SHAPA Supplement February 2016

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Solids Handling & Processing Supplement

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January - February 2016

MOVERS & SHAKERS

By Gus Bishop AS OTHERS SEE US…

A recent industrial survey concluded that at least 80% of service providers questioned said they provided a good service. A similar survey of customers of the same providers concluded that only 8% provided a good service – something of a chasm between conflicting views. Who do we believe?

– suffice it to say that this did not involve participants in our industries, but it serves as an awful warning to avoid complacency. Of course, good communication between suppliers themselves and also between suppliers and customers can go a long way towards reducing such gaps in credibility and good partnerships

continue...

Strengthen your process

A BRIGHTER OUTLOOK?

Indeed, manufacturing output and profitability, albeit briefly, increased during the latter part of the year. In spite of a steadily increasing value of the Pound, especially against the Euro, exports have not suffered too badly.

In fact UK manufacturing output has been trending upwards for some time now. Singlemindedness and dedication are key to this hard won success. Cooperation between supplying companies and partnership building with clients have contributed greatly to this success.

SNAKES AND LADDERS

Importers and exporters are affected by market fluctuations, great and small, around the world. Dips in the rate of growth in China and other erstwhile emerging powerhouse economies have checked the need for oil, with reduced manufacturing and shipping activity. Bad news at one level, but offsetting this is the consequent cost reduction for these activities here in UK, helping competitiveness in a nevertheless challenging market place. Low inflation, or even slight deflation here, but greater in countries such as Japan add to the task for exporters, as some countries endeavour to concentrate on “home grown” products and services. Cheap steel from China and India have hit domestic steel production hard, denting our opportunities to supply this industry.

Conversely, cheaper steel itself may help to reduce product manufacturers’ costs, but then again, there are issues with poorer quality or inconsistent materials.

Notwithstanding all of this, the solids and bulk handling equipment manufacturers and suppliers continue their key role in keeping a vast range of vital industries operating smoothly and efficiently.

AL wi with ith optional ventbox ntbox box and dropoutbox dropoutb

BTD BT TD Ball Type Diverter

When handling abrasive materials, the use of abrasion resistant rotary and diverter valves reduces the downtime for replacement or re-adjustment of worn parts, the refurbishment costs and thus the cost of ownership.

Also the valves have a more predictable and reliable performance, making preventative maintenance schedules easier to establish.

DMN-WESTINGHOUSE abrasion resistant ceramic coated or Ni-hard rotary valves and the specially designed, rugged BTD ball diverter can help you strengthen your process.

AIRLOCKS • BLOWINGS SEALS DIVERTER VALVES • SLIDE GATE VALVES MORRIS COUPLINGS

COMPONENTS FOR BULK SOLIDS HANDLING

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015 may well be receding rapidly into the mists of, for many, best forgotten memory.

The year threw up a bewildering barage of conflicting, disturbing, but occasionally encouraging events, data and information.

Both politically and commercially it was a year that jerked upon the reins of sanity, spooked any ideas about steady progress and made us all think and reassess our hopes and aspirations.

Inevitably the security of people, premises and data has come into sharper focus. Just as we become super-reliant on e-, i-, smart- and other internet driven functions for everything from material supply to marketing ( there’s even an app to tighten your shoes now!), we must make redoubled efforts to keep vital information, including customer data, secure. Nobody, particularly given the events around the world last year, would presume to be complacent – but life goes on and the wheels of business continue to revolve with gathering pace.

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

www.dmnwestinghouse.uk

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

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today. There is always much work to be done, however, as new materials, finer blends and technologically precise and often delicate materials join the ingredients list across a range of applications. So, following the successful introduction last year of the SHAPA Industry Awards scheme, the Association has developed an enhanced set of prestigious awards this year – with five categories available. They will be hotly contested by companies who demonstrate knowledge, commitment, enthusiasm and success in their fields. Hurry and visit www.shapa. co.uk for details – time is getting short!

ENGINEERING THE FUTURE

Material analysis become essential to ensure that what we supply is really what the customer wants and actually needs.

The need for shrewd, skilled and highly motivated people for our industries has never been greater. SHAPA recognise this ongoing demand and actively encourage up and coming engineers and managers to become the movers and shakers of the future. Regular Engineering the Future seminars encompassing education, networking as well as some entertainment feature in the Association’s calendar. The body of knowledge held by SHAPA via committed member companies is huge and growing day by day. We all recognise the need to “stick together” and this is well illustrated by member companies who are suppliers to and customers of each other. Not only that, they frequently find themselves as complementary colleagues working side by side on large projects. Inter-member networking is clearly beneficial.

THE COMING OF GUILDS

Clearly an association of manufacturers and suppliers, run on an equitable basis to aid communication would have many benefits. But there is nothing new in this idea. As far back as the 12th century trade guilds were emerging with the aim of standardising quality amongst individual tradesmen, to enable customers to have confidence in the goods and services that they were purchasing. Today’s surviving Liveried Guilds, whilst serving as a reminder of past enterprise, operate solely as charities for worthy causes. It took the Industrial Revolution, during which time “cottage industries” gradually combined to become factory workplaces attracting along the way increasingly complicated and onerous regulation, to spawn the idea of engineering trades associations to share and spread the load. Several generations passed, however, before they became properly established.

A MODERN DAY “GUILD”

In 1982 such an association formed. The Solids Handling & Processing Association (SHAPA) is still in rude health with 110 key member companies, many of which are long standing members and some even founder members. The original aims, to reduce costs, to combine knowledge and improve customer experience, are as true now as when the original Guilds were formed. Membership of a modern engineering trades association offers so many advantages, so well documented that repitition here seems hardly necessary – just visit www. shapa.co.uk

REWARDING MOVERS & SHAKERS

In all senses of the words the solids handling industry makes movers and shakers, eg. conveyors, sieves and screens, elevators and a host of processing equipment and controls, but more particularly it is the human movers and shakers who down the years have provided the innovation and impetus to develop and succeed with novel and better ideas. The SHAPA Council is very keen to acknowledge these worthy inventors and industrialists and other enablers who have brought our industry to the finely tuned science-based condition we see

Process controls

REALLY USEFUL MEETINGS

This is not an oxymoron for SHAPA members! Apart from facilitating development of shared insight, technical, commercial and marketing intelligence, the quarterly General Meetings are essential forums for idea exchange and partnership building. Enjoy the following pages whist pondering the real value of membership, or alternatively of putting your trust in SHAPA member company expertise.

Seminar workshop

Storage Silo 2sp

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

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.

Please notify them of your machine serial number to: hello@farleygreene.com. Also every entrant will receive a 10% off voucher for their next spares part order. This is only valid for the month of February, so do not hesitate to get your emails in!

ENERGY-SAVING WELDING FUME EXTRACTION IG Masonry Support Systems Ltd, a division of The Keystone Group – Europe’s largest steel lintel manufacturer – has recently invested in an energy-saving welding fume extraction system from specialist extraction engineers Cades Ltd part of the DCS group.

A vent-to-atmosphere weld extraction system was designed, supplied and installed by Cades Ltd to effectively deal with welding smoke, fumes and grinding dust from a new 10-bay steel lintel welding line at IG’s fabrication facility in Swadlincote, South Derbyshire. Here, the company produces brick slip masonry support systems in stainless steel and galvanised steel.

Each welding bay has a centrally located, 3m long fume extraction arm and captured welding smoke, fume and dust is removed via ductwork to a high-efficiency Gold Series® filter unit. The maintenance-friendly GS6 cartridge-type reverse jet filter contains six high-efficiency HemiPleat Gold Cone filter cartridges; providing optimum cleaning efficiencies, as well as increased filter life and reduced servicing requirements. Powering the system is a 15kW low-noise Moldow main extraction fan set, fitted with a variable speed drive.

A key feature of the installation is the inclusion of ECOGATE® energy-saving technology which is designed to reduce power usage on the extraction system by as much as 57%. Each fume extraction hood is fitted with an automatic ECOGATE® motorised damper and a PIR movement sensor which signals an ECOGATE® greenBOX12 controller to open or close the damper as welding stations come on-line or shut down. The greenBOX12 detects changes in extraction load and adjusts the variable speed fan drive accordingly. The result is an extraction system that provides precise extraction volumes, only when required.

