SOLIDS HANDLING PROCESSING
AND
including SHAPA News
JUN/JUL 2014
MANUFACTURING A SERVICE
Quality knowledge So far so good; but success needs a constant drip feed of new information, techniques, commercial and marketing intelligence, not to mention legal updates, to be sustainable. With so many industries and applications, there exists an insatiable appetitie for all of this that must be sated as far as possible. SHAPA members have a head start, with an accumulation of more than 30 years’ knowledge and experience readily available and regularly updated.
Reliable expertise
a “knowledge machine”. For more than thirty years, with steadily rising membership – now standing at more than 110 companies – the Association has been a group of dedicated engineers and company managers willingly offering their time and experience for the benefit of all member companies and for industry as a whole. Its place and reputation within British industry is assured.
New faces However, whilst most SHAPA activities are facilitated by voluntary effort, the Association employs a General Secretary whose rôle is to cement all activities, providing continuity and a readily available point of contact. We are dellighted to announce a new General Secretary in the person of Ian Birkinshaw, whose 40 years plus industrial experience and considerable knowledge gained in his post as Operations Director at member company Portasilo Ltd., will, we are sure, be of great benefit to SHAPA. Ian, who is taking early retirement from his present post and will be fully available from August, is at present at the hand-over stage, to ensure a smooth transition for his successor at Portasilo.
Being prepared Aside from his engineering life, Ian is also very prominent in the scouting movement, so we can rely on SHAPA being even better prepared in the future! Preparation comes in many guises and having a firm grip on market trends, both technically and commercially, is vital. Earlier this year the Association commissioned a further definitive Solids Handling & Processing UK Survey. The results were disseminated in April and were the culmination of a wide ranging interrogation of more than two hundred significant companies. Investment plans, drivers influencing investment, buying strategies and many other facets were probed as well as ways in which the profile of SHAPA within industry may be raised.
earlier in the year, this established annual event is set to be repeated with an updated event next year. This professionally led members’ event explains and demonstrates the latest thinking and methods, showing delegates how to maximise commercial advantage from social media and other up to the minute internet based tools. For many participants, the Digital Marketing Seminar is a good enough reason in itself to be a part of the SHAPA “family”.
Quarterly meetings The SHAPA General Meetings – one of which includes the AGM – continue to be well supported and there is always an invited speaker to provide an insight into industry related topics. This year’s general meetings will include subjects such as tax relief on development and later in the year an update on the economy by a Bank of England insider. With so many factors affecting the UK economy and our export prospects this update will be keenly anticipated.
Engineering the Future SHAPA committees are nothing if not holistic in their wish to offer a complete and, crucially, a continuing service to engineering. To this end the succession is key to maintaining standards as older engineers and managers look towards handing over to the next generations. The Association has held a number of events, part educational part social, to attract and enthuse up and coming staff who will be the next key managers and innovative engineers within our industries. November will see the next event in this series, with details becoming available shortly.
Enjoying the PII SHAPA supplement The next few pages give a feel for the commitment, expertise and sheer range of technologies available to project and process engineers, who can have confidence in the knowledge that SHAPA member companies have access to high quality engineering, technical, commercial and legal data. They are also keen to pursue consistent improvements into the future. If you would like to think about joining us, or you have a project requiring expertise, or you just have a technical question to ask, simply visit www.shapa.co.uk or contact us at info@shapa.co.uk.
Operators of solids handling and processing equipment will be well aware of the importance of procuring Digital marketing equipment from companies that have taken the time to Following the success of the Digital Marketing seminar research the properties and characteristics of their materials. Whilst very many materials are well classified, it is always prudent to make a thorough investigation to ensure that parameters such as attrition, abrasive wear, unwanted segregation due to unequal grain size and also explosibility are fully taken into account. SHAPA WESTINGHOUSE promotes good practice amongst its members and encourages knowledge sharing wherever practicable. Over the years member companies have been generous with their time and data to Servicing & Repairs expand this pool of knowledge over a wide range of related topics. Free of charge assessment by a DMN engineer Each stage of every process benefits from Genuine spare parts used to the original manufacturer’s specification this accumulated wisdom. Intake and storage, Comprehensive 12 month warranty with continued support including silos and daybins will only deliver with all refurbished DMN valves undamaged consistent material onwards if these elements are designed with the particular Refurbishment service by the original manufacturer materials in mind. This applies right through the ATEX certification and validation services production process from screening and sieving to mixing, conveying and further production activities, indeed right up to bagging or packaging for despatch and transport. Reliability long life with economic non-intrusive maintenance will lead to profitable operation and happy customers.
