8 Cover Safety Systems and Methods at a Glance
03-2017
8 COVER SAFETY SYSTEMS AND METHODS AT A GLANCE
30 POWDER TRANSPORT STAINLESS STEEL COMPONENTS FROM ONE SOURCE
40 CENTRIFUGAL PUMPS INDIVIDUALLY MANUFACTURED
54 FIBRE-OPTIC SYSTEM TIMELY DETECTION OF HOTSPOTS
PROCESS TECHNOLOGY FOR THE CHEMICAL INDUSTRY WWW.CPP-NET.COM cpp 03-2017 1 VISIT US AT POWTECH 26–28 SEPTEMBER HALL 3 / 3-418
FE75 CONTAINMENT PACKAGE + With up to 115 punch stations in a foot print under 2 m2 + Up to 166 % longer at dwell time pressure + Patent-pending method for easy, fast turret exchange + Closed cam system
www.fette-compacting.com NEW DIMENSIONS NEW IN EFFICIENCY 2 cpp 03-2017 cpp EDITORIAL
Expert Forum in Nuremberg
Only a few more days to go: for the 20th time, from September 26 to 28, the Nuremberg Exhibition Centre will be a meeting place for specialist manufacturers and processors of powder, granules and bulk solids. About 900 exhibitors will display their latest develop- ments for mechanical processes and related technologies such as measurement, analysis, control and automation. Manufacturers and plant operators in the chemical sector will discover technical solutions for many of the burning questions affecting the industry. The chemical industry is currently undergoing a transition on many levels. Process digitalisation helps achieve the goal of ensuring con- sistently high product quality, 24/7. The focus is also on curbing production costs and increasing energy and resource efficiency. What’s needed is maximum safety in the manufacturing process PROCESS VACUUM while maintaining a high level of flexibility – at multiple locations around the world. The accompanying programme of talks in the 100% CARE FREE Powtech Expert Forum will likewise offer new stimuli for further thinking on this and other topics in Hall 2, Booth 507. On the no downtime afternoon of September 26 and the morning of September 27, the Forum will be moderated and organised by our relevant trade journals: cav – Prozesstechnik für die Chemieindustrie, cpp – pro- chemically resistant cess technology for the chemical industry, dei – die ernährungs - industrie and Pharmaproduktion. The Forum lectures on “Safe oil-free handling and processing of powders and bulk solids – solutions for chemicals, pharmaceuticals and food” are aimed at experts in the chemical and pharmaceutical industries as well as food manufac- turers. For more information on the Forum contents, see www.prozesstechnik-online.de/messen/powtech. Our Powtech preview begins on page 8 with this issue’s cover story.
Günter Eckhardt, Editor-in-Chief www.vacuubrand-process.com
cpp 03-2017 3 cpp CONTENTS 03-2017
8 Cover In addition to a special stainless steel mesh filter, Rembe‘s Q-Rohr has an explosion vent with an integrated signalling system that alerts the process control system when the ex- plosion vent has opened.
26 The dispersing ma- 34 3M has developed a chine Conti-TDS produces technology for manufac- a very strong vacuum in turing PTFE parts without 44 cpp caught up with its dispersing zone, thus tools on a conventional Dr. Rita Dicke, Vice Presi- facilitating a high powder 3D printer. dent Product Manage- induction rate. ment for ion exchange resins, Lanxess, to discuss the company‘s current developments.
CPP NEWS PLANTS, APPARATUS, COMPONENTS 6 News 34 PTFE parts from the 3D printer Additive manufacturing with fully fluorinated polymers 36 Preparing the ground SPECIAL: POWTECH Chemical-dosing systems at two U.S. based locations 8 COVER Safety systems and methods at a glance 40 Pump selection without the burden of choice Everything you need to know about explosion safety Advantages of special centrifugal pumps consistently 12 Classifying wheel with exchangeable vanes exploited Wear protection meets fineness 42 Redefining maintenance 14 Forewarned is forearmed! Mobile worker concept: Industry 4.0 for hazardous Fire prevention concept protects milling processes at areas cellulose specialist Jelu 16 PRODUCTS 26 Clean, dust-free and no agglomerates PROCESS ENGINEERING Mixing powders into liquids 44 Ion exchange resins and membranes in demand 29 The future is nano Lanxess invests in water treatment technology Bead mill produces nanoparticles 48 Plate heat exchanger made from silicon carbide 30 Stainless steel components from one source Defies even strong acids Emission-free powder transport and complete drum emptying 32 Tough performers INSTRUMENTATION, CONTROL, AUTOMATION Filling systems for hazardous areas 54 Timely detection of hotspots 33 Ideal for use in Atex areas Fibre-optic temperature measurement in a tight space Dosing and shut-off valve with pneumatic sealing 56 Monitoring cell growth element Measuring optical density by means of NIR technology
4 cpp 03-2017 60 New construction or retrofit? SMB provides an example of how a safer, more up-to-date filling plant can be tailored to By installing a large 54 individual requirements. number of temperature measuring points inside a single tube reactor, hot- spots can be detected at an early stage.
PHARMACEUTICAL AND PACKAGING TECHNOLOGY 58 Certificate of retention performance Tablet press containment 60 New construction or retrofit? Future-proof filling plant custom-made
COLUMNS 3 The Third Page 4 Contents 50 PRODUCTS 57 Imprint 62 List of Advertisers 62 Contact the Editors
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More news, facts, products and solutions for the process technology in the chemical industry can be found on our internet page! www.cpp-net.com
cpp 03-2017 5 cpp NEWS
Investments of more than 17 million US dollars Process systems business ENDRESS+HAUSER EXPANDS US PRODUCTION SANDVIK HAS SIGNED A DIVEST AGREEMENT Endress+Hauser has further expanded its In Greenwood, Indiana, where the US sales production facilities in the United States. center is also headquartered, Endress+ The Raman analyser manufacturing plant in Hauser manufactures temperature measure- Ann Arbor, Michigan, was extended at a cost ment technology and system products since of 9 Mio. US dollars. The analysers manufac- 2008. The company has now invested more tured by Kaiser Optical Systems, part of the than 8 Mio. US dollars in a 3900 m2 state- Endress+Hauser Group since 2013, are de- of-the-art production facility. The new plant signed for examining the composition and will produce sensor elements, thermom-
material characteristics of solids, liquids and eters and thermowells as well as trans- Sandvik Picture: gases. Construction of the new plant took mitters, system components and recorders. Björn Rosengren, President and CEO of nearly one year and more than doubles the Sandvik floor space to 8100 m2. Sandvik has signed an agreement to divest Sandvik Process Systems to FAM AB, owned by the three largest Wallenberg foundations, To strengthen its position in the digital world at a price of 5.0 billion SEK. Sandvik Process EVONIK ALLOCATES 100 MILLION EUROS UNTIL 2020 Systems delivers advanced industrial process solutions based on high-end steel belts, Evonik is setting aside 100 million euros for the topic steel belt based equipment and process sol- of digitalisation and is also entering into a strategic utions within adjacent technologies. In partnership with IBM and the University of Duisburg- 2016, the operations, with approximately Essen, aimed at forging ahead with the digital change in 600 employees, had reported revenues of the chemical industry. By providing the financial means 1.7 billion SEK representing 2 % of Sand- and establishing the new strategic partnerships, Evonik vik’s total revenues and with a strong oper- is aiming to further strengthen its position in the digital ating margin. “The divestment creates addi- world. Henrik Hahn (CDO) said, “By the year 2020, we tional capacity for growth and expansion of
Picture: Evonik Picture: aim to see around 100 million euros going into devel- the core business of Sandvik”, says Björn Henrik Hahn coordinates opment and testing of digital technologies. It’s not just Rosengren, President and CEO of Sandvik. digitalisation activities for about data and technology, but especially about new Sandvik Process Systems will remain re- Evonik in his role as chief digital officer (CDO) business models and services for customers.” ported in other operations in the Sandvik fi- The partnership with IBM will see Evonik benefit from nancial statements. The closing of the trans- the latest technologies and projects IBM is spearhead- action is expected no later than early 2018. ing, encompassing technologies such as cognitive and cloud based technologies such as IoT and Industry 4.0.
cpp NEWS TICKER
Seeger also takes over a leading fices, a storage facility and appli- responsibility for the Schmersal cations laboratories. factories in India and China. Two awards for Eli Lilly Coperion K-Tron, Sewell, NJ, USA, Picture: Schmersal Picture: is proud to be a part of the supply Lauda Picture: New leading manager team for Eli Lilly and Company Herrmann joins Lauda The Schmersal Group has ap- who won this year’s prestigious Dr. Ralf Hermann (on the right) pointed Uwe Seeger as Director ISPE FOYA (Facility of the Year started work on June 1, 2017 as
for Asia Pacific Middle East Fritsch Picture: Awards) in two categories, Facility the new General Manager Con- (APME). Seeger will be respon- Fritsch opens US subsidiary of the Future and Process Inno- stant temperature equipment and sible for the further development In order to meet the demands of vation. Coperion K-Tron provided systems at Lauda. He will be lead- of markets and for expanding their customers in a growing mar- the continuous loss-in-weight ing approximately 80 agencies customer relationships in the ket it was time for the German feeders and material handling and coordinating nine sales com- APME region. He will be found- company Fritsch to have a branch equipment for each of the Lilly fa- panies abroad. Constant tem- ing new subsidiaries and expand- directly in the US. The new Fritsch cilities and worked closely with perature equipment is Lauda‘s ing the services offered by the Headquarters USA is located in the Lilly team in the integration largest business unit and holds tec.nicum safety services division. North Carolina. The team has of- and design of the feeder system. the greatest potential for growth.
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cpp 03-2017 7 cpp SPECIAL POWTECH Pictures: Rembe Pictures:
Everything you need to know about explosion safety SAFETY SYSTEMS AND METHODS AT A GLANCE
Whenever a production process generates dust, the plant concerned is potentially at risk of dust explosion regardless of whether it involves screening, drying, milling or filtration. The article gives a brief but comprehensive description of the basics of explosion safety and the protective systems available for this purpose.
8 cpp 03-2017 Stage 3 of a risk assessment: a matrix showing the poten- Explosion vents differ from one application to another and tial risks of individual plant components is set up based on precautions mostly involve the use of rectangular products the first two stages
Explosion safety covers a broad range of applications. To decide mix with inert gases. This has the effect of lowering the content of whether and to what extent precautions are required, you must in- oxygen from the air, so that no explosion can occur. itially conduct a systematic risk assessment. The first step is to gauge Preventive precautions concentrate on the avoidance of effective the probability that an explosive atmosphere might be created and sources of ignition. This includes, for instance, the use of suitable determine whether any potential sources of ignition exist. Next, the equipment to protect the product flow from impurities and moni- effect that an explosion might have has to be classified. Both assess- tor the system earthing with a view to preventing electronic dis- ments can be merged into a matrix. The resulting indicators tell you charges. whether or not the plant or parts of it have to be protected and if Protective precautions involve reducing the impact of a possible ex- so, how. A green box means that no precautions are necessary. A red plosion to a more moderate level, so that the resulting damage is box, on the other hand, signifies that precautions are urgently less severe. Conventional venting using explosion vents, flameless needed. The higher the numerical rating, the more extensive these venting, explosion isolation and explosion suppression are just a precautions should be. few examples. This kind of explosion safety is a vital necessity in virtually all plants for various reasons: How explosions occur • It is in the nature of the relevant processes that there can almost An explosion requires the availability of oxygen from the air, a never be absolute or complete avoidance of effective sources of ig- source of ignition and a combustible substance. In the event of a nition. dust explosion, the distribution of dust is another factor. However, • Inerting tends to be too expensive and/or impossible due to the not every dust-air mixture is explosive. What matters is the mixing characteristics of the processes involved. ratio. Specific explosion limits have been identified for every com- Other preventive precautions may be helpful in certain respects, mon type of dust, and within those limits an explosive mixing ratio though they cannot normally eliminate the risk of explosion com- can be expected. The lower explosion limit is the minimum concen- pletely. tration required to create explosive atmosphere. The upper ex- plosion limit specifies the point at which the mixture becomes too Conventional venting rich, so that the atmosphere is no longer explosive. There also needs If a plant is situated outside a building or if parts of it are next to an to be an effective source of ignition (TRBS 2152 Part 3, “Hazardous outer wall, one frequent safety precaution is to install explosion explosive atmospheres – avoidance of the ignition of hazardous ex- vents. Such precautions are usually applied, for instance, to station- plosive atmospheres”, page 2). Among the common sources of ig- ary silos, filters and elevators located outdoors. If an explosion oc- nition are hot surfaces, electric sparks and glowing embers arising curs, the explosion vent protects the system by opening. This re- during the process. duces any overpressure within the vessel and the explosion is re- leased to the outside. As virtually no two processes are the same, Explosion safety precautions there are numerous types of explosion vents which differ in shape Depending on the results of the hazard and risk analysis, a number and material as well as in their resistance to temperature, pressure of proven precautions need to be taken. They are divided into ex- and vacuum. Even processes with complicated hygiene require- plosion prevention and explosion protection. Preventive precautions ments can be equipped with explosion vents today. The EGV HYP are designed to prevent explosive atmosphere and therefore to re- explosion vent from Rembe, for example, was highly successful in duce the probability of an explosion. Wherever possible, combus - passing the EHEDG cleanability test. This test determines the in- tible substances are replaced by substances that cannot produce an place cleanability of plant components where this is a practical explosive mix. In addition, it is possible to overlay the substance-air requirement for manufacturing absolutely hygienic products.
cpp 03-2017 9 cpp SPECIAL POWTECH
A special mesh filter in the Q-Rohr cools Quench valves, open and closed: these valves are activated in response to down any flames, preventing both flames a rise in pressure or the formation of flames and pressure from emerging
Flameless venting Passive isolation differs in that it responds purely mechanically to If a plant is situated within a building, however, explosion vents are the spreading or loss of pressure on account of its structural charac- not suitable for pressure relief purposes, as the safety area around teristics. This also applies to explosion valves. During normal oper- them is inadequate to relieve the emerging dust and flames. Such an ation, an explosion valve in a pipeline is kept open by the flow. If arrangement would pose an enormous safety risk to humans and an explosion occurs, the valve is closed by the spreading of the machinery. This problem is often solved through the use of vent pressure front, thus effectively preventing the pressure and the ducts, which channel the spread of an explosion to the outside. The flames from propagating any further. disadvantage, though, is that these ducts rule out process-optimised plant design and are usually very expensive: the greater the distance Explosion suppression between an explosion and its source, the higher the pressure which Explosion suppression is another constructional precaution in addi- the vent duct and the plant need to withstand. This results in higher tion to the methods mentioned so far. It means eliminating the ex- (manufacturing) costs per vent duct. plosion at its onset. This is made possible by detectors with sensors Flameless venting, by contrast, is an option that is both economical which register the presence of sparks or flames and immediately and effective. Different manufacturers employ different flameless trigger the opening of tanks containing an extinguishing agent venting technologies. The special mesh filter that is used in Rembe’s (also installed in the system). A highly effective extinguishing agent Q-Box or Q-Rohr cools down any flames efficiently, preventing is released within milliseconds, nipping the explosion in the bud. If both flames and pressure from emerging, and ensures particulate required, an explosion suppression system can also be used for ex- retention. The typical increase in pressure and noise that accom- plosion isolation purposes. panies an explosion within a building is reduced to an almost im- www.cpp-net.com perceptible minimum, thus protecting both people and machinery. Online search: cpp0317rembe In addition to the special stainless steel mesh filter, the Q-Rohr and Hall 3, Booth 244 Q-Box each have an explosion vent with an integrated signalling system that alerts the process control system if the explosion vent opens.
Explosion isolation AUTHOR: In a production facility, the individual parts of the plant are always DR. JOHANNES LOTTERMANN connected by pipelines. The purpose of explosion isolation is to en- Director Explosion Safety, sure that the pressure and the flames cannot propagate, so that any Rembe adjoining parts of the plant are protected. A distinction is made be- tween active and passive isolation systems. An active system is alerted to an explosion at an early stage when the explosion begins to develop. This is done using sensors or detectors which register the rise in pressure or the formation of flames and respond by acti- vating the relevant isolator, e.g. a quench valve.
10 cpp 03-2017 SINTERGLASS
Borosilicate glass 3.3 with high chemical, thermal and mechanical resistance: Custom sintered elements made from VitraPOR ® are characterized by their neutral properties and open-pore structure. Even for the most unusual applications.
Our VitraPOR® glass filters are heat resistant up to 540°C and can withstand most acids, alkalis and solvents.
They can be used in many chemical, pharmaceutical, biological and technical processes, and they are pro- duced in porosity classes from under 1 μm to over 500 μm. VitraPOR® glass filters are always produced accor- ding to international standards, as are the custom-made solutions available in many shapes and sizes. Made in Germany
www.robuglas.com cpp 03-2017 11 cpp SPECIAL POWTECH
Wear protection meets fineness Classifying wheel with exchangeable vanes
The use of the ATP-PRO classifying wheel in the production of fine and abrasive powders considerably improves not only the product quality but also the overall processing efficiency. Equipped with exchangeable vanes, this wheel can be retro- fitted with ease in existing systems and moreover provides a freedom from contami- nation that was formerly only possible with ceramic classifying wheels.