For more information: Tel: 0845 838 6166 or visit www.cadesltd.co.uk

ROTAVAL – REFURBISHMENT & SERVICING OF ROTARY VALVES As well as supplying new rotary, diverter and special application valves, Rota Val is an experienced spares and refurbishment provider. With over 45 years of experience, their technical knowledge and expertise surpasses any third part service provider.

Rota Val can supply a full range of spares and also offers off-site refurbishment, their team is backed by decades of experience and offers a highly competitive schedule of rates. Their factory features space to specifically carry out refurbishments and when finished any old valve will look brand new.

Contact: T: 01249 651136 E: sales@rotaval.co.uk W: www.rotaval.co.uk

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KNOW YOUR DUST Mark Shannon from BS&B Safety Systems discusses the importance

of dust testing when taking protective measures against dust explosion risk WHY IS DUST DANGEROUS IN PROCESS INDUSTRIES? In any industry that handles or stores organic materials for processing, there is always a risk of dust explosions occurring. A myriad of powdered or ground organic materials ranging from carbon to milk powder are prime constituents for ignition and fuelling of ensuing primary explosions within process facilities.

Taking every precaution to ensure that such explosions don’t happen is of paramount importance for the protection of personnel, equipment and facilities.

Dust explosions occur when an ignition source ignites combustible organic material that is fuelled with oxygen in a closed atmosphere. This can take place inside a grain silo, process or storage enclosure, or even originate in pulverising or grinding process equipment. It takes only milliseconds for a violent explosion to occur after a rapid pressure rise in process equipment.

Depending on the type of equipment or vessel that holds the materials, certain fail-safes are implemented to stop an explosion occurring. This is where a thorough understanding of dust characteristics becomes important.

In the UK and Europe, there is a requirement to identify any potentially explosive substances in the workplace. In the UK this requirement is governed by the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). DSEAR classifies dangerous substances as those used or present at work that could, without adequate controls, cause harm as a result of a fire or explosion. In Europe, ATEX is the common name given to two European directives that specify what controls employers should use to prevent explosion risks, which are divided into danger ‘zones’.

BOTH DSEAR & ATEX RECOGNISE DUSTS AS EXPLOSIVE RISKS. As far as BS&B are concerned we offer various solutions to protect against dust explosions. Before we recommend the right ones to a client, the very first question we ask is “what type of materials are you handling in your facility?”

Different types of dust have different particle sizes, properties, ignition temperatures, and ignition sources, from each other.

Dusts are given explosion severity classifications; St1 to St3.

‘Not specified’, means the material is non-explosive and St3 is the most explosive type of material.

Most people think that dust is, for the most part, the same.

However, the range and qualities of dangerous dusts is expansive across the process industries and include organic materials that most of us would not even consider as an explosive risk. Nevertheless, for the purposes of manufacturing and processing, a closer analysis of dust characteristics is required to specify operational conditions and protection.

For example, according to the Health & Safety Executive’s

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guidelines Safe Handling of Combustible Dusts, wheat has an average particle size of 80 µm; wood flour is 65µm, tissue paper is 54µm; magnesium at 28µm, which has a classification of St3 and is highly combustible. Dust testing is designed to identify two key performance characteristics of dust, which in turn influence explosion protection equipment design and their application as well.

• The first measures maximum pressure of a dust explosion (Pmax in bar) • The second identifies the speed of the rise in explosive pressure (KSt in m/sec) Returning to the very fine and highly explosive magnesium powder as an example, the KSt value can be approximately 500 bar m/s. In comparison, wheat flour, only has a KSt value of around 110 bar m/s – a significantly slower rate of explosion pressure rise. Nonetheless, it could remain a danger.

“Of course there is no substitute for exercising good housekeeping in factory facilities.

Regular removal of dust accumulations in the factory space is also a vital means of mitigating against dust explosions.”

Testing under laboratory conditions will tell you what St class your dust is, based on its KSt value. It will also reveal the dust’s performance under specific equipment operations and processes; is it being milled, ground, poured or dried? What is its Minimum Ignition Temperature (MIT) while being subjected to these processes – in other words, what temperature will the dust withstand before it becomes an ignition risk? All aspects of the dust’s behaviour in relation to its process environment can be determined to inform the correct precautionary measures against a potential explosion.

MATCH THE PROTECTION TO THE TYPE OF DUST Because dusts have different explosive properties, these are often handled and stored in different ways and locations, the protective measures in each location will be tailored to meet the associated risk.

Facilities can be protected from the risk of dust explosions by various means depending on your application. An explosion protection consultant will advise on the best solution for your facility: SPARK DETECTION DEVICES: sense hot particles, sparks and flame that could become the ignition source for a fire or

explosion. They can include automated shut-down systems to interrupt the feed of combustible material along the process equipment. All processes may be monitored by an operative via a control panel to assess any further risks. Spark detection is particularly useful to manage fire and explosion risks in process equipment such as dust collectors, bins and silos.

CHEMICAL SUPPRESSION SYSTEMS: designed to detect the pressure wave at the very start of an explosion and deliver dry, inert chemical extinguishing agents into a developing internal deflagration. These suppression and isolation systems can be activated either by pressure, optical or vent sensors. Any deflagration travelling through interconnected equipment is quickly and efficiently extinguished, preventing any spreading explosion damage.

FLAMELESS VENTS: the preferred passive method to relieve explosive pressure in a process or storage vessel containing combustible materials. It is not always practical or safe to vent the pressure and flame to a particular area, therefore these vents intercept, quench and retain all burning materials, preventing them from expelling into the atmosphere. They are particularly useful for dust collectors, bins and bucket elevators.

ISOLATION: designed to prevent any kind of deflagration or explosion from spreading to other parts of process equipment.

There are two methods of isolation used. The Passive method does not require detectors, or control and indicating equipment.

These may be arrestor mesh, rotary valves, lock valves, rotary screws, flap valves or diversion valves.

The Active method is activated by detectors and a control and indicating equipment, which are parts of the system, such as pinch valves, chemical Isolation or fast acting valves. Even though chemical suppression is used to reduce the initial building pressure in an enclosure, some hot gasses will attempt to exit to areas of lower pressure. This causes a flow through the inlets and outlets of the enclosure, hence the need for isolation.

SAFETY COMES FIRST Of course there is no substitute for exercising good housekeeping in factory facilities. Regular removal of dust accumulations in the factory space is also a vital means of mitigating against dust explosions. Dust that accumulates in eaves, ceilings spaces and beams are waiting fuel to propagate a secondary explosion. Up to one ton of accumulated dust has been recorded as the fuel for a devastating explosion in a pharmaceutical facility in 2003.

Investigators of the disaster said it had collected in the ceiling spaces and workers were unaware that the risk was above their heads.

Conducting a factory survey and dust testing service for clients as a matter of course is essential to achieve optimal dust explosion protection. It’s the first step in ensuring that they receive the appropriate explosion protection solutions for their business.

When it comes to the safety of equipment and personnel in dust explosion risk zones, thorough identification of organic dusts is good business practice. IT PAYS TO KNOW YOUR DUSTS.

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Guest Feature

CHOOSING A POWDER TESTER FOR PROCESS OPTIMISATION

By Tim Freeman, Managing Director, Freeman Technology Ltd

P

owder processing presents widely recognised challenges.

Equipment selection and design typically call for specific expert input and even then, over the long term, day-to-day problems with product variability, blockages and stoppages often erode profitability. Powders usually have a specification defined on the basis of composition and particle size, but successful powder handling and processing requires greater insight into the potential behaviour of the powder than these analyses afford. Powder flowability is a property that is often identified as being useful to measure and there are a wide range of options when it comes to test equipment. This raises the question of how to choose a powder tester that is well matched to a specific, process-related need.

The commercial introduction of a new powder testing technique – uniaxial testing – makes it timely to review the most valuable testers for process support and compare their suitability for specific applications. Here we consider the advantages and limitations of uniaxial testing, biaxial shear cell analysis and dynamic powder testing within this context.

