SHAPA News January 2016

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Solids Handling & Processing Supplement

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January - February 2016

LIVE AND LEARN When you stop learning you stop living – an axiom of obscure origin but nonetheless more relevant today than ever. Learning for learning’s sake can be very rewarding if intellect and pressures of daily life allow. Learning to enable career progression is no doubt laudable; learning to keep one step ahead is equally beneficial. But what is really worth learning and how do we know that what we are absorbing is relevant, accurate, well informed, unbiased and even truthful?

THE NEED TO KNOW

Many successful companies have been founded by people with good ideas for a product orservice; somebody perhaps with a particular skill for design, project management communication or marketing, amongst many others. Whilst the company is small the other necessary but less developed skills could be acquired by the proprietor, at least to the level needed for the fledgling organisation to operate. A century or more ago the speed of communication, for example by letter or courier on horseback, allowed time to think and consider actions, time for discussion, with only a limited possibilities. Such a blissful situation is not the lot of the modern factory owner, engineer or manager. New technology (laboursaving devices all….!!) brings with it a truly huge volume of required knowledge in order for life’s participants to succeed in any business enterprise. Indeed, a snapshot of the range of knowledge underpinning the products and services offered by the solids and bulk handling and processing industries may be gleaned from the ensuing pages.

HELP AT HAND

However, for companies manufacturing and installing these products and services, as well as users processing equipment with their kaleidoscopic variety of applications, help is at hand. Actually it has been at hand for around 35 years in the shape of an engineering trades association founded and still run by industry professionals, giving their time and expertise voluntarily for the betterment of British industry – this unsung hero is SHAPA.

LEARNING TO SUCCEED

From the very beginning in 1982 the Association has existed to produce and disseminate high quality relevant technical, commercial, legal and marketing intelligence in a lively and engaging manner. A little look at this year’s programme of events will demonstrate this ambition of living and learning. Earlier in the year the 8 th Annual SHAPA Digital Marketing Workshop was presented. It’s hard to believe that this event is now 8 years old, but such is the pace of change and rate of uptake of all things electronic, that its future is now assured.

New ideas and platforms, commercial uses for social networking sites, ways to advertise effectively and economically – all clearly laid out with updates arising from progress since the last workshop in 2015. New subjects for this year included Content Marketing enabling more traffic to be directed to your own website. Google AdWords advertising was reviewed with fresh ideas, as well as selling in LinkedIn. This annual workshop is for anybody wishing/to promote their company by means of digital marketing in an entertaining, hands-on and extremely useful session.

Not every company principal is a financial whiz-kid. As alluded to earlier all sorts of people start and run companies. In our industry they are likely to be engineers and innovators. But, along with the fun part comes the vital need to keep finances in order. Profit and loss accounts, appeasing the taxman, even avoiding prosecution are all beneficial occupations to preserve peace of mind. Clearly it is important to monitor the financial health of the company as a whole. In May this year SHAPA presented a Financial and Commercial Awareness Workshop, the first of its kind in the developing world of SHAPA learning opportunities. Specifically aimed at those managers for whom finance was not their primary skill, the seminar set out to de-mystify the processes and jargon of financial accounting. One session concentrated on analysing financial information, describing such terms as “ratio trends” and how to apply “ratio analysis”. Delegates gained a better understanding of their own particular financial objectives and learned how to assess the financial implications of their day-to- day decisions.

They discovered how to make better use of resources allocated, but crucially they left with greater confidence through focused knowledge.

Coming up in November is another new course, to develop and hone negotiation skills. It is clearly important for supplier and client alike that satisfactory contract conditions are agreed, for the safety and security of all parties involved. The course will cover subjects such as structuring negotiations, how to deal with all kinds of developing scenarios by means of role playing, as well as demonstrating how to apply these skills in practice in the workplace. Good negotiation skills will ensure that any business relationship, whether internal or leading to new contracts, will get off to a good start with an identifiable structure to cover all eventualities as the relationship proceeds.

HOT TOPICS

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NEW High Pressure Rotary Valve

REWARDING SUCCESS

All in all, SHAPA takes on-going learning and education at all levels very seriously indeed. So, what about the rewards for success? This year’s SHAPA Industry Awards were well supported and the results, in five categories now including an Individual Award and SHAPA Customer of the Year have been well documented. Morale boosting and commercially uplifting, the Awards will, we are sure, go from strength to strength.

In challenging times SHAPA and all its member companies have risen to the challenges to promote a good future, whatever the political climate. The pages of this supplement will demonstrate some of the expertise and commitment that is the hallmark of our manufacturers and suppliers.

The DMN-WESTINGHOUSE HP valve with specially designed inlet is very suitable for handling granular formed products under a high pressure of maximum 3.5 bar g.

The valve has a very important advantage in air leakage: the special configuration of body, rotor and seals does not only protect product against degradation, it also does not allow any axial air leakage.

DMN UK Ltd. T +44 1249 818 400 dmn@dmnuk.com

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

Features: • Special inlet for maximum protection against product degradation • High filling efficiency • Lowest air leakage through special seals • Robust construction • Easy assembly and disassembly

360° video

COMPONENTS FOR BULK SOLIDS HANDLING

On a quite different tack the Association will hold a further ATEX seminar, slated for Januarynext year. This is a constantly relevant topic, with many newer engineers encountering its ramifications for the first time. The seminar will tackle categorisation with zoning, T rating, SIL and ignition temperatures – some jargon here, but all will be explained to those who attend. Information will subsequently be disseminated to all SHAPA members following the event.

Total cost of ownership is an old chestnut, but a very important consideration for all SHAPA members and their clients. It is well known that the capital cost of plant is only part of the story and all wise engineering purchasers will probe operating costs, planned maintenance and repair costs, set against WESTINGHOUSE the costs of unplanned downtime. Total life span and depreciation are obviously part of the mix too. All of this is being addressed by the Technical Committee and new information will be placed presently on the SHAPA website.

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DUST EXPLOSION PROTECTION – 10 COMMON MISTAKES IN A PROCESS FACTORY

Kevin Spiess from BS&B shares insights on what mistakes to avoid when protecting your facility from dust explosion risk With years of experience in providing protective solutions for dust explosion risk, BS & B Safety Systems has visited and surveyed factories in every process industry all over the world.

While owners are making the effort to comply with DSEAR and ATEX regulations and ensure their staff’s safety, the execution of preventive measures has not always been correct. Many facilities share common problems when it comes to the installation of protective equipment. In some cases,they inadvertently omit to place fail-safes where necessary.

Here are 10 cross sector examples of the most regularly encountered errors when it comes to protecting against dust explosion risk.

1. ISOLATION OF CONNECTED EQUIPMENT IS OVERLOOKED If an explosion vent is fitted to a dust collector, there must be isolation of the dirty inlet duct and isolation of the clean air outlet duct when it returns to the process area. This is necessary because the explosion could propagate along these ducts causing other safety risks to people and equipment.

2. DON’T FORGET TO PROTECT BUCKET ELEVATORS Bucket elevators are high risk equipment because they have many possible ignition sources.

What’s more, they are connected, so if one is the source of ignition, a primary explosion caneasily spread to the other processes. The risk is further exacerbated via secondary explosionwhich causes further damage to other items of equipment.

3. EXPLOSION VENT INSTALLATION ERRORS By all means fit an explosion vent, but make sure it’s done properly and that it’s the correct size for your process requirements. Failure to do so will result in a variety of dangerous health and safety risks.

• The possible leak of combustible materials from an incorrectly fitted vent results in burning materials being expelled at high pressure. The path of the flame becomes a secondary risk zone, both indoors and outdoors. The reach of a flame ball bursting from an incorrectly installed vent is typically between 10 and 30 metres long.

• Another common oversight is not

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factoring in changes of the manufacturing process being used in relation to the size of vent required.

