BULK MATERIALS HANDLING • POWDER HANDLING • QUARRYING • RECYCLING & WASTE BULK MATERIALS HANDLING • LOGISTICS • VALVES MANAGEMENT
DECEMBER FEBRUARY 2023 2017
PLANTFORCE TURN THE KEY ON A NEW HEAVY HAULAGE DIVISION FULL ARTICLE ON PAGES 18-19
HIGHLIGHTS:
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for weighing and
Longevity, Reliability
High precision feeders batching
Valve Actuators Built for
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Develon Wins Two Honours at CES 2024 Innovation Awards
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VIBRA-JET ® BIN DISCHARGE SYSTEM WEIGH HOPPER
DYNA-SLIDE TM HIGH PRECISION AIR-ACTIVATED FEEDER
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Dynamic Air Ltd. Milton Keynes, United Kingdom +44 (0) 1908 622344 • sales@dynamicair.co.uk
www.dynamicair.com
Issue 165
BST TEAM Sales Director: James Scrivens Production: Sarah Daviner Accounts Manager: Avery Hudson Office Manager: Katie Brehm
CONTENTS
BULK SOLIDS TODAY is published 6 times a year by Abbey Publishing Ltd ADVERTISING & EDITORIAL Please contact us at: Tel: 01933 316931 Email: editorial@bulksolidstoday.co.uk advertising@bulksolidstoday. co.uk Web: www.bulksolidstoday.co.uk Twitter: www.twitter.com/ BulkSolidsToday CIRCULATION To receive a copy free of charge, please send your details to subs@bulksolidstoday.co.uk No part of this publication may be reproduced by any means without prior permission from the publishers. The publishers do not accept any responsibility for, or necessarily agree with, any views expressed in articles, letters or supplied advertisements.
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NEWS
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VALVES
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FEEDERS & CONVEYING
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LOGISTICS & TRANSPORT
20 QUARRYING & MINING 22
BULK MATERIALS HANDLING
ISSN: 1365/7119 All contents © Abbey Publishing Ltd 2017
www.bulksolidstoday.co.uk Bulk Solids Today
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COMPANY NEWS
HIGH PRECISION FEEDERS FOR WEIGHING AND BATCHING When it comes to weighing and batching, choosing the proper dosing feeder is crucial to achieving a reliable and accurate system. Although scale accuracy is important, the accuracy of the feeder is even more important since the feeding needs to stop when the desired weight is
achieved. Because each material and application are unique, Dynamic Air offers a variety of feeders for weighing and batching, including screw feeders, air-activated feeders, vibratory feeders and more. Dynamic Air also offers complete custom designed weighing and batching systems.
Bulk Solids Today is the bi-monthly digital journal covering the storage, processing and handling of materials ranging from fine powders to the heaviest raw materials. To subscribe to Bulk Solids Today magazine or for more information, please feel free to visit www.bulksolidstoday.co.uk 4
Bulk Solids Today
https://www.dynamicair. com/products/dynaslidehp. html Dynamic Air Inc. St. Paul, MN (651) 484-2900 info@dynamicair.com www.dynamicair.com
WE DON’T DO A HUNDRED THINGS. WE DO ONE THING RIGHT! THE 6X®. OUT NOW! We have known this for over 60 years. That’s why this new radar level sensor is not available in 100 different versions, just one perfect one. The VEGAPULS 6X is highly versatile, absolutely reliable and works in any process and environment. The only thing it doesn’t do is stress.
VEGA. HOME OF VALUES. www.vega.com/radar
COMPANY NEWS
PACE AWARDED THIRD PROJECT BY BEDMAX This month, one of the UK’s leading designers and manufacturers of automated and robotic packing and palletising solutions has received its third six-figure order from an innovative manufacturer of environmentally sound equestrian products. PACE Mechanical Handling will follow up on its two previous projects for Bedmax in the New Year when it starts installing a state-of-the-art packing line at the company’s Newark factory. Bedmax, which makes dustfree horse bedding from pine wood shavings, will use PACE’s machinery to pack Hotmax dustwood logs, a by-product of the manufacturing process. One of the unique features of Bedmax is that the bedding is dust-free, which appeals to professional horse trainers. As a business that seeks to use everything that enters its factory, Bedmax’s production team realised they could use the dust extracted from the pine shaving to form fuel logs. The extracted dust is pre-dried, allowing it to be extruded under pressure into densely compacted wood heat logs bound together by the natural lignin inherent in the wood. PACE’s end-of-line solution comprises an automatic sack presenter, complete bag control (CBC) and robotic stack and wrap, which will work with Hotmax’s three types of packaging: 10 and 20kg bales in weatherproof material and 10kg paper sacks. PACE received the order for the Newark site after successfully installing similar lines at Bedmax’s factories in Northumberland and Andover. “The end-of-line solution that we have developed for Bedmax is one of our most sophisticated yet,” says Nick Cesare, managing director. “We have developed a new way of receiving the logs and have modified how the bag clamp works so that it can heat seal the 6
Bulk Solids Today
plastic bags with their gusset-out style and stitch the paper packs, which are gusset-in. We have learned a lot from installing the first two lines and will be making further enhancements to the third line, and once that has proven itself, we will retrofit the changes to the first two lines.” Before working with PACE, Bedmax relied on old and inefficient coal-packing machinery at all three sites. “We have an ethos of continuous improvement and refinement,” says Bedmax’s founder and managing director Tim Smalley. “We are always trying to improve the worst part of our process, and at the moment at Newark, that is how we pack our products. It is labour-intensive and difficult work. At our other sites, PACE’s end-of-line solution runs 24/7 and is reliable, accurate and easy to service and maintain. We want to have the same peace of mind at Newark.” As well as being more efficient, each of the £150,000 lines have a smaller footprint than the coal packing machines they replace, making the factory tidier and easier to work in. Production of Bedmax began in 2000 at Greymare in a purposebuilt plant. Hotmax fuel logs were launched in 2008, by which time
the company was exporting its bedding to France, Germany, the Netherlands and the Czech Republic and was chosen as the official choice of bedding at the Badminton Horse Trails. Today, the company has a turnover of over £17m and employs 60 people across its three sites. PACE Mechanical Handling was established in 1996 and uses four core products to develop reliable, efficient and costeffective automated packaging and palletising solutions: the Gemini twin head weigher, Orion Weigher, Orion Weigher and sack placer and the CBC sack placer and stitcher line. Thanks to its long-standing partnership with Motoman of Japan, PACE Mechanical Handling offers a wide range of robots, from pick and place to specialist heavy lifting models. By having its own team of fabricators and software engineers and extensive experience in designing and installing complete production lines, Nick and his team can deliver everything from a small automated packing robot to a complete turnkey solution. For more information about PACE and its end-of-line automated and robotic packing and palletising solutions, visit www.robotpalletizing.co.uk