The wear-protected ATP-PRO classifying the specific energy consumption of the • Low pressure drop wheel from Hosokawa Alpine combines the blowers and classifier drives reduced. The • Reduced maintenance effort advantages of conventional ceramic classify- proven operational reliability and easier • Lower specific energy consumption ing wheels with those of steel. This unique handling in comparison with ceramic clas- Existing classifiers and classifier heads can combination is expressed in the abbrevi- sifying wheels are of great significance, es- be equipped with ATP-PRO classifying ation “PRO”, which in this instance stands pecially with multi-wheel classifiers. wheels with only a minimum of conversion for “protected”. In addition, the uncompli- effort, leading to noticeable improvements cated exchange of individual vanes reduces Advantages at a glance in terms of fineness, throughput, energy the effort for maintenance, transport and Compared to steel or ceramic wheels of consumption and absence of contamination. storage and makes it possible to employ dif- conventional design, the ATP-PRO classify- Once the wear protection has reached the ferent vane materials, which in turn extends ing wheel offers the following advantages: end of its service life, the classifier vanes of the range of applications. • Much finer end products the most popular machine sizes 200 ATP- The ATP-PRO classifying wheel is not only • Improved wear protection due to material PRO and 315 ATP-PRO can be exchanged. suitable for use in classifier mills; it can also diversity Thanks to the new wear-protected classify- be employed for classifiers in grinding cir- • Speed reduction ing wheel, it is now also possible to reap cuits, e.g. in combination with ball mills, • Exchangeable vanes made from different the benefits afforded by the NG geometry where it serves to boost the performance. In materials when it comes to processing abrasive ma- this case, finer products can be achieved and • Less iron contamination terials. Different material groups can be combined by means of design measures as well as the use of modern materials and connection techniques. The vanes can be constructed from a combination of metal and non-metal materials for handling par- ticularly abrasive powders, for example. The wear-protection materials can be tailored to individual demands and the classifier vanes replaced as and when necessary.
Tests demonstrate the added value The potential of the ATP-PRO manifested itself some time ago in the testing centre. Tests with quartz powder not only showed processing performance on the highest level; they also revealed that the selected wear protection promises a long service life. The tests were carried out at up to 150°C to ensure suitability for use in the classifier
Pictures: Hosokawa Alpine Hosokawa Pictures: heads of fluidised-bed opposed-jet mills or Existing classifiers can be equipped with ATP-PRO classifying wheels mechanical impact classifier mills operated
12 cpp 03-2017 any additional measures. The actual status of the machines and necessary maintenance can be identified using the Alpine VIB sys- tem. This wireless system measures machine vibration and transfers the results to a tablet computer. www.cpp-net.com Online search: cpp0317hosokawaalpine Hall 4A, Booth 233
Different combinations of construction materials allow high flexibility
AUTHOR: DR. STEFFEN SANDER AFG fluidised-bed opposed-jet mill is oper- Manager Research & Development, ated with hot gas in order to process vari- Technical Division, ous industrial minerals. A ceramic 315 ATP Hosokawa Alpine classifying wheel had been used up to then. As a result of the wear-protected 315 ATP- PRO classifying wheel, the speed was practi- cally halved without compromising the end-product fineness. At the same time, the AUTHOR: smaller pressure drop opened the door for a DOMINIK KNAUER Research & Development, substantial reduction in specific energy con- Technical Division, sumption. It was possible to manufacture Hosokawa Alpine much finer products in this way without The exchangeable vanes reduce wear-in- duced costs and permit higher fineness values thanks to their special geometry
VIBRATION MEASUREMENT: COMPACT AND WIRELESS at elevated temperatures. The results achieved in the testing centre during the Whether used to measure ran- subsequent validation phase convinced two dom samples taken during regu- customers. The ATP-PRO was initially vali- lar control processes or to deter- dated for grinding a rare-earth oxide with a mine specific maintenance Mohs hardness of 5 to 6 using a 400 AFG requirements, the Alpine VIB fluidised-bed opposed-jet mill. The custom- system always gives a clear pic- er concerned had previously relied on a ture of the status of machines standard steel classifying wheel in the and systems. Thanks to this in- The Alpine VIB system always has an eye integrated 200 ATP classifier because the novative measuring system, vi- on the status of machines and systems traditional ceramic designs were unable to bration measurements can be deliver the stipulated fineness values. The carried out flexibly and neces - connection. A WiFi is used for downside was the extremely short service sary maintenance identified at mobile data transmission bet - life of the classifying wheel. The total con- an early stage. The complete ween the sensor and tablet. The tamination with iron compounds in the end package comprises both soft- Alpine VIB software thus visual- product was as much as 100 ppm. During a ware and hardware. Measure- ises and records the measured trial period with the ATP-PRO classifying ments are wireless via a tablet vibration values. The measure- wheel lasting several months, it was possible computer. The machine status ment curves for evaluating to reduce the end particle size by approxi- can thus be individually check- vibration levels are calculated mately 15 % (d90 = 1.0 μm). Over and ed, evaluated and recorded. Da- from raw data and displayed di- above this, the total contamination with mage and system failures are rectly (in accordance with DIN iron compounds in the end product was prevented in this way. Instal- ISO 10816–3). Measurement re- limited to a mere 5 to 6 ppm owing to the lation of the Alpine VIB system ports can be generated in a few new wear protection. is simple and flexible. The bat- simple steps. Graphs document tery-operated sensor can be the minimum and maximum Reduced energy consumption mounted on all machines either values as well as variations over In a further test, the validation was carried magnetically or with a screw time and much more besides. out on a customer’s premises, where a 630
cpp 03-2017 13 cpp SPECIAL POWTECH
Fire prevention concept protects milling processes at cellulose specialist Jelu Forewarned is forearmed!
Wherever inflammable materials are processed in finely distributed form, fire and explosion incidents with serious consequences may result for various reasons. Thanks to spark detection and extinguishing solutions tailored to each customer’s respective needs, it is possible to effectively prevent personal injuries and material damages as well as costly production downtime. Pictures: Grecon Pictures: Highly sensitive Grecon 1/8 spark detectors monitor the Jelu mills in Rosenberg
Cellulose is a versatile raw material which special crushing mills. The processing steps fire or dust explosion. The mill itself is also is used in many industries such as food (for entail many fire hazards. Fine dust, oxygen at risk. If material accumulates, overheat- example for dairy products and pasta), tech- and ignition sources in the form of sparks ing may result. nical (for example as a binding agent for or hot particles are a combination that can mortar and plaster) or animal fodder. easily start a fire. Extensive safety measures Numerous processing steps are necessary to If foreign bodies like stones or nails get This is exactly what happened to Jelu, a manufacture this all-natural product. Puri- into the high-speed crushing mills, flying company in south-west Germany. Founded fied fibre extracts, from which the cellulose sparks are inevitable. Moving system parts in 1908 as a grain mill, this family-run firm is dissolved and sub-sequently milled, are such as fans often ignite sparks due to today manufactures several thousand tons of utilised as raw material. Homogeneous wear. These sparks are transported via the cellulose for a variety of industries. A victim fibres whose size is exactly matched to the suction system of the mill into down- of several fires in the past, it began equip- application are an important quality factor. stream systems, for example a preseparator ping all endangered areas with Grecon spark Uniform wood chips are produced in or a filter system, where they could cause a extinguishing systems more than 35 years
14 cpp 03-2017 ago. All mills as well as transport and suction systems are meanwhile monitored for sparks and hot particles, which are extinguished with fine water mist in case of an alarm. “We protect all areas at risk with spark ex- tinguishing systems”, says Hubert Ehrler (Head of Engineering at Jelu) when asked to explain the safety measures in place.
Tailor made protection concept After the first spark extinguishing system was installed at Jelu back in 1982, the pro- tection concept was continuously expanded over the years. In 2005, all older control stations were modernised with newest-gen- eration spark alarm stations. If a spark or a hot particle is detected, the part of the system concerned is immediately Hubert Ehrler is extremely satisfied: Jelu has reduced the fire hazard significantly thanks switched off and automatic extinguishing to the spark extinguishing systems activated. “The fire hazard has been signifi- cantly reduced. Grecon spark extinguishing systems prevent 99 to 99.5% of all fires in particles in transport lines, Jelu also uses www.cpp-net.com production before they have a chance to DLD 1/8 detectors, which are insensitive to Online search: cpp0317grecon break out”, Ehrler continues. daylight, to monitor systems with incident Hall 4, Booth 201 The mill itself was likewise equipped with daylight. Furthermore, flame detectors an automatic extinguishing system. Even monitor whole areas such as the mill build- when the mill is switched off, it carries on ing remotely. running and stirring up dust for up to a “The investment in Grecon spark extin- minute, presenting a considerable risk in guishing systems has definitely paid off. We combination with oxygen and the ignition are very satisfied with the protection con- source. Following a short check, the mill is cept, which is specifically tailored to our AUTHOR: started up again and production can be re- needs, and in future we also plan to protects DENIS SAUERWALD sumed after only a minimal interruption. other areas like the transport lines to the Marketing, In addition to the highly sensitive FM 1/8 newly built hall using similar systems”, Fagus-GreCon Greten spark detectors for detecting sparks and hot Ehrler concludes.
Pulverize your processing times YSTRAL Conti-TDS Technology: No. 1 in Powder Wetting
Don‘t miss the Live-Demo of YSTRAL Conti-TDS:
Hall 3A, Stand 717
More information at ystral.com/powtech ystral – A Think Tank in Process Technology cpp 03-2017 15 cpp SPECIAL POWTECH
Efficient screw blowers Granulates down to 100 μm
rotor technology used in the ro- In recent years, many manufacturers of technical fine tary screw compressor sector. ceramics have opted for Eirich mixers for their build-up Another key factor is the non- granulation. Whereas, in the past, granulates were pri- slip direct drive with speed marily demanded in sizes ranging from 500 μm to transmission integrated into the several mm, today customer requirements tend towards airend. much finer ranges, down to 100 μm or even finer. For The blowers are exceptionally this reason, Eirich has developed rotor tools with a quiet, with sound levels in pri- special geometry that can be used to manufacture mary applications not exceeding granulates with even finer grain sizes. Even in this fine- 72 dB, which is equivalent to a ness range, the width of the grain spectrum or the grain modern vacuum cleaner. They size distribution can be modified with the aid of par- are designed for use over long ameters like the tool speed, granulating time and granu-
Picture: Kaeser Picture: duty cycles, including continu- lation moisture, and adapted to the particular require- ous operation, require little ments of the relevant application. Like its big brothers, the EBS maintenance, and can be in- In the size recommended for granulating, the Eirich and FBS, the Kaeser DBS screw stalled side by side, or even next mixer used for granulating only has one rotor tool, blower delivers unparalleled ef- to a wall. which can run at tool speeds of up to 30 m/s. This ficiency. The DBS screw blowers www.cpp-net.com makes it possible to generate high shear forces and dis- are significantly more efficient Online search: cpp0317kaeser tribute liquids quickly. The new rotor tools are also than conventional rotary Hall 4, Booth 236 available for laboratory mixers (from 1 l). blowers and also provide sub- www.cpp-net.com stantial energy savings com- Online search: cpp0317eirich pared with many competing ro- Hall 4, Booth 531 tary and turbo blowers. These benefits are made possible in no small part by the proven Sigma
16 cpp 03-2017 Pneumatic actuator for sterile applications
Sisto Armaturen S.A. launches a in a weight-saving aluminium double-acting or single-acting design. pneumatic actuator, which is The actuator can be fitted to the designed for diaphragm valves valve body without nuts as the used in sterile applications. A threads are integrated in the End-of-the-Line-Powder-Mixing special technical feature of the body, significantly facilitating (patented) MD30-MD202 actuator range is mounting. The orientation of KoneSlid®-Mixer that the actuator housing and the air connection can be ad- A symbiosis of excellent hygienic the valve bonnet are made from justed in 90° steps. Accessories and ergonomic design. a single piece of material. Com- such as travel stop, positioner or pared with predecessor models, proximity switches for actual- ✓ Extremely gentle mixing this design change substantially position feedback can be retro- process with short cycle reduces the actuator’s overall fitted by the operator as and times height so that considerably less when required. The actuators ✓ Ideal mixture qualities Additive com- space is required to accommo- can be replaced with manual ac- ponents date block-bodied multi-port tuation bonnets at any time. ✓ Filling levels can vary from valves. The actuators are also Sisto C valves can be operated at 10%- 100%. 45 % lighter than the two-piece pressures as high as 16 bar. design. In addition to the stain- www.cpp-net.com ✓ +LJKÀH[LELOLW\IRUWKHSURGXFWLRQ less steel variant, the two largest Online search: cpp0317sisto of stabilizers, nanoparticle actuator sizes are also available Hall 3, Booth 121 agents, pigments, plant protection chemicals and medicine
✓ Mixer available, if desired, with Fluidized bed several large, hygienically desig- dryer and ned CleverCut® inspection doors cooler
✓ Cleaning: comfortable, safe, ideally ergonomic, wet or dry, manual or automatic Picture: Sisto Armaturen Sisto Picture: ✓ On request with type- examination Ex II 1D (for Zone 20)
XL cutting mill ✓ Optionally, the mixer is manfactured as a pressure- Retsch have added a new model umes, resulting in a higher shock-resistant, to their cutting mill family: the throughput than is possible pressure-resistant SM 400 XL is suitable for pri- with smaller cutting mills. The and vacuum-proof version. mary size reduction of very high torque of the 3 kW drive large sample pieces measuring with flywheel mass allows for ✓ All components of the amixon®- up to 17 cm x 22 cm, but can exceptionally effective primary mixers are made in Germany. also achieve the required final size reduction of soft to medi- The production of the machines takes place exclusively in the fineness in one step, depending um-hard, tough-elastic, and fi- amixon® factory in Paderborn. on the application. The large brous samples as well as hetero- Packaging surface of the bottom sieve geneous material mixes. The SM ✓ Virtually complete discharge in (240 mm x 240 mm) permits 400 XL even processes tempera- a few seconds processing of large sample vol- ture-sensitive samples without too much heat built-up. When operated with the op- tional cyclone-suction-combi- nation the mill is also suitable for grinding light materials or small quantities. www.cpp-net.com
Picture: Retsch Picture: Online search: cpp0317retsch Hall 1, Booth 552 amixon® GmbH Halberstädter Straße 55 33106 Paderborn (Germany) Tel.: +49 (0) 52 51 / 68 88 88-0 Fax: +49 (0) 52 51 / 68 88 88-999 cpp 03-2017 17 [email protected] · www.amixon.com cpp SPECIAL POWTECH
CIP-cleanable paddle mixer
The Dutch company Dinnissen recently introduced the im- proved D-Topline, a model based on the familiar Pegasus double-axle paddle mixer. The geometry of the installation is
modified in such a way that the Dinnissen Pictur: upper sides of the mixing chamber lean towards each to this hatch, a version can be other, resulting in a drop shape. offered where the paddle axle The negative angle of incli- assembly can be driven entirely nation in the upper side of the from the mixing chamber. mixing chamber reduces the Furthermore, the improved risk of product adhesion. In ad- D-Topline is provided with a di- dition, the improved D-Top-line visible shaft seal, allowing the can be equipped with an addi- installation to be CIP-cleanable. tional hatch (front hedge) on www.cpp-net.com the front. This feature makes it Online search: much easier to inspect or clean cpp0317dinnissen the mixer. In some cases, thanks Hall 4, Booth 371
Rotary valve in CIP design Picture: Coperion Picture:
The ZRD 150 hygienic rotary fluence the flow properties of valve is used in pneumatic con- bulk materials and therefore veying systems and for the dis- also the correct design and ENGINEERING charge of powdered and pellet- layout of bulk material hand- ized materials. The EHEDG- ling components. SEPARATORS certified valve can be used in The ZRD hygienic rotary valve FOR DECADES. the food, pharmaceutical and offers an extra-large inlet for chemical industries for appli- high throughputs and is suitable cations demanding even the for pneumatic conveying up to CUSTOMIZING highest degree of hygiene and 1.5 bar(g). The rotary valves are SOLUTIONS cleanliness. In addition, they are smooth-surfaced, free of dead distinguished by their high re- spots, and manufactured com- DAILY. liability in operation. pletely in stainless steel. The As these rotary valves can be fully-automatic CIP capability readily inspected and also saves time on cleaning and SWECO invented the Vibro-Energy® cleaned quickly and thoroughly, therefore reduces costs. Round Separator in 1939. Every year since we have strived to perfect our they are ideal for applications www.cpp-net.com equipment by designing systems to involving frequent changeovers Online search: fit our customers’ exact needs. from one product to another cpp0317coperion Contact SWECO today and let us and/or for processing products Hall 4, Booth 290 engineer an innovative solution for TM with adhesive tendencies. Par- your application. Visit us at Round Separator POWTECH ameters such as particle size, cohesion and adhesion in- 4-260
We put18 technology cpp in03-2017 motion.™ ¨ www.sweco.com ¨ [email protected]
cpp SPECIAL POWTECH
Flexible solutions for coarse grinding
These modules for all three pro- cesses can be exchanged with only one single tool and thus correspondingly quickly. In
Picture: Hosokawa Alpine Hosokawa Picture: addition, the modules are very easy to dismantle and clean – Visit us! Powtech, Nuremberg, Germany there are no threads or screw September 26 - 28, 2017 In many applications, coarse and heads installed in the sections in Hall 1, stand 627 non-uniform feed material is contact with the product. crushed or pelleted in a first Dependent on the grinding pro- step with a primary crusher. The cess, the size of available screens distribution of particle sizes is ranges between 0.3 and 20 mm. dictated thereby by the combi- Especially in the extremely fine nation of rotor speed and screen range, these screens offer appli- size. The multi-purpose crusher cation possibilities that were MPC 150 offers three common barely possible before. As a grinding processes in module function of the mill type, the form that can be fitted onto a peripheral speeds range be- basic unit: tween 1 and 60 m/s. Most • Conical mill for soft to medi- applications are operated in the um-hard materials range between 1 and 20 m/s. • Flake crusher for brittle www.cpp-net.com materials that crush easily Online search: • Hammer mill for solid materi- cpp0317hosokawa als that are difficult to crush Hall 4A, Booth 233
Small inverting filter centrifuge SOME THINK With the HF 300.1 Heinkel is presenting the smallest inverting filter centrifuge in the HF series at Powtech 2017. With a basket diameter of 300 mm and a nominal A MARGIN capacity of 6.5 l, it is particularly suitable for scale-ups and small production units particularly when the prod- OF ERROR IS ucts are difficult to filter. This is ensured by the gentle process which guarantees there is no heel left after fil- tering as well as optional thin layer filtration. The her- ACCEPTABLE. metically sealed design and fully automatic, uninter- rupted operation offer maximum contamination protec- tion for users, the environment and the product. WE THINK www.cpp-net.com Online search: cpp0317heinkel Hall 4A, Booth 128 DIFFERENT.