If the materials that you are processing have changed and have a higher KSt and PMax value, the force of explosive pressures may increase.

Check and recalculate (if necessary) the vent area required and make sure your vent is correctly sized!

Vent ducting must be properly calculated and designed so that the flame path can escape freely to a safe area. In the past vent ducts have been installed and added to. There are strict guidelines when it comes to designing explosion vent ducts. Correct size and length of ductwork is key to the efficient performance of a vent.

Ensure that your vent discharge path cannot possible endanger nearby personnel. If there ishazard due to explosion venting (expelling pressure and flames) then that area must beclearly indicated with signage and cordoned off.

Do not obstruct the explosion vent path.

DO professionally install a properly designed vent and don’t try and make your own. The performance will be erratic and certainly unsafe! Once your vent is correctly installed ensure it is regularly inspected and that the inspection records are visible.

4. ELECTRICAL GROUNDING AND BONDING NOT IN PLACE Electrical sparking in a dusty environment is a recipe for disaster.

Ensure that grounding wires are not broken or unconnected. If there is piping across a flexible connection, make sure it is well bonded. These considerations are particularly significant when dealing with dusts that have a low ignition rating – it wouldn’t take much to cause a fire or explosion.

5. BAD HOUSEKEEPING Arguably the most logical activity but the most overlooked - cleaning the dust away. Dustaccumulations in the ceiling spaces, beams and walls can fuel an explosion to the point ofdestroying the facility. Make sure your employees know where the accumulation ‘hot spots’are and keep them clean.

Do not attempt to move dust with an air spray. It just creates adust cloud which is a secondary explosion risk hanging in the atmosphere.

6. DUCTING AND PIPING NOT SAFE Weak explosion ducts can ease the path of an ignition to a destructive result. The strength of explosion vent ducts should be calculated so that they can withstand the maximum pressure of a vented explosion (Pred). Avoid long horizontal runs of duct work which attract uninterrupted building up of dust.

7. SILOS AND STORAGE BINS INADEQUATELY PROTECTED Venting is often the most appropriate preventive measure for silos because of the potential explosive pressure that can build up inside them. Vents should be placed on the top of the silo or on the sides at a height above the contained material.

• Correct vent area sizing is critical so that the vent is large enough to prevent damage from explosive pressures. Silos need to be able to withstand venting pressures. Reduce the length to diameter ratio of the silo. Designing a larger diameter means that the vent area requirement will decrease significantly.

• Don’t forget to test the material to be stored or handled and determine its KSt value. The KSt will inform the size of vent area required in your silo.

8. NO MANAGEMENT OF HOT PARTICLE RISKS Identifiable sources of sparks and other hot particles can and should be detected and redirected or extinguished in situ. The installation of spark detection and suppression systems rapidly and safely eliminates this risk.

9. UNPROTECTED DRYING EQUIPMENT Fires and explosions occur in dryers quite frequently. Depending on the type of dryerexplosion protection can be achieved by venting, spark detection, isolation, suppression ordesigning them robustly enough to contain an explosion.

10. ABSENCE OF RISK MANAGEMENT Putting risk management strategies into play can mitigate mishaps on the factory floor. Forexample, if installation of safety equipment is not based on measurable and current process requirements, your facility will be under-protected.

Similarly, before the installation of safety equipment, carry out a combustible dust test and there after review your combustible dust classifications (KSt and Pmax levels) at regular intervals as process operations and materials change. This provision should be incorporated into Management of Change procedures.

For more information on BS&B Safety Systems explosion protection solutions visit: www.bsbipd.com.

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

HOW DOES A ROTAVAL ROTARY VALVE REDUCE CHANGEOVER TIMES BY 75%?

RotaVal’s Fast Clean rotary valves have transformed production efficiency for A Schulman, the international manufacturer of plastics, resins and masterbatch. With a simple, ergonomically efficient mechanism for cleaning the valve at product changeover with only a single tool required, RotaVal Modular Fast Clean valves require only four minutes per changeover, a reduction of up to 75% over A Schulman’s previous equipment. A Schulman have gained an incredible 2-3 hours of production time per month at their Gainsborough production site.

Cleanliness in production and the ability to guarantee that no material residue carries over when products change is a critical factor in A Schulman’s high-quality manufacturing process. At the same time, production pressure in a busy factory is ever-present, and it is vital that downtime is minimised. At every changeover, the process is purged, and that includes dismantling and cleaning the rotary valves. A Schulman identified that this was a bottleneck in their production processes and contacted RotaVal for a solution.

RotaVal’s Modular Fast Clean valves are easy to work with, with patented RotAlign and bottom mounted sliding rails the valve rotor to slide out to be easily cleaned then slide back in with the minimum of fuss. All the operator needs to do is release the air supply and undo a few bolts, easily accomplished with a single spanner. As Michael Ingall, A Schulman’s Production Manager, put it, “The previous gate valve used a lot of tools and was time consuming. With the aid of the RotaVal quick release we have saved a lot of time and money” He was echoed by Production Supervisor Richard Hodge, “Time saving is 12-15 minutes and, with the amount of changeovers we have, it’s a fantastic saving.”

Time saving is not the only one benefit. A Schulman have also identified that they are enjoying better quality control, with no operator errors. Richard Hodge went on, “A fantastic invention in what we do. Less risk of injury, it’s so swift to do, and clean.”

Minimal downtime, with better quality control. Increased productivity that’s safer and easier for the operators. Also, savings can seriously mount up a site with 20 Fast Clean valves and ten changeovers per week would see an improvement of around 2600 production hours.

For more information and a video filmed at A Schulman showing exactly how easily Fast Clean technology works in practice, see RotaVal’s website www.rotaval.co.uk

PADDLE BLADE MIXERS – MIXING AN ENVIRONMENTALLY SAFE SOLUTION FOR FCC ENVIRONMENT FCC Environment have installed two 7500 litre JR Boone Horizontal large scale paddle mixers in their Knostrop Treatment Plant in Leeds to treat and stabilise APCR waste from a network, of incinerators. Chosen for their robustness and reliability, the new mixers are now processing 25,000 tonnes per annum producing a stable material for safe landfill.

Air pollution controlled Residue is generated in the flue of large energy from waste processes such as FCC’s Eastcroft plant in Nottingham and is typically a powder mix of calcium hydroxide and sand. The powder is created when hydrated lime is introduced into the flue to remove atmospheric pollutants including heavy metals and hydrogen chloride. FCC Environment’s Knostrop plant takes in the resulting powder, using the JR Boone mixers to mix in acidified water and produce a ‘sludge’ that is safe for disposal to landfill.

High percentages of silica sand in the mix makes the process very abrasive, so the JR Boone mixers need to be very tough. The Paddle blade Mixers are fitted with wear-resistant mixer arms and blades, with the number of moving parts minimised. Two identical mixers are in place at Knostrop, between them processing around 20 tonnes per hour of waste material. The short length to diameter ratio of the mixers ensures that mixing is completed in the shortest time possible, while the ‘omega’ shape of the mixing vessel makes sure that all material in the mix is fully entrained by the blades, so every part of the powder is treated.

This project was first set out as long ago as 2010, and initial material trials were carried out in 2013, Ian Martin, FCC Environment’s General Manager at Knostrop stated: ‘Our customers’ incinerators are running constantly and we need to be able to process the waste on a continual basis. Any stoppages here run the risk of stopping the upstream process. He went on. “We identified the JR Boone mixers quite early on in the project and chose them because they are tried and tested and very robust. We worked with JR Boone on pilot plant, fine tuning motor sizes and looking at the way the equipment performed with different material densities’.