COMPANY NEWS
ALFA LAVAL AND BISVIRIDI PARTNER TO REVOLUTIONIZE BIOFUEL PRODUCTION FROM ORGANIC WASTE Alfa Laval, the global leader in heat transfer, centrifugal separation, and fluid handling, and Bisviridi, a new company part of the BioteCH4 group, the leading anaerobic digestion (AD) operator in the United Kingdom, are collaborating to elevate the sustainability potential of organic and food waste recycling. The partnership integrates Alfa Laval’s state-of-theart Prodec Oil Plus decanter, designed for efficient oil separation, with anaerobic digestion to convert oil and fats waste into biofuel. This groundbreaking process, developed and patented by Bisviridi, produces Bio Crude, an eco-friendly alternative to oil-based fuels. Notably, Bio Crude can be refined into sustainable aviation fuel (SAF), aligning with the aviation industry’s decarbonization goals and entering an emerging market. Lee Dobinson, Chief Commercial Officer of Bisviridi, highlights the value of the partnership, stating, “The fluctuation in oil prices over the last few years and the need for large biodiesel companies to find new sources of sustainable waste-oil streams has led us to develop a way of harnessing this waste material and diversify the output of the BioteCH4 business, increasing its revenues and sustainability. We are thrilled to collaborate with Alfa Laval, merging our AD expertise with their successful history in separation technology to further refine this process and potentially achieve large-scale production worldwide.” Carl Rehncrona, Business Unit President at Alfa Laval, emphasizes the commitment to success, stating, “Alfa Laval’s comprehensive product knowledge and global service presence will fully support the entire lifecycle of the decanter skid. Together with Bisviridi, we are setting a new standard in AD, and we firmly believe that we can make a significant positive impact on the industry by transforming food waste and creating a more sustainable and resilient future.” Recover every drop of value The Alfa Laval Prodec Oil Plus decanter, a key component in the Bisviridi process, seamlessly integrates into any AD facility, offering numerous benefits. Prior to methanogenesis, the decanter efficiently extracts oil from organic waste, removing oils, fats, and grease content. This allows the remaining components to be reintroduced into the AD system, with minimal impact on biogas production. The resulting bio crude boasts impressive purity levels of up to 99.5%, making it an ideal feedstock for refineries to produce biofuel for the SAF market. Through a recent collaborative effort with BioteCH4, the AD plant can achieve a remarkable production capacity of up to, but not limited to 300 litres of oil per hour, all while seamlessly increasing and diversifying
the AD operator’s revenue stream. The Prodec Oil Plus decanter’s innovative design ensures easy operation and maintenance, resulting in minimal payback time and total cost of ownership. It is available as a standalone component or as a plug-and-play skid, allowing for effortless integration into existing AD plants and processes. To learn more about the new Prodec Oil Plus, please visit: www.alfalaval.com/prodecoilplus .
Other Valves Fight Friction, We Designed it Out Unlike other valves that seal with friction, Posi-flate’s unique butterfly valve uses an inflatable seat to seal with air pressure. Thus it requires less torque and a smaller actuator, resulting in lower cost. Plus, the seat automatically compensates for wear, providing longer life. Some users have reported over six million cycles and the valves are still going strong. • • • • • •
Less friction Low torque Low maintenance Lower actuator costs Longer valve life More reliable Tel: +44 (0) 1908 622366
www.posiflate.com
Bulk Solids Today
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COMPANY NEWS
CLEAN METHOD FOR EMPTYING LARGE BULK BAGS Dynamic Air BulkBuster bulk bag unloaders provide the solution for safely and effectively emptying large bulk bags. The Series 422 Model H1900 BulkBuster bulk bag unloader provides a clean method of discharging bulk bags since it includes internal dust collection for containing fugitive dust. The removable bayonet mounted cartridge filters provide continuous cleaning, and they recycle fugitive dust by discharging it back into the process hopper
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Bulk Solids Today
below. The Series 422 Model H1900 unloader also features a viewport, work gloves to allow the bulk bags to be untied and emptied without contacting the bag contents, and a bag closing mechanism, which allows partial bag unloading. Also included are air operated bulk bag jostlers for faster discharging of difficult to handle materials. https://www.dynamicair. com/products/bagunloaders. html
Dynamic Air Inc. St. Paul, MN 651 484-2900 info@dynamicair.com www.dynamicair.com
COMPANY NEWS
If you would like to subscribe to receive a regular copy of the digital edition of Bulk Solids Today magazine, you can subscribe on our website - www.bulksolidstoday.co.uk If you are interested in advertising within Bulk Solids Today magazine or supplying editorial content, please feel free to get in touch using the details on our website or below. Bulk Solids Today is sent to our digital readership of over 9,000 Chief Engineers, Operations Managers and Technical Managers from within sectors including Chemicals, Food & Drink, Mining, Quarrying, Transport/Distribution, Recycling & Waste Management and more. www.bulksolidstoday.co.uk
Bulk Solids Today
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VALVES
DANFOSS POWER SOLUTIONS EXPANDS TRACTOR VALVE PLATFORM, ENABLING USE ON WIDER RANGE OF MODELS • ADDITIONAL ZERO-LEAK ELECTROHYDRAULIC MODULE SIZES AND NEW MECHANICAL MODULES ROUND OUT PROPORTIONAL VALVE OFFERING FOR AGRICULTURAL APPLICATIONS Danfoss Power Solutions, a leading global supplier of mobile and industrial hydraulics as well as electric powertrain systems, has enhanced its tractor valve platform with additional electrohydraulic module sizes as well as new mechanical modules, enabling the valve to be used on a wider range of tractor models. Proven in farm fields for more than 20 years, Danfoss’ tractor valve provides rear implement, front implement, and front loader control. Built on the PVG 32 proportional valve platform, the tractor valve offers a variety of components and features specific to agricultural applications. A range of valve modules — inlets,vworking modules for auxiliary functions, hitch modules, top-mounted modules, and endplates — enable customization for each specific application. Danfoss has added zero-leak electrohydraulic PVBZ 16, 40, and 48 modules to the platform, which enables the valve to cover flow rates of up to 170 liters per minute (44.9 gallons per minute). The new sizes enable customers to tailor the flow rate for each service more accurately. All PVBZ modules are based on the PVG 32 platform, eliminating the need for interface plates and allowing them to be combined in numerous configurations to match customer needs. The new
