump's specifi- cations. Check cords and switches for defects. Ensure proper ventilation. Place pumps in well-ventilated areas to prevent the buildup of haz- ardous vapors and to dissipate heat generated by the pump. Some pumps or applications may require the use of a fume hood or an external exhaust vent. Keep flammable chemicals away from pumps in use. 2 Training. Ensure all lab personnel are properly trained to operate the specific type of vacuum pump in use. 5 Keep the pump outlet clear. Ensure the pump outlet is unobstructed to avoid over-pressurization, which can disrupt seals and cause leaks. 6 Vacuum traps protect the pump or lines, personnel, and the lab environment from the material being pumped and exhaust vapors when placed between the vacuum source and the apparatus. Monitor trap liquid levels and use a secondary trap for overflow when performing vacuum filtration to prevent pump contamination. Use a cold trap for volatile materials and regularly check for blockages. Use an inline disinfectant trap for hazardous biological materials. Use a cold trap. Cold traps installed on the inlet protect the pump or central vacuum line from solvent or other vapors. Ensure the temperature and design of the trap are appropriate for the solvents used. 7 Install exhaust filters. To prevent contamina- tion or release of harmful gases or oil mist, install appropriate exhaust filters, especially for oil- based pumps. 8 Schedule regular maintenance. Follow a regular maintenance schedule to check oil levels, re- place filters, and inspect seals and gaskets for leaks or damage, as relevant. 9 Wear personal protective equipment (PPE). Use safety goggles, gloves, and lab coats during maintenance activities to protect against accidental exposure to chemicals or mechani- cal hazards. 10 Ensure chemical compatibility. Some appli- cations require pumps manufactured with specific materials or coatings. Confirm that the pump is compatible for use in applications involving reactive, flammable, combustible, or corrosive chemicals. 11 Avoid overheating. Monitor the pump for overheating, especially during extended use. Some pumps may require additional cooling systems. 12 Emergency shutoff. Ensure easy access to emergency shutoff switches and be aware of proce- dures in case of pump failure or another emergency. 13 Monitor operating parameters. Ensure critical operating parameters, like gas load, voltage, and temperature, remain within specifications. Technology-specific tips Oil-sealed pumps Glass vessels under vacuum or pressure can implode or explode, and without the proper protection, there is always the risk of being cut from projectiles or splashed by the flask's contents on the skin or eyes. Integrated exhaust filters Look for pumps with built-in exhaust filters, such as oil mist eliminators or chemical filters, to prevent the release of harmful fumes or particles into the lab atmosphere. Overload and thermal protection Pumps with built-in overload and thermal protection will automatical- ly shut down or adjust their opera- tion if overheating or electrical faults are detected, reducing the risk of accidents. Easy maintenance access Pumps designed for easy access to components for regular maintenance (such as oil changes or filter replace- ments) help facilitate consistently maintained safety measures without added complexity or downtime. Low noise operation Pumps with noise-reducing features or designs promote a safer and more comfortable working environment, as extended exposure to high noise levels can harm hearing. Vacuum control and monitoring systems Advanced vacuum control features, including sensors, pressure gauges, and digital monitoring systems, al- low for precise control of the pump's operation, preventing over-pressur- ization or system failure. Vacuum Pump Sustainability: Features and Purchasing Questions There are numerous considerations and features for vacuum pumps that can help minimize environmental impact and energy consumption. The following purchasing questions and features will help balance lab sustainability with your lab's functional needs. 1 Does the pump have an inverter or VSD? 2 Are there any energy-saving modes or features that reduce power usage when the pump is not in heavy use? Can the pump be integrated with automation sys- tems to adjust power or shut off when not in use? 3 4 How does the energy efficiency of this pump com- pare to other models in its class? 5 If the pump needs to be located in a fume hood, can operation be controlled and monitored remotely to allow the sash to be lowered during use? 6 Will a dry (oil-free) pump meet application require- ments to avoid using oil and the subsequent genera- tion of oil mist, associated waste, and other contami- nation concerns? 7 For high vacuum pumps, what are the roughing/ backing pump requirements? Is the pump made from recyclable or reusable mate- rials, and does the manufacturer offer take-back or recycling programs? 12 13 How does the manufacturer minimize the envi- ronmental footprint of the pump's production and shipping processes? 8 What is the expected lifespan of the pump with the intended applications? 14 What sustainability initiatives or environmental com- mitments has the manufacturer made? 9 Are the pump's components easy to repair or re- place to extend its service life? 15 16 Does the company offer guidance or tools to help labs operate more sustainably with their pumps? 10 Does the pump meet any sustainability certifications or adhere to green manufacturing practices? 11 Are consumables recyclable or made from sustain- able materials? Does the pump offer long-term cost savings through reduced energy use, maintenance, or consumable waste? Energy efficiency Inverters or VSDs allow the motor to run at varying speeds rather than full speed on/off. This capability is particularly useful for vacuum pumps, where demand fluctuates based on the process require- ments and stages. Reducing the motor speed during periods of lower demand considerably reduces the overall power consumption, making the pump more energy-efficient while better support- ing sensitive applications. Automation through smart control systems can further optimize operation, reducing energy consumption more effectively and efficiently than manual intervention. Pumps with energy-saving modes are ideal for reducing energy use during downtime. Labs can further conserve energy by turning vacuum systems off overnight in cases where 24/7 operation is not required. Minimizing oil waste Oil-free pumps eliminate the need for oil changes and waste oil disposal, reduc- ing environmental impact and mainte- nance costs. If an oil-sealed pump is required, inline filters can extend the life of the oil, reducing the number of changes and volume of hazardous waste. Continuing to run the pump post-use with the gas ballast can also help purge the system and oil of any