EXPLORING REQUIREMENTS FOR POWDER TESTING A robust assessment of the relative merits of alternative powder testing options relies, in the first instance, on understanding why testing is carried out within the process environment. Powder testers differ substantially in terms of the data they deliver. Matching the capability of each tester and the information they provide to defined process needs is the key to choosing an appropriately specified tester that will yield a good return on investment.

Powder flowability measurements can improve manufacturing efficiency in a number of ways and are routinely implemented in: • QA/QC – to assess the consistency of a raw material or finished product; to evaluate an alternative supplier; and/or to achieve value added product performance.

• Routine plant operation – to optimise aspects of manufacturing practice, such as hopper fill level and shutdown protocols; to troubleshoot issues with product quality or plant performance.

• Equipment design and specification – to determine

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whether existing plant can be re-used in the manufacture of a new product and/or to develop an optimal process design.

One of the first issues to consider when selecting a tester is relevance. To be relevant, and consequently useful, a tester must measure a property that correlates directly with performance in process. It is not unusual to test a powder in QA/QC against a defined specification and find it acceptable, but then encounter problems when the material is introduced into the plant or released to the customer. This situation results from a failure to define a relevant specification i.e. one that relates to how the powder will actually perform during a particular processing stage.

The sensitivity of a powder tester is crucial to its ability to support process optimisation. Certain techniques are inherently more sensitive than others but repeatability and reproducibility are also critical. Where instruments utilise the same technique, the one with higher repeatability and reproducibility will more successfully differentiate samples and, therefore, offer greater insight to advance process understanding.

Features which enhance repeatability and reproducibility include well-defined measurement protocols, precision engineering and a high level of automation. Such features also beneficially impact the third factor that influences the value of a tester, which is practicality. Ease of use and measurement time both affect the ability of a powder tester to provide efficient manufacturing support.

REVIEWING THE OPTIONS The limitations of simple powder testing methods, such as tapped density, flow through an orifice and angle of repose, have led many powder processors to seek alternative techniques to support in this area. Uniaxial testing, on the other hand, is a recently commercialised approach withconsiderable promise. Understanding what each of these techniques has to offer is crucial for their efficient application.

UNIAXIAL TESTING HOW DOES IT WORK AND WHAT DOES IT MEASURE? Uniaxial testing involves measuring the normal stress required to fracture a free-standing consolidated

powder column. It delivers values of unconfined yield strength (UYS) as a function of a preconsolidation or major principle stress, o1, the same terms that are generated less directly by translational/rotational (biaxial) shear testing.

Figure 1: Uniaxial testing involves the fracture of a consolidated powder column and directly measures UYS.

THE PRACTICALITIES OF APPLICATION Uniaxial testing is simple and fast, with measurement times in the order of just a few minutes. Furthermore, equipment costs are low - automated instruments are around £10,000, and manual versions around half this price. These are crucial advantages for the manufacturing environment.

The primary challenge in implementing uniaxial testing is to construct a uniformly consolidated powder column, and this is especially difficult for more free-flowing powders. Recently commercialised instrumentation for uniaxial testing (Uniaxial Powder Tester, Freeman Technology) has features that directly address this challenge and enable highly repeatable measurement for a wide range of powders. However, the technique is somewhat limited in terms of the conditions applied during measurement, with relatively high consolidation stresses. It is also less suitable for very free-flowing materials.

AREAS OF APPLICATION Uniaxial testing is arguably the simplest, most inexpensive way of quantifying powder shear strength, with high repeatability. Shear strength relates to how a powder flows, making uniaxial testing a cost-effective choice for the measurement and comparison of powder flowability. It is likely to prove particularly useful to powder processors who currently rely on test methods

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

Guest Feature that are failing to provide sufficient differentiation, or who currently have no access to powder testing. Uniaxial testing is well-suited to QA/QC for rapid assessment of the consistency of a raw material or finished product, and is an accessible choice for process optimisation/ troubleshooting when exploring the causes of problems such as variable fill weight or erratic hopper discharge.

BIAXIAL SHEAR CELL TESTING UNDERSTANDING THE TECHNIQUE AND WHAT IT MEASURES Biaxial shear cell testing involves measuring the forces required to shear one consolidated powder plane relative to another. Shear stress is measured at a range of applied normal stresses and the resulting data are used to generate UYS values by a process of extrapolation. Analogous methods are applied to measure wall friction - the friction between a coupon of an actual or potential material of construction and the powder in question. Combining both sets of data enables the calculation of flow function (FF) and flow factor (ff), the two parameters routinely used in hopper design.

generate parameters for hopper design and this remains a primary application. By measuring powder properties under the moderate to high stress conditions that develop in small to large hoppers respectively, biaxial shear cell testing is useful not only for design, but also for determining whether existing storage is suitable for a new powder product and for troubleshooting erratic or sub-optimal discharge, a perennial problem.

More broadly, shear testing enables the investigation and comparison of how consolidated powders transition from the static to dynamic state. Shear cell analysis is also used more widely to support process optimisation and can be effective within this context providing there is recognition of its limitations with regards to predicting the behaviour of free-flowing powders and performance in a low stress and/or dynamic environment.

DYNAMIC POWDER TESTING UNDERSTANDING THE TECHNIQUE AND WHAT IT MEASURES Dynamic powder testing involves measuring the axial and rotational forces acting on an impeller as it is precisely rotated through a powder sample. The properties measured include Basic Flowability Energy (BFE), which quantifies how easily a powder flows under forcing conditions, and Specific Energy (SE), which defines unconfined flow properties. Dynamic testing can be applied to consolidated, moderate stress, aerated or even fluidised samples, to comprehensively characterise flow behaviour across a complete range of process relevant conditions.

THE PRACTICALITIES OF APPLICATION Figure 2: All shear cell designs measure the forces required to shear one consolidated powder plane relative to another to quantify certain powder flow properties.

THE PRACTICALITIES OF MEASUREMENT Since shear cell testing was introduced more than 50 years ago, substantial effort has been expended in refining instrument design. Today’s shear cell testers vary in their level of automation and also in terms of cost, with the most precise instruments enabling effective control of the test conditions applied and highly repeatable measurement. However, even with the best systems measurement times remain in the order of 10 – 20 minutes and some expertise is required for effective application of the technique and processing of the resulting data. The fact that testing is carried out using consolidated samples means that the relevance of the data is limited for certain processes; however, this is also the case for uniaxial testing, which demands the application of higher consolidation stresses.

AREAS OF APPLICATION Biaxial shear cell testing was developed specifically to

fail to rationalise poor process or product performance.

The ability to measure as many as 25 – 30 different powder properties makes dynamic powder testers unrivalled in terms of troubleshooting capability, while exceptional sensitivity allows advantage for the robust differentiation of raw materials and products. The ability to directly characterise the response of a powder to air, up to and beyond the point of fluidisation, is a unique benefit that offers enhanced support for the optimisation of, for example, fluidised bed and pneumatic conveying processes.

Dynamic test methodologies are well-defined and instrumentation is precision engineered and highly automated. As a result, dynamic powder testers, though relatively expensive, deliver unrivalled sensitivity and versatility. For example, using dynamic testing it is possible to clearly differentiate samples that would be classified as identical with shear cell testing but would go on to perform differently in a process.

Measurement times are in the region of 5 – 10 minutes for a basic assessment of flowability, but the range of testing available means that longer, more in-depth investigations of the effect of variables - such as flow (or strain) rate, air and moisture content, storage time and electrostatic charge - are routinely implemented.

Testers that offer dynamic powder characterisation also enable shear and bulk property measurement and can be productively used to build a database of powder properties to support the optimal processing of specific powders in a wide range of different unit operations.

Figure 3: Dynamic powder testing measures the powder in motion and can be applied to samples in a wide range of different states to simulate numerous process environments.

MAKING A CHOICE No one powder tester offers the best cost benefit ratio for every application. The introduction of a new powder tester, the Uniaxial Powder Tester from Freeman Technology, brings greater choice in powder tester selection, and crucially, reduces the price point at which robust and repeatable powder testing is accessible.