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Bulk Solids Today
modules are compatible with PVE electrohydraulic actuators. For tractors with mechanical implement actuation requirements, Danfoss has added zero-leak mechanical MVBZ modules to its valve platform. The MVBZ modules can be combined with the electrohydraulic PVBZ modules, enabling the use of mechanical modules for auxiliary function control and electrohydraulic modules for hitch control. The new mechanical modules also enable the valve to be used on base-model tractors. “Danfoss tractor valves have long been used on many of the top tractor brands worldwide. With these enhancements to our valve platform, we are now a full-line valve supplier able to meet the needs of a wider range of tractor models, from small to large and basic to advanced,” said Jonas Lauersen, senior sales development manager, Spool Valve Solutions, Danfoss Power Solutions. “The valve offers a number of benefits, including a high degree of design flexibility and minimized parasitic losses. Danfoss’ unmatched global service and support rounds out the offering, providing our customers with a complete package.” Visit the Danfoss PVG valve webpage for more information.
VALVES
TORQSENSE TRANSDUCERS HELP TO GUARANTEE VALVE ACTUATOR PERFORMANCE Rotork Controls has established a global reputation for robust and reliable valve actuators, operating in some of the world’s most demanding and critical applications. Thorough testing of the motors used in the actuators is one of the keys to this assured performance, with TorqSense transducers from Sensor Technology playing a vital role in the test process. Rotork is the world’s leading manufacturer of electric, pneumatic and hydraulic valve actuators and associated control systems, valve gearboxes and valve accessories. The company’s electric valve actuator division offers an electrical solution to industrial valve control and actuation applications of virtually any size, description and complexity. Its capabilities encompass actuators and control systems for new plants, plant extensions and upgrades, together with life-of-plant support. The division’s unrivalled range of products offers a robust and economic solution for every valve duty and operating environment. Rotork Controls chief development engineer Geoff Beeho comments: “If you look at something like an oil line, then any failure of the valve actuator could potentially be costing millions of dollars a day. We have to be able to guarantee the performance of the actuators in the most demanding conditions, so testing is vital. TorqSense torque transducers from Sensor Technology are a key element of our test rigs.” Companies and businesses around the world rely on Rotork actuators, in applications as diverse as power generation, water and sewage, industrial processes, subsea, marine, HVAC, incinerators and cement plants. Common features in many of these applications are challenging environmental conditions, extremes of temperatures, and high costs associated with any downtime. Because of this, absolute reliability of the valve actuators is vital. Rotork Controls designs custom actuator designs built around motorised gearboxes, using non-standard open frame motors. “We use a variety of motors depending on the particular application, including DC motors, singlephase motors and three-phase motors, but we don’t rely on off-the-shelf products. Instead, we use open frame motors that we integrate directly into our own systems. “Performance testing is very important,” he continues. “The duty cycle is atypical – our motors are not in continuous use, only running intermittently and for short period. What is important to us is the short term ratings, and this data isn’t always readily available. We have to have performance data that will tell us exactly what we need to know about the motors in these most demanding applications.” Rotork Controls designed its own rig to test the motors, with Sensor Technology TorqSense transducers at its heart. “We needed non-contact torque sensors in the rig. The early design used magnetically coupled torque sensors but we were never completely happy with these. So when we upgraded the rig to be able to
perform a wider range of tests, we took the opportunity to look around the market and we found the TorqSense transducers.” “The TorqSense transducers immediately struck us as being a much more robust solution, better suited to handling the torques we were subjecting them to,” comments Beeho. The common practices of over-specifying a motor that guarantee reliable operation in standard applications simply don’t apply in valve actuation. “Motor sizing is critical,” says Beeho. “If we put in a motor that is too big, then we can risk damaging the valve. We can use motors that appear to be under-rated, but because our duty-cycle is so short we can get better performance from the motor. But the performance data to support this sort of motor use isn’t always available, or isn’t always reliable, so we need to perform our own tests. We also need to know how our motors will handle extremes of temperature in given applications so that reliability is never compromised. The TorqSense transducers allow us to make all the required tests.” An advantage of the TorqSense transducers in the Rotork test rig is that they provide both analogue and digital outputs. “This has proved to be a real bonus,” says Beeho. “Not only can we use one output to check the calibration of the other, but it also means we have the flexibility to use both outputs performing different tests. For example, we might use the analogue output to feed torque and speed data into the power analyser during a performance test, and then use the digital output for a temperature test. Here, we run the motor for 15 minutes at constant torque and see how hot it gets. The output from the TorqSense transducer allows us to close the loop so that we can keep the torque constant.” In any application, the fundamental considerations are the actuator’s ability to overcome the resistive forces of the valve, and the dynamic performance requirements to enable the valve to adequately meet the process demands. With its comprehensive testing procedures built around the TorqSense transducers, Rotork Controls has the confidence that its electrically operated valve actuators will always meet the application requirements. Bulk Solids Today
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VALVES
VALVE ACTUATORS BUILT FOR LONGEVITY, RELIABILITY High cycle actuators are often seen as having a short lifespan, with costly installation and maintenance requirements. However, many leading processors are realizing that well-designed actuators can offer reliable performance for years with minimal maintenance or repair. In food, pulp and paper, pharmaceutical, and chemical plants, processors often operate around the clock to produce chemicals, paints, resins, lubricants, ingredients, and other raw materials. To manufacture these products, high-speed, high cycle actuators open, close, or throttle valves to regulate, direct, or control the flow of gases, liquids, fluidized solids, or slurries. Regrettably, many processors today have become accustomed to the idea that high cycle actuators have a short lifespan and necessitate regular maintenance to replace parts prone to wear, such as O-Rings, springs, cylinders, and others. In some facilities, this task can consume a technician’s entire work schedule. However, many leading processors are beginning to reassess this expectation, given the high costs for installation and maintenance. The truth is that a well-designed actuator should be able to provide reliable performance for many years