The BEUMER fi llpac® R is a fi lling system with a diff erence. Using revolutionary microprocessor-based weighing electronics with vertical fi lling impellers and the bag discharge system including a check weigher, it delivers entirely new standards of precision and performance: automatic optimisation; 300-6,000 bags per hour;
Picture: Heinkel Picture: individual bag tracking and latest PMS generation; we know what it takes to streamline your end-of-line productivity. For next generation packaging solutions that make a diff erence, visit www.beumergroup.com
cpp 03-2017 21 cpp SPECIAL POWTECH
Tablet coater for the laboratory
The LC Lab laboratory coater is of modular design and can be equipped with the individual modules needed for the coating process or specific application. The en- gineers oriented the design of the coater fully to the requirements in the laboratory – starting with the choice of material for the housing. The latter is made of Corian. The FDA-compliant composite material with outstanding hygienic properties offers a whole series of advantages, particularly in the laboratory. It is easy to clean, resistant to solvents as well as impact-, scratch- and wear-proof and permits a joint-free finish. Seams that are problematic from a hygienic point of view were thus avoided from the outset in the LC Lab. Simplicity of handling has been consistently pursued with the LC Lab. For instance, the utilisable volume of the entire drum can be halved with ease while retaining the drum geometry. The nozzle arm was adapted to laboratory needs in co- operation with the experts of Düsen-Schlick. Two stan- dard high-performance nano nozzles are used. www.cpp-net.com Online search: cpp0317lödige Hall 1, Booth 517
Production of high performance materials Picture: Glatt Picture:
All over the world, the require- with different application-spe- ments placed on the structures, cific dopings and complex stoi- surface characteristics and com- chiometry can be realised. With positions of powder materials APPtec, high performance ma- are rising. With the Advanced terials can be efficiently pro- Pulse Powder technology duced, dried, calcinated and APPtec, a novel spray calcination coated with functional layers in process, Glatt will present at just one process step and with Powtech a technology that can reproducible quality – even create and configure primary with mixed oxide systems and particles in almost unlimited in small batches – free from ways in a hot gas reactor. For in- lumps or hardened particles. stance, special pigments with www.cpp-net.com innovative functionalities, Online search: cpp0317glatt chemically highly homogenous Hall 3, Booth 418 catalysers and optoceramics
22 cpp 03-2017 Clean filling of powder into PE bags SEPTEMBER 25 – 29, 2017 DÜSSELDORF HALL 13, 13E67
MULTILINE E – THE NEW CONNECTION DIVERSITY
LOCKING LEVER FOR OPTIMIZED MANUAL FORCE Picture: Haver & Boecker Haver Picture:
Adams stands for the filling of nology always provide dust-free powder-type products into PE surroundings along the entire packaging made of FFS film. value-adding chain and allow a Here the bag is formed inside clean and attractive product the filling machine from a pre- presentation. The cleanliness of made PE tubular film. The prod- the filling process is striking,
uct makes its way through the and as a result there is far less M12-ROUND CONNECTOR: dosing and weighing systems – wear and tear to packing sys- THE FORMAT FOR ALL SIGNALS which are matched to the prod- tems and downstream equip- uct – and is then packed into ment. The material costs for The modular kit system for multiple connectors for fl exible supply of compressed air, vacuum, gases, the bags as they are formed and maintenance and repairs fall, liquids, electrics and electronics. welded shut in the packing ma- and machine downtime is re- chine. The heart of the Adams duced. The result is improved EISELE.EU technology is its compaction capacity utilisation and reduced system which makes it possible operating costs. to pack even the finest powder www.cpp-net.com with FFS technology. Online search: cpp0317haver COME AND SEE US AT POWTECH Bags filled by the Adams tech- Hall 1, Booth 535 SEPT 26 – 28, 2017 HALL 4A, STAND 431
Packaging line on the mobile device
Under the banner of Industry 4.0 Beumer Group has developed the Beumer Overall Operation Monitoring app, an application with which the customer‘s em- ployees have all relevant indices of their packaging line displayed on their mobile devices at any time. The application shows the status quo of availability, per- formance and quality levels as well as the energy and compressed-air consumption. This ensures efficient operation of all systems. The program can be adapted to customer-specific requirements. www.cpp-net.com CAN DO! Online search: cpp0317beumer Hall 1, Booth 627 Every pipework system is unique, like a work of art. Our service is just the same, tailored exactly to your needs. With us, individual consultation is a given. And our inexhaustible range of standard and special parts ensures that your project will be realized. Really amazing, what we can do!
www.jacob-pipesystems.com NO. 1 IN PIPEWORK SYSTEMS Picture: Beumer Picture:
cpp 03-2017 23 cpp SPECIAL POWTECH
Blower series with 104 model variants
Thanks to 104 model variants, application and installation site. the Alpha Blower series provides The Alpha Blower are reducing a high degree of flexibility for pipe sound emissions: In case of numerious customer appli- three-lobe blowers, the proven cations. Aerzen large blowers are technology of interference positive displacement blowers. channels for pulsation attenu- They reach volume flows of up ation is still used, whereby the to 77,000 m3/h at a maximum outlet contour of the two-lobe overpressure of 1000 mbar and version is designed completely a maximum negative pressure of new. By the use of the multi- -800 mbar. Customers can select flow principle for reducing air from a range of two and three- turbulences via an integrated lobe rotors, as well as horizontal soft inlet, which reduces pul- and vertical conveying direc- sations, the pipe sound can be tions, depending on the field of significantly decreased. Thanks to the Airsilence technology, even downstream silencers can be of smaller dimensions now. www.cpp-net.com Online search: cpp0317aerzen Hall 4, Booth 271 Picture: Aerzen Picture:
Radar sensor for bulk solids
The level transmitter Vegapuls With a measuring range of up 69 operates at a frequency of to 120 m and an accuracy of 80 GHz, which allows a con- ±5 mm, the sensor has suffi- siderably better focusing of the cient performance capability transmitted signal. New micro- even for the out of the ordinary wave components allow the tasks, such as level gauging in sensor to detect even the smal- mine shafts or distance lest reflected signals. Even prod- measurement on conveyor sys- ucts, which until recently were tems. Completely unaffected by very difficult to measure be- dirt and build-up, the lens an- cause of their poor reflective tenna guarantees maintenance- properties (such as plastic free operation even in harsh en- powders or wood chips), can vironments. now be measured with very www.cpp-net.com high reliability. This consider- Online search: cpp0317vega ably extends the application Hall 4, Booth 514 range for radar technology in the bulk solids industry and opens up new application areas as well. Picture: Vega Picture:
24 cpp 03-2017 Paddle dryer with eccentric agitator
tional dryers with a concentric agitator. This means a threefold reduction in mechanical and thermal stresses on the batch being dried. As a result, even the most delicate and temperature- sensitive products are treated
Picture: Italvacuum Picture: with maximum care. The system is available with total volumes ranging from 150 Planex System from Italvacuum to 3200 l. Maximum loading ca- is a horizontal paddle vacuum pacity depends on the product dryer with eccentric agitator to be processed, and can vary featuring two independent from 15 to 80 % of the chamber movements, allowing it to sim- volume. ultaneously revolve around its Planex System is designed and own axis and to rotate tangen- manufactured in compliance tially to the drying chamber. with European Union Atex Di- Designed to dry wet feed from rectives and CE marking filtration and centrifuging pro- requirements, as well as with cesses Planex System is ideal for the increasingly stringent US the production of active phar- FDA standards and cGMP Cur- maceutical ingredients, fine rent Good Manufacturing Prac- chemicals and intermediates. tice Regulations. The combined rotations of the www.cpp-net.com agitator and its small size com- Online search: pared to the drying chamber di- cpp0317italvacuum ameter, ensures the perfect mix- Hall 3A, Booth 510 ing of the entire batch, and allows consuming at least three SEAL TECHNOLOGY times less energy than conven- ! & &$+" ƐѶѵƕ
Simultaneous calcination of zeolithes "$"!Ĺ The horizon is our finish line. Rotary tube furnaces are used for quick and easy production of laboratory-scale samples with excellent homogeneity for R&D and quality control. Carbolite Gero’s HTR 11/75 and HTR 11/150 furnaces allow for calci- nations, pyrolysis or reactive gas treatment of a great variety of
powders and granulates with Carbolite Gero Picture: YEARS volumes up to 50 or 700 cm3 respectively. The speed of the os- cillating reactor can be freely se- lected in a range from 1 to of zeolithe samples. This process 8 min-1. The sample is constantly is an important part of quality mixed and homogenised at a control and can now be realised temperature of up to 1100 °C. quickly and cost-effectively dur- For a chemical company a fur- ing production so that possible
nace was developed that accom- rejects are immediately detected. We are proud and grateful for the success of our family business: modated 4 HTR 11/75 rotary www.cpp-net.com mѴƏĺƒՓѷo=;ul-m1olr-mb;vl-h;b||oƐƔƏĺm7;-u;;;mlou;;1b|;7 reactor tube furnaces arranged Online search: =ou|_;1olbm];-uv-v|_;Ѵ;-7bm]vrrѴb;uo=ru;1bvbomv;-ѴvĺmouƐƔƐv|;-uķ ;om1;-]-bm_-;ouvb]_|vv;|om|_;_oubomķ-Ѵ-vom|_;Ѵooho|=oum; in a very small space to simulta- cpp0317carbolite voѴঞomvŋ=ouo-m7=ou|_;=|u;ĺ
neously calcinate a large number Hall 1, Booth 552 Hand in hand with you of course!
cppwww.COG.de/en 03-2017 25 cpp SPECIAL POWTECH
Mixing powders into liquids Clean, dust-free and no agglomerates
You could be forgiven for thinking that mixing powders into liquids is easy: switch on the stirrer, wait for a vortex to form and add powder. It isn’t difficult but it leaves a lot to be desired all the same. Considerable amounts of dust are produced, large agglomerates develop in the liquid and there are wet powder crusts on the wall of the vessel. The Ystral Conti-TDS proves that it doesn’t have to be this way.
Nearly all powders are mixed into a liquid no partially wetted crusts or baking inside • External vacuum disperser installed in a when they are processed. Instead of dosing the vessel, which could sooner or later pipe them onto the surface of the liquid, it is far crumble into the product or cause powder to Vacuum vessels are the most complex alter- more effective to induct them into the liquid be carried over into the next batch. native and by far the most expensive. The directly. No dust is produced in this way. No Induction takes place under vacuum. There vessel must be completely vacuum-proof. dust extraction system or filter is needed. are basically three possible options for this An external vacuum pump produces the in- There is no product loss. The entire powder process: duction vacuum by exhausting air from the is mixed into the liquid. And because there is • Vacuum vessel headspace above the liquid. The powder is no dust hovering over the liquid, there are • Induction mixer installed in the vessel added via a nozzle below the liquid level. The powder jet is thus inducted directly into the liquid underneath the surface. This The TDS induction method is not suitable for powders which mixer requires neither a are difficult to wet: these are inducted dry vacuum pump nor a vacuum-proof vessel through the liquid and into the vacuum pump. Coarse, crystalline or agglomerated powders are likewise critical because their loose structure means that air is sucked in and the vacuum in the vessel is reduced. Components of the liquid which are volatile under vacuum, too, are exhausted by the vacuum pump in an uncontrolled way. TDS induction mixers are the cheapest op- tion by a long way. For one thing, they mix the vessel contents more effectively and more homogeneously than an ordinary stirrer because they circulate it vertically rather than rotating it horizontally. For an- other, the vacuum which is necessary to in- duct the powder is produced by the mixing head itself according to the Venturi prin- ciple. No vacuum vessel and no vacuum pump are needed for this reason; the mixers can be operated in a simple, open vessel or attached to a movable lift in drums or con- tainers. The powder is always inducted di- rectly in the mixing head and is mixed there intensively. Unfortunately, though, there are also limits
Pictures: Ystral Ystral Pictures: to what a TDS induction mixer can do. The
26 cpp 03-2017 filling level in the vessel must be high The Conti-TDS dispersing enough to cover the mixing head properly. machine is installed outside the vessel High-viscosity or very sticky powders im- pose further limitations. The powder is mixed in thoroughly but without being dis- persed satisfactorily. The maximum length of the machine is restricted as well. Large vessels with a capacity exceeding about 4 m3 and significant variations in the level cannot be realised. The only machine that can process any powder type, viscosity, vessel geometry or filling level, and which does not simply in- duct the powder but disperses it thoroughly into the liquid, is the Conti-TDS – a dispers- ing machine which is installed outside the vessel and which produces a very strong vacuum in its dispersing zone, thus facilitat- ing a high powder induction rate.
Flexible in use The Conti-TDS can be installed in a loop liquid. The powder has been fully processed. One property of air is that it is compressed with just a single vessel or in combination Whereas the processing time used to be sev- under pressure but expands to a multiple of with several vessels. In the food industry the eral hours, it is now virtually zero. its normal volume under vacuum. The vac- machine is often located in a totally separate uum which is produced by a Conti-TDS de- powder chamber and connected via pipes Principle of the Conti-TDS pends on the vapour pressure of the liquid. and valves to numerous other process A Conti-TDS machine inducts the powder In the case of water, the Conti-TDS achieves a vessels of all sizes, possibly a considerable into its dispersing zone under vacuum. Vac- maximum vacuum of 30 mbar abs, corre- distance away. One or two machines thus uum has the effect of separating the powder sponding to a ratio of 1:33 in relation to at- suffice to meet the company’s total powder particles. To understand this effect, it is im- mospheric pressure. The vacuum in other induction needs. portant to know that every powder contains liquids can be even higher. In-line powder induction while filling the air. Although the particles are in contact with When powder is inducted into water, in process vessel is another interesting alter- one another, there is always air between other words, the air contained in it can ex- native. In the production of cleaning agents them. Heavy powders are composed of up to pand to as much as 33 times its initial vol- or cosmetics, for instance, the complete 75 % air by volume; the figure for light ume. The distances between the individual process – from powder induction through powders can be more than 95 %. The exact particles increase dramatically. It is possible, dispersion to homogenising – is over as air content can be determined by calculating for example, for every single particle to be soon as the vessel has been filled with the the ratio of bulk to solid density. completely wetted from the outside within
26.09. - 28.09.2017 Hall 3A; Booth 406 your competent partner for solids handling!
XMechanical / pneumatic conveying XProcessing screws XFilling / emptying XBig Bag handling XFeeding / dosing XMixing / breaking up XDust extraction systems XWeighing / controlling / regulating
EMDE Industrie-Technik GmbH ƒ D-56377 Nassau +49 (0) 26 04 - 97 03 - 0 ƒ www.emde.de ƒ [email protected]
cpp 03-2017 27 cpp SPECIAL POWTECH
Agglomerate break-up under vacuum and simultaneous dispersion
Very large agglomerates only break up after passing through a second time
the dispersing zone, in which the liquid and outside the agglomerates but also inside usually sufficient to achieve complete de- the powder come into contact with one an- them. The agglomerates are so solid that agglomeration. Occasionally, though, the other due to turbulence and shear energy. they keep their shape nevertheless and do agglomerates are so large or so stubborn Some powders, however, do not only consist not break up. Only the air on the inside is that they only break up fully after passing of individual primary particles; they also expanded, most of which escapes. through a second time. A few residual ag- form compact, solid agglomerates. The finer, The contact with the liquid takes place in glomerates survive. In this case, the disper- wetter and more cohesive the powder, the the dispersing zone under maximum vac- sion process continues. stronger the tendency to agglomerate. There uum. The agglomerates are completely The residual agglomerates are inducted into are more than twenty reasons why agglomer- wetted from the outside as a result of inten- the vacuum dispersing zone again in the ates may form: adhesive and cohesive forces, sive dispersion. The air which has already loop, this time already completely enclosed moisture and sinter bridges, temperatures escaped due to expansion is separated from by liquid. There is also a dry zone contain- below the dew point or simply temperature the agglomerates, which remain dry on the ing a small amount of air on the inside. The changes during storage as well as compres- inside – after all, they are filled with air. air expands again under vacuum. As a result sion under conditions of vibration, to name However, the gaps between the individual of the high shear energy under vacuum, ex- but a few. This property is exploited with cer- particles now contain air which has in- cess air is separated and the remaining ag- tain powders, amongst other things, in order creased in volume several times over. glomerates are completely wetted on the to prevent hazardous dust. Immediately after passing through the vac- outside. The dispersion is immediately All agglomerates have air between their pri- uum dispersing zone, the powder-liquid dis- pushed in again under maximum pressure. mary particles. However, solid agglomerates persion is pushed into the outer centrifugal The residual agglomerates then break up do not break up so easily under vacuum: it area of the machine under maximum pres- too, similar to an implosion. Even strongly takes rather more than that. sure. The abrupt change from maximum vac- agglomerated powders are completely dis- uum to maximum pressure inside the ag- persed in this way. Eight steps to break up agglomerates glomerates causes the air which has just ex- www.cpp-net.com The break-up of agglomerates under vac- panded to not simply contract but be com- Online search: cpp0317ystral uum and simultaneous high-shear mixing pressed to a much smaller volume. The air Hall 3A, Booth 717 in a liquid is completed in between four which previously expanded to 33 times its and eight steps. In the first step, the dry, normal volume inside the agglomerates now solid agglomerates are sucked towards the contracts to a fraction of that volume under dispersing zone by the vacuum. In the pro- pressure, similar to an implosion, and sucks AUTHOR: cess, the vacuum increases from atmos- the entire enclosing liquid into the agglom- DR. HANS-JOACHIM pheric pressure at the inlet of the induction erates. This effect causes the agglomerates to JACOB Process- and Application system to its maximum value on reaching break up into primary particles. The high Engineering, the dispersing zone. The stronger the vac- shear energy supports de-agglomeration. Ystral uum, the more the air expands – not only A single passage through the Conti-TDS is
28 cpp 03-2017 Bead mill produces nanoparticles The future is nano
Known substances that are milled into nanoparticles take on new properties. Active ingredients increase their potency, thus allowing better drug formulation and dos age for a more targeted fight against diseases. The nanoparticles can be prepared on the Nanowitt-Lab from Frewitt.