However, over the long term, alternative testers can ultimately yield a greater return, providing that the information they produce is relevant to the process need, and therefore of practical and commercial value.

Rigorously reviewing what a tester can deliver, against what is required, is the key to an optimal choice.

AREAS OF APPLICATION Dynamic powder testers provide detailed and valuable information from early product and process development through to QC, but most rapidly deliver an attractive return on investment when other techniques

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HOSOKAWA MICRON USE AIRFLOW DYNAMICS SIMULATION TO OPTIMISE DOWNFLOW BOOTH AND WORKSTATION DESIGN Leaders in containment technology, Hosokawa Micron Ltd, are now offering customers the opportunity, to accurately check, at design stage, how the placement of objects, equipment and operatives in their downflow booth may affect airflow patterns and containment all important to the achievement of critical OELs. This leading edge airflow dynamics modelling package complements Hosokawa Micron’s existing ergonomic modelling to combine to deliver the most appropriate downflow booth solution to meet the customer’s needs and working practices.

Explains Carl Emsley, Hosokawa Micron Ltd, ‘Customers can see for themselves how airflow in the booth can be effected by protective screens, local extract ventilation, ancillary equipment, as well as the presence of an operative. The simulations represent conditions under normal established operations – starting with an empty booth demonstrating the down flow with primary ventilation system running. Further simulations can then be created to demonstrate how airflow would change when equipment or operatives are brought into the booth – this means Hosokawa Micron engineers can optimise positioning of

Advanced computer modelling provides a visual demonstration of local extract as part of a downflow system. equipment and operations within the booth; right at early design stage.

Using the airflow simulation package allows Hosokawa engineers to produce a proven downflow booth design for both standard and non-standard units and is invaluable when designing for complex, multi-use operations.

With this software not only can we see the clear airflow patterns but workers can also see for themselves how they will be protected when handling potentially hazardous materials, giving them confidence in the task they are required to undertake. We can also say that in installations where downflow booths are placed within cleanrooms, where sometimes the ventilation systems can conflict, this new software is proving invaluable.’

For more information contact Hosokawa Micron Ltd, Runcorn, Cheshire Tel: +44 (0) 1928 755100 Email: info@hmluk.hosokawa.com Web: www.hosokawa.co.uk

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PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

BARTON FABRICATIONS HAS INSTALLED A 40 TONNE FLOUR SILO AT SPECIALITY BREADS’ NEW £3 MILLION BAKERY IN MARGATE The 12 metre high, 3.5 metre diameter ATEX compliant silo has been installed on the 3,000 square metre site, situated close to the bakery’s existing production facility. Speciality Breads, which is a Red Tractor-certified company, will use the new facility to produce around 20 handmade lines, while providing essential additional cold storage, work space and ovens for the team’s artisan bakers.

Commenting on why Barton Fabrications was chosen for the installation Peter Millen, Managing Director at Speciality “Barton

Fabrications have a fantastic reputation not just in the UK but around the world for their expertise and service so it wasn’t too difficult a decision. Their professionalism was top notch and there was no problem or issue which they couldn’t counter or have a strategy to solve.’’

Barton silo being installed at Speciality “In any build, whether it’s for a new site or a site Breads’ new Margate site being redeveloped, there are always issues, delays and problems on a day to day basis. For this reason, it is essential that you have a team who can be pro-active, re-active, adaptable and flexible. The Barton team ticked all these boxes.” The new bakery was opened in 2015 by MP Sir Roger Gale who cut a giant ciabatta at the inaugural event.

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

BRITISH REMA LAUNCHES INTERCHANGEABLE BLENDER British Rema Process Equipment has launched an Interchangeable Blender which enables the homogeneous blending of multiple granular products, dry powders, and liquids into powders, including fragile and abrasive products of varying densities and batch sizes, whilst meeting exacting process requirements in terms of blending

efficiency.

Suitable for laboratory and small-scale production with a capacity of between 5 and 100 litres, the Interchangeable Blender comprises a base section with motor/gear box, support structure and cantilevered arm capable of holding a wide range of different blender body types and sizes which can be easily interchanged.

As a result customers wishing to blend different products with different densities can do so without the capital expense of procuring multiple blenders or the resulting poor quality blending and longer blend times associated with process compromises such as over or under filling blenders.

Further benefits are that cross contamination is eliminated as individual products can be dedicated to a single blender cone or section.

The blender base can be fitted with V Cone, Double Cone, Ribbon, Octagonal and IBC blender bodies. Bodies of varying sizes, in a range of 5 to 100 litres, can be kept in storage on a dedicated trolley. When required, the trolley is presented to the blender base and, with a simple connection, the bodies changed in a matter of minutes.

Also available as an optional feature is a RFID system which works with the controls package to ensure that only the correct body dedicated to a specific product or recipe can be used. The software will not allow the blend to run if the correct blender body is not installed.

Founded in 1927, British Rema was an early pioneer in the field of particle size reduction and size control specialising in blending, milling, micronising and classification. Today the company is a leading supplier of powder processing equipment to the Pharmaceutical, Food, Plastics, Metal Powders and Chemical industries.

For more information on the Interchangeable Blender please contact Debbi Marlow on +44 (0)1246 269955 or email info@britishrema.com For more about & other products contact British Rema Process Equipment Ltd, Chesterfield, Derbyshire go to www.britishrema.co.uk

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

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LOW POWER DUST TIGHT CONVEYING

Multiple Outlet Tube Chain Conveyor for Kaolin Many industrial processes need to move dusts and powders around the system. The holy-grail is to achieve this with low cost of ownership and consume low amounts of energy. The conveyor needs to take in all of the material and discharge all of it at the required outlet without damaging the material. The Schrage Tube Chain Conveyor meets these objectives.

It enjoys the following benefits: • Low power consumption – the smallest conveyors can move 0.45m3/h and only consume 250W – less than an office computer! The upper limit to throughput is 60 m3/h with 11kW. • Gentle handling – your delicate product is discharged in exactly the same physical form as it entered the conveyor • Low wear rates – due to the slow speed of operation, the life of wear parts is measured in years.

• Low maintenance – a simple check every month is all that is needed, just taking a few minutes. If required at all, major maintenance can normally be planned for an annual shutdown.

• ATEX ratings available – conveyors can be supplied to Cutaway Section meet all ATEX levels; safe zone to ATEX 20.

• Totally dust tight – the all steel construction means no leakages, all of the product you put into the conveyor comes out at the other end. As there is no pressure inside the conveyor, there is no internal force trying to push material out.

• Range of steel types – from carbon steel right through to 318 stainless (corrosion and abrasion resistant) • Large conveying runs possible – 60m horizontally or 40m vertically. The conveyor can run at any angle from 0o to 90o.C Three dimensional configurations possible – this can reduce the machine count significantly, enhancing plant reliability.

• Multiple inlets and outlets – feed and discharge your material in any combination.Characterised by long life time and excellent cost to performance ratio, the tube chain conveyor is the solution to many conveying problems. Totally dust tight, all product passes through the conveyor without losses, increasing process efficiency and having very low power requirements. We are always happy to discuss applications and create the optimal configuration for your process.

For more information contact: Renby Limited - Tel: +44 (0)1829 740913 Email info@renby.co.uk |Web: www.renby.co.uk / www.schrage.de

FROM STAND-ALONE BULK HANDLING EQUIPMENT TO INTEGRATED SYSTEMS

Individual bulk handling equipment from Flexicon includes: Flexible Screw Conveyors, Tubular Cable Conveyors, Pneumatic Conveying Systems, Bulk Bag Dischargers, Bulk Bag Conditioners, Bulk Bag Fillers, Bag Dump Stations, Drum/Box/Container Tippers, and Weigh Batching/ Blending Systems. Each of these product groups encompasses a broad range of models that can be custom engineered for specialized applications, and integrated with new or existing upstream and downstream processes and storage vessels.

For large-scale bulk handling projects, Flexicon’s separate Project Engineering Division provides dedicated Project Managers and engineering teams on four continents to handle your project from concept to completion. Working with your engineering firm or directly with your team, Flexicon adheres strictly to your unique standards, documentation requirements and timelines through a single point-of-contact, eliminating the risk of coordinating multiple suppliers.

