Research worldwide

Around the globe, more than 400 research staff are at work creating innovations for KSB’s customers. The pump and valve manufacturer invests in research and development at its locations in the pursuit of very different goals. Here are some examples.

Gradignan | France Chrystelle Tandonnet

Chrystelle Tandonnet (left) and her team are always on the lookout for something new.

Curiosity as a driving force

Our tasks and projects are extremely interesting, and even quite gripping. But we are also under pressure, because KSB’s future products depend on our ideas. I head the French branch of the KSB Group’s valves research and innovation department. We research and test new technologies and develop technical concepts for the valves of tomorrow. 3D printing of polymers, equipping valves with sensors and handling a range of related technological and regulatory tasks are just a few examples. We are exploring interesting fields of application with increasing volumes, such as the hydrogen sector and CO₂ capture. All of this requires a globally functioning network and cooperation with colleagues from different disciplines. I value the mutual exchange of ideas and cooperation – everyone contributes their skills, their experience and their personality. We work closely with our French and German colleagues, as well es with the teams in Luxembourg and India. We are also creating new research capabilities for the KSB Group to develop a global vision of the requirements facing us in the future. In addition we naturally work together with external working groups and scientists.

We are motivated by curiosity and the drive to create something new. And we keep track of all technologies, market developments, manufacturing processes and applications of our customers. Ultimately, we try to adopt a broader view and consider developments in other sectors, too.

Hydraulics expertise for the world

Every application requires a specific set of properties from a pump. Frankenthal’s hydraulics experts thus work to modify pumps’ characteristic curves with the goal of achieving optimised operating behaviour – from small circulators to power plant pump sets weighing several tonnes. This is not just about efficiency. Our calculations also incorporate pump head and performance profiles as well as cavitation behaviour. To ensure the optimal adjustment of our pumps, we analyse their fluid mechanics on the computer and determine the best solution on a case-by-case basis. Sometimes we also conduct tests on models with different pump impeller types. The development process also sees us working with external research institutes and internal specialists. In future, we want to accelerate our work even more using artificial intelligence. Intensive collaboration with our colleagues from other departments plays an important role for us. We are glad to make our experience and know-how available worldwide.

When it comes to customised solutions, we work particularly closely with the sales departments, who often deliver the impetus for new developments. The people I deal with every day are as diverse as our tasks. I find that particularly enriching.

Frankenthal | Germany Frank Hafner

Frank Hafner and his colleagues determine pumps’ ideal operating behaviour.

Dr Harry Tian (centre) and his team investigate new technologies and trends in materials engineering.

Grovetown | USA Dr Harry Tian

Fully committed to long pump service lives

Since the mid-1990s, I have been heading the materials research and development department at GIW Industries, Inc. in the USA, which is part of KSB. Our research focuses on developing and applying materials specifically used in slurry pumps found in the mining industry. In these applications, the pump sets typically experience substantial material loss on those components that come into contact with the fluid handled. This is due to heavy wear, corrosion or erosion. It is thus necessary to ensure ongoing development of new materials for this highly competitive market. Our specially alloyed white cast iron materials and innovative coatings are a good example. Research at KSB also involves evaluating and developing polymer elastomers as well as ceramics and composite materials for extreme applications including hard rock mining and oil sand transport. In addition, I investigate trends in materials engineering and new technologies. I likewise collect customer requirements for the materials we incorporate in our pumps. I then propose research topics and cultivate ideas for potential applications. In ideal cases, these form the basis for successful projects and further development.

Our team carries out frequent experiments to provide material evaluations from scientific and technical standpoints. To conclude research projects successfully, we often collaborate with other departments in the KSB Group around the world on cross-functional activities. We also maintain contact with customers and suppliers, who assist us by providing feedback and other valuable information. Materials engineering is very important for our product range as a specific service life must be achieved for the critical parts used in slurry pumps. New materials are the basis for our success in demanding fields of application. The markets and applications we cater to are highly complex, and competition is extremely intense. We constantly have to face changing challenges due to different materials – it never gets boring. That is what my team and I enjoy every day.

Pegnitz | Germany Dr Andrea Kühl

Dr Andrea Kühl and her colleagues conduct research into materials for cutting-edge manufacturing processes such as 3D printing.

Perfection through trial and error

KSB’s competence centre for materials technology is located in Pegnitz. Experts from various disciplines research and develop new materials to produce components with improved properties. Today, KSB can offer unparalleled global expertise in metals, ceramics, polymers, coatings and composites. This is something our customers appreciate.

Since 2007, I have been working on publicly funded research projects at the materials laboratory. Some exceptional projects saw us developing coatings of diamond and diamond-like carbon on ceramic bearing components – even including integrated temperature sensors – in cooperation with project partners. These coatings help reduce friction and wear in the event of dry running and insufficient pump lubrication. In a nutshell: The pump set offers a longer service life.

We have been researching materials for use in additive manufacturing processes such as 3D printing and laser beam melting for several years. One example is the material-efficient production of pump impellers from high-alloy steels. We are continuously expanding our range of materials for these manufacturing processes.

Our work cannot really be done from home. New ideas and proposed solutions are often found during practical experiments in the laboratory. I greatly appreciate the contributions of all my colleagues because research and development is teamwork. Within KSB, we work across locations and in direct contact with companies as well as with various institutes worldwide. We also make special use of KSB’s global network of experts. In addition to regular meetings, workshops also help us to resolve specific issues.

I haven’t had a single day of boredom at KSB. What continues to drive us is turning ideas into real innovations. If we can improve the robustness of our pumps and valves, then they will last longer. And if we can simultaneously increase energy efficiency within our value chain, we are supporting sustainability.

Creating new products, improving existing ones

In order to remain competitive on today’s market, companies need to develop new products and continuously improve existing ones. As Head of Valves at KSB Tech, I am responsible for the development of gate, globe and check valves in India. Our company is an engineering and IT service provider that works exclusively for KSB worldwide. Our task is to fulfil the requirements of the Group’s production plants around the globe.

Together with my team, I am responsible for the design and development of valves, primarily for the manufacturing plants in India and China. We also work closely with valve development in Germany. We undertake projects for new valve designs, adapt designs to the latest versions of standards and codes, provide technical expertise in preparing quotations, supply design solutions for operations and support our service colleagues in analysing and resolving complaints. Not only do we improve existing designs, we also improve the associated processes. This is how we contribute towards increasing efficiency in the company.

Pune | India Ganesh Devale

Ganesh Devale designs and develops various valves with his team.

Teamwork is extremely important in every step of our work – whether internally within the department, across departments or in collaboration with different KSB locations. In addition, we are creating a worldwide network. Everyone involved benefits from long-term cooperation. We are continuously expanding our capacity and expertise to support other locations. One example is our collaboration with colleagues in Pegnitz. We compile and update KSB’s technical documentation and product literature – an important task within the Group.

We are closely involved in the development of new products. For example, we are developing new design tools to minimise the time needed for calculations. We also carry out CAD work for our internal customers, supporting the further development of KSB’s portfolio and products.

I am particularly proud of one of my employees’ projects. Our valves team has developed various design processes and tools in order to quickly respond to new requirements in product development. This allows us to offer optimal product solutions while streamlining workload. Using minimal resources gives us a competitive edge. Our department has even applied for two patents for optimal design concepts in this area.

Developing new products and improving existing ones has been my passion since day one of my career. What I especially enjoy about my work is the perfect synergy between our team of highly experienced product experts and our colleagues around the world.

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