The Paddle Mixer is a very versatile machine also used as a processor-producing compounds with variable amounts of shear heat and under vacuum e.g. 100M HPBM for investment casting manufacturer Clan Ceramics (more information available on request). JR Boone also produce high shear Delta Blade mixers, low shear Helical Blade mixers and very low shear Rotary Drum Mixers for a wide variety of industrial applications. Mixers are available for test for each type of machine to demonstrate the clear advantage in choosing Jr Boone mixers and blenders for your process.

For more information contact John R. Boone Ltd, Congleton, Cheshire. Tel: 01260 272894 Fax: 01260 28112 E-mail: sales@jrboone.com Website: www.jrboone.com

Prevention Venting Isolation Suppression

EXPLOSION HAZARDS LTD

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FOR ALL YOUR EXPLOSION SAFETY NEEDS www.explosionhazards.com +44 (0)1925 755153

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

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THE RISING TIDE OF SUPER SEAWEED

Tipped as one of the superfood trends of 2016, seaweed is packed with minerals, vitamins, fibre, omega 3 and protein, often being added to food as a nutrient boost. Claims that it can prevent colon cancer, control blood glucose level and aid digestion make it of significant dietary and health interest whilst sustainable farming and harvesting methods have led to seaweed’s recognition as a ‘futurefood’ as well as a superfood.

The fibrous, wet and often sandy or gritty, seaweed is however difficult to process with costly and time consuming drying times. To reduce the drying process seaweed is often chopped to facilitate more rapid, less nutrient destructive drying processes.

For many years processing experts Hosokawa Micron Ltd have offered processing solutions to alginate producers across the world. To meet the demands for milled, freshly harvested seaweed Hosokawa Micron Ltd has developed a two stage system comprising of a Prebreaker and Vertical Disintegrator. This low energy system offers uniform particle size reduction of wet or moist seaweeds for further processing, which offers higher levels of availability compared to conventional hammer mills.

Once the friable materials have passed through the initial size reduction (Prebreaker) stage, they are transferred directly to the Hosokawa Micron Vertical Disintegrator to be further reduced to a uniform particle size.

Designed for the reduction of fine to coarse, wet, moist or dry materials, the Hosokawa Micron Vertical Disintegrator provides automatic and continuous separation of disintegration resistant materials with redirection through the system from the exclusive secondary discharge.

Uniform particle size is achieved as materials are subjected to repeated impact and attritional force from the high speed rotating hammers, and carried by centrifugal force through a perforated sizing screen. The vertical screen frees itself of product instantaneously during processing, which is ideal for products with a high moisture content.

Barry Walmsley, Product Manager, Hosokawa Micron Ltd says, ‘The sturdy system, can operate at 12- 20 t/h. It is low noise and delivers product in a narrow particle size distribution, resulting in higher yields and less effluent. The Disintegrator is designed to withstand corrosion caused by the low pH often involved in the process and erosion caused by the natural inclusions which determines a predominant use of higher abrasion resistant materials of manufacture.’

For more information contact: Hosokawa Micron Ltd, Runcorn, Cheshire.

Tel: +44 (0) 1928 755100 Fax:+44 (0) 1928 714325 Email: info@hmluk.hosokawa.com Web: www.hosokawa.co.uk

THE WOLFSON CENTRE FOR BULK SOLIDS HANDLING TECHNOLOGY HAS DEVELOPED A NEW COURSE The efficient processing of bulk materials to obtain a high quality end product is at the heart of the vast majority of industrial activity undertaken in the UK. However, how many engineers actually understand the fundamentals of the processing steps (size reduction, particle formation/agglomeration, grading, blending, etc.) that they are required to interact with or to specify. In order to help engineers better understand the characteristics and limitations of different types of ‘value adding’ plant.

The Wolfson Centre has developed a new course that is intended to present the range of equipment types, their mode of operation and which applications are best suited to their use. The course is aimed at engineers that a new to industry or established engineers that would like to refresh their understanding of the subject.

For more details of this and other courses on offer, go to the web site of The Wolfson Centre for Bulk Solids Handling Technology at University of Greenwich, www.bulksolids.com

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PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

PROCESS INSTRUMENTATION – A LEVEL PLAYING FIELD?

By Richard J Farnish, CEng MIMechE - The Wolfson Centre for Bulk Solids Handling Technology In recent decades, inventory monitoring systems for silos and bunkers have improved in terms of technology and quality. Such equipment types can be employed to offer indications of material volumes held in storage for equipment that cannot be readily inspected visually. Thus such systems can improve Health & Safety (i.e. no staff access to assess inventory) but also allow the adoption of fully automated processes.

Common types of equipment used to monitor storage equipment include radar, ‘dipping’ probes, level probes and load cells. The effectiveness of these approaches is largely dictated by the nature of the installation – with particular emphasis on the discharge behaviour of the silo/hopper/ bunker that is being monitored. The flow pattern that develops within the vessel is key to the level of performance achievable, and in this respect it is important for the reader to understand what can develop.

The two main discharge behaviours that can develop in silos and bunkers are as shown in the figures 1 & 2 below, which illustrate these flow patterns in the context of conical silos, but the principles are equally applicable to bunkers.

Fig 1: Core (funnel) flow Fig 1, illustrates a discharge behaviour called core flow, where the bulk particulates d i s c h a r g e preferentially down a vertical channel above the outlet. The bulk particulates are fed into the flow channel from the top free surface and the product around the walls remains static until the level descends to the point where it becomes the top surface and discharges. If this discharge behaviour is present, then it can impact on the process in several ways: • The vessel will operate on a first-in, last out stock rotation (which can result in the unpredictable appearance of aged or different material on the process line if the inventory is maintained at a high level for a significant length of time).

• An increased variability in bulk density throughout the discharge cycle of the bin may become apparent due to variations in particle packing due to variability in residence time before discharge (recalling that the vessel will draw down freshly introduced material).

• If the material blend is subject to surface effect segregation (i.e. tends to separate in such a way that fines enrichment occurs in the central region – whilst the periphery of the vessel demonstrates a lack of fines), then initial discharges from the store will be fines rich (correlating to high bulk density or blend

imbalance) whilst the final stages of the discharge will tend to feature a higher coarse content (low bulk density or blend imbalance).

By default, this discharge behaviour is most likely to be found in most processes and equipment types.

Fig 2: Mass flow Fig 2 illustrates a discharge behaviour called mass flow. By contrast this type of discharge is arrived at by designing the vessel/equipment to suit the measured flow characteristics of the worst case material to be handled. If this discharge behaviour is present, then the following benefits can be derived: • The vessel operates on a first-in, first-out basis and as such maintaining a high inventory level does not affect the residence time of material being discharged.

• Stagnant regions of material are eliminated.

• The inventory is drawn down evenly through the equipment – thus providing a degree of recombination of radially segregated bulk particulates.

• Discharge can be sustained reliably without resorting to discharge aids.

The above (brief) descriptions summarise the principle differences in discharge behaviour between the two types of vessel geometries. It should be borne in mind that although the illustrations show conical type vessels, these discharge characteristics can be found in all other shapes and sizes of equipment.

Considering core flow (as this is the default flow behaviour in process plants) it can be appreciated that accurate monitoring of inventory can be problematic for a variety of reasons. The characteristic ‘crater’ that forms during discharge can present issues for radar or ‘dipping’ probes, in that the point at which the respective reading is taken may only represent a height at a single surface radius – thus some calibration would need to be undertaken to allow for the actual gradient (and hence volume) within the vessel. This approach would be further complicated if the material changes (i.e. the gradient may steepen or become more shallow) and introduce an error. Equally if the vessel is prone towards rat-hole formation (i.e. the flow channel empties, but material does not flow into it), then the diameter of the rathole and its height would represent missing ‘capacity’.

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

FURTHER MORE...

