AAL Electroplating Pickling Case Study-123-Meibao Pump | China's Largest Corrosion-Resistant Pump Manufacturer

Home Wastewater & Exhaust Gas Treatment AAL Electroplating Pickling Case Study-123

Electroplating PicklingIndia Completed: November 2025

Zero-Leakage Vertical Pickling Pump:
450 L/min, 7+ Months of Continuous Operation

How an Indian electroplating facility reduced downtime and acid-related corrosion by switching to PPH vertical pumps for mixed-acid pickling circulation.

Meibao pumps provide stable corrosion resistance and rarely leak during continuous operation. Compared with other brands, they need much less maintenance and have significantly reduced production downtime.

Patel
Director

AAL

Success Story

From Three Major Leakage Incidents to 36 Months of Bulletproof HF Transfer

Viet Semiconductor Components JSC operates a 200mm wafer fabrication facility in Ho Chi Minh City, Vietnam, processing 12,000 litres of hydrofluoric acid daily for silicon wafer etching. A history of pump failures and toxic HF leakage incidents made this one of Meibao's most demanding | and most rewarding | installation projects.

Acid Fumes, Corrosion, and Repeated Pump Failures

AAL is an electroplating company in India. Its pickling process uses a 20% hydrochloric acid and sulfuric acid mixture at 60°C to remove oxide from metal surfaces.

The pickling tanks continuously circulate the acid solution through filter machines to keep the bath clean. However, the open tanks release corrosive acid fumes into the workshop. At the same time, the acid contains a large amount of iron oxide sludge, creating both chemical corrosion and particle wear inside the pump.

The Problems

Before working with Meibao, AAL had tried several pump brands, but none could provide stable operation under these conditions.

The main problems included:

Acid fumes attacked the motor and bearings.
Iron oxide particles caused wear on the impeller and pump casing.
The average pump service life was only about 12 months.
Pump failures caused repeated repairs and replacements.
Production downtime reached around 15 days per year.
Acid leakage occurred 2–4 times per year, creating safety and EHS concerns.

The customer needed more than a pump with better corrosion resistance. The solution also had to address acid-fume exposure, leakage, and changing tank levels.

Root Cause

Why were the previous pumps failing?

1. Acid-fume exposure
Open pickling tanks continuously released HCl + H₂SO₄ fumes. Horizontal pumps left the motor and bearing area exposed to the corrosive environment.

2. Corrosion + particle wear
The 20% mixed acid attacked wetted components, while iron oxide sludge accelerated mechanical wear.

3. Shaft-seal leakage
The shaft seal became a weak point under corrosive conditions, leading to repeated acid leakage.

4. Tank-level changes
Changes in liquid level could make the horizontal pump more likely to lose stable suction conditions, increasing the risk of cavitation.

Before Meibao

Metric	Before Meibao	Impact
Pump Lifespan	About 1 year	Frequent replacement
Annual Downtime	15 days/year	About 2 weeks of production lost
Leakage Incidents	2–4 times/year	EHS and operator safety concerns
Annual Pump Cost	$500/set	Purchase + labor + downtime
Acid Concentration	20%	HCl + H₂SO₄ mixed acid
Operating Temperature	60°C	Increased corrosion and seal wear

A Vertical Pump with PPH Wetted Parts

After reviewing AAL's actual operating conditions, Meibao identified three key requirements:

Keep the motor away from acid fumes. Prevent shaft-seal leakage. Maintain stable operation when the tank level changes.

A conventional horizontal pump could not fully address these issues.

Meibao therefore recommended the MIT-40VK-55NF vertical pump.

Its vertical design places the motor above the liquid level, while the seal-less structure removes the traditional shaft-seal leakage point. PPH wetted parts were selected for the customer's mixed-acid application and 60°C operating temperature.

Why MIT-40VK-55NF?