All equipment is available to food, dairy, pharmaceutical and industrial standards and conforms to ATEX, UL, CSA, CE and other electrical standards.

For more information contact Flexicon Europe Ltd Tel:+44 (0)1227 374710 E-mail: sales@flexicon.co.uk Web: www.flexicon.co.uk

VISIT THE VEGATRUCK ON ITS UK TOUR The VEGA TRAINING TRUCK has been specially designed to be a memorable experience for people involved with level and pressure measurement, and it tours the UK in February and early March 2016. An iconic American truck hauls an amazing ‘Formula One’ built trailer, which converts into an interactive training space for level and pressure instrumentation.

Once inside, you will find working process displays of both solids and liquids applications, operational instruments to see and handle, along with a presentation area. Be assured, this is not just another mobile exhibition. It will be stopping at a number of venues where you can come along and visit, they include: Aberdeen; Grangemouth; Liverpool; Hull; Grimsby; Derby; Coventry; Peterborough; South Wales and Burgess Hill.

This facility is specially designed to educate, inform and inspire engineers or stakeholders involved in processing and manufacturing at all levels. Come along, bring colleagues, and our experts will be there to help you get the best from it. Take away a great experience, some new ideas, a training certificate and memento of a visit you will be glad you took time to see.

If you would like to come along for a session contact linda.macdonald@vega.com for further details, locations and timings.

Made in Britain

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PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

ADDING & RETAINING VALUE IN BULK MATERIALS PROCESSES

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By Dr Robert Berry, Consultant, The Wolfson Centre for Bulk Solids Handling Technology

ost manufacturing plants employ multiple processing steps to take raw materials or (pre-processed) materials and create a finished particulate product that is required to have consistent bulk properties and functional performance, e.g. taste, dissolution properties, chemical composition etc.

These processing steps might include operations to; create particles (spray drying, centrifuging), modify the particle size (grinding and crushing or comminution and agglomeration), blend or separate different particulates (mixing, grading screening) remove moisture (band dryer), and finishing processes (coating, tableting or packing into big bags, sacks, sachets etc).

In order to achieve these successive processing operations, the bulk particulates must be conveyed through the factory from one step to the next using; mechanical conveyors; screw, chain, vibratory, pneumatic conveyors, belt conveyors or manual handling. Since these processing operations require a continuous material feed for efficient operation, buffer storage in the form of a hopper, silo, bulk bag is required before each process.

In many industries it is the performance of the storage and handling equipment that can limit the process throughput, due to the potential for material arching over the outlet of a silo or block in a conveyor due to cohesion i.e. particles sticks together when compressed. Cohesion is primarily a function of particle size, as this reduces inter-particulate forces (van der Waals) dominate over gravity forces. As typical values, most materials start to exhibit cohesion when the particle size reduces below 100microns and some become non-flowing when the particle size approaches 1micron. However, the forgoing assumes the absence of liquid; the surface tension of the liquid on wet material can generate cohesion when the particle size is of the order of several millimetres.

Free flowing materials can also generate processing problems but presents different challenges. These are the: • Propensity for the material to segregate, i.e. particles separate by size, shape or density when poured to form a heap, as occurs when they are gravity loaded into a buffer silo or into some types of conveyor.

• Separation of dust or fines (typically below 50microns) occurring when material is charged into an open space at high velocity, e.g. pneumatic loading of a silo or equipment fed by long gravity chutes (e.g. where processing steps feed from one floor down to the next).

Thus process plant design and efficient operation is complicated by the interrelations between the numerous processing operations and the flow characteristic of the storage vessels and conveyors being used, which can also generate unintended changes in the particulate material. For example: • process steps that change the particle size, or drive of surface moisture will result in changes in the way the bulk material flows through the conveyors, most operating less efficiently as the particle size reduces, or surface moisture increases (below saturation).

• Furthermore some conveyor types lead to particle attrition in operation. For example in a pneumatic conveyor the particles suffer an impact against each bend in the pipeline

leading to particle fracture, fines generation and an unwanted change in the size distribution of the product.

• Another common challenge is that poorly designed silos can drive segregation of particles by size, which can undo preceding blending operations and result in a finished product that is out of specification.

Segregated Bulk Materials

When troubleshooting a processing line or defining modifications to a plant it is critical that a holistic view of the interaction of the complete assembly of equipment. Failure to do so considerably increases the risk associated with such projects. Most of the above problems can be predicted and equipment can be designed to either eliminate or minimise the effects. However all these design methods require characterisation of the relevant flow properties of the material to generate relationships between particle and bulk scale, which requires testing on representative samples at process appropriate conditions of temperature, relative humidity and storage pressure.

INDEPENDENT EXPERTISE: PROVIDING COST-EFFECTIVE SOLUTIONS TO INDUSTRIAL PROBLEMS

Degraded Breadcrumbs

Biomass Caking Characterisation of Grain Samples

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

The Wolfson Centre for Bulk Solids Handling Technology is internationally recognised for its expertise in fields associated with bulk particulate handling and in the science and practical application of technologies to deliver improved process efficiencies. Our mission is to help industry to get powders and bulk materials to behave predictably through processes.

Industry sectors benefiting from our services range widely and include power generation, chemicals, pharmaceuticals, foods, plastics, paper, minerals and cosmetics. Our clients are predominantly based in the UK, although many European and overseas companies take advantage of the independent and bespoke nature of our work.

We have developed our portfolio of services over nearly four decades of interaction with industry, trade associations and professional bodies. We offer consultancy services to industry, conduct industrially focused research related to bulk solids handling issues and offer specialist short courses targeted at industry professionals. If you have a problem with your plant or process, we have the knowledge and experience to provide cost effective answers that you can rely on.

The centre is situated at the University of Greenwich’s Medway Campus, where we are part of the School of Engineering. Our location offers excellent transport links within the UK and EU enabling us to provide a prompt and flexible response to site visit requests and client meetings.

Our experts have between them over one hundred man-years of experience of solving problems in the flow and processing of powders, granules and lump materials, in all industries from pharmaceuticals and food to mining and chemicals; from biomass waste and recycling to household goods and pet foods.

They concentrate on the needs of the industry and share their knowledge through the provision of technical research papers, articles and editorials through the media and at conference and exhibitions where they often present papers or hold workshops.

Our industrial-scale pilot plant is available to test a processing step, or mock up a whole handling process or logistics chain, at full scale or near full scale. This can be used to find and solve the problems off-line, then when you transfer the same process or material to your own or your customers’ plant, you can be confident it will work!

Contact us now on Tel: 020 8331 8648 E-mail: wolfson-enquiries@gre.ac.uk to find out how we can help you.

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DUST SUPPRESSION WITH FOG

– JUST ONE OF MANY USES FOR FOG

By Robin C Travis, B.Eng MIET, Managing Director of Renby Limited

Fog; microscopic sized water droplets suspended in the air – often an alien tool for many - is finding favour in a broad range of applications. It may not be a panacea for everything but it is proving highly useful in numerous areas.

The Renby MicronFogTM system objective was to use it for dust suppression. As experience with the technology has increased, a whole host of other uses have materialised in previously undreamt of applications.

WHAT IS FOG? At this time of year in The UK, you are often surrounded by it. That is; microscopic droplets of water suspended in the air. The Renby MicronFogTM system recreates this phenomenon demand from pure drinking water, there are no additives. To be a fog, mist or haze the water droplet size is the same, it is just the quantity or density of water droplets that varies.

The Met Office defines fog or mist by visibility i.e. quantifying the distance that you can see through it: • Haze: Visibility over 2km • Mist: Visibility between 1km and 2km • Fog: Visibility less than 1km, With MicronFogTM we can produce anything from a fine haze to a thick fog with visibility falling to a few metres!

The key to fogging or misting is to keep the water droplet size small and therefore light enough to be suspended by the air molecules. To achieve this, the droplet size needs to be in the range 5 to 20 microns. With droplets in this size range, the fog hangs in the air and dwells for some time after the system has been stopped. This effect cannot be achieved with a sprinkler system where the droplet size tends to be in the region 200 micron and droplets are heavy enough to fall straight to the ground. The small fog droplet size is important for several other reasons as well, more of which will come later.