Such problems of inconsistent surface profile can also develop if the vessel is subject to regions of time consolidated material (cliffs) that occur asymmetrically. Level probes may be considered as an approach to overcome these short comings, but their operation can also be compromised by the characteristic presence of long term resident material on the flanks of the cone into which the probes intrude. This is particularly an issue if the material being stored is cohesive, in which case ‘tuning fork’ type probes will simply indicate that they are covered – even though the vessel has discharged what contents can be reclaimed by gravity (often leaving substantial regions of ‘dead material’ if discharge aids have not been adequately maintained). ‘Paddle type’ sensors can also be vulnerable to build ups of cohesive materials that have consolidated and can, in some cases, simply excavate a ‘cavern’ resulting in a signal indicating an absence of material – despite quantities still being in place. Load cells can also issue spurious information in the event that the vessel contains long term resident material that cannot self-drain. In such cases, it has been known that some companies progressively ‘tare’ systems through a year in order to only monitor ‘live’ capacity (thankfully not with a food grade product!).

In contrast if mass flow discharge behaviour is obtained, inventory control becomes a considerably simpler and more reliable proposition. Under such circumstances, the surface profile (the shape of which will be dictated by the bulk materials and the filling method) is likely to be highly repeatable and even throughout the vast majority of the discharge cycle to empty.

This makes the detection of the surface and any subsequent initial calibration of systems much simpler and more likely not to require ‘tweaking’ over time. The establishment of a full cross-sectional flow will also avoid the potential problems of rat-hole formation and long term stagnant regions. Thus level probes mounted on the walls of the vessel will actually ‘see’ the true inventory as the level reduces. Similarly, load cells will not need to take account of an unknown and growing mass of long term resident material (all of the inventory will ‘live’ during discharge operations).

SUMMARY

In summary, it is widely recognised that without effective monitoring of inventory levels processes can be extremely vulnerable to short falls in feed stock or spillages through over filing of bulk and day bins. However, the influence of the storage equipment discharge pattern is seldom taken into account when selecting monitoring systems – and yet a lack of consideration of this factor is often at the root of a range of process problems (of which monitoring is only one!).

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NEW DMN-WESTINGHOUSE HIGH PRESSURE VALVE BEATS AIR LEAKAGE At the Powtech DMN-WESTINGHOUSE has presented its newly designed HP high pressure rotary valve. This valve has a very important advantage in air leakage: the special configuration of the body and rotor does not only protect product against degradation, it also does not allow any axial air leakage. This means that this valve has an air leakage reduction of one third against other standard high pressure valves.

The DMN-WESTINGHOUSE HP rotary valves with specially designed inlet are very suitable for applications in the metering and pneumatic conveying of granular formed products under a high pressure of maximum 3.5 bar g. The configuration of the body, rotor and seals has been specifically developed to minimise degradation of the product which runs through it, whilst retaining the best possible pocket filling efficiency.

The HP valves are supplied with a 316 stainless steel body and aluminium end covers, in order to have maximum protection against wear. The standard full end disc rotor is made of 316 stainless steel and has 12fixed blades. Due to the state of the art manufacturing facility, a high accuracy and tight rotor clearances can easily be attained. The end covers have outboard bearings, lubricated and sealed for life. The special construction of the shaft sealing guarantees the lowest air leakage. All models offer optimum venting through the large vent hole, so a maximum product flow into the vented pockets is guaranteed . DMN-WESTINGHOUSE fits SEW drives as their standard.

The HP valves are available in 3 consecutive sizes from 200 - 300, covering a capacity range of the rotor from8.3 - 30 litre per revolution at 100% filling. The standard models are suitable for handling products up to a temperature of +80°C and a maximum pressure difference of 3.5 bar.

DMN-WESTINGHOUSE have been designing and manufacturing rotary valves and diverter valves for bulk solids handling for more than 45 years. Offering tailor made solutions to the global food, dairy, plastics, (petro)chemical, pharmaceutical, mineral, power and biomass industries, our range comprises a number of universal components suitable for many applications. Additionally we supply components that are USDA Dairy Accepted, pressure shock resistant to 10 bar, flame proof, ATEX 94/9/EC compliant, EHEDG Type EL Class I compliant, etc.

For more information Contact: Tonneke Krempel-Caspers, E-mail: t.krempel@dmn-nwh.nl Tel: +31 252 361 800 Web: dmnwestinghouse.com

FULLY INTEGRATED PACKAGING SYSTEMS FROM COPERION – THE COMPLETE RANGE FOR WEIGHING, BAGGING AND PALLETIZING Coperion and Coperion K-Tron are system and equipment suppliers, including extruders, feeders, components, pneumatic conveying and packaging.

Coperion’s complete packaging solutions for a variety of industries like plastics, chemicals and food, are easy to operate, very flexible, adaptable to a wide range of products and easy to maintain.

Coperion’s packaging equipment is specially designed for free flowing granular bulk materials and includes all required features to reliably manage bulk density variations and cross contamination.

These machines combine all functions like weighing, bagging, marking, qualifying and palletising in one single unit. The innovative and modular designs for bagging and palletising are ideal for end of the line material weighing and packaging.

With more than 40 locations, 2500 employees and numerous representatives world wide, Coperion and Coperion K-Tron can respond quickly and offer local support where it is needed.

For more information contact: Coperion K-Tron Great Britain Ltd, Unit 4 Acorn Business Park Heaton Lane, Stockport, SK4 1AS United Kingdom Tel: +44 (0)161 209 4810 E-mail: info@coperionktron.com Web: www.coperionktron.com and Web: www.coperion.com/ packaging

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PNEUMATIC CONVEYING PERFORMANCE Dynamic Air offers 16 different pneumatic conveying concepts: Each system has its own unique set of operating characteristics for pressure, conveying line velocity, efficiency and performance. Because each and every material to be conveyed reacts differently under a given set of operating conditions, it is critical to match the system operating characteristics to the material to be conveyed in order to achieve the most desired conveying performance and to provide the best value.

Dynamic Air’s 16 different pneumatic conveying concepts have the ability to convey at almost any conveying velocity desired to suit a given material to be conveyed. We can convey many materials with conveying velocities as low as.25 m/sec. using our HDP 6000 dense phase pneumatic conveying system and, using our LDP 2000 dilute phase pneumatic conveying system, we can convey at velocities well over 35m/sec. Plus our conveying capacities range from just 100kg of material per hour up to 400 tons per hour and conveying distances exceeding 1500 m in length.

For more information contact Dynamic Air Ltd, Milton Keynes, Buckinhamshire Tel: 01908 622344 E-mail: sales@dynamicair.co.uk Web: www.dynamicair.com

BARTON’S SPACE SAVING SILOS Sanko Gosei Automotive Systems has saved considerable warehouse space and significantly reduced raw material costs by installing two aluminium, plastic granule storage silos supplied by Barton Fabrications. The two 3.5m x 12mhigh silos are used to store polypropylene granules used in the company’s automotive parts moulding processes. The50 tonne storage vessels are bulk filled from road tankers and replace large plastic sacks and cardboard Octobins previously used on-site.

As part of the installation, the two Barton silos were fitted with load cells and telemetry system. This allows real-time visibility of stock levels and usage by both Sanko Gosei and the raw material supplier, which in turn simplifies management of the company’s plastic granule consignment stock.

Commenting on the benefits of the decision Two Barton silos installed at to move to silo storage, James Bradley Sanko Sanko Gosei’s Skelmersdale Gosei’s Production Engineering Manager site said: “As part of our Kaizen process, we were tasked with removing waste from our warehouse. We identified two materials as high use with good potential for improvements in materials handling and storage. The decision to install two storage silos has allowed us to save significant warehouse space. Additionally, we have reduced both fork lift truck movements and the need to dispose of plastic storage sacks & cardboard Octobins.

“We have also lowered direct materials costs by buying in bulk and our surcharge / transport costs are less. We are absolutely delighted with the new Barton silos and were very happy with the whole installation process” The Sanko Gosei project is the latest Barton Fabrications installation that supports the supply of plastic moulded parts for the UK’s automotive industry.