solvent contamination. Oil return systems that capture and return oil mist that would otherwise be vented conserve oil and improve safety. Sustainable design and manufacture Look for pumps made from recyclable materials or those manufactured with sustainable practices, reducing the overall environmental footprint. A durable pump with a long service life reduces the frequency of replacements and the environmental burden of manu- facturing new equipment. Look for robust designs that resist wear and tear, especially if the pump will run for long periods. Some manufacturers offer take-back programs to recycle old pumps to support circularity and conserve resources. Low emission, containment, and recovery systems Choose pumps with exhaust filters or other features that minimize emissions of hazardous chemicals or particulates. Pumps with effective vapor containment systems, such as integrated traps, help minimize the release of harmful sub- stances into the lab or environment. Con- sider models that integrate with solvent recovery systems. Reduced water consumption Pumps with efficient water cooling sys- tems or closed-loop water-cooling features help minimize water waste. Air-cooled alternatives can avoid water use entirely. Thater aspirators continue to drop in popularity due to the enormous environ- mental footprint courtesy of water waste and environmental contamination. Thhile recirculating aspirators reduce water consumption, labs are left with volumes of solvent-contaminated water that must be properly handled and disposed of. Product Spotlight Smart-Controlled Vacuum Pump Systems More efficient, more convenient, and safer. KNF SC 820 G and SC 840 G LABOPORT® vacuum pump systems feature four versatile operating modes, high solvent recovery rates, and an integrated gas ballast for efficient operation. A Bluetooth remote control allows for safe operation outside closed fume hoods. These compact, chemically resistant, and oil-free systems are ready to take on a wide range of laboratory applications. Their newly designed touchscreen display with an extremely precise vacuum regulator provides complete process control. Thanks to the large user interface, users always have an overview of what's important. CLICK HERE TO LEARN MOREVacuum Pump Selection Choosing the best vacuum pump for the application will ultimately save time and money while contributing to safety and sustainability in the lab. Vacuum pumps are typically specified by two key factors: flow rate (or pumping speed at atmospheric pressure) and ul- timate vacuum (the deepest vacuum the pump can achieve). However, pumps with identical specifications can perform differently under actual lab conditions due to variations in how they behave from the starting pressure to their ultimate vacuum point. Vacuum pump performance curves plot the relationship between pumping speed and vacuum pressure, showing how a pump's performance changes as it approaches its ultimate vacuum. These curves help predict how effectively a pump will operate at specific working pressures. Users can review performance curves, which any vendor should provide upon request, to identify which pumps maintain higher pumping speeds near their desired vacuum level, ensuring faster, more efficient processes. This insight can help labs choose the most efficient solutions that meet their needs, potentially saving time and money. Technology Ultimate Vacuum Example Applications Notes Diaphragm Pump 100 to 1 mbar General laboratory vacuum applications such as filtration and aspiration Diaphragm pumps are also oil-free and chemically resistant, making them suitable for handling corrosive gases and vapors in lab environments. They are relatively low-maintenance and quiet but limited to rough vacuum levels. Rough Vacuum: 103 to 1 mbar (low vacuum) Medium Vacuum: 1 to 10-3 mbar Dry Scroll Pump Rotary Vane Pump (Oil- Sealed) Turbomolecular Pump 10-3 to 10-10 mbar Surface analysis techniques, including scanning electron microscopy and X-ray diffraction Diffusion pumps use a vapor stream to push gas molecules out of the system. They are cost- effective for ultra-high vacuum applications, though they require cooling and are sensitive to contamination. Cryogenic Pump 10-6 to 10-11 mbar High-vacuum coating and thin- film deposition Cryogenic pumps work by freezing gases onto cold surfaces, effectively trapping them to create high vacuum conditions. They require regeneration cycles to vent captured gases. Piston Pump 1 to 10-1 mbar Piston pumps are robust and can handle higher flow rates. They are commonly used in industrial, hospital, and commercial settings for vacuum packaging and other rough vacuum applications. Piston pumps may be oil-sealed or dry. Maintenance Matters Regular maintenance of vacuum pumps is crucial to ensure safety, efficiency, and sustainability while avoiding costly repairs or replacements. Thhile rough vacuum pumps will typically show signs when maintenance is required-like increased operating noise and temperature or reduced perfor- mance-proactive maintenance and checks help prevent wear and tear, reduce the risk of contamination, and address poten- tial issues like reduced vacuum levels or overheating before they cause major failures. For high- and ultra-high-vacuum pumps, proactive maintenance is even more critical. Always follow the manufacturer's guidelines for service, maintenance, and checks, and inspect critical components such as seals, filters, and oil levels regularly. Logging oper- ational parameters will also help identify potential prob- lems proactively. Timely maintenance and care will ensure optimal performance, extend the lifespan of the pump, and minimize downtime in the lab. As a general trend, pump manufacturers are producing equipment with reduced maintenance demands and length- ier service windows. The following sample maintenance checklist offers an approximate guide, though needs and recommendations will vary based on the type and model of pump and the application and operating conditions. Always read the manual and follow the manufacturer's instructions exactly for all maintenance work, paying careful attention to part installation, pump assembly, and cleaning guidelines. Daily/Weekly: KNF Neuberger, Inc. is a leader in precision vacuum and liquid pumps and systems for industry and academic laboratories. Choose LABOPORT® vacuum pumps and systems for rotary evaporation, distillation, vacuum concentration, filtration, degassing, gel drying, vacuum ovens, desiccation, and most other common laboratory applications requiring vacuum. KNF LIQUIPORT® and SIMDOS® pumps are ideal for precise liquid transfer and dosing/metering needs. KNF liquid pumps are self-priming and can run dry without damage. All KNF pumps are oil-free, chemically resistant, compact, and energy efficient, with low maintenance and low total ownership costs. www.knf.com In partnership with