HOW IS FOG GENERATED?

Rapid Assembly Fog Line appearing as a mist. For an industrial process, fog is required upon demand, so a controlled approach is required that can be switched on or off at will.

There are in fact several ways to produce fog artificially.

In an increasingly energy sensitive environment, it is important to opt for the lowest energy approach. The solution to this is to pressurise the water to significant pressures – 70 Bar / 1000 psi or more.

The water is then fed through lengths of tubing to a network of nozzles and forced through a tiny orifice in the nozzle to produce a plume of fog. The quality of the orifice is essential to producing an even, fine spray of fog. There are many cheap nozzles available with rough edges around the opening. These tend to produce over-size droplets and are often identified by an irregularly shaped cone of fog emerging from the nozzle.

Renby MicronFogTM nozzles use laser drilled ruby orifices to ensure a smooth, round opening every time. With openings as small as 85 microns, it is crucial that the water in the system is clean. A two stage water filtration system is used to remove particles and sediment from the water.

Poor Drilled Nozzle

Nature has developed a very effective way to produce fogs and mists naturally, by localised changes in temperature, resulting in air becoming saturated and the surplus moisture

Laser Drilled Ruby Nozzle

Without good filtration, the nozzles will block regularly and this extra stage pays dividends in longevity of the nozzles. Likewise, hard water can cause problems, so every system is supplied with an electronic descaler that ensures lime does not precipitate out before the water leaves the nozzle. The electronic descaler also means that there are no softening chemicals to be topped up.

FOG SAFETY Legionnaire’s Disease is another important consideration. If a system does not pay full attention to this then avoid it at all costs. It may be cheap in the short term, but who wants to be the one to explain to a family that they have lost a loved one as a result of saving a little bit of money? As the water droplet size is so small, it and whatever it contains can easily enter the body, therefore, it is essential that the water used in the fog is extra safe. To this end, we insist that mains potable water is used as a supply and then take the supplemental step of further disinfection using ultra violet light. This is interlocked with the system control which prevents the system from operating if the UV lamp is not functioning or has reached the end of its life.

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ENERGY USE By using high pressure water, the energy requirement is approximately 1/8th of alternative techniques and uses relatively small amounts of power. All systems come with motor inverters to further reduce power consumption. As an example, a major onion packer uses a system that consumes less than 1.25kW power to suppress dust in a building with an area of 1100m2 and uses 28 nozzles. At the other end of the scale, a biomass store with a floor area of 6000m2 uses 5.5kW low flow nozzles. In both cases, the systems must not wet the product in the building. This has been achieved through the use of careful nozzle placement and electronic controls on the system. Those familiar with dust collection systems will find these power figures remarkably low, making fog a cost effective solution for dust suppression in large warehouse type areas.

DUST SUPPRESSION WITH MICRONFOGTM This a major use for fog. Many industrial processes generate dust. Once airborne, this will hang in the air for hours and can be breathed in by operatives, pollute the process and clog equipment.

Fog works as a dust suppressant due to the small droplet size. This is a similar size to the dust particle enabling the two to stick together when they collide. Typically, several dust particles adhere to the water droplet. As a result, the overall weight of the agglomerate becomes large enough to fall out of the air, removing the respirable airborne dust with it.

growth.

MicronFogTM replaced a low pressure spray system that was humidifying a group of polytunnels used for mushroom growing. Not only was the result a more precise control of humidity levels but it also reduced water usage as the older technique was wasteful.

When required, the system can be expanded to measure and control the humidity in each tunnel. This versatile function enables the system to provide precise humidity levels in each tunnel, responding to the crop requirements at each stage of the growth cycle.

Exotic Mushrooms Grown with MicronFogTM

LANDSCAPE AND ARCHITECTURAL Whilst not strictly an industrial process, the versatility of the system is such that it can produce great effects for art installations and sculptures. The ability to switch fog on and off at will facilitates the design of a whole new area of kinetic sculptures providing an immersive experience to visitors. The system has been used to provide effects ranging from banks of fog for visitors at a tropical rainforest attraction to atmospheric effects for film sets. The image shows a kinetic sculpture designed by a leading UK sculptress, renowned for some of Europe’s largest kinetic sculptures.

Dust Suppression of an Energy from Waste Fuel Intake

MicronFogTM nozzles can be placed around the source and in certain cases can drop the dust back into the process. In other applications, for instance warehousing, a more general arrangement can be configured at roof height. Any airborne dust is then captured and dropped to the floor. There is often concern about wetting the product but MicronFogTM has been usedsuccessfully on dry powder bagging lines, potato and onion packing. In each of these applications, it is essential that product remains dry. If not, the product becomes unsaleable.

At present, there is a Government public education campaign about COPD (Chronic Obstructive Pulmonary Disease). Whilst smoking is a cause of this, breathing in workplace dust is another common cause. There are already regulations in place limiting exposure to silica dust to 0.1 mg/m3.

There is discussion about reducing this further to 0.05 mg/m3. Fog has been used successfully to bring the levels below this tighter requirement and will be an essential tool to meet the stricter requirement.

Kinetic Sculpture with MicronFogTM

CONCLUSION The objective of this article has been to give an insight into the breadth of applications that can use fog. Fog offers a comprehensive range of options that can be tailored to address all manner of applications. When using fog in any application it is essential to ensure that due consideration is given to water safety. MicronFogTM has been proven to offer a practical,economical and low energy solution for all manner of uses.

HUMIDIFICATION AND COOLING Another effect that occurs with fog is flash evaporation. Once again, due to the small droplet size, the fog droplet can rapidly evaporate into the air. As the flash evaporation occurs, there is a corresponding drop in temperature. In a building, this can occur after a few minutes, but it has also been observed within seconds on a ducted system. For instance, when a fan is used to force air into a process, the compression can cause the air to increase in temperature. By introducing fog downstream of the fan, cooling will occur due to flash evaporation. We have observed temperature drops from 40oC to 25oC within seconds on process air.

For food cultivation, the control of humidity is an essential ingredient for promoting crop

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

For more information contact Renby Limited Tel: +44 (0)1829 740913 E-mail: fog@renby.co.uk Web: www.micronfog.com 13sp

IS YOUR PLANT VULNERABLE TO CYBER-ATTACKS? Easy steps to closing the door

High profile cyber attacks on banks, charities, telecom companies etc have hit the headlines lately, but your plant is just as much at risk! Have you evaluated how secure your plant is?

In a bid to help industrialists better prepare for possible infringement to their industrial control systems network security, experts at the Wolfson Centre for Bulk Solids Handling Technology have devised a one day short course that examines this topic from design through to installation. It will inform attendees of best practice in industry such as strategies, activities, or approaches, which have been shown to be effective through research, evaluation and implementation.

The Chancellor has pledged to increase spending on cyber security to £1.9 billion by 2020.

You are not being asked to spend a billion; just £490 will secure your place on this one day course on 9 March 2016 at the Centre’s premises in Chatham Maritime, Kent.

Contact details: Wolfson-enquiries@gre.ac.uk 020 8331 8646 www.bulksolids.com

INTERNATIONAL SYMPOSIUM, FUNCTIONAL NANOMATERIALS IN INDUSTRIAL APPLICATIONS Hosokawa Micron Ltd announces their three year partnership and sponsorship of the International Symposium on Functional Nanomaterials in Industrial Applications organised

by University of Central Lancashire (UCLan), Preston, UK. The academic-industry meet will take place at UCLan, Preston on 29th – 31st March 2016.

Bringing together researchers from both academic and industrial organisations on a single platform, organisers believe that after 25 years of research in nanotechnology, the time is right for academic researchers to discuss with industrial organisations an exploitation plan and future strategy for the ultimate goal i.e. Benefit for society.

The symposium aims to discuss three major thematic areas; (i) Nano-energy/environmental for a better society; (ii) Nano-medicine for health and diagnostics and (iii) Nano-catalysis for green technology.