For more details on Barton Fabrications’ silo solutions, contact Mark Barton:Tel: +44 (0) 1275 845901 E-mail: sales@bartonfabs.co.uk Web: www.bartonfabs.co.uk

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

EFFECTIVE, INNOVATIVE EXTRACTION

MHEA ANNOUNCES BULKEX16 The Materials Handling Engineers Association is proud to announce the dates for its annual BULKEX conference.

BULKEX16 – to be held again at the prestigious Harrogate International Centre, will take place on the 5 th and 6 th October.

The two-day event is aimed at professionals, organisations and academics from across the bulk materials handling world.

Michael Kaye, the new President of the Materials Handling Engineers Association, believes the 2016 event will build on the success of BULKEX15 and will be the biggest and best event in the MHEA’s 78 year history.

Those wishing to make extra impact can take advantage of a BULKEX16 sponsorship package.

From ‘Headline’ gold sponsorship and silver sponsorship to bronze sponsorship, hospitality ;and paid-for advertising, BULKEX16 will offer a range of sponsorship opportunities to suit all budgets.

Companies looking to exhibit at the event or to find out more about sponsorship, can contact BULKEX16 event’s team on 01787 226995 (ask for Teresa or Julie).

For further information please visit the BULKEX16 website at www.mhea.co.uk/bulkex16

Dust Control Systems Ltd specialises in providing dust and fume extraction solutions across many industries, including major projects in solids handling, food and beverage, pharmaceuticals, vehicle manufacture, and the waste recycling sector.

Saving energy and increasing production efficiency, while ensuring a safe working environment, are key requirements of most processes and the company’s reputation has been built on its ability to provide the most suitable and cost-effective solution, whatever the project. DCS aim to improve their customers’ profitability by providing the best in current filter technology, significantly reducing energy usage with the Ecogate ® extraction optimisation system, and ensuring that expectations are met by focusing on system reliability.

The DCS commitment doesn’t end there, but extends through lifetime service programmes customised to meet customers’ specific needs. To assist companies with compliance on COSHH Regulations, DCS also offer comprehensive LEV(Local Exhaust Ventilation) testing and examination packages that include inspection and service to ensure extraction systems continue to comply with regulations.

For more information contact Dust Control Systems Ltd, Tel: 0800 040 7116 E-mail: sales@DCSlimited.co.uk or visit www.DCSlimited.co.uk

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

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Guest Article

IMPROVE MANUFACTURING

FLEXIBILITY

By Richard Lockwood, Business Development, Manager Food, Matcon Ltd The increasingly complex and challenging nature of the recipes that consumers demand today mean manufacturers need to adapt in order to survive. How can manufacturing methods be improved to satisfy these customer needs whilst also balancing product quality, safety and production costs?

A modern Lean philosophy combined with the right technology can revolutionise profitability and the agility of manufacturing to quickly react to changes in market demands. In this article, we examine how a production system using Intermediate Bulk Containers (IBCs) can offer total recipe flexibility, reducing lead times and controlling Inventory levels.

SO WHAT IS YOUR WEAKEST LINK? In-line process systems by their design are linear – the raw materials enter the process in the Formulation Area before the final product is delivered out of the far end of the process line. No matter whether it is a 500kg or 10 ton production run, of a particular recipe, the same approach and the same equipment will have to be used.

The problem here is that the process line will only be

again whilst Packing is completed. This results in an inadequate OEE (overall equipment effectiveness) rate both for individual equipment as well as the process line as a whole.

With ever increasing consumer demands resulting in recipe proliferation, this means that ever more frequent recipe changes further destroy the effectiveness of this conventional way of processing. So much down-time is spent ‘cleaning’ between recipe changes, particularly where cross-contamination is a real risk. In an attempt to keep all the processes moving, some companies resort to creating large quantities of WIP/WIQ (work-in- progress/ work-in- queue) which is costly to store and runs the risk of going to waste.

INCREASE EFFICIENCY BY 300% An efficient way to work is to apply a parallel processing approach whereby batches are handled through the ‘process line’ all at the same time. Does this sound alarming from a safety standpoint? It shouldn’t do if the appropriate technology and a well system design is used.

Parallel Processing means separating off the process steps (decoupling) so that Formulation, Blending, Packing and Cleaning take place simultaneously. IBCs (Intermediate Bulk Containers) are used to transport materials throughout the production processes, which enables them to operate independently and be continuously fed with

Separate Mixing

as effective as its weakest link. There are typically vast arrays of processes that happen along the way, from dispensary & mixing, to sieving packing, and in some cases, more complex processes such as granulation and drying are also involved. It is almost impossible to have all these processes completely synchronised, so as a result, there is a lot of waiting time between one process and another. Mixing and Packing stand idle whilst Formulation of the recipe takes place. Then the Mixer remains inactive

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IBC Blender

product, giving good OEE rates. The IBC itself becomes the blending vessel so there is no product contact with the blender, which means no down-time for cleaning between recipe changes. In fact, IBCs are cleaned off-line so do not disrupt the manufacturing time and process line flow. Some IBC systems have high containment levels as the system remains fully closed at all times so there is no risk of cross-contamination or dust generation, which in combination with the fact that no product comes into contact with the blender, means that several different recipes can be processed at the same time without compromising safety – a key benefit By adopting the parallel processing concept, rush orders can easily be fitted in to the production schedule, enabling rapid response to customer demands. OEE rates can increase from a very low 15-20% to 75-80%, generating significant additional revenue per annum. The right IBC system offers a Lean solution ensuring ‘right first time’ production, reducing scrap and waste and reducing the cost of the final finished product. With an additional contribution towards Sustainability goals through reducing waste.

A STAGED APPROACH TO PROCESS IMPROVEMENTS If you are not in a position to make a full-scale switch to an IBC System in one go, it is certainly possible to take a ‘staged approach’. The modular nature of the design allows for equipment to be added into the system as the need arises.

Typical changes made by our customers have been to: • Decouple mixing from packing - this can double the capacity of either or both pieces of equipment in these areas. No longer does packing and blending have to wait for each other to complete their processing, but by decanting the mixed product from the fixed Mixer into an IBC, it means that the Packing lines can be continuously fed with product whilst the new batches are formulated and mixed. This rapid emptying of the Mixer results in reduced turnaround times and increased throughput.

• Decouple raw material batching/dispensing from mixing – decoupling these operations typically increases available process time (and thereby efficiency) by some 50% or more. Formulating recipes into IBCs offline then using these to fill the fixed Mixer speeds up the loading process significantly.

• Replace static mixers for premixing - high volume

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

Guest Article

production lines benefit operationally from pre-mixing the micro and minor ingredients.

Static mixers have exceptionally poor OEE in this application, often involving double bag handling for both filling and emptying such mixers. An IBC Blender can be used to create a pre-mix offline. The IBC can then be used to dose directly into the fixed Mixer.

A Matcon IBC contains the unique Cone Valve technology which ensures the mix does not become segregated on transfer due to product being discharged with mass flow not funnel flow.

• Replace static Mixers with IBC Blending - By installing an IBC Blending System, all idle time is eliminated. Recipe formulations are prepared offline into IBCs then taken for blending. Because the IBC is the blending vessel there is no need to clean-down between recipes so any recipe can be run at any point in the production schedule. In fact, multiple recipes can run at the same time without risk of cross-contamination. Packing lines are continuously fed with product, with one IBC Blender able to supply up to 4-5 packing lines, allowing for different packing formats to be accommodated in one batch run.

THE MARKET IS MOVING ON, ARE YOU? Both large multinational manufacturers and smaller SMEs have embraced IBC system design. A leading spice blends contract manufacturer is now able to hygienically handle their portfolio of over 1,000 flavouring mixes and achieve a consistent 3 day ‘make to order’ regime without creating costly inventory by utilising an IBC system.