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Bulk Solids Today
beyond the warranty period. If maintenance or repair is needed, it should be infrequent and simple enough for a single technician to handle, using common tools. For maintenance or repair purposes, the actuator should be easily accessible without the need to remove it from the valve. This is a crucial factor, as valve manufacturers will invalidate warranties if the actuator is detached from its mount. HIGH DEMANDS ON ACTUATORS
Actuator usage and stress are often linked to the frequency of valve opening and closing cycles. The cycle count often varies based on the environment or application. Some actuators are seldom used, while others operate regularly. High cycle, high-speed valve actuators – often found in processor operations – can fire rapidly and repeatedly many times per hour, nonstop throughout the year. The core issue lies in the high utilization and demand placed on the actuator. Actuators come in different styles based on the mechanical action required, such as linear or rotary, but all involve moving parts that experience considerable force, wear, and stress. In processing
VALVES plants, actuators are also installed in highly corrosive industrial settings. Many designs fail to account for these factors and are poorly engineered, leading to excessive side loading, wear on non-wearing parts, and various other issues. High reliability is another crucial factor that holds significance for Scott Howard of NewGen Products, a specialist in valve automation. Many of his customers are in the aerospace industry, where valves with actuators regulate the flow of cryogenic gases for fueling and storage operations. For critical applications like these, Howard often recommends a top-of-the-line actuator, purpose built for the application. Although there may be a higher initial cost, these actuators are designed to perform reliably in challenging and harsh environments. Even within this category, however, many actuators are not expected to last. “Many of the higher end actuators are rebuilt every three to four years,” says Howard. There are exceptions, including what Howard refers to as the “Ferrari” of actuators from Tomball, Texas based QTRCO actuators. Founded in 1998, QTRCO has innovated designs specifically for high cycle, high speed, high reliability applications. The actuators are built with a robust mechanical design that eliminates common failure points like sliding parts, side load forces, and multiple seals. This makes them perfect for demanding applications in extreme temperature, corrosive, or submerged environments. NO MORE LUNCHBOX
Among the more innovative designs from QTRCO is its answer to the common aluminum “lunchbox” actuator and its inherent design limitations. The actuator, which gets its name from its onepiece aluminum extruded body and cylinder that resembles a lunchbox, is popular because it is compact, inexpensive, and works well. Aluminum lunchbox actuators are not very reliable and often break, however, in more demanding environments or applications. To resolve many of these issues, QTRCO designed an actuator with an internal “rack and gear” mechanism as an alternative to its traditional rack and pinion design. The actuators are designed with offset cylinders that align the piston axis with the pinion gear pitch circle diameter, eliminating cantilever forces and friction. The company also replaced the sliding blocks, wear pads, and bushings with specialized rollers. As a result, the rack and gear actuators have extremely low internal friction. The new design also eliminates one of the primary causes of failure of a lunchbox actuator: the O-rings on the shaft. In a lunchbox actuator, air is forced through ports in the body. The air pushes the piston outwards, and springs push the piston back in. Each cycle pressurizes the shaft, which typically has two O-rings, one at the top and one at the bottom. As
the shaft cycles back and forth 90 degrees, the reciprocating motion places significant stress on the O-rings. In QTRCO’s design, this action is reversed, and the air is forced inward through the end cap. The spring return applies no pressure to the shaft seals, which prevents premature O-ring wear. This configuration also has benefits when valve throttling is required. Due to the design of the company’s Q Series and because the piston is located close to the end cap, much less air fill volume is required, and the actuator responds much quicker and is easier when throttling. QTRCO took a similar approach as an alternative to Scotch yoke actuators. Also known as a slotted link mechanism, the Scotch Yoke is a simple and effective mechanism that has been used for a long time. However, with typical Scotch Yoke actuators, the force applied to the piston rod is also applied to the shaft and shaft bushings, resulting in friction and bushing wear. To resolve these issues, QTRCO designed a patented Flat Yoke mechanism that can accurately and reliably position any rotary control valve requiring up to 500,000-inch lbs. of torque. The Flat Yoke is designed with quad body slots that absorb the mechanism’s side loading forces, leaving the piston rod completely free of bending stresses while allowing termination of the rod at the yoke. Like the Q Series, these F Series actuators also have extremely low internal friction, consume minimal air volume, and can handle the most severe throttling applications. FREQUENT REPLACEMENT
With an actuator specifically designed for reliable and long-lasting performance, processors can save on costs associated with more frequent replacements. In one processing plant he visited, Howard says the actuator fired twice a minute throughout the entire year, adding up to over a million cycles per year. Given the usage, the plant would replace the actuator annually during planned outages. According to Howard, the replacement of an actuator typically requires an entire day for a single technician, often with the help of at least two additional individuals. If the actuator is large enough, a crane is required. Considering the potential costs for hourly labor rates and rentals, a plant could save thousands of dollars every time it eliminates the need to replace an actuator. “If a plant doesn’t have to change the actuator every year, they just saved a fortune,” says Howard. When preventative maintenance or repair is required, it should be easily conducted using common tools and without removing the actuator from the valve. With large, metal-seated ball valves, it is critical to mount the actuator with extreme precision. A slight misalignment during mounting can result in severe damage to a valve that carries a hefty price tag of hundreds of thousands of dollars. The connection is so Bulk Solids Today