Nanotechnology refers to the production, ling quantities ranging from a few milli- tions, the DS supports direct in-line sam- analysis and application of structures that grams to up to 1.5 kg. The specified range pling and integration of an in-line particle are at least one dimension smaller than depends on the solids content. size measurement. 100 nm. The particles are 1000 times This compact lab device is easy to integrate The Nanowitt’s cGMP design furthermore thinner than the diameter of a human hair. and – thanks to its intuitive control system offers user-friendly operation and easy bead The use of nanotechnology is not only in- – can be set up and made ready to work in a handling combined with high product re- creasing for surface treatment but is also de- very short time. The patented Nanowitt de- covery. livering impressive results in the medical sign unites short milling times with low industry. Frewitt has tackled the nano chal- specific energy, resulting in gentle product Modifications with a flick of the wrist lenge with the development of a bead mill, processing, no hot spots, only minimal Frewitt has retained its proven modular sys- known as the Nanowitt. This device for drug product contamination and tight particle tem for changing the milling head on the development and formulation is further de- size distribution. The unique dynamic sepa - Fredrive-Lab platform. With just a single tri- tailed in the following. The Nanowitt-Lab rator (DS) with no filter prevents clogging clamp, the particularly lightweight nano allows materials to be wet-milled down to a and hectic operation, which are continual milling head is readily interchangeable and particle size of 50 nm. The milling problems with other technologies. In addi- integrates conveniently into a rigid or flex- chamber’s modular design is ideal for mil- tion to providing stable processing condi- ible isolator. After removal, the milling head can be cleaned quickly and easily. The Nanowitt-Lab is designed to mill all types of powders, achieving a homogeneous product whose particle size can be measured with a real-time PAT solution if desired. Batch or semi-batch processing and simplified filling/emptying round off the technical features of this new bead mill for nanoparticles. www.cpp-net.com Online search: cpp0317frewitt Hall 1, Booth 343 Pictures: Frewitt Pictures:
AUTHOR: CHRISTIAN RHÊME Senior Project Manager – Nanotech, Frewitt
The Nanowitt bead mill produces nanoparticles with a size of 50 to 500 nm
cpp 03-2017 29 cpp SPECIAL POWTECH
Emission-free powder transport and complete drum emptying Stainless steel components from one source
Especially with highly active substances and chemicals, safe transport within an operation is of great importance. Moreover, cross contamination and product loss have to be avoided. Stainless steel components for powder handling from Bolz Intec ensure safety in production.
The emission-free powder transport sys- range from 2 to 220 l, depending on the tablet presses, for example. The container tem (EPTS) from Bolz Intec was designed diameter. Various adapter elements can be can be filled and emptied in a protected at- for sealed transport of small quantities of mounted on the loading side, such as mosphere (glove box) or vacuum. solids (powders and granules) under sterile funnels or adapter parts which can be ren- conditions. This system consists of a cen- dered inert and sterilised. This also applies Emission-free powder transport trifugally optimised central container to the outlet. The high quality of the sur- A funnel for filling and/or a CIP chamber equipped with flap valves on the loading face, with Ra < 0.25 μm on all process-side for cleaning the entire system can be at- and emptying sides as well as a modular set surfaces, is very important for efficient and tached to the valve on the upper part of the of attachments and sealing parts (tri- optimal emptying. The system is thus adapt- container, while the flap valve at the outlet clamp). The active substance volume can able for use with reactors, batch tanks or of the EPTS has a connection for the reactor to be filled. When filling, the CIP chamber is completely removed in order to attach the funnel. The filling funnel is flanged onto the upper part of the EPTS and the medium (powder) is added using a vacuum/suction process. The flap valve is then closed and the CIP chamber remounted, so that the EPTS can head to the reactor, where it is docked and the powder is added to the process by creating a vacuum in the reactor. If neces - sary, the trolley can be raised to line up with the reactor. The EPTS clean-in-place system ensures 100 % emptying and cleaning of the entire system without emissions. Inte- grated spray heads and rotating nozzles can be used for CIP cleaning or to ensure opti- mal emptying of process fluids in a closed system. The EPTS is optionally available with Hastelloy or Halar coatings. Besides silicone, other seal materials are also available, such as EPDM or PTFE (FDA compliant).
Residue-free drum emptying When emptying containers, there is the problem of residues which are left behind. To handle this problem, a funnel with a flap valve is usually placed on the rigging of a
Pictures: Bolz-Intec Pictures: stainless steel drum secured with a tension- The EPTS (Emission-free Powder Transport System) is adaptable for use ing ring and turned over so that the drum with reactors, batch tanks or tablet presses can be emptied. However, experience has
30 cpp 03-2017 shown that residual quantities still remain 315, 375, 400, 450, 500 or 560 mm. The on the funnel neck as well as on the rigging. surface is available in bright-milled, This can be attributed to dead spaces in the polished or electro-polished. The roughness design which trap residual powdered or vis- depth is between 0.8 and 1.2 μm by default, cous media during emptying, wasting valu- though other roughness depths as low as able products and posing a high risk of both 0.3 μm are possible on request. The trans- internal and external contamination. In ad- port and emptying system can be delivered dition to product loss, this also significantly in the following materials: 1.4301, 1.4404, increases the cleaning effort required to 1.4435, 1.4539, or Hastelloy C22 2.4602. meet GMP and FDA regulations. Product The silicone round-snap seals with FDA ap- residues are therefore a risk in terms of proval, USP Class 6 and BSE/TSE approval safety and can also hurt the bottom line. ensure a secure, airtight closure. Sealing ma- Bolz Intec has developed a practical, multi- terials such as EPDM or Viton are addition- functional emptying system for drums ex- ally available. The Sole Valve is used to con- plicitly for use in hygiene-sensitive areas, trol and steer the flow. This valve permits which optimises the dead space between continuous feeding of granules and the emptying cone and the drum. The powders without material stoppage, as well specially designed funnel with a flap in as even dosage during the feeding of pro- various systems is fixed simply and securely cessing machines. to the drum with a clamping ring and a seal. Users can then resort to their normal GMP-compliant lidded drums technology for emptying. To achieve an un- GMP-compliant lidded drums, which are With the multi-functional emptying system obstructed product flow, the part of the offered with volumes from 0.5 to 300 l as for drums the part of the funnel coming into contact with the product extends into funnel coming into contact with the prod- well as in different diameters, are well the drum uct extends into the drum, whereas pre- suited for storing hygiene-sensitive prod- viously contact was on the funnel itself. The ucts in the pharmaceutical industry. They are funnel is mounted on the drum not unlike a dull WIG welded with welding filler mate- lid, thus allowing the drum to be com- rial and without gaps. The seams are rolled pletely emptied. A cap with seal is used flat and finely polished inside and out. They during transport and to protect the product. are moreover easy to clean and absolutely The drum can be supplied with different residue-free and exhibit high stability even bottoms. Tri-clamp connectors can be at maximum load. The surfaces are polished welded in the version with a dished bottom or electro-polished for optimum product and foot ring. These are suitable for blasting output with <0.25 μm roughness. The reus- the container with nitrogen during the able clamping ring cover with insertable emptying process (air shock) as well as for round cord seal in materials such as sili- adding further product components or cone, EPDM or Viton permits simple, air- using measurement technologies. A CIP tight sealing along with the FEP-coated seals lance can also be easily installed either to with FDA approval. Drums in Hastelloy C 22 are offered for ex- capture the process liquid for reuse during In addition to industry-standard materials treme conditions rinsing or to reuse the drum once emptied. such as 1.4301/AISI 304 and 1.4404/AISI A stirrer is likewise possible to gently mix 316L, drums for extreme conditions are the product during emptying in order to also offered in Hastelloy C 22. Due to and loss-free. The broad range of Bolz Intec prevent bridging. increasing demand for Hastelloy C 22, Bolz- funnels extends from asymmetrical and Intec has now decided to put this drum into symmetrical designs to conical drums. Simple drum handling mass production. Hastelloy C 22 is very re- Openings with inside diameters as small as The emptying system can be transported by sistant to chloride ions, iodine and bromine 40 mm can be made from one piece. Both means of a drum carriage, drum roll, drum as well as to acids like sulphuric, phospho - the angle and the surface are freely selec - lifter or other transport device. For safety rous or nitric. table as bright-milled/2B, polished or elec- reasons, the system has been reinforced tro-polished. The material thickness is with a footrest and a rail to protect the con- Single-use or dedicated application 1.5 mm. 60° and 90° angles are standard in tainer when used in unprotected production Thin-walled stainless steel such as 1.4301 is conical funnels, though funnels can also be processes. Correct handling can prevent used for the best-cost stainless steel drum made according to specific customer damage to the drum and the tension for single-use applications, with a diameter requirements. closure. Another advantage is that since the of 450 or 560 mm and a volume of 100 or www.cpp-net.com footrest and the rail are also utilised as 200 l. The drum provides very high quality, Online search: cpp0317bolzintec handles, protection and a transport aid, they stability and breaking strength. It is priced Hall 1, Booth 148 facilitate the emptying process. The drum about one-third lower than the standard seal is tightly welded and very stable to stainless steel drums. prevent contamination. The system can be When emptying the drums, stainless steel supplied in various sizes with a diameter of funnels make the whole process dust-free
cpp 03-2017 31 cpp SPECIAL POWTECH
Filling systems for hazardous areas Tough performers
The semi-automatic FSL-PRO S filling system from Bizerba manufactures flammable, corrosive, foaming or highly viscous liquids without any problems. This flexible all-round system ensures to-the-gramme filling and weighing accuracy as well as gentle dispensing in hazardous areas.
The filling operation at the end of a pro- either gravimetrically from elevated tanks or valve must instead be positioned above the duction line can be performed by a semi- or by pumps. container. Apart from potential time savings, fully automatic system. The only difference Semiautomatic systems are often the most this also eliminates the hard labour required between them has to do with container economical solution for small batches. The for palletising heavy containers. handling. In semiautomatic systems, con- container is first of all placed manually on a tainers are manually fed and positioned in weighing platform. A movable filling valve Safe even in hazardous areas the filling station, while the filling process then allows the filling nozzle to be lowered In sensitive areas such as the chemical or itself is done automatically. In fully auto- into the container. A more sophisticated so - paint industry, particularly tough systems matic facilities, on the other hand, the con- lution is required for containers that must are vital because flammable, poisonous and tainers are automatically conveyed from a be filled and weighed while standing on a corrosive substances are quite common in magazine to a separation unit and the filling palet. In contrast to single-container filling this kind of environment. All components of station before being transported onward. stations, where the containers must be posi- a filling system should be designed for The product itself can be fed to the facility tioned underneath the filling valve, the highly sensitive products and hazardous areas. To offer maximum protection, the en- tire filling process can also take place within a protective enclosure. This highly safe ap- proach additionally lends itself to appli- cations with high hygiene requirements, including the pharmaceutical and food sectors. The semiautomatic FSL-PRO S filling system ensures appropriate filling and weighing even of goods with difficult processing characteristics (e. g. flammable, corrosive or foaming substances). Amongst other things, it can be used for highly sensitive liquids in the paint and varnish, chemical, petro- chemical, construction material, pharma- ceutical and food industries. As a flexible all-round system, it ensures to-the-gramme filling and weighing accuracy as well as gentle dispensing in hazardous areas (Ex zones 1 and 2). It is also in conformity with Atex guidelines. Products can be filled into different containers. The use of multiple valves enables fast product and container changeovers without any risk of cross-con- tamination, thereby providing maximum flexibility and reducing downtime. www.cpp-net.com
Picture: Bizerba Picture: Online search: cpp0317bizerba The semiautomatic FSL-PRO S filling system ensures to-the-gramme filling and Hall 3, Booth 531 weighing accuracy as well as gentle dispensing in hazardous areas
32 cpp 03-2017 Dosing and shut-off valve with pneumatic sealing element Ideal for use in Atex areas
The DKZ 103 APS and DKZ 110 APS rotary valves are based on the continuously optimised butterfly valves in the centric APS series from Warex. The shut-off func- tion involves the sealing element being pneumatically pressed against the valve disc. This technology offers several advantages.
The APS (Air Pressure Sealing) system en- BVS 03 Atex H024 X N6 type examination. (pneumatically operated) 180° pendulum- sures that in the closed position, the entire Another application for this rotary valve is in type drives, which always provide half the circumference of the seal is uniformly in- vacuum transport systems. Depending on the capacity of one full revolution of the rotor, flated to adapt to the full circumference of thickness of the material being transported, and electric drives. Electric drives enable the the disc. This technique provides a number the piping is either partly or, in the case of rotor revolutions to be set precisely to match of advantages in terms of both pressure- free-flowing products, completely filled. The the dose rate. Thanks to the low installation tight shut-off and low-friction, material- rotor delivers uniform portions right up to a height and compact design, this rotary valve friendly operation. Several different versions full flow in the 22° position. The chemical can also be incorporated into existing sys- (diameter, speed, density of medium) are and pharmaceutical industries as well as food tems in a space-saving way, so that refitting available. The customer benefits from a processing are just a few of the many poten- or upgrading becomes an attractive option. product that is optimally designed for the tial uses. The intelligent design of the rotary www.cpp-net.com task at hand thanks to specific feature op- valve allows various relatively small, and Online search: cpp0317warex tions relating to the material and drive type. therefore energy efficient, drives to be Hall 4, Booth 391 Depending on the sealing material which is mounted. A distinction is made between selected, the application temperature range extends from -40 to +200 °C. If the medi- um being transported is expected to reach a temperature of 130 °C or more, for example plastic granules or products and raw materi- als in the food sector, silicone seals are used. Rotary solutions with metallic sealing can be supplied for even higher temperatures. Although pressure tightness cannot be en- sured here, most granules are unable to pass through due to the small gap size.
Wide range of applications Wear occurs both at the rotor and in the interior of the butterfly valve seal, es- pecially with abrasive media. Soft-sealing rotary valves are thus a reliable choice in this area because abrasion is partly com- pensated by the inflatable seal. In fact, ma- terial loss is fully compensated up to a cer- tain degree of wear because the highly adaptable cuff still provides reliable sealing. The maintenance and repair intervals are significantly longer than with conventional methods, ensuring greater economy. A further advantage is that the seals are normally interchangeable. The DKZ Warex rotary valves with an 103/110 APS rotary valve is ideal for use inflatable seal are based on in hazardous areas in accordance with the Valves Warex Picture: the APS centric butterfly valve
cpp 03-2017 33 cpp PLANTS, APPARATUS, COMPONENTS Pictures: Dyneon Pictures: 3M has developed a technology for manufacturing PTFE parts without tools on a conventional 3D printer
Additive manufacturing with fully fluorinated polymers PTFE parts from the 3D printer
At its Burgkirchen site Dyneon is evaluating the use of PTFE formulations on a 3D laboratory printer and the properties of the moulded parts manu- factured with it. The objective of the tests is to bring the new additive manufacturing process to the production stage, i.e. making lot sizes as small as one item economically viable.
Whether for aerospace components, lots. Optimised production processes in- Limits of conventional manufacturing prototypes in automotive manufacturing or volve very high start-up costs for tools and These conventional manufacturing processes chemical engineering, conventional indus- require complex steps to be programmed. require a lead time, for example for order- trial manufacturing processes come up These costs are recovered very quickly, how- ing tools and programming the machining against their limits wherever small compo- ever, owing to the scale effects which result operations. Furthermore, design engineers nent lots contributing high value are con- from the manufacture of hundreds of thou- are obliged to ensure that components can cerned. In situations like this, 3D printing sands or even millions of the same compo- be manufactured using conventional enables considerable cost savings as well as nent. The most common processes are ther- methods. More complex components with new design options. In future, 3M will be mal ones in which metals or plastics are several functions therefore generally consist offering precisely that for fully fluorinated fluidised and cast in prefabricated moulds. of various individual parts that must be as- polymers such as polytetrafluorethylene They are often subtractively machined after- sembled afterwards. This in turn creates (PTFE). wards. Special tools such as drills or milling sealing points. The industry has been striving for years to heads remove material until the desired ge- Non-melt-processable materials necessitate manufacture components in ever bigger ometries are achieved. subtractive machining from blanks. This
34 cpp 03-2017 produces considerable quantities of unus- able production waste – which is very un- economical when expensive materials are a must. A further disadvantage is that moulded PTFE parts manufactured in the conventional way are almost always solid, thereby increasing the component weight. This is detrimental for aerospace or auto- motive engineering, where every additional gram counts.