s i e g n e l l a h c y r e Ev e s i u g s i d n i y t i n u t an oppor
Human approach So, membership of SHAPA really should be a natural starting point for manufacturers and suppliers of solids handling and processing equipment. However, SHAPA is more than simply
SOLIDS HANDLING AND PROCESSING
DMN UK Ltd. T +44 1249 818 400 dmn@dmnuk.com
COMPONENTS FOR BULK SOLIDS HANDLING
It is hard to believe that six years have already elapsed since the beginning of the UK recession – but now clear blue horizons beckon. Statistical analysis and speculative reporting in equal measure would have us believe that all parts of the economy have now moved up a gear. Nevertheless, the manufacturing sector still lags its peak output by around 7%, whilst the economy as a whole has now crept above its size at the beginning of 2008.The only small grey clouds, may be the gradually growing strength of the pound (GBP) particularly for exporters, and possible future interest rate rises. So, the good news for suppliers to manufacturing industry is that there is both the will and indeed the scope for considerable improvement. Companies who have survived the downturn will be better placed to succeed, having rigorously examined their costs and aspirations and built more efficient and secure platforms from which to head into the future.This situation in itself bodes well for SHAPA member companies, but manufacture is only a part of the body of industry supplied by members of our Association. Handling and processing of dry materials in bulk (in large of small quantities) affects a huge range of industries from mining and quarrying, through to pharmaceutical research and development, as well as the massive food and drinks sector. In fact a quick glance at the Equipment Finder on the SHAPA website at www.shapa.co.uk will reveal a plethora of such industries and applications.
By Gus Bishop – Solids Handling & Processing Association
www.dmn-shop.co.uk
www.dmnwestinghouse.co.uk
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NEW 3D SIEVE SHAKER OCTAGON 200CL For precise, reproducible and error-free sieving processes Endecotts’ new Octagon 200CL competes with the most advanced sieve shakers in the world. Several unique features have been developed specifically for this machine, including the ‘Closed Loop’ amplitude control for ultimate reproducibility. The sieve shaker is powered by an electromagnetic drive which has no rotating parts making it maintenancefree and extremely quiet in operation. The vibratory, three-dimensional motion produced by the power unit moves the sample over the sieve in a unique way resulting in faster, more efficient sieving, while the rapid vertical movements help to keep the apertures from blinding. The Octagon 200CL is designed to work with Endecotts’ SieveWare, the new software for easy evaluation and documentation of the sieving process. The new Octagon 200CL will be available as of July 2014.
NEW FEATURES: • ‘Closed Loop’ total amplitude control ensures reproducible sieving • Digital controls for easy and reliable operation • Easy-to-use sieve clamping system • Accepts up to 8 full height 200 mm (8”) diameter sieves • Suitable for dry and wet sieving • 3D sieving motion allows for high separation efficiency and non blinding sieving action • Full compatibility with new SieveWare evaluation and control software via RS232 Port (printed or digital protocols) • Voltage-independent For more information please contact Endecotts Ltd, Lombard Road, London. Tel: +44 (0) 20 8 542 8121 Fax: +44 (0) 20 8 543 6629 E-mail: lbergen@endecotts.com Web: www.endecotts.com/octagon-cl
GLOBAL LEADER IN EXPLOSION AND PRESSURE SAFETY SOLUTIONS LAUNCHES REVOLUTIONARY DUST DETECTION SYSTEM A global fire, explosion and pressure relief solutions company has introduced a revolutionary product that will assist in the prevention of dust explosions and as such eliminate the risk of potentially devastating disasters occurring in the workplace. Fike UK, based in Kent has enhanced its already extensive range of high quality, safety driven products with the introduction of the Fike Dust Detection System (FDDS). The FDDS functions by signalling the presence of unusually high airborne dust particles enabling the prevention of explosion devastating the workplace. Keith Avila, General Manager of Fike UK said of the new product launch: “A dust explosion can be potentially catastrophic. We are very proud to be the first in the industry to introduce such ground breaking technology and be at the forefront of providing safety solutions like this which prevent devastating and irreversible effects.” Featuring unique technology the FDDS - a processor based device - can identify levels of dust that can cause explosive hazards whilst also having the ability to validate the protection of non-zoned areas. The