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VALVES crucial that most major valve manufacturers will void warranties if the actuator is removed. In rare cases, like with QTRCO designs, the actuators can be easily maintained without removal from the valve. This enables hassle-free removal and replacement of end caps, cylinders, and O-rings, often without special tools. SAFETY
According to Ross Evans, also with NewGen Products, safety is another concern during preventative maintenance and repair. Actuators of considerable size may require two people for lifting and moving. “Imagine being in a plant environment and climbing six flights of stairs to a catwalk to service an actuator. With that kind of weight, what does it take to get your cranes and rigging in place to safely take off the actuator? You have to remove all the pneumatic airlines, disconnect the electrical, and you need a couple hands. There’s a lot of cost and time and risk involved,” explains Evans. “The alternative is, I can do maintenance on the valve while it is in place,” adds Evans. “I shut down the unit, tag it out, take off the end cap, inspect the cylinder, remove an O-ring, grease it, and put it back in place. In about 10 minutes per cylinder, we are back and running.” The actuator’s design can also contribute to safety concerns. Many Scotch Yoke designs feature a lone piston assembly on one side of the unit. Lifting or rigging an unbalanced, single piston assembly is challenging due to its significant lean on one side. For high speed, high cycle processing applications, QTRCO recommends sizing up to a two-piston version of its Flat Yoke design. The two pistons balance the forces on both sides of the shaft, preventing bushing wear. The design also includes the addition of a weight and force balancing second force module diagonally offset from the first. By balancing the forces, there is less friction and wear and no net force applied to shaft bushings. The balanced weight also makes lifting and handling of the actuators safer and easier, while reducing valve neck stress that can occur in unbalanced scotch yoke actuators. Another issue is the spring set used in many lunchbox actuators, which are under load and must safely be controlled once the end cap is removed. If the spring becomes jammed and the mechanism that contains the spring fails, the force exerted can be equivalent to a shotgun. “In one actuator, the end cap corroded and failed. It discharged the spring out of the actuator across the shop,” says Evans. He says he has personally observed experienced field technicians that regularly work on actuators, who move out of the line of the cylinder to remove the 14
Bulk Solids Today
end cap on the actuator. “Anybody that’s done any type of maintenance on an actuator, they know the potential energy contained in the spring,” says Evans. With QTRCO, the spring is fully captured using a solid stainless-steel rod that goes through the spring retainers and there is a safety collar that locks it into place. Replacing the springs simply requires removing the end cap and replacing the cartridge. “Once they capture those springs, it is designed not to ever come apart again – it remains captured. It is a big safety feature,” says Evans. Cost-Effective Solution for Processors Installing actuators that are built to last and require minimal maintenance or repair not only brings significant benefits, but also proves to be more cost-effective in the long run, even if the initial cost of ownership is higher. When multiple actuators are installed in a processing plant, the savings can add up. “If you put a well designed actuator in one of these demanding applications and rarely have to do any maintenance or replace it very quickly, the total cost of ownership is far less,” says Evans. “If you can get an extra three or four years of run time on an actuator, you just made up whatever cost difference you had on the initial price,” notes Evans, adding that does not even take into consideration the number one thing that costs the plant money: downtime. Today, design advancements in high speed, high cycle actuators make it easier for food, pulp and paper, pharmaceutical, and chemical processors to create high-quality products. With an actuator specifically designed for reliable and long-lasting performance, processors can reduce costs associated with a labor-intensive manufacturing component that today too often requires frequent maintenance, repairs, and replacement.
VALVES
If you would like to subscribe to receive a regular copy of the digital edition of Bulk Solids Today magazine, you can subscribe on our website www.bulksolidstoday.co.uk If you are interested in advertising within Bulk Solids Today magazine or supplying editorial content, please feel free to get in touch using the details on our website or below. Bulk Solids Today is sent to our digital readership of over 9,000 Chief Engineers, Operations Managers and Technical Managers from within sectors including Chemicals, Food & Drink, Mining, Quarrying, Transport/ Distribution, Recycling & Waste Management and more. www.bulksolidstoday.co.uk bst@abbeypublishing.co.uk
Tuf-Lok ring grip pipe and tube couplings are rugged, heavy duty, self-aligning and self-grounded couplings with a high end pull. They can be used for almost any application where pipe or tube ends need to be connected. The Tuf-Lok self-aligning couplings install quickly and easily with little effort. Features • Self-aligning • Self-grounding • High pressure rated • Full vacuum rated • Stainless or mild steel • Usable on thin or thick wall pipe or tube • Low cost • Reusable • Absorbs vibration • Externally leakproof
Tuf-Lok (UK) Tel: +44 (0) 1706 822512 Email: sales@tuflok.co.uk • www.tuflok.com
Bulk Solids Today
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FEEDERS & CONVEYING
NEW TO THE MARKET: BOBCAT FORKLIFTS AND WAREHOUSE EQUIPMENT The logistics market has recently acquired a new brand of forklift trucks: Bobcat. The brand is world famous for an extensive range of compact machines, which are used in construction, the agricultural sector, landscaping, demolition, recycling and many other industries. Bobcat loaders and telehandlers, which can be equipped with attachments such as buckets, grabs, bale clamps, dump hoppers and pallet forks, are often used for material handling and logistics tasks. It is therefore no surprise that products from sister company - Doosan Industrial Vehicle (DIV) forklift trucks and warehouse equipment - are now part of the Bobcat family. These material handling machines will be produced in the well-known Bobcat colours from 1st January 2024. The history of Bobcat forklift trucks goes back to 1968 when the first forklift truck was produced in South Korea under the Daewoo brand. In 2005, the company was taken over by Doosan, after which DIV was founded in 2011 as part of Doosan Infracore. In 2021, Doosan Bobcat took over the company and all of the elements of the organisation. These include two factories in Incheon (Korea) and Yanta (China), where forklifts are produced, and a factory in Lübben
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Bulk Solids Today
(Germany) where pallet trucks and stackers are made. The company is currently active in more than 90 countries. WAREHOUSE AND PRODUCT INSPECTIONS