Small lot sizes In contrast to established large-scale manu- facturing, the trend in Industry 4.0 is mov- ing towards economical production of very small lots. Additive manufacturing is an im- portant link in a digital engineering chain. In future, it will be possible to manufacture lightweight, ready-to-install, multifunc- tional moulded parts from CAD data in a single step, avoiding tool costs and long lead times. In additive manufacturing without tools, the parts are printed in 3D. Based on digital Moulded parts up to 35 x 30 x 55 mm in size can design data, each component is built up be produced with the 3D layer by layer through the deposition of laboratory printer material. Unlike in the private sector, addi- tive manufacturing processes are already widely accepted in numerous industrial ucts. However, it has not been possible to tually universal chemical resistance as their applications. The first factory to use exclu - process PTFE using conventional additive conventional counterparts. sively additive processes opened this year in processes in the past. 3M has now devel- PTFE processing by means of additive Germany. Serial parts are already being oped a technology for manufacturing PTFE manufacturing opens up new options for printed for aerospace engines, while the parts without tools on a conventional 3D fast and inexpensive production of very automotive industry is shortening the devel- printer. Out of the various processes investi- small series or even one-offs. Manufacturers opment times for prototypes with the help gated, it was stereolithography that proved can thus design complex shapes, reduce of 3D printing technology. to be most promising for processing PTFE. weights and advance the integration of In the process developed by 3M the fully functions, to name but a few of the benefits. PTFE for extreme requirements fluorinated polymer (in this case PTFE) is Above all else, manufacturers and users will In view of the above, this manufacturing printed with the aid of a binding agent to in future save time because they will be able process is highly attractive for the family of form a so-called hydrogel. The binding to print moulded parts directly from the fully fluorinated polymers such as PTFE, agent is photosensitive, hardens under UV CAD data, for example in order to manufac- which are almost universally chemically re- radiation and is thermally removed after ture PTFE prototypes or spare parts. sistant. Their operating temperature range printing. 3M currently prints moulded parts www.cpp-net.com exceeds 500 °C, covering temperatures from up to 35 x 30 x 55 mm in size with the 3D Online search: cpp0317dyneon -250 to +260 °C. PTFE is practically non- laboratory printer. flammable. Its long-chain structure and high density lead to very good sealing prop- Density of printed moulded parts erties. The electrical properties are equally Many properties of the components manu- good. PTFE and other fully fluorinated ma- factured on the 3D laboratory printer ex- AUTHOR terials can be used when all other alter- hibit a comparable profile to conventional DR. FEE ZENTIS Development of 3D Printing natives fail to meet the requirements. They PTFE moulded parts. Some properties may Technology for PTFE, add considerable value, for example as re- even be superior. Examinations of moulded Dyneon liable and durable seals or linings. Fuel sys- parts around 1.4 mm thick show compo- tems involving high temperatures as well as nents manufactured without tools reaching corrosion protection or sealing applications density values of 2.12 to 2.17 g/cm³. These in processing plants utilising aggressive values are comparable to those of conven- chemicals are just two of the typical appli- tionally manufactured moulded parts. AUTHOR cations. Neither pores nor cavities are discernible in INA VRANCKEN Market Segment Manager, Industrial users and drivers of additive scanning electron microscope images of Dyneon manufacturing technologies are at the same printed and conventional moulded parts. time important purchasers of PTFE prod- Printed moulded parts offer the same vir-
cpp 03-2017 35 cpp PLANTS, APPARATUS, COMPONENTS
Chemical-dosing systems at two U.S. based locations Preparing the ground
Cooling and boiler water of power plants on the premises of chemical factories must be conditioned in a similar way to the water of large-scale power plants. This is an important basis for an efficient energy supply when manufacturing substances such as fertilisers. During the water treatment, various chemicals are added by special dosing stations. Designing such dosing equipment for the U.S. market turns out to be challenging, though.
MPT of Rodgau (Germany) was commis- alone, the operator wanted them to have a size bolts. Furthermore, the dimensions of sioned by Thyssen Krupp Industrial So - uniform design to ensure ease of instal- the dosing stations in all general arrange- lutions to furnish two U.S. based chemical lation, operation and maintenance. Finally, ment drawings are in feet and inches while plants operated by CF Industries with they had to be sufficiently robust to last for the weights are in pounds. These dimen- 27 dosing systems. Four dosing stations for many years.America uses Imperial rather sions and weights formed the basis for the oxygen scavenger, amine, phosphate and than metric units, meaning that all tanks customer’s wind load calculation. The com- caustic were erected in Donaldsonville, and flanges had to be secured with Imperial ponent parts were coated according to a Louisiana. Two dosing stations for each of seven other fluids were also installed there: surfactant, dispersing agent, corrosion in- hibitor, sodium bromide, sodium hypo- chlorite, sulphuric acid and sodium hydro- xide. One dosing system for each of the fol- lowing media was shipped to Port Neal, Iowa: oxygen scavenger, ammonium hydrox ide, sodium hypochlorite, corrosion inhibitor, dispersing agent, sodium bro- mide, non-oxidising biocide, sulphuric acid and sodium hydroxide. Each of these stations basically consists of a storage tank, which is filled by means of gravity or compressed air, as well as two or more dosing pumps. The pumps for each dosing line are embedded in a redundancy concept: if one pump fails, the other one cuts in automatically.
Project requirements American dosing pumps were installed in this project in order to permit maintenance within the U.S.A. The entire electrical equip- ment – such as motors, transmitters and switches – had to be U.S.-certified either by FM Global, a mutual insurance company lo- cated in Rhode Island, or by UL, the Illinois based safety consultant. The pressure gauges and flow indicators likewise had to be ap- Pictures: MPT Pictures: propriately designed. Since 18 dosing sys- Pump assemblies as part of dosing stations. At the bottom right, there is a tems were delivered to Donaldsonville calibration pot.
36 cpp 03-2017
cpp PLANTS, APPARATUS, COMPONENTS ®
Innovations for heating
Flexible electrical heating technology
• Flexible tracer heaters
• Heating hoses systems
Separate delivery of large tanks within the U.S.A. • Analytical heating lines
• Surface heating elements specification which only applied to the the dimensional deviations which can occur • Ex-heatings pumps and motors. Although not specified during assembly. in the contract, MPT coated the polyvinyl Component parts subject to maintenance – chloride and polypropylene piping for the i. e. safety valves and the above-mentioned Donaldsonville systems with a special UV dosing pumps – can be serviced and re- protectant because they were intended for paired by local businesses, making any outdoor use. maintenance work much easier for the op- Standards are of particular interest in the erating company. U.S.: thus, for example, API 675 for positive The thoroughly prepared, comprehensive displacement pumps and the NEMA stand - and detailed sets of documentation – in- ard for motors had to be adhered to. NEMA cluding piping and instrumentation dia- (National Electrical Manufacturers Associ- grams, general arrangement drawings and ation) also publishes standards for product assembly and operating instructions – safety information such as symbols, warn- smoothed the transition to these complex ing messages in product manuals and warn- process facilities. ing labels attached to the product itself. In Throughout the project, MPT’s great flexi- America, product safety information must bility as system manufacturer proved to be fulfil strict comprehensibility requirements. particularly helpful for the client: a com- Whereas ISO symbols cannot be understood pany-wide flat hierarchy and quick deci- without being learned, a U.S. symbol de- sions paved the way for comprehensive cus- picts a risk of injury very drastically in tomer support, enabling prompt answers to order to maximise the deterrent effect. In the questions that always arise when instal- addition, the black-and-white presentation ling and commissioning such systems. makes for a better contrast. Last but not www.cpp-net.com least, U.S. symbols are larger than their ISO Online search: cpp0317mpt counterparts as they are not framed by a warning triangle or a blue circle.
Coping with problems For MPT, the size of some of the tanks AUTHOR: turned out to be challenging as regards SVEN BRIOL packing and transport. To keep logistics Project Manager, costs as low as possible, extra-large tanks MPT were ordered, delivered and installed di- rectly in the U.S.A. solution had to be found Hillesheim GmbH to make this relatively simple in spite of the Am Haltepunkt 12 separate delivery. The pump group was D-68753 Waghäusel · Germany therefore connected to the appropriate tank Phone: +49 72 54 / 92 56-0 with flexible tubing, easily compensating Fax: +49 72 54 / 92 56-20 E-Mail: [email protected] www.hillesheim-gmbh.com cpp 03-2017 39 cpp PLANTS, APPARATUS, COMPONENTS
Advantages of special centrifugal pumps consistently exploited Pump selection without the burden of choice
The selection of a pump involves significant risks, particularly for applications with media which are difficult to pump, which can be quite a challenge for standard pumps to master. Furthermore, the chemical industry is continuously developing new substances whose behaviour can create problems in the pumping process. Many of these problems can be solved ahead of time using special centrifugal pumps, which are individually manufactured for the respective application.
When it comes to pump selection, along- side technical issues and regulations relating to safety and environmental protection, for instance, the financial aspect is regarded as the most important factor. If we only con- sidered the procurement costs, however, it would be like comparing apples with or- anges. Special centrifugal pumps from Bun- gartz are used for unconventional solutions to complex pumping tasks, of which the chemical industry boasts an abundance. They are designed for those situations where conventional pumps fail, being devel- oped and built on site exclusively for a par- ticular application. Such situations typically include the replacement of an old pump, retrofits due to frequent failures within a process chain or initial installation in a new construction project.
Engineers love solving problems “The more difficult the operating condi- tions, the more important it is to have ex- cellent teamwork between everyone in- volved”, explains Sadko Meusel, Head of Sales at pump manufacturer Bungartz. Our common goal is to find the technically and economically optimal solution. Over the course of decades, the company has devel- oped its own philosophy with which to achieve this, based on its special pump tech- nology backed up by corresponding special methods. In contrast to manufacturers that sell standardised pumps, Bungartz relies on custom-built centrifugal pumps. Fur- thermore, competent and dedicated staff in The assembly of the pumps takes place based on the design plans, which are developed the sales offices are available to advise for the individual application of the pumps clients in Germany and worldwide. They are
40 cpp 03-2017 life from just six weeks previously to more than six months”, says the CEO, describing the experience of the Bungartz team. What’s more, the selection and use of these special pumps eliminate virtually all known causes of faults in advance, as one real-life example illustrates. At the Gendorf chemical plant, a process change required different chemical waste water flows (acidic, solids) to be pumped from production processes into another operational area. Josef Lehner, Head of the “Pumps” specialist unit, chose to go with Bungartz pumps (see cav 5/2015 “Ohne Netz und doppelte Pumpe” (Without a safety net or double pumps)). Lehner is a renowned expert on the Pump Engineering distance-learning course (www.pump-engineer.org). Bungartz was
Pictures: Bungartz Pictures: known to the pump specialist as a supplier, The special centrifugal pumps from Bungartz are designed on a requirement-specific as were the advantages of the V-AN pumps, basis, and manufactured in the Eifel region of Germany which get by without additional control systems. As an experienced practitioner, he also knows that two of the fundamental solution-oriented and familiar with a wide Pillar one: the sealing technology. Almost all requirements when considering a manufac- range of requirements thanks to several dec- pumps combine the hydrodynamic shaft turer’s quotation are how reliable their ades of experience. Since they are com- seal as a primary seal with a downstream statements about pump characteristics are mitted to achieving the best possible so - secondary seal capable of dry running. The and how smooth their teamwork is during lution, just like the manufacturer’s engineers permanent dry-running safety results in an commissioning. and designers, they know that efficient extremely long service life. “In practice, communication between all stakeholders in what that means is this: in very aggressive Functional models the planning process is essential. Consul- applications, which are challenging for “We are always looking for new methods to tants, planners, plant and operations engi - seals, the pumped medium is kept well illustrate our technology”, says Sadko Meu- neers and technicians in the customer’s rel- away from the actual seal during operation sel. When words are not enough, explana- evant departments each contribute their re- and even in the idle state. Very often, the tory models are needed. At trade fairs, con- spective expertise, as do the specialists at traditional (secondary) seal never even ventions and industry exhibitions, Bungartz Bungartz’ production facility in Euskirchen. comes into contact with the medium and is has for some time been offering functional This can get interesting where special chal- therefore not subject to much wear. This models to try out. “Our local Technology lenges arise, such as sensitive media that alone leads to a far longer service life”, Days event uses our mobile demonstration must be pumped in explosive atmosphere, Bungartz adds. stand and has proven very effective”, Meusel temporary pumping tasks or fluids with a comments. The pumps can be operated tendency to crystallise or polymerise. How- Effective self-regulating behaviour either in normal suction mode or, as Bun- ever unusual the application, a technically Pillar two: the special physics. This is what gartz calls it, in abnormal mode. This high- and economically optimal solution is always we call the effective self-regulating behav- lights the advantages of the special physics developed. “There’s a real sense of achieve- iour of the V-AN pump series. These pumps and makes the differences clearly visible. ment, working together with process and automatically adapt to changing feed rates. www.cpp-net.com project engineers to develop our self-regu- Their NPSH value is almost 0, meaning that Online search: cpp0317bungartz lating pumps for use in different plants. they are cavitation-free, even if the vapour Customers are always amazed that they pressure is reached in the pump reservoir. don’t need any additional control system This occurs without any mechanical or elec- technology. If it’s also possible to economise trical regulation equipment, making these on construction work that had previously pumps intrinsically safe. The high level of been considered or planned, they’re delight- intrinsic safety allows plant and mainte - AUTHOR: ed”, says Meusel. nance costs to be kept continuously low. ANNETTE VAN DORP Pillar three: the choice of material. The Freelancer Discovering alternatives range of materials comprises all castable and “You can’t use something that you haven’t weldable stainless steel grades, special alloys heard of”, says the current CEO, Frank Bun- (titanium, zirconium), grey cast iron and gartz. He describes the principle as follows: even components made from SiC. “Selecting “Our three-pillar model allows us to devel- the correct material makes the pumps very op the most suitable pump for even the robust. In some highly complex cases, most difficult application.” changing the pump can increase the service
cpp 03-2017 41 cpp PLANTS, APPARATUS, COMPONENTS
Mobile worker concept: Industry 4.0 for hazardous areas Redefining maintenance
Thanks to smartphones, tablets, sensors and smart HMI systems, maintenance activities are no longer a reaction to a problem but provide an opportunity to prepare in advance and avoid unplanned shutdowns, gain competitive advantages and realise cost savings. The decisive factor for corporate success is not a single component or solution but an interconnected ecosystem of compatible hardware components combined with a software solution stack for mobile workers.
Industrial enterprises can benefit enor- Wichmann, Head of Mobile Solutions at environments using mobile solutions – mously in terms of productivity and data Bilfinger Maintenance GmbH. “I was dis- making them more efficient while saving quality from digital, mobile solutions. How- pleased that the mechanics had to document time and money”, Wichmann explains. ever, experience shows that – due to a lack their maintenance work in writing and then Thanks to digital mobile solutions, main- of budget, compatibility or the necessary again in the SAP system”, he says. “We were tenance workers, technicians, experts, teams certificate of compliance – many tasks are therefore considering how to avoid this un- and project groups can work together faster, still performed with a clipboard and paper. necessary duplication of effort, reduce more flexibly and in real time, whether in Mobile computers are only used in offline paper consumption and simultaneously im- manufacturing, maintenance, plant con- mode and essential devices or peripherals prove the quality of the documentation.” figuration and control or machine, tools turn out to be incompatible. These archaic “Predictive maintenance” was the answer: and inventory management, supply chain methods bring increased risk and inflexibil- particularly in industries with extensive ter- management, inspection rounds, repairs or ity to the business, being error‐prone and rain or hazardous areas, consistent, preven- plant security checks. inefficient while creating potential safety is- tive maintenance activities call for new sues and affecting the well-being of the forms of communication and data ex- Maintenance now more targeted workforce. change. “Ecom is the ideal partner to help Daily inspections in chemical plants, re- One person who was dissatisfied with the us improve the quality of documentation fineries and other hazardous areas are vital traditional maintenance process is Oliver processes in potentially dangerous working but time-consuming for businesses seeking to ensure the smooth running and reliabil- ity of their facilities. Maintenance techni- cians typically carry out such inspections throughout the day and afterwards enter the results into the company’s maintenance management system. The reaction time be- tween damage detection and repair is need- lessly slow – with risks for personnel, assets and production. For almost a decade, Bil - finger Maintenance has developed practice- oriented mobile solutions for maintenance purposes. Ecom’s smartphones, tablets and peripherals, which are Ex-certified up to Zone 1/21 and Division 1, are the technol- ogy underlying these interconnected appli- cations. Modern mobile devices and apps let mobile workers pursue a more targeted mainte - nance strategy. Specific procedures and measures can be individually assigned to Pictures: Ecom Pictures: Important data is visualised on the mobile device of a service technician, who is permanently each technician or mechanic. In other connected to the central IT system and can communicate job-related information directly words, each mobile worker only actually
42 cpp 03-2017 Oliver Wichmann, Head of Occupational safety is crucial to prevent injury to persons and is naturally also integrated Mobile Solutions at Bilfinger in the workflow. Risk assessments and near misses can be documented with only mini- Maintenance GmbH mal effort and reported directly to the HSEQ managers.
sees the jobs for which they are personally cost-effective, largely maintenance-free op- responsible on their smartphone or tablet tion (even at maximum transmission power, display. Historical maintenance records can the battery only needs to be replaced after be consulted on their mobile devices, show- four years) for collecting asset data and con- ing how often a particular defect has oc- necting it to back-end systems. They require curred in the past and how it was rectified. only a single access point to deliver in- Wiring diagrams or manufacturer in- formation back to the company, quickly formation can also be visualised, providing identify potential threats or downtime or an additional technical resource. Once a job help improve workflows, with the result is done, the mobile worker can document that engineers can cut down on the time the procedure on the mobile device and log they spend on administrative tasks at the the completed process steps or tasks, the end of every day and significantly increase amount of time needed and the materials wrench time. In addition, BLE beacons used. Modern apps automatically sync this allow in-depth insights into operational information wirelessly with an ERP system, procedures and asset information such as and even without device data connectivity it plant drawings, login data, the number of can also be read offline, updated and then deployments and the average dwell time – uploaded the next time the company net- even temperature measurements and other work is accessed. metrics can be implemented. Mobile solutions like the Tab-Ex 01 tablet allow maintenance technicians access to the latest information anywhere and at any time New maintenance technologies Predictive maintenance Bluetooth beacon technology, well-known When used together with the right apps, from the retail and consumer markets, has beacons, smartphones, tablets and sensors into account, is key to greater efficiency, the potential to fundamentally improve offer fast access and a compact overview of productivity and flexibility. Businesses real- maintenance activities as well as the way data, knowledge and information. The sys- ise competitive advantages such as more ef- businesses operate, secure and manage their tem warns of potential downtime or risks. fective workflows, predictive maintenance assets or plants in hazardous areas. Loc-Ex Employees in charge of production and and streamlined decision-making processes 01 BLE beacons from Ecom combine digital plant operations can evaluate the data live. which deliver higher margins. and physical data into a single, unified busi- Based on this, they can detect deviations or www.cpp-net.com ness intelligence unit. For example, if a anomalies, act proactively rather than reac- Online search: cpp0317ecom technician approaches a particular asset, in- tively, identify trends and make data-driven formation specifically tailored to the rel- predictions. In short, they prevent possible evant task, person and access authorisation causes of lost production before they have a can be visualised on the screen of the tablet chance to occur. AUTHOR: or smartphone with an app, without having “Maintenance 4.0” is essentially all about PAULO JORGE DE to manually navigate to the right content. one thing: networking. Flexible and secure ALMEIDA System Engineer Mobile The device promptly initiates the appropri- communication over long distances is there- Computing, ate workflow and enables data reception. fore a must. A powerful mobile enterprise Ecom At the same time, these beacons provide a concept, taking both hardware and software
cpp 03-2017 43 cpp PROCESS ENGINEERING Picture: Held Picture:
Dr. Rita Dicke, Vice President Global Marketing/Product Management Liquid Purification Technologies, Lanxess, presented ion exchange resins and their use
Lanxess invests in water treatment technology Ion exchange resins and membranes in demand
Water treatment plants continue to be in demand. In line with this trend, Lanxess has in recent years invested in plants that produce ion exchange resins and reverse osmosis membranes. cpp caught up with Dr. Rita Dicke, Vice President Global Marketing/Product Management for ion exchange resins in the Liquid Purification Technologies business unit, to discuss current developments.