advanced technology is installed in ducts and will alert a business to any early warning signs of potential contamination caused by nuisance dusts. The system works by detecting the normal amount of dust particles passing by with an easy ‘trafficlight’ notification system indicating the levels of dust concentration within the duct. Commenting on the benefits of the new product Keith said: “As well as detection, it comes with an additional layer of protection which removes any potential hazardous dust zones, whilst also being able to detect leaking filter bags. One of the key benefits of the FDDS for our customers is it requires little or no maintenance – a feature that really appeals to them in terms of cost efficiency and resourcing.” The use of innovative Inductive Electrification technology sets the product ahead of other optical or tribo-electric devices by determining the background acceptable level of dust during normal process operation
Prevention Venting Isolation Suppression
and triggering alarms at different pre-set dust concentration levels when these are attained. This is coupled with running advanced filtering algorithms that can detect the smallest of dust concentration variations and provide the most accurate dust measurement signalling. Dust is a serious health and safety consideration with a wide range of materials capable of causing a dust explosion. These include anything from agricultural products and metals, through to chemicals, wood and many more raw materials. Dusts can be caused through various means including transporting, handling, processing, and polishing; through to abrasive blasting, cutting and mixing. The dust explosion is caused by a sudden ignition of a mixture of air and a high concentration of suspended combustible dust particles. Fike has almost 70 years’ experience advising on fire explosion and pressure relief solutions with a team of in-house engineers, application specialists, and combustion researchers specialising to companies across the food, power, wood and pharmaceutical/chemical industries. Keith added: “In our industry, Fike has unprecedented expertise and is committed to providing quality safety products that are fully explosion tested. The FDDS has been developed over a considerably long period of time and carry the highest industry standards to ensure our customers have the safest potentially life-saving product.” Fike is a globally recognised company supplying products and services which protect people and critical assets from fire, explosion and over/underpressurisation. A leader within the industry, Fike manufacture solutions for a diverse range of process industries, providing products ranging from bursting discs and explosion protection systems to energetic oil and gas products for the offshore markets. Other UK branches of Fike also provide fire suppression systems, fire detection devices and alarm panels. For more information please contact Fike UK, Maidstone, Kent. Tel: +44 (01622) 677081 Fax: +44 (01622) 685737 E-mail: sales@fike.co.uk Web: www.fike.co.uk
EXPLOSION HAZARDS LTD
37
YEARS
FOR ALL YOUR EXPLOSION SAFETY NEEDS www.explosionhazards.com +44 (0)1925 755153
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SOLIDS HANDLING AND PROCESSING
DEALING FAST, HIGH WITH DUST CAPACITY AND FUME PRECISION MIXING Dust Control Systems Ltd specialise in providing dust and fume extraction solutions across many industries, including major projects in the recycling and waste management sector. Saving energy and increasing production efficiency while ensuring a safe working environment are key requirements of most processes. And this particularly applies to the controlling and management of dust and fume generated in recycling and waste management processes. The DCS reference list of projects in the sector includes systems to serve various processes in glass recycling, paper recycling and tyre rubber processing. Recent successes for DCS include the supply and installation of a complete extraction DCS extraction system handles system to minimise 60,000 m3/hr of dust laden air dust from waste at at North Wales MRF. a major material recycling facility (MRF) in North Wales for UPM Shotton. To assist companies with compliance of COSHH Regulations, DCS 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, Dewsbury, West Yorkshire Tel: 0800 040 7116 Fax: 01924 482530 E-mail: sales@dcslimited.co.uk or visit Web: www.dcslimited.co.uk
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SOLIDS HANDLING AND PROCESSING
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 please contact Dynamic Air Ltd. Milton Keynes, Buckinghamshire. Tel: +44-1908-568155 E-mail: sales@dynamicair.co.uk or log on to http://www.dynamicair.com/ products/mixer_b350xn.html Or visit Web:www.dynamicair.com for other information.