Premixing using IBC’s

Bakery manufacturer British Bakels installed an IBC System to produce their high variety, low volume product lines which sits alongside their fixed mixing system that is producing the high volume, low variety lines. This additional line has cut cleaning time between recipes from 480 to 70 man hours, released £175,000 of cash due to less Inventory, reduced labour costs by25%, cut manufacturing time in half as mixes with fat are done as ‘single-stage’ mixes and enabled the company to expand their product range to meet changing consumer tastes. Indeed, the IBC- system has enabled British Bakels to develop their gluten-free range of bakery products. Simon Dawson, Operations Engineering Manager said “we can now offer an enhanced product range, better flexibility of pack sizes, along with significantly enhanced quality assurance and customer service.”

Hero, an Infant Nutrition manufacturer now uses IBC Blending to add micro/minor ingredients as a pre-mix. They had been using a horizontal ribbon mixer to blend the pre-mix and whilst the actual blending time was just minutes, the ribbon blender had to be supervised by an operator, took hours to fill and empty and demanded 1-2 hours for a full-clean down. This resulted in the pre-mixing stage being painfully slow and labour intensive with large amounts of down-time between different batch runs. The system limited production capacity and flexibility. The answer was to use IBC Blending for the pre-mix, which removed the need for cleaning the ribbon blender between batches, thereby dramatically increasing capacity and eliminating the bottleneck issue. They were able to double their production capacity, whilst achieving a 30% reduction in stock, save 1000 man hours of cleaning and reduce lead times. If you have a wide portfolio of recipes or need to produce smaller batch runs, tailor-made to your customer’s needs it might be worth considering what an IBC system could offer you.

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Guest Article

HEAT:

THE FORGOTTEN ELEMENT OF ANAEROBIC DIGESTION

By Matt Hale, International Sales Manager, HRS Heat Exchangers Anaerobic digestion (AD) produces many valuable and useful products, including biogas (which can then be turned into heat, electricity or biomethane gas) and digestate, a biofertiliser rich in nutrients and organic matter. However, many farm AD plants also produce incidental heat, which can be captured and used within the AD process or for other on-site operations.

Wasted heat is becoming increasingly important, not only from an economic point of view, put also politically. In the UK the Renewable Heat Incentive is the key policy driver to encourage the utilisation of heat from renewable sources, including incidental heat from the AD process, while some European countries now specify targets for the use of heat from AD plants.

SOURCES OF HEAT

Surplus heat produced by biogas combustion in a combined heat and power (CHP) unit is the most common heat source within an AD plant. Other processes which result in residual, usable heat include: • Digestate pre-heating • Digester heating (especially in summer when less heating is required) • Pasteurisation (either before or after digestion) • Electricity generation (e.g. via CHP) • Biogas upgrading to biomethane (heat is required for the process, but up to 75% of it can be recaptured and reused) • Digestate concentration For example, a minimum temperature of 70oC may be required for pasteurisation, leaving 30-40oC of ‘left over’ heat, which has historically been wasted to the atmosphere. This heat could instead be put to good use elsewhere within the AD process.

Equally, heat left over from concentrating digestate could be used within pasteurisation.

WHAT IS A HEAT EXCHANGER?

Heat exchangers take heat from one process or place and transfer it to another. In practice, they allow the heat from a liquid or gas to pass to another liquid or gas without the two having to mix together or come into direct contact. Common everyday examples include domestic radiators (which transfer heat from a boiler to a room) and car radiators (which take heat away from the engine).

Heat exchangers are used for numerous applications, including space heating; cooling; air conditioning; sewage treatment; food processing; and in chemical industries. Increasingly, their potential role in the anaerobic digestion sector is being recognised, with more plants specifying their inclusion at the design stage or retrofitting them, either to improve overall process efficiency or to use heat which would otherwise be wasted.

TYPES OF HEAT EXCHANGER

There are different types of heat exchanger and it is important that the right type is selected for a particular application.

Two of the most common types in use today are Plate Heat

Exchangers and Tubular Heat Exchangers. However, within these broad categories there are many different models and refinements and it is important to understand what is being offered.

It is therefore advisable to consult a specialist who can explain the benefits of different types and perhaps offer different solutions. For example, viscous fluids such as digestate can quickly foul tubes and surfaces. For this reason, scraped surface heat exchangers are usually recommended, as they will constantly remove such fouling. However, another option is to use a tube design, which will minimise fouling in the first place. HRS corrugated tube heat exchangers are designed so that the constant swirling of the fluid in the tube prevents sediment and clogging.

Whichever system is proposed, it is important to compare running costs, including maintenance and cleaning, over the full life of the plant – downtime caused by regular dismantling or cleaning can quickly eat into any capital savings made at the time of purchase.

POTENTIAL USES FOR HEAT IN THE AD PROCESS

So, having identified a source of heat, what can be done with it?

There are a number of options with the AD process, including: preheating feedstock, which can help to speed up the digestion process or improve gas production; for pasteurising, for example to meet PAS 110 requirements for digestate or to ensure crop hygiene; and to improve the quality and reduce the volume of digestate. Using surplus heat in an HRS Digestate Concentration System (DCS), for example, can reduce digestate volumes by around 60%, bringing significant savings in storage, transport and application to farmland, while retaining all the nutritional benefits.

Finally, using waste heat to upgrade biogas to biomethane, for use as a transport fuel or for injection into the gas grid, is also becoming increasingly common and helps to fulfil AD’s potential as a diverse energy source. What’s more, depending on the exact technology used, as much as 75% of the heat used for biogas upgrading can then be recovered.

OTHER USES FOR HEAT

Captured heat can be used almost anywhere, provided that it is economically and practically feasible to transfer it. Even

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

low temperature water can be used to reduce the amount of additional heating required, for example by a boiler.

There are many uses of heat at an AD plant whether it’s farm or food based. For farms, heat can be used for space heating of greenhouses and polytunnels to drying crops or biomass fuels. Many livestock buildings require heat, particularly for pig and poultry production, and where farms have diversified to create office or business centres there is often the scope to install district heating systems. And at a food plant, heat can be used for space heating and cooking, to heating liquids to aid processing as well as pasteurising and sterilizing foodstuffs.

In other parts of the world more unusual uses for heat have also been seen, such as aquaculture for fish production; further electricity generation through the use of Organic Rankine Cycle (ORC) technology and Kalina Cycle low temperature generation systems; or transporting heat in containers which utilise latent heat storage technology.

With careful planning and a long term approach which considers the full life of an AD plant – not just initial purchase prices – the individual heat loads of each process within an AD operation can be greatly reduced by using recaptured heat, resulting in improvements in both efficiency and product quality.

AN ENDLESS CYCLE?

It may be tempting to think that you can keep recapturing the heat used over and over again, but unfortunately, this isn’t possible. However, what is possible is to reuse some of the leftover heat to improve operational efficiency. Systems which do this, such as an HRS digestate pasteuriser, can often deliver efficiency savings of 40% or more compared to traditional pasteurisers without heat recovery.

With careful planning and a long term approach which considers the full life of an AD plant – not just initial purchase prices – the individual heat loads of each process within an AD operation can be greatly reduced by using recaptured heat, resulting in improvements in both efficiency and product quality.

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FARLEYGREENE CELEBRATES 40 YEARS OF SIEVING TECHNOLOGY Farleygreene Ltd, established in 1976, celebrate their 40th year with a 2016 Ruby Jubilee. From modest beginnings Farleygreene now provide one of the largest ranges of UK manufactured sieving machinery available across the Globe. Renowned for design and build quality they pride themselves with supplying some of the most prestigious names in the food, pharmaceutical, chemical and additive manufacture industries.