Dr. Dicke, what is the current trend in the market for ion exchange Dr. Dicke: The Liquid Purification Technologies (LPT) business unit, resins and RO membranes? which is part of the Performance Chemicals segment at Lanxess, has Dr. Dicke: External sources, such as the Global Water Market 2017 subsumed the business with products used to treat water and liquid study carried out by GWI, indicate annual growth rates of around media. We represent the ion exchange resins from the Lewatit prod - 10 % for reverse osmosis membrane technology and still around uct line and the Lewabrane reverse osmosis membranes. Customers 4 % for ion exchange resins. That represents solid growth for a can design their water treatment plants using the Lewaplus technology that has already been established for several decades. engineering software. In 2016, Lanxess also reorganised the marketing structure for its How large is the annual demand for ion exchange resins iron oxide adsorbers. LPT incorporated marketing of Bayoxide iron worldwide? oxide adsorbers for water treatment – manufactured by Lanxess’ In- Dr. Dicke: In 2016, global sales amounted to around 1.7 billion organic Pigments (IPG) business unit – in its comprehensive port- euros. Lanxess is one of the market leaders in this segment. Our folio. In order to harness synergy effects, LPT is now responsible for strength is that our portfolio boasts membrane technology and iron all water treatment products business. Unlike Lewatit ion exchange oxide adsorbers in addition to ion exchange resins. resins, Bayoxide cannot be regenerated but must be disposed of af- ter use. Lewatit, Lewabrane and Bayoxide applications can be broad- How is the ion exchange resin and membrane technology business ly split into four segments: industrial water treatment, drinking wa- embedded in the Lanxess group structure? ter, the chemical industry and food processing. Industrial water treatment accounts for around a third of the total annual sales.
44 cpp 03-2017 How well is the business unit performing? Dr. Dicke: Sales in the Performance Chemicals segment rose by 2.7 % in 2016 to about 2.14 billion euros. The development of sales in the LPT business unit contributed positively to this performance. Business is generally good: it’s a development which is being driven by a number of recent projects such as the expansion of our produc- tion plant at the Leverkusen site, the opening of a new facility in India and investments in reverse osmosis technology in Bitterfeld.
At which sites does Lanxess produce ion exchange resins and membranes? Dr. Dicke: Ion exchange resins have been produced on an industrial scale in Leverkusen since 1956. We have consistently refined our products ever since. Styrene and divinylbenzene based polymers began to replace condensation resins as early as the 1950s. The first monodisperse polymers were developed at the start of the 1980s.
Ion exchange resins have been manufactured at the Bitterfeld site Lanxess Picture: since 1938. Reverse osmosis membrane elements were added in Lewatit ion exchange resins help to protect the environment and water – 2011. We have also had an ion exchange resin plant at our Jhagadia a valuable resource site in India since 2010.
What resin grades are produced at the various sites? the production of polymer beads by emulsion polymerisation. A Dr. Dicke: Certain grades can be produced at more than one plant monomer and cross-linker mixture is placed in an inert solvent in a while others are mainly manufactured at a single facility. The same beading tank to form a finely distributed emulsion. Strict complian- level of quality is maintained across all sites. If one plant is un - ce with the reaction parameters is crucial to ensure that the poly- available, another can take over, thus safeguarding our ability to de- mer beads are of a high quality. The process steps for this purpose liver and ensuring flexibility for us and our customers. Phthalimide, are mostly automated. Three-dimensional polymerisation and which is required to make anion resins in Leverkusen, is an exam- cross-link ing take place in the tank. The non-functionalised polysty- ple of a site-specific technology. These resins have particularly high- rene or polyacrylonitrile beads are separated from the liquid reacti- quality properties and can potentially be used in the chlor-alkali in- on medium via Nutsche filters and functionalised in the next phase. dustry, for example. They are utilised to treat the brines for chlorine In the case of weak acid cation exchange resins, carboxyl groups are production. Ion exchange resins employed as catalysts in the chemi- used. Due to their negative charge, the functional groups are capa- cal industry are likewise manufactured at the Leverkusen site. These ble of binding cations. can be used to produce important plastics precursors. Other prod - Why did Lanxess specifically decide to expand the Leverkusen site? Dr. Dicke: We chose Leverkusen because the infrastructure of the re- “Overall, we have invested around levant production plants was already excellent at that site and there 10 million euros in the Leverkusen site to was space for a fourth line. Another reason was the fact that the Eu- ropean market for resins used to treat drinking water is relatively expand the production plant.” large for us. However, there is also the option of manufacturing these products in India, so as to supply the Asian market from there. The resins produced in Leverkusen will primarily be utilised to ucts from Leverkusen are the weak acid cation exchange resins make cartridges for treating drinking water. It was therefore also (WAC resins) which are used in cartridge systems and improve the important to us that the food-grade packaging unit could serve all taste and quality of water. lines. This unit is vital for these types of WAC resin because no other industrial-scale methods are used by customers to purify the resins. Lanxess expanded the production plant in 2014 to include these cation exchange resins. What was the reason for this investment? What structural measures needed to be implemented for the food- Dr. Dicke: One reason was the positive market development of the- compatible filling unit? se WAC resin grades. The demand for special cation exchange resins Dr. Dicke: Packaging takes place in a separate building that is divi- is growing by between 3 and 5 % each year. We added a fourth ded into black and white zones, the white zone being maintained plant to the three lines that we already had for this product type. under cleanroom conditions. Pipes are used to feed the resins di- Overall, we have invested around 10 million euros in the site. This rectly from the tank into the packaging unit. Access to the white zo- figure also includes the construction of a food-grade packaging unit ne is closely regulated and the personnel employed there wear pro- for the resins which can serve all four lines. tective clothing. The white zone is supplied with filtered air and kept under positive pressure to prevent the ingress of impurities Did the plant expansion result in any changes to the production from the surrounding environment. Inside this 300 m2 hall, pro- process? ducts are fed from several silos into big bags and drums on stainless Dr. Dicke: The technology of the fourth WAC resin line is based on steel pallets, so that they can immediately be weighed, labelled and our existing plants. Of course, we are continuously improving the transported. A rail conveyor system is employed instead of conven- production process across all plants. The batch process begins with tional forklifts. Before being transported to the adjoining storage
cpp 03-2017 45 cpp PROCESS ENGINEERING and dispatch build ing, the containers are transferred fully automa- tically to wooden pallets and sealed in weatherproof film.
Are there already plans to further increase capacity, including at other sites? Dr. Dicke: We are currently looking into potential areas for invest- ment, but it is too early to confirm anything as yet.
What differentiates Lanxess’ ion exchange resins from the prod - ucts of other manufacturers? Dr. Dicke: An ion exchange resin is a product that inherently requi- res explanation, since it has a wide variety of applications. Unlike other manufacturers, we offer both monodisperse and heterodisper- se resins. The performance characteristics of our products are what differentiates them from those of our competitors. What’s more, our service includes not only the sale of the product concerned but
also the design of the water treatment plant using the Lewaplus Lanxess Picture: software as well as technical advice. Lanxess has invested a total of some 10 million euros in expanding the production of Lewatit weak acid cation ex- change resins in Leverkusen What plants can be planned using the Lewaplus software? Dr. Dicke: We started off designing ion exchange resin plants for water applications, but the range of products we can plan using Le- waplus software is regularly expanded. Following the introduction achieve enhanced properties for the selective removal of certain of reverse osmosis membrane technology, we incorporated it into ions. The product is particularly attractive for new plants, which can the software as well. This is an advantage because the two technolo- be built specifically to facilitate its use. gies are often combined, especially in water treatment. The ion ex- change resins are sometimes applied before the membrane elements Are you also developing customised Lewatit resins? in order to remove substances from the water that are harmful to Dr. Dicke: In many instances, we are able to recommend a special the membrane. Ion exchange resins are also required following re- ion exchange resin from our extensive product range to solve a verse osmosis to enable fine purification of water for applications custom er’s problem. If we are unable to find an adequate solution, requiring very high purity. and if a corresponding order volume will result, then we will deve- lop a resin to meet that customer’s needs. This is a simple business How do I know when I need to regenerate the ion exchange resin cal culation. or even replace it entirely? www.cpp-net.com Dr. Dicke: Ion exchange resins are regenerated using a regeneration Online search: cpp0317lanxess fluid such as 4% sodium hydroxide solution or sodium chloride solution that is passed through in the reverse direction. We are able to calculate the volume required for regeneration and design the cycles with a high degree of accuracy using our LewaPlus software. This allows a customer to plan the times between regeneration cycles and the anticipated costs of the regeneration process. The customer should also monitor the process continuously, for exam- ple by measuring concentrations in the purified stream. The length of time before regeneration becomes necessary depends to a large extent on the application. Resins can continue to be used for years THE INTERVIEW WAS CONDUCTED BY: in some applications. In others, however, they are subject to very DANIELA HELD high wear and regeneration is neither possible nor economically Editor viable. As a result, their service life is much shorter. To check whether a particular resin is working correctly, customers can send us samples and we will then judge whether that resin can still be used or whether it needs to be replaced.
Does your portfolio currently include any new products? Dr. Dicke: We have several new products for each segment, e.g. an acrylic resin for removing sulphates from citric acid, a new product for separating glucose and fructose and a mixed-bed resin for puri- fying water in heating systems. We have introduced Lewatit MDS TP resins for the chemical industry. MDS stands for “MonoDisperse Small”, which means that the average size of the ion exchange resin beads is very small. This resin delivers particularly good results, for example in chlorine electrolysis. The small beads make it possible to
46 cpp 03-2017 We know what makes a good powder
Meeting the highest standards for drying and powder quality
To make superior powders, look for a GEA drying At our extensive test facilities, experienced process system. We specialize in supplying industrial drying technologists and test engineers will help you move systems designed to match your exact product and rapidly from idea to product development and plant specifi cations. With more than 10,000 references profi table production. worldwide our expertise is unsurpassed. Our comprehensive product range includes spray dryers, Contact details: gea.com/contact or meet us at fl uid bed systems, fl ash dryers, ring dryers, rotary POWTECH in Nuremberg, Germany at our booth in dryers, spray congealers and spray dryer reactors. hall 3A, 312 from 26-28 September 2017
cpp 03-2017 47 cpp PROCESS ENGINEERING
Defies even strong acids Plate heat exchanger made from silicon carbide
Plate heat exchangers constitute a highly efficient solution for heat transfer. Especially for use in corrosive applications, they combine design advantages with the almost universal chemical and abrasion resistance of the ceramic silicon carbide material.
There are many criteria such as size/foot- sense to combine the design advantages by machining the so called green body, i. e. print, weight, heat transfer area, volume, with the almost universal chemical and ab- the isostatically pressed but not yet sintered fouling factors or cleaning effort where rasion resistance of the ceramic silicon car- plates. Depending on their size and design, plate heat exchangers are superior to classic bide material. The corrosion rate is mostly these plates have a total thickness of ap- shell-and-tube apparatus. For example, the well under 10 mg/cm2a, even when ex- proximately 6 to 10 mm, from which the average space requirement is 40 to 50 % less posed to severe chemical stress. It is the channel cavity for the media is machined and sometimes even more, depending on modification that is decisive, though: this on the inside. The channel surface has pro- the application. The plates have usually a excellent, practically universal chemical re- files for guiding the flow, producing turbu- wall thickness of 1 to 2 mm, allowing effi- sistance is only offered by directly sintered lence and supporting the channel against cient manufacturing by forming. The range alpha silicon carbide, otherwise known as the next plate. The meandering channel of materials in this production process is SSiC. structure ensures efficient utilisation of the limited to stainless steels, special alloys, heat transfer area without short circuits or copper, titanium and other ductile metals. Meandering channel structure dead spaces. Other design elements can be However, these materials have only limited Yet the use of ceramic materials requires a implemented depending on the plate size chemical resistance, especially in extremely rethink in terms of manufacturing technol- and the requirements of the application. corrosive applications. It therefore makes ogy. The silicon carbide plates are moulded The basic concept for plate heat exchangers made from SSiC was developed to market maturity by 3M Technical Ceramics, for - merly ESK Kempten. The material-specific manufacturing challenges were a key prior- ity. When the series was taken over by GAB Neumann, the latter‘s long-standing appli- cation expertise and experience in classic chemical apparatus came into play. This heat exchanger type complements the Corresic product family with shell-and-tube and block-type SSiC heat exchangers. As part of the transfer, the product was optimised and its overall structure adapted to the appli- cation requirements.
Universal corrosion resistance The 3M SiC Type C plate material is a pres - sureless sintered SSiC with universal cor- rosion resistance. The maximum dimensions of ceramic plates are limited compared to metal apparatus. There are two reasons for
Pictures: 3M Technical Ceramics Technical 3M Pictures: this: firstly, the green body must be sintered Plate heat exchangers with SiC plates combine design advantages with the almost at approximately 2000 °C, so that larger universal chemical and abrasion resistance of the ceramic material plates are ruled out by the complex sinter-
48 cpp 03-2017 devices must be connected in series to pro- vide the required cooling capacity or heat transfer area. A whole set of applications, particularly if there are temperature over- laps, are problematic if not impossible with shell-and-tube or block apparatus.