BULK BAG FILLER BRINGS FILL HEAD TO OPERATOR
Flexicon’s patented Swing-Down® Bulk Bag Filler features a pivot-down fill head that enables the operator to connect empty bulk bags at floor level and resume filling operations rapidly, eliminating the need to climb steps, strain to reach overhead connection points, or risk injury associated with operation of conventional fillers. The filler simultaneously lowers and pivots the fill head, stopping it in a vertically-oriented position that places the bag inlet spout inflatable connection, inflator button, and four bag loop latches within one arm’s length of an operator standing on the plant floor. Once bulk bags are filled, the controller deflates the spout connection collar, releases the loop latches, and raises the fill head to fully disengage the spout. Optional vibratory decks de-aerate and densify material in the bag at preset set points to create a solid, stable bag, ready for shipment. For more information please contact Flexicon (Europe) Limited, Herne Bay, Kent. Tel: +44 (0)1227 374710 E-mail: sales@flexicon.co.uk Web: www.flexicon.co.uk
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KNOW YOUR FLOW PROPERTIES By Dr Rob Berry PhD Mechanical Engineering - The Wolfson Centre For Bulk Solids Handling Technology
Many process industries suffer problems as a result of inconsistencies in the flow properties of the particulate materials that they handle which adversely affects operating costs and process efficiencies. Process problems can range from extremes of; poor flowing materials that occasionally form stable obstructions within storage vessels (see fig 1) or stick in chutes/ conveyors, requiring operator intervention with a hammer to reinitiate flow; to materials that fluidise readily and flow uncontrollably, requiring plant shut downs to unblocking over-filled feeders and cleaning up spillage. In the current market place there are numerous relatively low cost automated powder flow testers (shear cells) available for undertaking characterisation tests on the bulk flow Fig 1 Flow stoppage due to properties that allow cohesive arch formation over process operators to the outlet of a hopper better understand their powders. Traditionally flow properties have been used for the equipment manufactures to specify and design of new storage and handling equipment, but these measurements can also be used by powder manufactures, or manufactures of products with powdered ingredients to meet a range of objectives from; general bench marking of material and quality control; comparing new versus current ingredients; to assist reformulation and reverse engineering of equipment. However, before looking at these different potential uses, it is useful to review the principal flow properties and what they mean as many Engineers will be unfamiliar with them.
What are the key flow properties and how do they relate to process problems The primary flow property is the flow function which is best explained using the concept of the ‘sand castle’ experiment shown in fig 2. In the first stage a powder is compacted into a cylindrical mould to a controlled consolidation stress. In the second stage, the cylindrical mould is removed to reveal the unconfined powder sample ‘or sand castle’. An increasing Fig 2 The uniaxial unconfined consolidation stress is reapplied to the failure (sand castle) test. sample ‘or sand castle’ until it fails. The peak stress represents the unconfined failure strength of the powder, the strength of the powder at a stress free surface, i.e. at an arch over the outlet of a storage vessel. The test is then repeated using a range of larger consolidation stresses which results in a proportional increases in the unconfined failure strength. The results of these tests are presented a flow function (shown in fig 3), a plot of the consolidation stresses (load used to compact the sand castle) on the horizontal axis versus the unconfined failure strength (strength of the sand castle) on the vertical axes. The flowability of a material can be loosely classified using the flow indices demarked by dashed lines in figure 3, highlighting the free-flowing, easy flowing, cohesive, very cohesive and non-flowing regions. An important secondary flow property is the bulk density, i.e. the weight of particulates that can be stored in a known volume. This can be measured in a shear cell by tracking the reduction in volume of the sample of known weight as a function of consolidation stress, to give a compaction or compressibility curve as show in fig 4. Alternative simpler
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Fig 3 The flow function of a very cohesive ultra-fine powder and a free-flowing coarse particulate techniques commonly used are the poured and tapped bulk density which gives a similar indication by does not give reference to the consolidation stress.
What is the significance of the bulk flow properties The potential for a material to bridge or arch over the outlet of a storage vessel and thus cause a processing problem as shown in fig 1 is dictated by both the unconfined failure strength of the material and the bulk density. It is the strength of the material that provides resistance to flow, while it is the materials self-weight under gravity that generates stress to break the obstruction and ensure flow. Thus a material with a high strength and low bulk density is likely to give flow problems while a material with a low strength and high bulk density will be free flowing. The flow properties can thus be used to determine the outlet size required for reliable gravity flow.
Common factors effecting flowability While the flow properties are very much material dependent, for a given particulate material there are two factors that significantly effect the flowability, namely the particle size and the presence or not of a surface liquid. Assuming a dry particle, above a diameter of 100m most materials are free flowing (as shown by a typical coarse particulate in fig 3). As the particle size is reduced below this value the material becomes more difficult flowing and flow function gets steeper as the self-weight of the particle reduces relative to cohesive inter particle forces (Van der Waals forces), as shown for the very cohesive ultra-fine powder in fig.3. In the case of wet particulates, liquid bridges connect neighbouring particles and it is the surface tension of the liquid that generates the cohesive strength. Thus as the moisture content increases the material becomes more difficult flowing (flow function gets steeper) until the moisture level approaches saturation and the material becomes a slurry. Thus for wet materials with particle sizes of the order of 20mm diameter can be cohesive. The bulk density can also be used to give a good indication of flowability as shown in fig 4. E.g. free flowing materials have a tendency to be incompressible as their particles naturally settle into close packing structures, while particles of a poor flowing material (where gravity forces are low relative to interparticle forces) settle in a very open particle packing structure and therefore tend
Fig 4 The bulk density (compressibility) functions of a compressible ultra-fine powder and a incompressible coarse particulate to be highly compressible when stored under the action of their self-weight.