Included within their ‘SIEVMASTER’ portfolio are the popular ‘Artisan & Bakery’ sifters, ‘Slimline’ check sieves, ‘Segregator’ linear feed screeners, ‘Rota’ centrifugal sifters, and the ‘Multiscreen’ vibratory grading separators. In addition, Farleygreene provide bespoke powder sieving stations designed to customers’ exact requirements including sack handling, conveying and transfer options.

Not just satisfied with this success, Farleygreene have launched their new line of innovative high technology sieving equipment. Titled ‘SIEVGEN’, this new range represents the companies next generation of sieving equipment, and commitment to moving the technologies forward for the future.

The first design, launched in late 2015, was the SIEVGEN SG400-US unit, which is aimed directly at the additive manufacturing sector. Other models and innovations will be launched during 2016, along with a special microsite dedicated to the new ‘SIEVGEN’ technologies.

Since 2010 Farleygreene have grown substantially, this is due to a combination of moving to a new larger manufacturing site in December 2014 where they can now provide full test facilities; secondly, and most importantly they have experienced staff across all departments to provide their customers with a comprehensive service to support them during the life of the machine, starting from the initial enquiry right through to aftersales support.

Farleygreene are delighted and proud to celebrate their first 40 years and look forward to taking this success through to their next anniversary.

Farleygreene would like to celebrate their 40th Birthday in February with their customers by giving away a bottle of Champagne to 10 owners of the oldest operational Farleygreene sieving machine.

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PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

Guest Article

NEW SERIES-E IRIS DIAPHRAGM VALVE FROM MUCON Those of you that have utilised Mucon Iris Diaphragm valves over the past sixty years they have been on the market, will have doubtless noted that, at least in the manually operated form, it is possible to vary the diameter of the valve’s orifice almost infintiely between fully closed and fully open.

Over this period Mucon has developed and launched a number of powered versions of the Iris Valve including the well known Series-E Iris Diaphragm Valve.

Historically, in order to both control and monitor the position of these powered valves they have been fitted with open and closed limit switches and one, or perhaps two, intermediate position switches somewhere in between; often referred to as the ‘trickle’ position.

More recent developments including the Series K2P and A2P Iris valves have improved the ability to vary the diaphragm orifice still further by providing a pulse generator switch; offering the end user the ability to programme up to thirty positions between fully open and closed.

Once programmed, the controller can utilise any 4-20mA or 0-10V input signal to give direct, closed loop, control over the open diameter of the valve orifice. When this control module is used in conjunction with a powered Mucon Iris Valve, feedback from a weigh scale can be used to slowly close the valve as it approaches the target weight or in the case of a mill the feed rate can be controlled in real-time, based on an interpretation of the load on the drive motor.

The module also monitors torque and can be programmed to gently push to a closed position whilst protecting the motor from damage; we believe this will allow us to apply electrically powered Iris Valves to applications like big-bag neck choking, amongst many others.

If you want to know more about this story or the products and services offered by Mucon you can contact us in the following ways: Tel: +44 (0)1625 412000 E-mail: sales@mucon.com Web: www.mucon.com

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

STARCLEAN BELT CLEANING REVOLUTION ARRIVES ProSpare has launched a new, unique product which tackles the challenges of belt cleaning in a completely different way to traditional belt scrapers.

FE Schulte Strathaus & Co KG have been at the heart of changing the way conveyor belts are cleaned across Europe, but their ground breaking new system has not been available in UK or Ireland - until now! ProSpare are pleased to announce that a new Distribution Agreement was signed at Bauma, the worlds largest construction equipment exhibition, officially appointing ProSpare as sole stocking distributor for Starclean belt cleaning systems in UK and Ireland.

Starclean conveyor belt cleaners are recognised as a huge leap forward in belt cleaner design: Twist-swing solves the problem Separate Starclean blade segments are tensioned onto the belt individually using the ingenious “twistswing” design. Optimum belt contact pressure is maintained as each blade segment automatically compensates for different wear rates independently of the others. The result is a gentle cleaning action which is more effective, protects belts and reduces blade wear rates.

Fastest, simplest maintenance Starclean quick-release tensioning devices combined with quick-change, slot-in blade design has changed belt scraper maintenance forever. Likened to a F1 pit stop, in-house site staff can carry out maintenance in minutes without the need to call in expensive specialist contractors, leading to substantial savings.

James Bullock, MD of ProSpare commented: “Through our close cooperation with TBK Group, we have been growing sales of conveyor components such as Spill-Ex skirt sealing, Friflow Impact beds and Centrax belt trackers, but we were repeatedly asked for belt cleaning solutions. Starclean completes our range perfectly and we now offer a strong one-stop conveyor belt solution. We are very pleased to have teamed up with one of the most respected belt cleaner manufacturers who offer a market leading product which ideally complements our existing range”

If you experience belt cleaning problems, more information about Starclean belt cleaners or the rest of their conveyor components range can be found on the www.prospare.co.uk

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MILLING TECHNOLOGY SELECTION FOR PARTICLE SIZE REDUCTION

By British Rema The selection of the most appropriate milling technology for a particular application is not always straight forward and the most appropriate answer is not always the most obvious. Failure to identify feasible alternatives can be extremely costly over time. Identifying these alternatives often requires trials, not theory, and a potential purchaser of either equipment or processing services needs to ensure that their chosen supplier can advise and conduct trials across the appropriate range of alternative techniques.

The controlled reduction of the particle size of solid materials is a process required in many industry sectors, and is applied to an astonishingly wide range of materials from inhalable active pharmaceutical powders through food ingredients and fine chemicals to large-scale mineral processing applications.

Not surprisingly, there are different technologies available on the market to meet these challenges, exhibiting different combinations of capability and cost (both capital investment and running costs). Some tasks can be carried out using more than one technique, the choice becoming a trade-off between the required performance (usually expressed as an output particle size distribution and throughput) and cost. Some materials require different techniques depending on the input particle size and/or shape, and the inexperienced can be surprised to find that the same material chemistry-wise may mill much less efficiently (or not at all) on a particular mill type in one physical format (eg extruded product) when the same mill type was quite effective on a different product format.

Handling heat sensitive materials, such as polymers with a relatively low softening point(typically a function of its chemical composition, molecular weight and glass transition temperature), can also be problematic, but the cost implications of failing to recognise that the conventional cryogenic milling solution (1) may not actually be required for the particular task in question can be profound.

majority of milling applications in one form or another are as follows:

AIR MICRONISERS Air micronisers (or “jet mills”) are used to grind a wide range of materials, particularly where the feed material is already relatively fine. The technique relies on particle-on- particle impact to break down the material, having been introduced into what are very high speed air jet streams inthe body of the mill. There are two types of jet mill: (i) a spiral flow jet mill which is commonly jet mill which can handle harder materials (up to 10 on the Mohs scale (3) with classification achieved by means of a high speed rotor.

ROTARY IMPACT MILLS Rotary impact mills, also known as beater mills, use high-speed rotors with a rotor tip velocity of up to 120 m/s. Grinding takes place through the impact of the powder particles on the rotating and fixed grinding surfaces. Typically used for softer materials of up to 3 Mohs hardness, an impact mill provides an operationally cost-effective solution when hardness and particle size parameters fall within its range.

ASSESSING THE TASK

BALL MILLS

As a supplier of a wide range of equipment and an experienced operator of all the equipment types in our own plant as a contract processor, in our experience there are three key pitfalls to be avoided: 1. Don’t take the specification for granted – the first step with customers who arrive armed only with a numerical specification (eg “d50 < 12 microns”; or “100% < 50 microns”) (2) of this specification. Not only are there different definitions of what, say,“d50” means, but different measurement systems can also yield very different results.