Compact plate apparatus SiC plate heat exchangers allow a high de- gree of variability as well as easy implemen- tation of multi-channel functionality in the apparatus. This is impressively demonstrated by the example of 70% sulphuric acid cool- ing, where a temperature difference of 140 °C/45 °C must be realised with cooling The meandering channel structure ensures water at 25 °C/38 °C. Two very long, efficient utilisation of the heat transfer area slender shell-and-tube units (DN 125, each without short circuits or dead spaces 4.5 m long), can be replaced with a very compact plate apparatus just 0.6 x 0.6 x 0.35 m in size. The plate appa - ratus has a heat transfer area equivalent to ing equipment, and secondly, the effective- just under 30 % of entire transfer area of ness of the plate principle, namely between both shell-and-tube units. The heat transfer two and four times more heat transfer than coefficient, too, is inversely proportional. A with other classical heat exchanger types. total of 34 SiC tubes 14 x 1.5 mm/4.0 m High transfer rates can thus be achieved long were compared with 30 SiC plates with small heat transfer capacities. Three measuring 500 x 200 x 7 mm. The same series (plate sizes 260 x 120, 500 x 200 and applies to applications with higher or high- 585 mm x 250 mm) currently exist. The viscosity media, where the advantages of apparatus meets even the highest hygienic plate heat exchangers are similarly clear. standards, e. g. the German KTW, and can In a SiC plate heat exchanger installation, optionally be supplied with an FDA com- consisting of four apparatus for preheating pliant design. and cooling a specific sulphuric acid prod- uct, huge graphite shell-and-tube units were Potential applications successfully replaced with SiC plate ex- Silicon carbide material is primarily used in changers with heat transfer areas of between highly corrosive and/or abrasive process 1.5 and 2.5 m2 and operating temperatures conditions for economic reasons. Providing from 15 to 150 °C. it is appropriately prepared, it is also suit- www.cpp-net.com able for high-purity processes (up to ppt) Online search: cpp0317gabneumann due to the fact that there is no risk of con- tamination or emissions. The Corresic port- folio of silicon carbide heat exchangers now includes SR shell-and-tube type exchangers, SE block heat exchangers and SP plate ap- paratus. The SP plate type is ideal for high- AUTHOR: TOBIAS SCHNURPFEIL performance applications with low-to- Managing Director, medium mass flow rates. The dilution of GAB Neumann highly concentrated sulphuric acid, for example, goes hand in hand with a relatively high mixing temperature. Al- though the acid rates are often low (a few m3/h), so that a small cross-section is called AUTHOR: for, the large target temperature differences DR. MATTHIAS REITZ Product Manager SiC heat (about 100 to 140 °C) result in a high ca- exchangers, pacity and comparatively large transfer area. GAB Neumann In such situations, both tube bundle and block apparatus usually require multiple passes that enlarge the transfer area still further because the mean temperature dif- ference is reduced. In many cases, multiple
cpp 03-2017 49 cpp PRODUCTS
Reduce alarm rates efficiently Vertical dryer offers reduced handling
The alarm statistics report in view of alarms that is clearly or- The Guedu vertical dryers from nology allows savings due to B&R’s Aprol process control sys- ganised and intuitive. It pro- De Dietrich Process System adds the total cycle time reduction (a tem provides a clear, intuitive vides key performance indi- an important benefit for drying single pan dryer can replace sev- overview and makes it easy to cators (KPIs) for efficient alarm of powders in process indus- eral tray dryers) and also sav- reduce the frequency of nui- management per the require- tries, cosmetics and food. The ings from the improved heat sance alarms. A sustainable ap- ments of EEMUA 191, ANSI/ISA vertical dryer is unlike hot air transfer during drying (reduc- proach to alarm management 18.2 and IEC 62682. The conse- dryers and tray dryers. The ing utilities costs). The mechan- can relieve plant personnel and quential alarm report effectively powder is stirred under vac- ical mixing during drying im- improve safety. The alarm stat- identifies cause-and-effect rela- uum, that allows an improve- proves product homogeneity. istics report provides an over- tionships between alarms to ment of the drying time by a Therefore, at the end of the help minimize the occurrence factor 2 to 10 compared to tray cycle, the product comes out of consequential alarms. Aprol dryers, and a total cycle time perfect evenly dried, with resid- alarm reports are available via reduction by a similar ratio ual moistures below 0.1% the intuitive web-based user in- (by reducing the necessary where required. terface that requires no addi- handling). www.cpp-net.com tional software other than a web In fact, the vacuum drying tech- Online search: cpp0317dedietrich
Picture: B&R Picture: browser. www.cpp-net.com Online search: cpp0317bur Bringing real-time plant data to personnel
Emerson‘s DeltaV Mobile enables trends and data available on Del- Safe lockout for large gate valves on-site teams to quickly and se- taV operator workstations to iOS curely connect with off-site ex- and Android mobile devices, as Brady‘s collapsible gate valve off- or on-position. Its tri-fold- perts, extending organisation- well as alarm alerts via push, lockout can block gate valves up ing system makes it practical to wide expertise and collaboration SMS, or email notification. to 18 inch to neutralise or se- store or carry, while still being beyond the plant. Intuitive mo- DeltaV Mobile is a core platform cure the flow of energy or ma- able to cover and lock large, 18 bile views and customisable fil- solution in Emerson’s Always terials to machines. Every inch valves. With just three size tering ensure that users see clear Mobile portfolio, which also in- worker servicing a machine can variations to lock a range of and relevant data and alerts about cludes Asset View for the AMS apply a padlock to the lockout valves from 3 to 18 inch, this the safety and performance of fa- Ares asset management platform device to lock a gate valve in the lockout solution is also a very cilities. It easily provides alarms, and Guardian Mobile. Always off-position while maintenance flexible and practical tool to re- Mobile technologies deliver op- is ongoing. This prevents other duce accidents in the workplace. erational mobility solutions that workers from inadvertently re- The collapsibleg gate valve lock- improve productivity and collab- energising machinery. Collaps- out is a rugged, injection oration. With instant access to ible gate valve lockouts can also molded styrene construction. It operational information in intu- be used to secure the flow of can be coupled with any of itive views, personnel at all levels water to firefighting systems for Brady‘s range of padlocks, avail- of organisations can make effec- example. able in several materials. tive, business-critical decisions. The device can easily be rotated www.cpp-net.com www.cpp-net.com Online search: cpp0317brady around a valve to lock it in the Emerson Picture: Online search: cpp0317emerson
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50 cpp 03-2017 More diversity and service
The multiple couplings and It is approved for voltages up to multiple media connectors of 630 V. The M12 power plug is the Eisele Multiline E series designed for cables with diam- offer an innovative modular kit eters up to 2.5 mm2. The adap- system for combining com- tive insert with up to five power contacts provides up to 16 A per OUR EXPERTISE pin and is reverse polarity pro- tected, shockproof and vi- bration-proof. IS YOUR BENEFIT! The Multiline series will also in- clude an optimised housing ver- e
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Picture: Eise Picture: connection and disconnection within seconds. This quick- pressed air, vacuum, gases, cool- change system also requires less ant, liquids, electronics and manual force, making it very electrical wiring in one connec- convenient to operate a Multi- tor body. The German manufac- linre E multiple connector that turer continues to develop the is completely equipped with veryv t Multiline E and presents now drip-free adaptive inserts. Short delideliveryGeG rm time the M12 power plug for power www.cpp-net.com Made in Germany 011 electronics. Online search: cpp0317eisele ISO 900190
Compact and flexible Profinet switches
Siemens offers the Scalance together with approval for use in XF-200BA line of compact hazardous areas (Atex Zone 2, switches. The flexible use of vari- IECEx) allow reliable use, even in ous bus adapters allows users to harsh environments. set up electrical and optical line, Both versions support up to four star and ring structures. Bus ports and various firmware- adapters are available with RJ45, functionalities. For example, vir- SCRJ and LC connection systems. tual LANs divide the physical Mini-Turbine Pumps Two types of switches are avail- network into several virtual sec- able: Scalance XF204-2BA, a tions to minimise the number of High-quality standard units plus individual designs standard switch for universal, broadcasts in the network. Re- for water, solvent, acids, bases and more... cross-industry use, and the Scal- dundancy protocols permit a ance XF204-2BA DNA Y-switch high availability of machines and Gather makes it possible! for special tasks in process auto- plants. • Differential pressure up to 5.0 bar mation. An extended tempera- www.cpp-net.com ture range from -40 to +70 °C Online search: cpp0317siemens • Temperature range from –200 °C to +450 °C • Capacity from 20 to 2,400 l/h
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cpp 03-2017 51 Pump Technology · Dosing Technology · Coupling Technology cpp PRODUCTS
Operating software for rotary drive WE ARE The Tensor drive series offers a vidual control characteristics, to THE variety of setting options and adjust the adjustment curves of evaluable data already in the the control valve or to program basic version, due to its internal different speeds for individual MIXING electronic control and monitor- control ranges (travel dis- ing system. The setting takes tances). EXPERTS place via the standard on-board www.cpp-net.com operation. Since summer 2016, Online search: cpp0317aris Aris Stellantriebe has been offer- ing a tensor with an expanded range of functions and, in the context of this, an operating software with which the Aris customers can more easily oper- Ulrich Schär ate and adjust the Tensor via a General Manager / Sales notebook or tablet. This user in- Aris Picture: terface can then be used to Àǔ˾ǔȭǷˁȭǔǜʊnjʁɁȧÀďŘʁƬǜǒƬŽƬȭƋǒȧŘʁǘ change speeds, to set up indi- njɁʁŘǜǜŘǔȭǔȭǷȧŘ˾ǔȧˁȧʊɡƬƋǔǞƋ ǜǒʁɁˁǷǒɡˁǜƙɁˁǜʊǜŘȭƞǔȭǷʁƬǚǔŘŽǔǚǔǜ˿Řȭƞ ˁȭŽƬŘǜŘŽǚƬǚǔnjƬǜǔȧƬƖÄ˹ǔƞƬ˸ŘʁǔƬǜ˿Ɂnj ɁɡǜǔɁȭʊŘǚǚɁ˹ʊŘȭǔȭƞǔ˸ǔƞˁŘǚƋɁȭǞǷˁʁŘǜǔɁȭ ɁnjǜǒƬȧǔ˾ƬʁǜɁȧƬƬǜƬ˸ƬȭƋɁȧɡǚƬ˾ Ultrasonic flow sensor with hygienic design ɡʁɁƋƬʊʊʁƬɴˁǔʁƬȧƬȭǜʊƖ The non-contact Dosic ultra- MTI – the mixing company. sonic flow sensor is used to de-
ÀďÀǔʊƋǒǜƬƋǒȭǔǘȭǜƬʁȭŘǜǔɁȭŘǚȧŽƀ˹˹˹ƖȧǜǔȊȧǔ˾ƬʁƖƞƬ tect the flow volume of conduc- tive and non-conductive liquids. With its measurement channel and stainless-steel housing, the ultrasonic flowmeter is suitable Every child for measuring tasks in hygienic and highly demanding environ- ments. Two configurable digital
is one of a kind and unique. Each child needs inputs and outputs and up to Sick Picture: individual support according to their needs. two analog outputs, as well as Thank you! Please help us by donating. an IO-Link interface to a super- tion, the sensor has a straight, ordinate control unit, ensure seal-free, and self-emptying that you get just the right start measuring tube made of stain- position. The IO-Link reduces less steel (316L with Ra ≤0.8). cabling and also enables com- The stainless-steel housing also plete control and monitoring of provides the necessary rugged- the sensor in Industry 4.0 ma- ness and resistance. The sensor chine environments. has EHEDG certification and The absence of moving parts in demonstrates FDA conformity. the sensor eliminates potential www.cpp-net.com contamination risks. In addi- Online search: cpp0317sick
Safe handling of high quality drugs
Tyvek Isoclean single-use cover- out bacteria. Protective suits alls are designed for use in clean- made of Tyvek are also suitable rooms and controlled environ- for activities involved in the ments demanding high levels of production of cytostatics and Tel.: 0800/50 30 300 (free of charge) IBAN DE22 4306 0967 2222 2000 00 microbiological protection. offer different levels of protec- BIC GENO DE M1 GLS Additionally, with a bacterial fil- tion depending on hazard type. www.sos-kinderdoerfer.de 2016/1 tration efficiency of >98 %, these www.cpp-net.com coveralls offer the ability to filter Online search: cpp0317dupont
52 cpp 03-2017 Digital pressure gauge for high pressures
proof way for this version – the thin-film cell is not welded, but PURE rather it is inserted solidly into a conical pressure channel. Via the new smartphone app, EFFICIENCY the CPG1500, which is already
Picture: Wika Picture: intuitive to operate, can be used The FreDrive-Lab integrates 5 different even more flexibly. Versions for milling processes in a single system with guaranteed iOS and Android operating sys- scale up to the FreDrive-Production Series tems are available for free-of- Wika introduces the CPG1500 charge download from the re- precision digital pressure gauge spective stores. The app enables in extreme ranges – the instru- a mobile parameterisation of ment can even measure press- the instrument and also the ures up to 10,000 bar. reading and evaluation of the The high-pressure version of the information from the data digital pressure gauge works logger, which can record up to with an accuracy of 0.5 % FS. 50 measured values per second. The measured value registration www.cpp-net.com WE has been adapted in a rupture- Online search: cpp0317wika CARE
VISIT US AT THE POWTECH 2017 IN NUREMBERG, GERMANY ABOUT FROM 26TH - 28TH SEPTEMBER 2017 / HALL 1 / BOOTH 1-343 MILLING Outlet valve with a 60° outlet nozzle WWW.FACEBOOK.COM/FREWITTSA WWW.FREWITT.COM
To allow an easy interchange- (60°) as well as the exact posi- ability and compatibility to its tion of the outlet nozzle flange. customers in pharmaceutical This allows easy retrofitting on and fine chemical field, De Die- existing reactors and tanks made trich Process Systems (DDPS) of glass-lined steel, stainless Will & Hahnenstein GmbH has extended its range of disc steel or nickel alloy. All features The Heating Specialist ! bottom outlet valves by adding of Cleanvalve 45° are preserved since 1919 a 60° outlet nozzle version. As with the following advantages: an alternative to the approved • Patented flat seat to avoid col- 45° valve, Cleanvalve with all its lection or build-up of materi- PHARMA DRYERS special properties is now avail- als in the annular area between able, with a 60° outlet nozzle the valve seat and nozzle wall HEATING + DRYING + COOLING according to DIN 28140-1. This • Self draining design of the in- DIN Norm defines the angle ternal components and body for trays, containers, • Cleanvalve is able to accom- component cleaning modate temperature measure- Options ment sensors, measurement solvent condensation and recovery, electrodes at the lowest point vacuum operation in the vessel • All DDPS glass-lined valves are made of cast steel coated with the standard DD3009 enamel identical to the reactors on heating and cooling jackets which they are installed. for standing or lying blending tanks Wetted parts feature the same characteristics of all other tailored to your glass-lined equipment. specific www.cpp-net.com requirements Online search: cpp0317ddps
L Talbahnstr. 1, D-57562 Herdorf Tel. +49 (0) 2744 9317-0 - Fax +49 (0) 2744 9317-17 E-Mail: [email protected] E www.will-hahnenstein.de Picture: DDPS Picture:
cpp 03-2017 53 cpp INSTRUMENTATION, CONTROL, AUTOMATION
Fibre-optic temperature measurement in a tight space Timely detection of hotspots
A fibre-optic temperature measuring system developed by Siemens enables tem- perature profiles to be determined in tight spaces, for example in tube or tube bundle reactors. By installing a large number of temperature measuring points inside a single tube reactor, areas with excessive temperatures (hotspots) can be detected at an early stage and action taken to control the flow of heat. Following successful trials at Evonik Resource Efficiency GmbH, this measuring system is now available.
In-line measurements of temperature pro- fibre-optic temperature measuring system ranged at individually defined points on the files in applications where space is restricted developed by Siemens in response to this sensor probe. The transmitter sends light represent a daunting challenge for the problem is based on the fibre Bragg prin- waves to the fibre-optic sensors and evalu- measuring equipment. This is particularly ciple. Fibre Bragg gratings are created by in- ates the reflected portions. In the trans- true when it comes to determining the tem- scribing optical periodic structures into the mitter, light is generated in the wavelengths perature profiles in tube or tube bundle core of an optical fibre. Since only a defined from 1500 to 1600 nm and output to the reactors. A large number of temperature wavelength of the incident light is reflected sensor probe by means of a continuously measuring points are needed in order to while all others are transmitted, each grat- tunable laser. Each fibre Bragg grating re- optimise and maintain the catalyst activity; ing acts like a filter with a narrow band- flects light of a defined wavelength, which these were difficult to achieve using con- width. varies depending on the temperature at the ventional measurement technology owing measuring point. to the small diameter of the reactor tubes, Wavelengths determine temperature Since the measured value transfer (reflection the required number of measuring points Sitrans TO500 temperature transmitters use of the light) takes place in the same fibre, and the necessary measurement speed. The fibre Bragg gratings (FBGs), which are ar- no additional cables are necessary, so that a much smaller cross section of the protective tube is possible for this measurement set- up. This firstly means that more reaction space is available in the reactor, with a posi- tive impact on the throughput. Secondly, the sensors have faster response times because the damping effect of the air gap between the fibre in which the gratings are inscribed and the tube walls can be reduced to a minimum.
Synchronous measurements The system consists of a transmitter to which up to four fibre-optic probes with up to 48 FBGs each can be connected. 192 tem- perature measuring points can therefore be processed synchronously by a single measuring system. Siemens tailors the measuring probes – the length, number of sensors and sensor positioning – individ- Pictures: Siemens Pictures: The Sitrans TO500 temperature transmitter based on the fibre Bragg prin- ually to each specific application. ciple enables temperature measurements in tight spaces Each probe with a diameter of less than
54 cpp 03-2017 Catalyst loading reduced Applications for non-contact measurement methods with fibre-glass sensors are in- creasingly widespread in the chemical in- dustry. These sensors are insensitive to elec- tromagnetic interference and resistant to the majority of chemicals. The ability to couple the optical signals is a further advantage. In
Structure of a fibre Bragg sensor: the transmitter sends light waves to the fibre-optic sensors and evalu- the Evonik installation, Siemens uses a fibre- ates the reflected portions optic coupler to connect the measurement fibre in the reactor and the transmission line to the transmitter. This coupler can simply be disconnected for maintenance, for example in order to open the reactor cover. Prior to inspecting the reactor or re- placing the catalyst, the measuring probe can be removed easily and rolled up on a spindle for safe and problem-free transport. The speed and accuracy of the temperature profile measurements, for instance during gas-phase reactions in a fixed-bed reactor, helps determine the thermal load within the catalyst filling and initiate suitable counter- measures to keep it active. The optical measurement system implemented by Siemens provides an elegant way to simulta- neously determine and process a large number of temperatures for monitoring and optimisation purposes. Disturbances can be Fibre Bragg gratings are arranged at indi- “The fibre-optic temperature measuring vidually defined points on the sensor probe, system helps us prevent the catalyst from detected efficiently and the reaction courses which can be inserted into a tube or tube being destroyed or ageing prematurely due optimised, leading to a higher product bundle reactor, for example to overheating”, explains Matthias Hüning throughput in the plant. Following an in- (left), who works in the electrical measure- ment and control systems section at Evonik tensive trial phase, the application described Resource Efficiency GmbH here is now being introduced into produc- tion at Evonik. www.cpp-net.com 2 mm measures temperatures in the range to the fibre-optic measuring system, we can Online search: cpp0317siemens from 0 to 400 °C with an accuracy of install a sufficient number of temperature <0.5 K. The response time is equally im- measuring points in a single tube reactor to pressive, namely less than 4 s for T90. enable us to detect excessive local tempera- A gas cell with a fixed absorption line serves tures at an early stage and initiate suitable as a reference in the Sitrans TO500 and the corrective action”, explains Matthias Hün- AUTHOR: wavelength determination is continuously ing, who works in the electrical measure- JOACHIM KÖLSCH Product Manager adjusted by it. The transmitter provides the ment and control systems section of Evonik Temperature, values which are determined in this way for Resource Efficiency GmbH’s High Perform- Siemens analysis in control systems via a Profibus DP ance Polymers Business Line in Marl. “Our interface, so that they can be made available operators are now aware of any hotspots for management of the assets and optimis- which occur, or any change in the catalyst ation of the process. The parameters of the activity, in good time. In the former case, Sitrans TO500 are set via the integrated we use this information to take steps to re- AUTHOR: Ethernet interface. duce the temperature, for example. In the MARTINA WALZER latter instance, we can carry out mainten- Manager Technical Concepts, Pilot project in Marl ance procedures such as replacing the cata- Siemens A pilot study with the Sitrans TO500 trans- lyst at precisely the right moment in the mitter was conducted at a manufacturing ageing process. Both applications extend plant for laurinlactam, a starting product the lifetime of the catalyst in the reactor. for Vestamid L, belonging to Evonik Per- Predictive maintenance on demand is now a formance Materials GmbH of Marl. “Thanks reality.”
cpp 03-2017 55 cpp INSTRUMENTATION, CONTROL, AUTOMATION Pictures: Exner Pictures: Thanks to the Excell230 NIR sensor, optical density can now be monitored continuously, both on a small laboratory scale and in complex production processes
Measuring optical density by means of NIR technology Monitoring cell growth
In the pharmaceutical and food industries cell growth is mostly measured optically. As part of the PAT initiative, the FDA is calling for online measurements of all process parameters relevant for quality. With the help of the Excell230 NIR sensor, optical density can now be monitored continuously, both on a small laboratory scale and in complex production processes.