Uses of the flow properties To conclude, a knowledge of the flow properties of your material can be used in a number ways to improve process efficiency and minimise the chance of problems as outlined below. Bench marking tests to check the consistency of the flow properties of the product over time, as a method of inferring quality or looking for problem batches. As examples, these tests could be used to identify; differences due to variations in the particle properties of the input materials (seasonal variations in particle size and shapes of grains); variations in the mix ratio of a blended product and drifts in the ambient temperature and humidity. Comparing potential new versus current materials – When changing the supplier of input material, or reformulating a blend, a thorough evaluation of the flow properties of new and current materials should be undertaken. This will high light any significant differences in their relative flow behaviour so that the potential for process problems can be factored into any purchasing decisions along with cost and other processing characteristics. Research & Development of new products - When formulating new products flow property measurements can be used to systematically evaluate the effects of changes to the particle size, the blend additive (such as free flow additives, liquid binders, fillers) type and level on the materials flow and handling characteristics. Thus the flow properties can be optimised to minimise the tendencies for flow problems. Reverse Engineering of Equipment – If different materials are handled on the same processing line with different levels of success i.e. some flow acceptably while others do not, then flow property measurements could be used to determine an operating window that the flow properties must fall within for successful processing. The Wolfson Centre for Bulk Solids Handling Technology University of Greenwich, Chatham, Kent Can be contacted via: Tel: +44 (0)208 331 8646 Fax: +44(0)208 331 8647 E-mail: r.j.berry@gre.ac.uk Web: www.bulksolids.com
SOLIDS HANDLING AND PROCESSING
SPIROXXX Supplement & Process Industry Informer Advert_Layout 1 26/06/2014 08:14 Page 1
DELIVERING THE SOLUTION
A UK company with a global reputation for solids and bulk handling. Spiroflow conveying and weighing systems are in operation worldwide and are acclaimed for their outstanding versatility and prolonged working life in the most demanding environments. In food and pharmaceuticals, cosmetics and chemicals, minerals and plastics, Spiroflow's experience and proven capability is providing the answer to every conceivable handling need.
Sack Tip and Flexible Screw Conveyors
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Spiroflow Limited Lincoln Way, Clitheroe, Lancashire, BB7 1QG, UK. T: +44 (0) 1200 422525 F: +44 (0) 1200 429165 E: sales@spiroflow.com
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SOLIDS HANDLING AND PROCESSING
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Dust - why it’s an issue and
what the processing industry should be doing about it… by James Miller – Managing Director – Dustcontrol UK Limited
Dust is a major problem across a wide range of industries, and those involved in the processing industries certainly fall within this bracket. Despite the impact of dust, many people don’t seem to be aware of just how serious or how important the issue of dust really is. Not only do they underestimate the significance of its impact, they fail to appreciate how tackling the problems caused by dust can both improve business turnover, and provide a ‘greener’ way of working. The negatives of industrial dust are many fold. It creates a dirty working environment, hinders production efficiency, lowers staff morale, affects product quality and provides a health and safety risk for those in close proximity. The many and varied forms of dust means that a lot of people underestimate the negative influence it can have. Dust is often associated with a feather duster and a can of spray polish. It’s seen as a household nuisance rather than an industrial menace. If we’re to combat the adverse impact of dust in the workplace, then attitudes towards its effects need to change. That isn’t to say that mindfulness of dust related issues doesn’t exist. There are those involved in the processing industries that do attempt to address the situation, but most of these are not being as effective or efficient as possible in their approach. If you walk into a processing plant, in many cases you’re likely to see an abundance of cheap mobile dust extractors. The fact that an attempt is being made to rectify dust-related issues is certainly a positive. But it’s often the case that in large processing plants these can become more of a nuisance as opposed to providing any real assistance in resolving the matter. The mobile dust extractors used in these instances are often fitted with low quality filtration and are poorly maintained, as personnel are unwilling to take responsibility for keeping them clean and ensuring that they’re looked after. It’s also more than likely that they constitute a health and safety risk, with leads and cables stretching across the production area. These not only pose the risk of tripping, but also make the area look untidy, which isn’t ideal during a client factory tour. There’s also often a lack of understanding on just how these extractors should be used, with many companies opting to use them after processing rather than during. Mobile dust extractors might seem like an attractive short-term solution to workplace dust and the balance sheet, but they usually fail to achieve the desired results with running costs actually making them more detrimental in the longer term.