2. Don’t over-specify the end product – having established that a particular particle size distribution of a material has the required functionality in application, it can be worthwhile exploring its specification limits. Sometimes a relatively small relaxation of one parameter can have a substantial impact on the milling performance or efficiency and can, in extremis, enable the switch from one technology to another. Working with an unnecessarily stringent specification might suit the equipment or service provider as it will be more costly, but it is not in the best interests of the customer, and some careful work to define what the specification limitations truly are can pay dividends in the long run.

3. Don’t presume you know the answer – try it! Be sceptical of a supplier who quickly and confidently tells you what the right solution is going to be.

Ball mills, and other forms of tumbling mills such as tube mills and rod mills, comprise a cylindrical shell slowly rotating around a horizontal axis, partially filled with a grinding medium(such as ceramic or steel balls) to which the material to be milled is introduced. Typical in the ores, minerals, paints and general chemicals industries, ball mills can be designed to operate continuously (fed at one end and discharged at the other), or on a batch basis.

Each of these mill types can then be combined with external classifier stages, with or without feedback, to create an overall process that is as efficient and cost-effective as possible.

TECHNOLOGY TYPES There are several different underlying technologies used for milling, and then a multitude of variations and hybrids. The common underlying technologies which, between them, address them a

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CASE STUDY In expanding its operations to the European market, a global manufacturer supplying resin powders for use in composites and membranes for the aerospace, electronics and other hightech industries, approached British Rema to address its milling requirements.

These end applications demanded a highly-regulated quality control environment and the customer had previously used cryogenic grinding followed by a screening process to achieve the particle size distribution. Although ultimately achieving the required results, the use of liquid nitrogen required complex enclosed systems and the application of stringent health and safety procedures.

Rather than presume to replicate the existing methodology, British Rema recognised that, in this particular case, cryogenic milling may have been unnecessary, and British Rema’s solution was to use its classifier mill, albeit especially adapted for the purpose.

Classifier mills are a type of rotary impact mill (referred to above)

which have the benefit of being a single machine with an integrated impact mill and classifier in the one housing. The CLM mill is commonly used for multi-stage, closed loop grinding and is ideal for products with properties of a more challenging nature and/or requiring a tightly controlled particle size distribution (see figure 1).

This process achieved the desired particle size but, importantly, processing costs were significantly reduced. In addition, the stringent health and safety precautions associated with theuse of liquid nitrogen were no longer required.

CONCLUSION The selection of the most appropriate milling technology for a particular application requires experience, trials and an open mind.

A failure to identify feasible alternatives can be extremel costly over time. Unnecessary over-specification of the finished product can also lead to higher costs than necessary, and a close, collaborative working relationship between customer and supplier is needed to develop the optimum long run solution to any particle size reduction project.

Figure 1 – British Rema Classifier Mill

The classifier mill works on a four stage process as shown in the diagram: Stage 1 The material is introduced into the mill via the primary air feed where the material is mixed with air, thereby minimizing the risk of agglomeration.

Stage 2 The material enters the grinding chamber where grinding takes place in the same way as a conventional rotary impact mill. The secondary air inlet further aerates the product and provides the option to introduce chilled air if the material has a low melting point.

Stage 3 The milled material passes into the classifier wheel. Material of the desired size passes through whilst oversize particles are rejected and pass to the next stage.

Stage 4 The rejected oversize material passes to a separate section of the grinding wheel where it is ground separately from the in-feed material and then once again directed to the classifier wheel.

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

TWO NEW KEY APPOINTMENTS AT BRITISH REMA Powder processing specialist British Rema has announced two new appointments which will further strengthen the company’s service to customers.

Dr. Richard Mellor has been appointed Technical and Quality Manager, joining the company with years of experience in the development and supply of new materials. James Bell has been named Engineering and Safety Manager and brings extensive experience gained in the health and safety arena for a number of wellknown organisations.

Dr. Mellor has both a scientific grounding in, and a practical experience of, powder application. He will work closely with British Rema’s in-house design engineers and trialling and laboratory facilities to optimise customers’ powder specifications from both a functional and processing point of view.

He has previously worked on supply and development projects throughout the world including for the defence departments of the UK and the USA. Until recently he was Technical Director for Purification Products where he was instrumental in the company receiving the Queen’s Award for Export.

Mr. Bell joins British Rema from a blue chip company where he was responsible for fire and emergency safety across four of the company’s manufacturing sites. He previously spent 24 years in the Royal Navy as an air traffic control specialist. At British Rema he will be responsible for developing internal process improvements in both health and safety and engineering, including the implementation of preventative maintenance programmes that are integrated into the overall supply chain management systems of British Rema’s core aerospace customers.

For more information contact British Rema Process Equipment Ltd. E-mail: info@britishrema.com Web: www.britishrema.com

WORLDS FIRST 80 GHZ RADAR LEVEL SENSOR FOR LIQUIDS VEGA introduces VEGAPULS 64, the first 80 GHz frequency contactless liquids radar level sensor. This higher frequency enables improved focusing of the radar beam, making measurement easier and more reliable, even under difficult conditions, in vessels with heating coils, baffles or agitators.

The VEGAPULS 64 has a beam angle starting from only 3° with an 80mm/3” antenna size.

This allows the sensor to be used in vessels with many internal installations or heavy build up on the walls, the focused microwave beam simply avoids them. The smallest antenna is no larger than a £1 coin, yet still has a narrow 10° beam angle. These compact dimensions enable the sensor to offer an excellent level measurement solution for even the smallest of process vessels. The new device has an ultra-wide dynamic range, which means even foaming, turbulent product surfaces, condensation, or antenna build up have little or no effect. It can also even measure very low dielectric products like hydrocarbons and liquid gases reliably, with an accuracy of +/-2 mm, over a range of up to 30 m.

Designed for use in the chemical, oil and gas, pharmaceutical and food industries, the VEGAPULS 64 has a wide range of resistant materials, connections and hygienic designs.

In addition to mainstream manufacturing and processing industries, this sensor opens up application possibilities in pilot plants and even laboratories which, for space reasons, could not use radar level technology before. Bluetooth programming options using free downloadable app or PC offer added convenience and user safety.

More information available at: www.vega.com/radar or contact VEGA Controls Ltd by Tel: 01444 870056 or E-mail: info.uk@vega.com

Made in Britain

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

15sp

BULK BAG LIFTING FRAME WITH ADJUSTABLE ARMS Flexicon has introduced a new bulk bag lifting frame with telescoping arms that accommodates bulk bags produced in an increasing range of sizes.

The lifting frame is optional on all BFC models of Flexicon’s BULK-OUT ® discharger line, and available for up to two tonne capacities to replace conventional lifting frames of any make or model of discharger that employs a hoist to position and suspend bulk bags.

The telescoping arms can be adjusted using clevis pins and safety clips to a range of settings to accommodate bulk bags from 81 to 119 cm square at the upper sew seam. This adjustability also allows the lifting frame to work safely with rectangular bags.

Available in carbon steel with durable industrial coatings or stainless steel to industrial or sanitary standards, the adjustable frames are equipped as standard with Flexicon’s patented Z-CLIP™ strap channels that hold the straps securely while allowing rapid insertion and removal.

Other dischargers offered by the company include BFF models with a lifting frame for forklift loading of bulk bags, low-profile BFH half frame models that require a forklift or plant hoist to suspend the bag during unloading, and BFX split frame unloaders that allow loading of the upper frame on the plant floor, and then forklifting it onto the sub frame within several centimeters of the ceiling.

The company also manufactures bulk bag conditioners, bulk bag fillers, flexible screw conveyors, tubular cable conveyors, pneumatic conveying systems, bag dump stations, drum/box/container tippers, weigh batching systems and engineered plant-wide bulk handling systems with automated controls.

For information contact Flexicon Europe Ltd, Whistable, Kent Tel: +44 (0)1227 374710, E-mail: sales@flexicon.co.uk, Web: www.flexicon.uk.com 16sp

PROCESS INDUSTRY INFORMER July 2016 - SHAPA Supplement

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