In 1993, DIV started selling in mainland Europe from a location in Belgium. In 2007, the company moved to a warehouse and distribution centre for forklift trucks, warehouse equipment and spare parts in Sint-Niklaas in Belgium. The European headquarters of DIV is also located in Sint-Niklaas, where the sales, marketing, customer service, technical support administration and HR departments are based. This branch of the company, which has now been renamed Doosan Bobcat Belgium, will undergo a number of changes, involving an investment of approximately two million euros. The offices are being renovated and refurnished in the Bobcat corporate identity, to create a modern and attractive workplace. In addition, the facilities for technical inspections, predelivery inspections and service are being expanded and modernised. For example, new lift bridges and a spray booth are being installed. In addition to SintNiklaas, DIV has its own sales offices in France, Italy
FEEDERS & CONVEYING
and Germany. In other countries, the company works with importers/resellers. PRODUCT PORTFOLIO
The Bobcat range for logistics and material handling now consists of various product lines: a series of diesel forklift trucks with lifting capacities from 2 to 16 ton; a series of LPG forklift trucks with lifting capacities from 2 to 7 ton and a series of electric forklift trucks with lifting capacities from 1.2 to 10 ton. The latter segment also includes a line of electric forklifts with three wheels for light work from 1.2 to 2 ton. The warehouse solutions include pallet trucks, stackers and reach trucks. During the last LogiMAT exhibition in Stuttgart in Germany, Doosan Bobcat introduced a number of new machines. The new B80NS forklift truck was on display, which is part of a series of electric counterbalanced forklift trucks with lifting capacities of 8 and 10 ton. In addition, two prototypes were on display: the three wheel B18NT electric forklift with a lithium battery and the B30X-7 Plus hydrogen forklift. BOBCAT DNA
The DIV website states that the company strives to bring simple and powerful machines to the market that offer the driver a lot of comfort and that are also environmentally friendly. These ambitions make it clear that the two companies are a great fit,
because Bobcat’s principles are virtually the same. Both companies also invest heavily in innovation to develop valuable and reliable products for their customers, so that they can perform their work efficiently and get optimal return on their investment. Thanks to the integration into Doosan Bobcat, DIV can benefit from Bobcat’s extensive R&D facilities, a number of exciting machine management innovations, marketing know-how and Bobcat’s extensive dealer network, while Bobcat now has a virtually complete portfolio of compact machines. For more information about Bobcat and its products, visit www.bobcat.com. Bulk Solids Today
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LOGISTICS & TRANSPORT
PLANTFORCE TURN THE KEY ON A NEW HEAVY HAULAGE DIVISION Plantforce invests in nine new state-of-the-art lorries and trailers to kick start a new heavy haulage division to offer a new service of movement of heavy plant and machinery around the UK. As an established Tier 1 Plant Hire provider that covers the length and breadth of Great Britain, Plantforce is no stranger to the art of efficiently and safely moving all sorts of heavy equipment around the country to all kinds of locations. That is why they have been able to offer a credible and competitive service of plant and machinery movements to both new and existing customers. As well as meeting customer demands, increasing safety and reducing emissions have been at the heart of the decision-making process when evaluating which trucks, they would start this division with. This is why Plantforce has selected Volvo Trucks as their preferred supplier for this latest round of investment that sees a range of FL 4 wheel rigid beavertails, FM 430 8 wheel rigid beavertails, FH 540 6 3 axel with step frame trailers in addition to FH 540 and flagship FH16 750 4 axel with step frame trailers join the fleet of existing trucks. With all of the fleet Euro 6 compliant and fitted with the Volvo Connect telematics system, Plantforce
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Bulk Solids Today
has the ability to manage their fleet effectively to maximise their efficiency, whilst customers can utilise a tracker system installed on all trucks to give an extra level of visibility to exactly where the vehicle is and calculate an accurate arrival time. To reinforce this, Plantforce Heavy Haulage have CLOCS Champion and FORS Silver accreditations, but the team are not finished there. They are already well working towards being awarded the FORS Gold accreditation. This approach to compliance also means that all vehicles are TFL, FORS and
LOGISTICS & TRANSPORT
HS2 compliant, meaning deliveries to tier 1 projects is within their capabilities. However, as always, investing in training and developing the people working within the team is even more important. That is why all drivers are qualified with NPORS Loader Securer and Plant Mover qualifications. Safety has also been a key area of focus for the launch of this service offering, with all trucks fitted with audible warning systems, blind spot aids and close proximity sensors. Extra protection is provided by 360 degree camera systems and in-cab cameras as well as fall restraint systems giving protection to drivers when they are required to be on the trailer bed. Plantforce Heavy Haulage Transport Manager, Ian Blackburn said; “I am very excited to be launching this division. Our team have built a real depth of knowledge managing the transport of our fleet of hire machines, which puts us in a great
position to use this knowledge to support others moving their plant and heavy machinery – adding real value at a competitive rate. I am also really pleased with the units we have invested in. As tried, tested and most importantly, trusted units that are well established in the market, we know we offer a reliable service that minimises environmental impact”. Bulk Solids Today
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QUARRYING & MINING
DEVELON WINS TWO HONOURS AT CES 2024 INNOVATION AWARDS Develon, formerly Doosan Construction Equipment, has won honours in two of the categories in the CES 2024 Innovation Awards to be announced during the CES 2024 Exhibition, the world’s largest electronics trade show, being held in Las Vegas in Nevada, USA from 9-12 January 2024. In the first category - Vehicle Tech & Advanced Mobility - Develon presented ‘Smart Collision Mitigation with Sensor Fusion’. Smart Collision Mitigation (SCM) is an active safety system that detects objects around an excavator through Sensor Fusion of camera and radar. The excavator is equipped with four or more cameras to provide a 360-degree All Around View. Using AI technology, it can selectively detect people or objects. In addition, three wide-angle radar sensors with 180-degree horizontal field of view (FOV) are used to minimize blind spots and accurately measure the distance of detected objects. When a pedestrian or an object is detected within the warning/danger zone, visual/audible warnings are activated, and the swing and driving speed on the excavator are reduced and then automatically stopped to actively prevent accidents.