Eight keynote speakers who have made outstanding contributions to their field and four eminent and enthusiastic plenary speakers from Europe, USA and India, including Iain Crosley, MD, Hosokawa Micron Ltd, will deliver presentations to an international audience. The additional submission of over 130 abstract presentations, from every continent, means delegates will find the broadest representation on each of the three symposium themes.

‘After our many years of research and pioneering advancement in the developments of our technologies to create new functional nanopowders and a diverse application menu, Hosokawa Micron welcomes this opportunity to share ideas for a future, concerted andglobally beneficial nanomaterials strategy.’ Iain Crosley, MD, Hosokawa Micron Ltd For Symposium information: www.hosokawa.co.uk For further information/reader enquiries, please contact: Hosokawa Micron Ltd, Runcorn, Cheshire, WA7 3DS. Tel: +44 (0) 1928 755100 Email: info@hmluk.hosokawa.com www.hosokawa.co.uk

FAST, HIGH CAPACITY PRECISION MIXING The new Bella XN double shafted Fluidized Zone Mixer by Dynamic Air includes access doors which not only increase accessibility but also make it much easier to clean when necessary. The Bella mixer achieves fast, high capacity, low shear, precision mixing of either dry bulk solids or liquids with solids. Regardless of particle size, shape or density, materials are mixed with a fast, efficient, and gentle action - typical mixing times are 60 seconds or less. A weightless zone created by low-speed counter rotating shafts generates very low friction without shear. This makes it ideal for fragile products that cannot tolerate rough handling. Even flakes or spray-dried bodies remain intact. The Bella XN mixer includes twin bomb-bay door openings for fast, efficient discharging and to minimize segregation during discharge. The Bella mixer is available in stainless steel for sanitary applications. Custom sizes, finishes and materials of construction are available upon request.

For more information contact Dynamic Air Ltd. Milton Keynes Tel: +44-1908-568155 E-mail: sales@dynamicair.co.uk Web: www.dynamicair.com

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WEIGHING UP CONVEYING OPTIONS FOR THE RIGHT MATERIAL SOLUTIONS

By Dr Will Weston, Head of Materials Handling, Spiroflow Limited

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Conveying of bulk solid materials within a factory setting is a complex area. Manufacturers require dust-tight systems that can provide optimum performance, whether equipment is required for food ingredients such as flour, cereals and coffee granules, efficiently transporting waste for the nuclear power industry, or accurately controlling the flow of materials for the chemical and mineral sectors. Here Spiroflow, one of the world’s leading manufacturers of a full range of equipment for handling dry bulk solids and ingredients, takes you through the conveying options available depending on the customer’s materials, processes and the factory layout.

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t Spiroflow’s well-equipped material characterisation laboratory within its UK technology centre in Clitheroe, Lancashire, scientists measure the fundamental physical characteristics of a customer’s material, determining how it will flow into and through conveying equipment to enable the design of the feed hopper and decide which, if any, mechanical flow aids are needed. The type and design of conveyor is matched to the nature of the ingredient. This knowledge enables customisation of machinery exactly to clients’ needs.

Here is a list of questions that will need to be answered as a minimum before the choice of conveyor can begin: 1.The product(s)? 2. Its/their bulk density(ies)? 3. Its condition (moisture content, average particle size, temperature etc)?

4. Is the product likely to change in anyway in the future? 5.

From what is the product being conveyed (silo, big bag, sack tip station)? 6. To what is the product being conveyed (mixer, sifter, mill, reactor)? 7. If it’s a reactor of any type, is there any steam, gas or solvent given off that might enter the conveyor?

8. The horizontal conveying distance? 9. The vertical height to which the product has to be conveyed?. 10.The route of the conveyor (inside, outside, number of bends required etc)? 11.

The conveying rate in kg/hour or the batch size over a given time? 12. Is the conveyor to transfer a pre-weighed batch, is it transferring material to a receiver of a given size / on load cells or is it a continuous process? 13. How often / for how long will the conveyor run each day? 14. Is it important to deliver the material to the receiver in a homogenous manner - such as when flakes are added to a liquid to make a lump-free paste? 15. If the product is a mixture, is it essential that the integrity of the mix is maintained?

16. Is the material fragile and how important is it to minimise damage during conveying?

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What accessories are required (sack tip station, bulk bag discharger, receiver hopper, etc)? 18. Is the conveyor to operate in a dusty or otherwise

hazardous area (i.e. do the Atex/Desear regulations apply)?

19. Is the conveyor manufacturer to supply the control panel, level sensors, etc? 20. Will the conveyor be readily accessible for maintenance purposes? 21. For how long is the conveyor expected to run between services

Cableflow™,Tubular Drag and Pneumatic conveyors – to meet the most testing conveying challenges. Each technology best suits different sub-sets of classes of material as explained below: Flexible screw conveyors are more than just flexible in the mechanical sense – the range of materials they can convey is very wide and the range of designs can deliver from 25 L to over 40 m3 per hour. It uses the product as the ‘bearing’ for the spiral and as such is both cost effective to purchase/ maintain and very easy to clean. Depending on the material and application Spiroflow offers nine sizes and four different spiral designs in a range of materials and finishes.

Aeromechanical conveyors move material in pockets between fast moving discs inside a rigid line. For throughputs between 15–60 m3hr1 this could be the conveyor of choice. For materials with a high densification potential, such as titanium dioxide, aeromechanical conveying is the ideal option. Additionally, the

TAKE ACCOUNT OF THE MATERIAL, HAS IT BEEN CHARACTERISED & UNDERSTOOD, HOW DOES THIS GUIDE THE SOLUTION? The consistency of component concentrations in a mixture can be a key consideration in their quality. Depending on the differences (size, density, fluidity, shape etc.) the choice of conveyor can be critical to preserving the homogeneity of the ingredients during the handling operation.

The integrity of fragile material, such as dry foods like breakfast cereal and pasta, clearly needs to be preserved, but this can also apply to specialist powders. For example, spray drying is often chosen as a size increasing mechanism to aid flow or maintain the integrity of a powder blend. For both fragile particles (>2mm) and fragile powders (<2mm) mechanical conveyers offer a more gentle handling solution than a pneumatic system.

For applications that require the product to be contained away from the local environment (which may be to keep foreign materials out or hazardous substances in) the options within the Spiroflow conveying range can be a very good solution.

Complete containment can be readily achieved – not true of older technologies like belts or bucket elevator systems.

Conveying rate and route through a factory environment also needs to be addressed to define the type of transit system required. An aeromechanical conveyor is ideal for a high rate, a flexible screw conveyor for a difficult route and a pneumatic conveyor for a really tortuous path.

WHICH EQUIPMENT CONVEYS THE BEST SOLUTION? There a wide range of solutions - Flexible Screw, Aeromechanical,

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

energy usage per tonne conveyed is less than a fifth of that of a pneumatic system which can be a significant consideration in a high rate 24/7 application. They are perfect for vertical conveying, with no loss of throughput.

Cableflow™ conveyors are ideal for fragile material such as a coffee granule or breakfast cereal. Compared to a traditional bucket conveyor they offer significantly better containment along with lower downtime and maintenance costs, while conveying up to 21 m3hr1of material.

Tubular Drag If you want to move dense, hot or highly abrasive material then none of the equipment detailed above is likely to be suitable. Here is where a Dynaflow™ conveyor is likely to be the best choice. A Dynaflow™ drags material with a disc and chain assembly inside a heavy duty transfer line. It can convey via complex routes and at any angle.

These conveying solutions are underpinned by Spiroflow’s 40 years’ process experience and an ability to measure the fundamental characteristics of the materials to be conveyed..

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ENERGY SAVING AND EFFICIENCY IN DUST & FUME CONTROL Chris Oldfield of Ecogate Ltd reports According to the Environment Agency’s Greener Business Report, poor energy efficiency is costing UK business over £6 billion a year.

However, for many companies employing processing operations, identifying areas of wastage may not be immediately obvious. In industrial processes where dust extraction systems are used, more and more firms are benefiting from retrofitting energy-saving upgrades which result in dramatic savings in electricity usage.