Selection Requirement	MIT-40VK-55NF Advantage
Acid-fume exposure	Motor is positioned above the liquid level and away from the main fume area
Corrosive liquid	PPH wetted parts are designed for corrosive chemical service
Leakage prevention	Seal-less design removes the mechanical shaft-seal leakage point
Changing liquid levels	Vertical submerged pump design helps maintain stable liquid intake
Circulation flow	Up to 450 L/min for filter-machine circulation

Key Advantages

Vertical Design · Seal-Less Structure · Stable Operation

· Motor away from acid fumes: The vertical design keeps the motor above the liquid level, reducing exposure to corrosive fumes.

· No shaft-seal leakage: The seal-less design removes a common leakage point found in conventional shaft-seal pumps.

· Better handling of changing liquid levels: The submerged pump section stays in the liquid, helping maintain stable suction as the tank level changes.

· PPH wetted parts: The wetted components are made from PPH for corrosion resistance in the customer's mixed-acid application.

Selected Pump Specifications

Specification	MIT-40VK-55NF	Key Benefit
Wetted Material	PPH	Corrosion-resistant wetted parts
Drive Type	Vertical direct drive	Seal-less pump design
Max. Flow	450 L/min	Stable circulation to filter machines
Max. Head	21 m	Handles system back pressure
Motor Power	3.75 kW	Suitable for the application
Units Installed	6	Covers the customer's pickling system
Sealing	Seal-less	No mechanical shaft seal
Certification	None required	Standard industrial application

Project Timeline

Stage	Timeline	What Happened
Application Review	Week 1–2	Reviewed the pickling process, liquid-level changes, and piping layout
Production & Testing	Week 3–5	Six MIT-40VK-55NF pumps were customized to match the customer's connections and fully inspected before shipment
Installation & Commissioning	Week 6–7	Pumps were installed, connected, tested, and commissioned under load
Stable Operation	Month 7+	Pumps have continued running without failure and are still being monitored

The Result

Zero Leakage and Stable Operation for 7+ Months

Since installation and commissioning were completed in November 2025, all six MIT-40VK-55NF vertical pumps have operated continuously for more than 7 months in AAL's pickling workshop.

During this period:

0 leakage incidents
0 days of production downtime caused by the pumps
Stable circulation of up to 450 L/min
No pump failures requiring replacement
Significantly less maintenance compared with the previous pumps

The vertical design also keeps the motor above the liquid level, reducing its exposure to the acid-fume environment.

At the same time, the seal-less design removes the shaft-seal leakage point, helping keep the working area cleaner and reducing EHS concerns related to acid leakage.

Customer Feedback

“Meibao pumps provide stable corrosion resistance and rarely leak during continuous operation. Compared with other brands, they need much less maintenance and have significantly reduced production downtime.”

— Patel, Director, AAL

Before vs. After

Area	Before: Horizontal Pumps	After: MIT-40VK-55NF	Result
Corrosion	Wetted parts required replacement after about 12 months	PPH wetted parts have operated for 7+ months with no reported corrosion-related failure	Longer expected service life
Acid Leakage	2–4 incidents/year	0 incidents	Leakage eliminated during the reported period
Production Downtime	15 days/year	0 days caused by pump failure during the reported period	Production interruptions reduced
EHS Risk	Repeated acid leakage created safety and environmental concerns	No reported leakage since installation	Lower leakage-related risk
Annual Pump Cost	About $500/set	About $200/set equivalent based on reported annual saving	About $300/year saving

Note: The reported 7+ month operating period confirms the current performance of the installed pumps. Longer-term service-life improvements will be evaluated as operation continues.

IT-40VK-55NF Vertical Pump

Specification	Details
Flow	450 L/min
Head	21 m
Wetted Material	PPH
Motor Power	3.75 kW
Drive	Vertical direct drive
Temperature Rating	80°C
Quantity	6 Units

Configuration: Standard configuration. No additional spare parts package was supplied.

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