So what is the best option?... The best way for processing plants to address the issue of dust is to install centralised vacuum systems. These can fit into the building in question, and have a number of plug-in points running off them, avoiding the need for messy leads running everywhere. The systems can run for 24 hours, and are even self-cleaning. Lease finance for this type of equipment is becoming a much more common way of avoiding large Capex sign off and helping to manage cash flow. Central vacuum systems are also energy efficient. Depending on the number of open outlets, the RPM of the vacuum producer can be optimised generating just as much vacuum as needed. And when no outlets are open the vacuum automatically switches to a saving mode, thus reducing both carbon emissions and running costs. What’s more, a centralised vacuum system can help solve any ‘product loss’ issues - where what’s coming out at the end of the production line is less than what’s being put in at the start. The systems can show visibly what they’ve collected during the process, so if there are still serious ‘product loss’ issues these can be backed up with accurate
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data. Dust or product that is removed during the extraction process can also be recycled where necessary. The benefits of a centralised vacuum system are many. Working in a cleaner environment will not only improve staff morale, it will also reduce the risk of potential health issues for employees. Dust extraction at source will help to tackle occupational asthma and other such respiratory illnesses. For example, in regards to the food processing industry, employing dust extraction equipment helps to negate the peril of ‘Baker’s Lung’, which is a form of lung disease caused by prolonged exposure to allergens contained in many food-processing ingredients.
Reducing the risks… It’s also important to bear in mind the fact that many dusts are combustible. When a material is suspended in the air in a finely divided form, in the right concentration and in the right conditions, explosions can occur. Again referring to food processing, foodstuffs such as sugar, spice, starch, flour, feed and grain are amongst the materials that are most dangerous in the workplace. Whilst these generally aren’t immediately regarded as explosive substances, the risk that they can potentially pose if poorly handled is considerable to both workforce and equipment. It’s therefore imperative to reduce the risks presented in an environment where these materials are both in abundance and being processed in a way that causes dust to form. A centralised vacuum system is one of the key methods of doing so, providing a comprehensive solution to dust-related hazards. It’s not just in relation to potential health hazards where extraction can provide assistance, however. On a more business minded level, dust extraction will help to improve product quality as it removes dust from both the product and its associated packaging, whilst also reducing the need for maintenance, which allows valuable resources to be spent elsewhere. Dustcontrol UK Limited, Whittlebury, Northamptonshire Can be contacted via: Tel: +44 1327 858001 Fax: +44 1327 858002 E-mail: sales@dustcontrol.co.uk Web: www.dustcontroluk.co.uk
SOLIDS HANDLING AND PROCESSING
PREVENTING DUST EXPLOSIONS Explosions and fires within the processing industry from combustible materials are a known hazard and can give rise to serious injury - perhaps even fatality - as well having as the potential to cause extensive plant and buildings damage and substantial loss of production. A dust cloud of any combustible material will explode if the concentration is above the minimum explosible limit and in the presence of an effective source of ignition. Self-heating and contact with hot surfaces (giving rise to spontaneous ignition) can give rise to additional hazards and must also be considered.
SPIROFLOW UNVEILS NEW BIN ACTIVATOR FOR DIFFICULT MATERIALS
Guidance is available from many sources to prevent dust explosions and protect against them. One such source is the 1 day training course entitled ‘Dust Explosions – How to Demonstrate DSEAR/ATEX Compliance’ on 29th October 2014 run by the Wolfson Centre team at the University of Greenwich in Kent. For more information contact the Wolfson Centre for Bulk Solids Handling Technology, University of Greenwich, Central Avenue, Chatham, Kent. Tel: 020 8331 8646 E-mail: Wolfson-enquiries@gre.ac.uk Web: www.bulksolids.com
The UK’s largest manufacturer of aluminium silos • 30 years supplying the food and
Spiroflow Ltd is launching a new bin activator into the UK market that will help manufacturers in process industries such as food, beverage, chemicals, plastic and oil and gas to eliminate material flow problems that can lead to potentially dangerous blockages in factory piping or tubing applications. Incorporating the latest technology, Spiroflow’s bin activator has integral vibrating blades to maintain a steady momentum and minimise bridging. It is exceptionally well suited to ensuring the steady flow of materials that are hazardous, toxic, require sanitary handling or are simply challenging, such as Titanium Dioxide. The blades are fully adjustable for accurate control of solids, while energy is imparted directly into the materials by the vibrating blades to ensure continuous flow. Effective shut–off is managed with close tolerance blades by the discharger control valve and these can be customised by Spiroflow to fit customers’ own specifications. Manufactured in carbon or stainless steel, making the equipment easy to wash down for applications like food processing and beverage bottling, Spiroflow’s bin activator is designed to minimise risk in potentially hazardous or explosive environments. Shifting millions of tonnes of potentially dangerous ingredients is part and parcel of many production processes for manufacturing companies, which must have systems and equipment in place that adhere to the European Union’s ATEX Directive 1999/92/E - implemented by the Dangerous Substances and Explosive Atmosphere Regulations 2002 (DSEAR) act in the UK. Spiroflow is a world-leading manufacturer of ATEX approved conveying and bulk handling systems that meet regulatory requirements for transporting and handling powders and other materials in environments containing a potentially explosive atmosphere, such as chemicals or oil and gas.