During the product development and pro- have critical parameters such as optical den- fils all the requirements for measurements cess optimisation stages in development lab- sity, from which important conclusions can in both small laboratories and complex pro- oratories, optical density has so far mostly be drawn on the course of process, available duction processes. Thanks to its tiny diam- been determined offline in order to obtain throughout the product development stage. eter of just 12 mm, it fits into almost any information on the progress of the process, If these parameters are recorded continu- development fermenter. Attached to a the cell number or the biomass. The PAT ously when a product is developed and op- 12 mm port in the cover plate, it monitors (Process Analytical Technology) initiative timised, implementation in a large-scale and controls the process in the same way as launched by the FDA in 2002, however, process is much easier. with pH or oxygen measurements. The same requires online measurements of critical sensor can also be used in large-scale pro- and quality-relevant process parameters to One sensor for all applications duction processes owing to its standard fit- guarantee the quality of the final product. It The Excell230 NIR sensor developed by tings and the values it delivers are consis - is therefore reasonable and necessary to Exner specifically for such applications ful- tently identical to the underlying laboratory
56 cpp 03-2017 measurements. The days when time-con- Fields of application suming correlations had to be determined The optical sensor provides an easy way to between the measuring methods employed determine cell growth and cell density in in the laboratory and those installed in the numerous processes, for example mamma- process are gone. lian cells for the production of monocular By measuring in the near-infrared spectrum antibodies or bacteria cells for manufactur- (NIR), colour effects are eliminated and op- ing toxins, vaccines, enzymes, therapeutic timal absorption is achieved for most cells. agents or food products. Yeast and fungal The sensor meets all the specifications for a cells or microalgae are likewise monitored PAT device and the measurement takes place and optimised with the help of optical den- online. Robust and easy to handle, it has sity. The optical density parameter enables traceable calibration filters for direct, un- reproducible conclusions to be drawn about complicated sensor checking and cali- the total number of cells in the measured bration. The integrated measurement ampli- medium. The actual growth curve recorded fier connects the sensor with the process during the product development stage in the This robust sensor can be sterilised directly control system via a Modbus, USB or laboratory serves as a basis for optimal in the process as well as autoclaved 4…20 mA communication interface in further development and safe process con- order to start the measuring process. The trol. calibration data and all necessary settings are Since the same sensor is utilised both in the saved in the system. A functional test can be laboratory and in the subsequent production carried out before and after the application stage, the process parameters determined using various calibration filters. This ensures when the product is developed are easily that all recorded measurements remain cor- transferable, leading to enhanced process AUTHOR: rect and traceable throughout the process. It control, reproducibility and output quantity DETLEF EXNER goes without saying that the sensor can be and quality. CEO, sterilised directly in the process as well as www.cpp-net.com Exner Process Equipment autoclaved. A positive EHEDG report about Online search: cpp0317exner in-process sterilisability is available.
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T +49 2961 7405-0 | [email protected] Your Specialist for EXPLOSION SAFETY © REMBE | All rights reserved and PRESSURE RELIEF Consulting. Engineering. Products. Service. Gallbergweg 21 | 59929 Brilon, Germany | F +49 2961 50714 | www.rembe.de Visit us: Powtech, hall 3, stand 244
cpp 03-2017 57 cpp PHARMACEUTICAL / PACKAGING TECHNOLOGY
Tablet press containment Certificate of retention performance
As a complete solution for the safe and efficient production of tablets under containment conditions, Fette Compacting has introduced the Containment Guard: a quality certificate that characterises the retention performance of containment tablet systems even before the final risk assessment.
Anyone involved in pharmaceutical first step in the area of tablet production. turer of the medication forms the basis for production who wants to exploit the The Containment Guard is the first quality the containment system design. Manufac- opportu nities for growth associated with certificate to determine and document the turers determine the maximum permitted new, highly active substances, has to have retention performance of containment tab- limits from this assessment. This process in- safe and efficient containment solutions. let systems even before the operator’s final volves the use of models such as the occu- But that’s not all. Protective measures are risk assessment. It is both a test procedure pational exposure limit (OEL), the per- increasingly also required for a large and the foundation for the technical devel- mitted or acceptable daily exposure (PDE, number of medicaments that in the past opment of containment solutions in tablet ADE) or the maximum workplace concen- have been manufactured without taking production. The Containment Guard addi- tration (MAK). The limits specified in this special precautions. Low-dust production tionally offers comprehensive service, train- way serve as a reference for the subsequent systems are the new minimum standard. ing and consultation, precisely matched to risk assessment when the overall system is In practice, however, precise specifications the needs of production under containment put into operation based on the standard- for the individual process steps have not conditions. ised measurement of equipment particulate been available until now – in spite of airborne concentration (SMEPAC). This pro- comprehensive guidelines and stricter Based on toxicological limits vides a suitable framework for general as- enforcement by regulators. The toxicological assessment of the active sessments of a system’s containment quality. Fette Compacting is therefore taking the ingredients to be processed by the manufac- To enable a reproducible assessment specifi- cally for containment tablet systems, the Containment Guard supplements the SME- PAC guideline with further, practically rel- evant aspects: • Positioning of the measuring probes • Whereabouts of the operators • Number of samples taken • Operating states of the machine • Behaviour of the system in the presence of faults or malfunctions • Calculation of the system’s overall per- formance, including process equipment
Precise measurement, low expense The measuring criteria used by the Contain- ment Guard correspond to those of the SMEPAC guideline. However, this method al- ways covers the complete system, including the process and safety equipment.
Pictures: Fette Pictures: The structure and sequence of the test pro- High-containment plant with an isolator from Fette Compacting in use at Dr. Kade cedure are likewise standardised. Fette Com-
58 cpp 03-2017 An overview of the modular Containment Guard range Example of a total solution meeting Containment Guard 3: FE75 tablet press with containment package and process equipment
pacting performs the test in a specially lower manufacturing costs. Fette Compact- Level 5: Maximum safety equipped room at its Customer Centre in ing’s FE55 and FE75 tablet presses are the Encapsulating tabletting solutions that meet Schwarzenbek. After passing the test, the ideal technological solution here. When Containment Guard 5 offer maximum safety equipment receives the Containment Guard fitted with an optional containment pack- in production as well as optimum protec- certificate. Fette Compacting hands over the age and associated process equipment, they tion for operators. They are based on Fette documentation together with the system. form the basis for Containment Guard 3 Compacting’s isolator technology. The iso- This forms the basis for the operator’s risk upward. lators can be fitted with a range of options assessment and reduces ongoing expendi- In the FE series, the tabletting process is such as an upward de-duster, a metal detec- ture after the plant has been put into oper- fully automatic. From the filling of the ma- tor and an IPC Checkmaster for in-process ation. chine to tablet discharge, containment is monitoring. All transfer interfaces and flaps unbroken. The machines are accessible of the plant are sealed absolutely tightly. The Multi-stage model from every side through glove ports. The operator can carry out all the work required As a complete solution, the Containment containment package for the FE55 and on the machine or in the isolator with the Guard takes in all tabletting system compo- FE75 includes a flap valve for secure prod- help of the integrated glove ports and RTP nents. This particularly refers to third-party uct feeding, hermetically sealed and auto- accesses. Individual compression and in- process and safety equipment as well as matically lockable window flaps, rapid process monitoring steps can be supervised Fette Compacting’s patented air manage- transfer ports (RTP), a low-dust tablet out- via the HMI. The same applies to air clean- ment system. The individual stages of the let, H13 HEPA filters, a hand vacuum hose ing, which the operator can monitor using Containment Guard are oriented towards for initial manual cleaning, an interface for the software-controlled air management the pharmacological and toxicological clas- the process and safety equipment and a system, including a vacuum emergency sys- sification of the active ingredient (occupa- special software safety concept utilising the tem. In combination with a WiP Centre the tional exposure band, OEB). The OEB levels human-machine interface (HMI). plant can be cleaned automatically in a very are clearly illustrated in the containment short time. pyramid of the International Society for Level 4: Optimised cleaning www.cpp-net.com Pharmaceutical Engineering (ISPE). Con- When processing highly active and toxic Online search: cpp0317fette tainment solutions for tableting at OEB pharmaceutical ingredients, the use of Level 3 or higher – i. e. substances with a wash-in-place (WiP) systems significantly low pharmacological effect – are relevant in reduces the exposure of machine operators practice. during cleaning. The effort required for product changes is also reduced, so that Level 3: Low-dust standard there is far less machine downtime. The In the light of the increase in potentially containment tablet presses in Fette Com- hazardous substances, it can be assumed pacting’s i-series are supplied with a man- that products incorporating substances ually operated washing gun and a vacuum with low pharmacological activity and cleaner nozzle that easily remove product with relatively low dust exposure will be- residues from the compression chamber. An come the minimum standard for tablet RTP access is likewise integrated for insert- production. Efficiency is the central key to ing and exchanging tools.
cpp 03-2017 59 cpp PHARMACEUTICAL / PACKAGING TECHNOLOGY
Future-proof filling plant custom-made New construction or retrofit?
In mechanical and plant engineering, the term retrofit refers to the modern- isation or conversion of existing plants. Users wishing to preserve the tried- and-tested have their equipment updated to the latest state of the art. However, the complexity, scope and downtime should be carefully consider- ed in advance. SMB provides an example of how a safer, more up-to-date filling plant can be tailored to individual requirements.
Higher speeds and changing requirements often pose specific challenges for the oper- ators of filling systems. Drums, canisters, containers or other receptacles are used de- pending on the liquid or bulk material. In addition, the properties of the material to be filled are triggers for many more deci- sions: what form of explosion protection is now needed and will a cleanroom be necessary in the future? In particular, com- plex plants for high-risk materials call for a sophisticated and future-oriented strategy to ensure consistently reliable operation. Users seeking to adapt their filling systems to cur- rent safety standards must regularly exam- ine whether retrofitting the existing system makes eco-nomic sense or whether it might be better to invest in a new one.
Decision on a case-by-case basis The decision-making process can be illus- trated taking the example of an SMB cus- tomer in the chemical industry. The com- pany wanted to convert its semiautomated system to support smaller containers – in this case, steel drums – in response to new customer requirements. “Our expert team took a look at the initial situation and im- mediately noticed that, in addition to the containers themselves, other aspects like- wise play an important role in plant conver- sion”, reports Andreas Heckel, Managing Director of SMB International. “If a system has already been in operation for some
Pictures: SMB International SMB Pictures: time, it may no longer meet current stan- About 50 % of the components were replaced, expanded and equipped with new safety technology dards and regulations. It might not be ap-
60 cpp 03-2017 proved in this form today. That’s why adapt- ing to current safety stand-ards is also a key task.” The SMB engineers initially assessed the possibilities for extending the plant’s life- span. Old assets can often be preserved with the help of new and more advanced tech- nologies. The costs are moderate compared to purchasing a completely new system. “We decide and calculate on a case-by-case basis which variant we recommend to our customers. If the majority of the system components are so obsolete that spare parts are difficult to obtain or have ceased to be available, a retrofit measure is no longer worthwhile in the long run”, Heckel ex- plains. It is theoretically possible to convert up to 70 %, but with most projects less will also do the job. With 50 % of the components having to be removed, replaced, expanded Future-proof filling plant due to modern- The conveyor technology allows a process and equipped with new safety technology, isation of safety standards which is both safe and fast SMB classified the chemical plant as suitable for retrofitting. In close consultation with the customer, Andreas Heckel and his team in the filling plant. SMB also integrated a developed an individual concept to meet fu- new clinch unit, where the drums are auto- ture requirements. The goal was to realise an matically provided with lids that are fixed easy-to-use, future-proof filling line that with clamps. Moreover, a calibrated scale conformed to all the latest safety standards ensures that the product quantity always and provided all the functions necessary to meets the specifications exactly and that the increase the company’s productivity. goods leave the production plant ready for sale. The semiautomated system even be- Safety came fully automated as a result of instal- Numerous measures were implemented to ling these components. update the obsolete safety technology to The complete conveyor system supplied by current standards. Light barriers and addi- SMB is precisely matched to the container tional sensors greatly improve occupational for a process which is both safe and fast. A safety. The system can even distinguish be- user-friendly portal rounds off the im- tween containers and people – and stops proved system. The entire filling process can immediately if the safety limits are ex- now be controlled with very little effort, in ceeded. The new inerting station, too, en- other words without any restrictions or the sures the highest level of protection. The previously unavoidable manual interven- oxygen from the air is displaced by adding tion, such as opening the drums. nitrogen, an inert gas, thus preventing the The plant was recommissioned by the Andreas Heckel, Chief Executive Officer of build-up of explosive atmosphere. Ex Zones chemical company following a three-week SMB International 1 and 2 were also installed throughout the conversion phase and a successful FAT (fac- plant, of course, according to the level of tory acceptance test). Customer-specific risk and equipped with certified technology. documentation, including spare and wear gineers in Quickborn also manufacture parts lists as well as mechanical drawings of smaller components such as filling lances in Automation individual assemblies, was provided as part their own production shops. Spare parts can Filling plant and system technologies are of the final inspection. “Even after commis- be supplied at very short notice. This is an- constantly optimised. For example, SMB has sioning, we attach great importance to cus- other factor that companies should consider developed its own system for exchanging tomer satisfaction. This is why we compile when choosing between “new or retrofit”. filling lances automatically, in which the the documentation according to each www.cpp-net.com quick-release fastener is pneumatically con- client’s specific standards and are always Online search: cpp0317smb trolled. A crane system collects the lances available to answer questions – as well as for via a chain hoist and transports them to the training and maintenance contracts if AUTHOR: filling station. The extended functions of the required”, says Heckel. “To enable us to de- STEFAN WESENBERG filling lances with integrated filling hoses velop customised plants in a short time at Project Manager, and camera recognition enabled the cus- our in-house facility, we have opted for a SMB International tomer’s process to additionally be optimised high level of vertical integration.” The en-
cpp 03-2017 61 cpp CONTACT THE EDITORS
GÜNTER ECKHARDT LUKAS LEHMANN URSULA FISELY-BUSTORFF DANIELA HELD Editor-in-Chief Assistant Editor-in-Chief Editor Editor Phone +49 711 7594-291 Phone +49 711 7594-290 Phone +49 711 7594-373 Phone +49 711 7594-284 [email protected] [email protected] [email protected] [email protected]
JANOSCH MENGER DR. BERND RADEMACHER ANGELIKA STOLL CARMELINA DIVIGGIANO Editor Editor Editor Editorial Assistant Phone +49 711 7594-287 Phone +49 711 7594-263 Phone +49 711 7594-300 Phone +49 711 7594-415 [email protected] [email protected] [email protected] [email protected]
cpp LIST OF ADVERTISERS
amixon GmbH, Paderborn 17 Gather Industrie GmbH, Wülfrath 51 Samson AG, Frankfurt 22 AZO GmbH & Co. KG, Osterburken 5 GEA Wiegand GmbH, Ettlingen 47 Siebtechnik GmbH, Mülheim 19–20 GreCon, Alfeld 18 Siemens AG, Nürnberg 7 Singold Gerätetechnik GmbH, Schwabmünchen 25 Bausch + Ströbel Maschinenfabrik Sweco Europe S.A., BE-Nivelles 18 Ilshofen GmbH + Co. KG, Ilshofen 37–38 Hillesheim GmbH, Waghäusel 39 Beumer Group GmbH & Co.KG, Beckum 21 Vacuubrand GmbH + Co KG, Wertheim 3 Vega Grieshaber KG, Schiltach 64 Fr. Jacob Söhne GmbH & Co. KG, Vibra Maschinenfabrik Schultheis Porta Westfalica 23 GmbH & Co., Offenbach 24 C. Otto Gehrckens GmbH & Co.KG, Pinneberg 25 Coperion GmbH, Stuttgart 16 Maschinenfabrik Möllers GmbH, Will & Hahnenstein GmbH, Herdorf 53 Beckum 49 MTI Mischtechnik International Eisele Pneumatik GmbH, Waiblingen 23 GmbH, Detmold 52 Emde Industrie-Technik GmbH, Ystral GmbH, Ballrechten-Dottingen 15 Nassau 27
Rembe GmbH Saftety + Control, Brilon 50, 57 Fette Compacting GmbH, Robu Glasfilter-Geräte GmbH, Hattert 11 Schwarzenbek 2 Frewitt Fabrique de Machines SA, CH-Granges-Paccot 53
62 cpp 03-2017 Industrie
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media.industrie.de cpp 03-2017 63 The ultimate for small tanks! The future is 80 GHz: a new generation of radar level sensors
When it comes to contactless level measurement of liquids in small containers, smaller is better. With the smallest antenna of its kind, VEGAPULS 64 is simply the greatest! With its excellent focusing and insensitivity to condensation or buildup, this new radar sensor is truly exceptional. Simply world-class!
www.vega.com/radar
POWTECH: Hall 4, stand 514
Wireless adjustment via Bluetooth with smartphone, tablet or PC. Compatible retrofit to all plics® sensors manufactured since 2002.
64 cpp 03-2017