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Bulk Solids Today
Develon is the first construction equipment manufacturer in the world to use fusion technology to supplement a machine’s cameras and radars. Adding fusion technology greatly elevates accuracy in detecting obstacles and distance from equipment compared to machines with a single sensor. Develon’s X-Agent system was honoured in the second category - Mobile Devices, Accessories & Apps. X-Agent is a solution that improves the productivity and skill of drivers of excavators, wheel loaders and articulated dump trucks. X-Agent has an AI function that comprehensively analyses information such as driver/equipment status and work plan to create an optimised route to improve the productivity of unskilled workers by about 30%. Also, for remote control using vision information, it extracts meta information based on the networks and sends minimum information even in an
QUARRYING & MINING
incomplete network environment (2G, 3G). This allows smooth remote operation. As a product optimized for complex mechanical work, it can save on labour, be environment-friendly, and save about 15% in energy. Develon’s advanced technologies portfolio will be a prominent feature of the company’s stand at the Intermat Fair in Paris in April 2024, as part of a display
under the theme of ‘Powered by Innovation’, including the first demonstration in Europe of the Develon Concept-X 2.0 autonomous construction equipment solution. For more on DEVELON, please visit the website: https://eu.develon-ce.com/en/
If you would like to subscribe to receive a regular copy of the digital edition of Bulk Solids Today magazine, you can subscribe on our website www.bulksolidstoday.co.uk If you are interested in advertising within Bulk Solids Today magazine or supplying editorial content, please feel free to get in touch using the details on our website or below. Bulk Solids Today is sent to our digital readership of over 9,000 Chief Engineers, Operations Managers and Technical Managers from within sectors including Chemicals, Food & Drink, Mining, Quarrying, Transport/Distribution, Recycling & Waste Management and more.
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BULK MATERIALS HANDLING
FIRST BOBCAT BRANDED PORTABLE COMPRESSOR AT EXECUTIVE HIRE SHOW PA7.4 (7/45) compressor to be shown alongside Bobcat electric excavator Doosan Bobcat will be showing the first Bobcat branded portable power product to be seen at an industry event in the UK on Stand I40 at the sold out Executive Hire Show (EHS) from 14-15 February 2024. The PA7.4 (7/45) compressor equipped with a generator option being presented in Bobcat colours is part of a complete line of portable compressors, generators and light towers that now form part of the Bobcat range, building on decades of success and experience in the portable power market. The PA7.4 (7/45) compressor-generator will appear alongside one of the models from the expanding range of electric compact excavators and loaders now available from Bobcat. Being held once more at the Coventry Building Society Arena in Coventry, the EHS is firmly established as the only annual national event in the UK aimed at tool, equipment and plant hirers and the suppliers serving this dynamic industry. The EHS enables hire professionals to not only see key suppliers they already do business with, in one place, but also to get in front of new companies from around the world who are looking to serve this important market. BOBCAT BRANDED PA7.4 (7/45) PORTABLE AIR COMPRESSOR WITH GENERATOR OPTION
Designed with a focus on simplicity, durability, reliability and transportability, the PA7.4 (7/45) compressor-generator provides 4.0 m³/min (140 cfm) of compressed air at 7 bar nominal pressure. Like all Doosan portable compressors, there is a wide range of options and customizations available for the PA7.4 (7/45) to meet customer needs. The integral 8.5 kVA generator is one of these options and meets a specific requirement in utility work to meet the demands of the latest fusion welding equipment, providing electrical power that can also be used for lights and tools together with compressed air for powering breakers and other pneumatic equipment. The addition of the portable power range products is the latest broadening of the Bobcat product portfolio, which has grown significantly over the past five years, launching more 22
Bulk Solids Today
machines during this period than previously in its entire history. CLEAN AND QUIET OPERATIONS
Another area of expansion in the Bobcat range is in elecrtrically-powered compact equipment. This began in 2019 with the launch of the E10e, the world’s first 1 tonne electric mini-excavator, which marked the company as a true pioneer in the field of battery-powered equipment. Bobcat has since launched the larger E19e electric mini-excavator featuring the same profile, external dimensions and comparable performance as the popular E19 mini-excavator. Like the E10e, the E19e boasts the same stability, lift capacity and breakout forces as its conventional counterpart, while its constant torque curve (a feature of electric motors) ensures dependable and powerful operations. With a width of just 98 cm, this electric model is easy to operate in even the most confined workspaces, making it ideal for tasks such as demolition as well as outside applications that require quiet, zero-emission operations. At EHS, Bobcat will show either the E10e or E19e on the company’s stand. These products have been followed up with the development of other leadingedge electric-powered compact products, including the company’s unique T7X and S7X models, the world’s first electric compact track and skid-steer loaders, respectively. For more information about Bobcat and Bobcat products, visit www.bobcat.com
BULK MATERIALS HANDLING
PIZZORNO ENVIRONNEMENT EQUIPS SORTING CENTRE IN LE MUY WITH NEW DEVELON DX230WMH-7 MATERIAL HANDLER Specialising in the collection and sorting of household and industrial waste, Pizzorno Environnement, the international group based in Draguignan in France, has just purchased from 510 Location, an agent for the Develon dealer, HMD in Arles, a new 24.5 tonne Develon DX230WMH-7 material handler for its sorting and recovery centre in Le Muy, one of the most modern in the country. A new DX230WMH-7 material handler from Develon, formerly Doosan Construction Equipment, has recently begun operation at Pizzorno Environnement’s materials sorting and recovery centre in Le Muy in Var in France. The machine, the first to be sold in Europe, operates 13 hours a day, 6 days a week. One of the largest and most modern in France, this site receives nearly 120,000 tonne of recyclable waste from selective household and industrial collections every year. “This material handler is used for sorting and reloading waste into our customers’ semi-trailers. We previously had a 20 tonne machine that was at the end of its life cycle. We chose a larger 24.5 tonne machine to improve our productivity. And our choice fell on the DX230WMH-7, which met our specifications. In addition, the Develon (formerly Doosan) agent in Var, 510 Location, like us has its head office in Draguignan and we’ve always been keen to work with local players,” explains JeanCharles Devalle, Director of the General Affairs division of Groupe Pizzorno Environnement (2500 employees, 226 million euros in sales in 2022). The Develon material handler purchased by Pizzorno has a six-metre straight boom and 4.20 m straight arm, equipped with a sorting grab for handling various materials. This is the first DX230WMH-7 sold by 510 Location, a specialist in the rental and sale of Develon equipment in the Var region. Adille Chakir, CEO of 510 Location, and Gislain Pennacchio, sales representative, emphasize that “we had to win this contract for a 100% Dracenois partnership. We hope there will be more! The main advantage of this machine is that it gives operators good visibility when loading trucks, so they can work in complete safety.”