Spiroflow bin activators, which can be tailorplastics industries made to suit customers’ needs, are exceptional equipment for facilitating the steady discharging • Fully ATEX compliant of powdery or granular materials from storage • Aluminium or stainless steel silo bins, silos or hoppers. The bin activator ensures optimum feeding of the materials, avoids bridging construction and can also be incorporated into material handling • Dual tower silo manufacturing equipment like dischargers and feeders. In addition to bin activators, Spiroflow Ltd is facility also a manufacturer of bulk bag fillers, Flexible Screw Conveyors, Aero Mechanical Conveyors, Tubular Cable and Chain Drag Conveyors, Vacuum Conveyors, Bulk Bag Dischargers, Ingredients Handling and Weighing Systems. The company’s technical and engineering expertise has led to it developing an international reputation for an unrivalled range of products with state-of-the-art control systems. For more information about their products & services please contact Spiroflow Ltd, T: 01275 845901 Clitheroe, Lancashire via E: sales@bartonfabs.co.uk Tel: +44 (0)1200 422525 Fax: +44 (0)1200 429165 W: www.bartonfabs.co.uk E-mail: sales@spiroflow.com Toll Processing NEW Ad (125x175)_Layout 1 28/05/2014 13:13 Page 1 or visit www.spiroflow.com
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Specialists in size reduction, classification and multi-processing techniques, Hosokawa Micron’s Toll Processing Service is designed to support companies seeking the swift route to market of even difficult to handle new products.
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SOLIDS HANDLING AND PROCESSING
PROCESS TECHNOLOGIES FOR TOMORROW SM
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HOSOKAWA MICRON POWDERS – TOLL PROCESSING PARTNERS DELIVERING ADVANTAGES FOR ADDED VALUE Choosing the right toll processing partner can make all the difference to your business in satisfying the fluctuating demands of today’s challenging marketplace or developing new products for the market. From modern production facilities in Germany, Netherlands and United Kingdom customers can eliminate many of the risks associated with new product development, overcome temporary capacity shortages and produce niche products that would be out of the scope of their normal processing activities; without the need to invest in their own processing or storage facilities. Hosokawa Micron Powders is a specialist toll processing partner offering a range of toll processing services and access to more than 20 individual processing suites that can give you all the above plus other significant production advantages that come directly from their unique and specialist processing heritage. Comprehensive in-house analytical and test facility support is available to substantiate your new product development or trial work and to deliver optimum quality assurance, choice and design of equipment. Hosokawa Micron Powders can handle multi-tonne lots or ultra small batch processing; production of materials requiring processing in a contained environment; food products processed within BRC accredited suites and micronisation and classification of materials to sub-micron size. Manufacturers of food, chemical, mineral, plastic and metal materials can select from a range of processing and finishing technologies including; Size reduction, Granulation, Mixing, Coating and Compaction, pack-off into FIBCs, sacks, drums or boxes and warehouse storage and delivery directly to customers. All with the added benefit of the extensive processing know-how of Hosokawa Micron engineers. For further information/reader enquiries, please contact: Hosokawa Micron Ltd, Rivington Road, Whitehouse Industrial Estate, Runcorn, Cheshire, WA7 3DS. Tel: (01928) 755100 Fax: (01928) 714325 E-mail: info@hmluk.hosokawa.com Web: www.hosokawa.co.uk
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AN EXTRACTION SYSTEM, BUT ONLY WHEN NEEDED…
Extraction systems play a significant part in the energy costs for organisations and also in the effect organisations are having on the environment. Dust and fume extraction systems operate throughout the working day, whether they are needed or not. Normally each position is open and extracting with the fan running at full power during working hours. Based on 40 years of experience in the extraction manufacturing and installation industry UK engineers have designed Inteliair. This system looks at the demand at individual positions and extracts only where needed. Fan speeds are adjusted accordingly saving in excess of 40% in energy costs for users. This type of control system offers not just cost savings but can expand the capacity within an installation. Air movement and air quality managers have ultimate control and can also access the units wirelessly to gather operating data or change the system setup with a simple software interface. Following a year on the UK market with several large customers including Dyson and Dunlop, Inteliair will now be released in Europe. For more information please contact Sarah Turner, European Business Development Manager, Inteliair, Western Air Ducts (UK) Ltd, Midsomer Norton, Somerset. Tel: 00 44 (0)7764 967985 E-mail: sarah@inteliair.co.uk Web: www.inteliair.co.uk