In most existing dust extraction systems the extraction fans are in constant use and operating for anything from an 8 hour shift, 5 days a week, up to 24 hours a day, 7 days a week. Additionally, with a traditional constant pressure system, the minimum extraction pressure must be adequate to properly extract from the workstation farthest from the fan. This requirement wastes considerable energy and the extraction system is often consuming as much electricity as the lighting and the rest of the process machinery combined. With an energy-saving extraction system, optimum extraction is managed dynamically according to actual workstation requirements.

Installing a proven ‘Extraction-on-Demand’ system can slash electricity bills by up to 80% and will typically pay for itself in just two years. Such systems employ a central controller, automatic motorised gates, remote machine sensors and variable speed technology. When a machine comes online, a sensor signals the controller to open the motorised gate of that particular machine to provide extraction and the controller determines the optimum fan speed, which is achieved using variable speed technology. When the machine is turned off, the gate automatically closes and fan speed is adjusted accordingly. The result is an optimised system that only uses energy when required.

WHY DOES IT WORK?

Just for a change, the laws of physics are on our side! Fan speed and extraction volume are directly proportional; if you vary the fan speed, the volume changes by the same percentage.

However, the relationship between volume and power is cubic, which means a relatively small change in volume gives a much larger change in power consumption – reducing fan speed by 20% reduces power consumption by nearly 50%. More typically, on-demand systems only require around 70% of the full air volume capacity. At this point, the system uses only about a third of its full-power electricity consumption.

By significantly reducing the amount of electricity you use, ‘Extraction-on-Demand’ reduces the environmental footprint of your operations, moving you closer to sustainability.

A recognised leader in the field of ‘Extraction-on-Demand’ systems is California-based Ecogate, Inc. whose products are distributed in the UK and Europe by Ecogate Ltd. ECOGATE® systems have been saving energy on extraction applications worldwide for over ten years, and there are hundreds of installations in place, with over 20,000 ‘Ecogates’ currently in use. In the UK, the

company provides Ecogate products and services to authorised installers, including Airplants Dust Extraction Ltd, Cades Ltd and Dust Control Systems Ltd. The ECOGATE System is a microprocessor-controlled extraction optimisation system, employing a central control unit – the greenBOX® – which constantly monitors the operation of individual machines. The system is also designed to maintain minimum airflow in the duct system, by opening additional gates when necessary, delivering good system balance and preventing dust settling in the ducting system.

The ECOGATE system offers total design flexibility – whether it’s a dust plant serving two or three machines, or large production facility with a plethora of dust-creating machinery.

ECOGATE offers a choice of control systems: The greenBOX 12+ controller is designed for plants with one main extraction fan and up to 12 workstations. The greenBOX 12+ can be serialised, working in tandem to control up to 24 machines. For larger manufacturing facilities, the greenBOX MASTER SRL is capable of controlling up to 4 extraction fans, handling as many as 200 workstations.

Operated by a 24V DC geared motor, motorised dampers (Ecogates) are an integral component of the system. Available to suit a wide range of ducting sizes, they are fabricated in zinc-plated metal or stainless steel. Ecogates are activated via Volt Sensors which read any AC or DC voltage and detect changes in voltage when a machine is turned on or off.

System monitoring and evaluation of energy savings can be managed from a central location, using Windows-based software. Extraction fan motor speed is controlled by the Ecogate Power MASTER – a variable speed drive inverter unit, with integral controller, which maximises energy savings by providing continual adjustment of fan speed.

For further info call: 01924 566770 or email: info@ecogate.co.uk Website: www.ecogate.co.uk

Prevention Venting Isolation Suppression

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

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PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

SAXLUND WINS A FURTHER MAJOR ORDER WITHIN BIOENERGY WORTH OVER £2.7 MILLION AT PORT CLARENCE To design and supply two automated fuel management systems providing 40MW of renewable energy The energy and environmental technology Saxlund has won another large order from Babcock & Wilcox Vølund A / S, Denmark for the delivery of its first-class management of bioenergy projects in Teesside, near Middlesbrough, North Yorkshire.

Overall, this means that the company has within 12 months won over £8 million in orders with Babcock & Wilcox Vølund for various projects in the UK. Saxlund’s will design and supply of two complete, automated fuel management system, both with full capacity to provide 100% redundancy a fuel content of up to 125 MW. Previous projects are at Margam in South Wales and Templeborough Biomass Power Plant in Sheffield.

The two systems will be for the reception, delivery and mixing of fuel storage. The entire fuel management system, including storage and feed systems, will be designed for efficiency, minimum maintenance and high availability, while the environmental impact in the form of dust and noise is limited. The system also offers flexibility in the use of waste wood of different types and quality. The order value is over £2.7 million and is due to handover in 2017.

Speaking for the Saxlund Group, Harald Wehner, Managing Director of Saxlund

“We are proud to help Babcock & Wilcox Volund build this first-class project. We supply equipment that is critical to ensure high availability, efficiency and flexibility for our customers.

With extensive operations in Germany, the UK and Sweden and around 60 years of experience, we can provide innovative and proven solutions for most applications.”

International GmbH said:

Matt Drew, European Sales Director and UK Managing Director Saxlund

International added: “I believe the quality of our materials handling systems is second to none and is the reason we have been chosen. The Port Clarence project will provide 40MW of renewable energy to the UK energy market through the combustion of waste wood, and will have the capacity to consume about 250,000 tonnes of waste wood per year. “ For more information contact Saxlund International Ltd, Southampton, Hampshire.

Tel: +44 (0) 23 8063 6330 E-mail: info@saxlund.co.uk Web: www.saxlund.co.uk

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

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JOB VACANCIES AT WRIGHTS DOWSON GROUP, GAMLINGAY, BEDFORDSHIRE ENGINEERING MANAGER Candidates should have a hands on approach, be a qualified mechanical engineer capable of operating AutoCAD and or SolidWorks, plus experience of running an engineering team to meet customer expectations and company goals. Knowledge of the bulk solids industry and screw conveyor design would be an advantage, but not essential.

Remuneration package commensurate with knowledge and managerial experience to fulfil this demanding position.

AUTOCAD/SOLIDWORKS MECHANICAL DESIGN ENGINEER Candidates should be suitably qualified in mechanical engineering discipline, with a good all round understanding of engineering and design office best practices. Knowledge of the bulk solids industry and screw conveyor design preferred, but not essential.

Remuneration package commensurate with knowledge and experience to fulfil the position.

Please send covering letter and CV to Robert Hudson – MD – r.hudson@dowsongroup.com

IF YOU ARE NOT A MEMBER OF SHAPA, WHY NOT BECOME ONE? SHAPA has been the UK’s leading specialist Association for the solids handling and processing industry since its formation in 1981. Our support and assistance has allowed our members to maximise their profitability, whilst taking advantage of the many benefits afforded by the Association.

WHO ARE SHAPA? With regular meetings, guest speakers, awards, exhibitions and export assistance, you will find SHAPA an invaluable aid in promoting ideas and opportunities for your business.

STRUCTURE With full member involvement in the running of SHAPA, you have immediate and effective input to the operation of policy, finance, technical issues and marketing activity.

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MILESTONES Since 1981, SHAPA has grown to be the foremost authority on solids handling and processing industry matters. Here are a few milestones in our development.

REDUCED CAPITAL EXPENDITURE SHAPA members, with the support of the Association, are recognised for competitive prices and the highest quality solids and powder handling products and systems.

CUT OPERATING COSTS Drawing on years’ of specialist experience, SHAPA members can deliver a tailored solution designed to optimise your operation and minimise your costs.

INCREASE PRODUCTION RELIABILITY The technical and product information resources provided by SHAPA enable all members to keep abreast of the latest product developments and legislation in a wide range of solids and bulk handling technologies.

SHAPA ALUMNI The Shapa Alumni Group is open to those who have previously worked in the Solids Handling Industry who woud like to keep in touch. for more information go to www.shapa.co.uk and select the Alumni web page To apply to become a member please fill out our membership application form by going to: http://goo.gl/xlMsHO You can also read about the benefits of being a member by going to http://goo.gl/Mg4QO3

PROCESS INDUSTRY INFORMER January - February 2016 - SHAPA Supplement

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