The DX230WMH-7 is equipped with a standard elevating cab that can be raised by 2.5 m to reach a floor height of 3.75 m in the raised position. The operator can adjust the height of the cab without leaving their seat, thanks to a lever at the rear of the seat. Inside, the operator can access the video feed from the side and rear cameras on a screen. They can also monitor vital machine information. “We wanted an elevated, soundproof cab. We also wanted high-performance telematics for maintenance, so that we could closely monitor the machine, as it is used by several operators,” says Jean-Charles Devalle. The Develon Fleet Management TMS 3.0 Cellular telematics system on the DX230WMH-7 provides owners, dealers and the manufacturer with geolocation information as well as complete operational data for the machine, transmitted via computer or smartphone, in order to manage maintenance and reduce operating costs. A 510 Location technician presented the machine to operators on delivery, together with a demonstration of the maintenance procedures. “Even if it’s still too early to assess the machine’s productivity gains, we’re satisfied with it,” sums up Jean-Charles Devalle. Other orders on the horizon? “We manage four other sorting and recovery centres, but they are of a smaller size. We’ll see,” concludes the Director of Corporate Affairs for Groupe Pizzorno Environnement. For more information on Develon: https:// eu.develon-ce.com/en/ Bulk Solids Today
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RECYCLING & WASTE MANAGEMENT
NEW COPERION TEST CENTER FOR OPTIMIZING PLASTICS RECYCLING Coperion Recycling Innovation Center is Up and Running Coperion has successfully launched operation of its new Recycling Innovation Center. In this high-tech test center for plastics recycling applications, every recycling process step – from material handling and feeding to extrusion, compounding, pelletizing, material postprocessing and deodorization – can be tested. Extensively equipped recycling systems are available that can be modified in myriad ways, depending upon the specific requirements of the recyclate to be produced. Coperion’s new Recycling Innovation Center is the perfect complement to the Herbold Meckesheim Test Center, where customers can simulate and test the mechanical pretreatment of plastic, allowing customers to experience first-hand the significant reduction in organic impurities by using Herbold Meckesheim’s hot washing system, as an example. Herbold Meckesheim has been part of Coperion’s Recycling Business Unit since 2022. RECYCLING MACHINERY ON THE CUTTING EDGE OF TECHNOLOGY
The Recycling Innovation Center is located in Niederbiegen near Weingarten, Germany, directly
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Bulk Solids Today
adjacent to Coperion’s existing Test Center for Bulk Solids Handling. Along with proprietary research and development projects, first tests have been performed for customers, in which new, sustainable products and recycling processes have been developed and tested. Coperion process engineers can modify the available recycling technologies such that the recompounds are manufactured with the highest efficiency possible while maintaining a consistently high level of product quality. The results achieved can then be effortlessly scaled up to production level thanks to the constant base parameters of all Coperion technologies. Every new technological development from Coperion that optimizes plastics recycling has been integrated into the Recycling Innovation Center’s machinery and can be tested there. For example, in the area of material conveying, the energy-efficient FLUIDLIFT ecodry® flash drying process is available – moisture remaining in recycling grinds following the washing process is reduced during material transportation. Moreover, the MIX-A-LOT bulk solid mixer, which can create premixes including flakes or powders, and the innovative buffer hopper solution using the ARW discharge agitator as well as the Smart
RECYCLING & WASTE MANAGEMENT
Weigh Belt (SWB) feeder are integrated in the system. Coperion has also installed the ZS-B MEGAfeed side feeder, especially for extruding and compounding plastic recyclates with bulk densities starting as low as 20 kg/m³ at high throughputs. With its innovative design, the ZS-B MEGAfeed handles flakes and fibers such that they can be fed into a ZSK twin screw extruder in large quantities without energy-intensive compacting. “The new Recycling Innovation Center shows how important it is for us to advance technology that helps our customers work towards more sustainability solutions and a functioning circular economy. The Recycling Innovation Center offers the ideal environment, both for our own research and development projects as well as for our customers, to master the challenges of plastics recycling”, said Frank Lechner, General Manager of Process Technology and Research & Development at Coperion. “With this new Recycling Innovation Center, we’re in a position where we can simulate the entire plastics recycling process. Our customers can test the complete process, from mechanical pretreatment of plastics in Herbold Meckesheim’s Test Center up to compounding and pelletizing, prior to making the investment. As a supplier of entire recycling systems, we are very proud to be able to offer our customers this enormous added value”, said Massimo Serapioni, General Manager of Coperion’s Recycling Business Unit.
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BUYERS GUIDE Aero Mechanical Conveyors
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Bulk Solids Today
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BUYERS GUIDE Sieves & Sifters Cont’d
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Screw Feeders, Mixers & IBC Systems
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InterBulk GROUP
Bulk Solids Today
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