SOLIDS HANDLING AND PROCESSING
FB CHAIN TASTES SUCCESS WITH FOODGRADE CONVEYOR SOLUTIONS A new range of lube-free plastic combination chains for the food processing and pharmaceutical industries meets strict EU hygiene standards. The traditional stainless steel chains typically used in the food processing and pharmaceutical manufacturing industries are ripe for premature wear. A risk of contamination from lubricants, especially where direct contact with consumables is unavoidable – means that the chains are frequently required to operate dry. With a short service life and high replacement costs (increasing steel prices show no sign of abating), these chains can be a drain on resources. Enter FB Chain, who have developed a new range of corrosion resistant chains specifically for the food processing and pharmaceutical manufacturing industries that do not require lubrication for optimal performance and meet strict hygiene standards. FB Chain’s plastic combination (PC) chain is constructed from food-grade engineering plastic inner links, supported by 304 grade stainless steel bearing pins and outer link plates. The PC chain matches the strength of standard stainless steel chain but has a much lower friction co-efficient, eliminating the need for lubrication and increasing wear life. The PC chain is also much quieter and an impressive 50% lighter, helping manufacturers to meet energy efficiency and environmental targets, while enjoying a significantly lower total cost of ownership. Furthermore, the bushed design of the plastic inner link ensures that in wash down applications there is no risk of residue becoming trapped between the chain components and resulting in contamination over time.
Available from stock
FB Chain’s PC chain is available from stock in foodgrade blue. A general purpose white engineering plastic is also available, with both versions supplied in sizes from 3/8” to 3/4” pitch. The chain is dimensionally interchangeable with stainless steel chain, meaning no adjustments to sprockets or other existing conveyor components are required to accommodate it. Nevertheless, the company is able to supply a wide range of sprockets made from either stainless steel or food-grade approved polymers, as well as high quality thermoplastic chain guides as part of a total package. Robert Young, process industry sales manager at FB Chain says: “Plastic combination chain – even of the non-food-grade variety – is currently only available from a small number of chain manufacturers. We aim to be the leading supplier in this niche, helping customers in the food and pharmaceutical industries – or indeed with any clean-room application – to significantly improve their safety, efficiency and profitability.” For more information contact FB Chain Ltd, Letchworth, Hertfordshire Tel: +44 (0) 1462 670844 E-mail: sales@fbchain.com Web: www.lubefreechain.com
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DID YOU KNOW There are approximately
?
50 reported dust explosions in the UK each year.
Keep reading to see more facts...
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Weighing up the benefits of an electronic scale system Whether producing, handling, packaging or shipping, it is vital that each step of any production process is accurately documented and accounted for. Laura Wilks from Avery Weigh-Tronix explains how an electronic scale system can efficiently weigh and document product information, allowing manufacturers to monitor, trace and control production—and all materials involved—from start to finish. To optimise processes, weighing equipment can be used at every step, from tracking incoming raw materials and inventory, to measurement of ingredients, quality control and shipping finished goods. As well as efficiently gathering, documenting and storing weight information, high-accuracy scales can increase revenue in these applications by reducing giveaway and ensuring customer orders are accurately invoiced and managed.
Efficient management of incoming and outgoing goods Properly managing inventory and billing in processing environments depends upon documenting and weighing both inbound and outbound freight. Whether verifying load weights for incoming ingredients or shipping finished goods for ongoing distribution, accurate weighing is essential. With the high cost of fuel, bulk carriers also have to balance the need for optimal loading with concerns about safety. Weighbridges and axle weighing systems can help to ensure that both incoming and outgoing vehicle loads are weighed quickly and accurately. For increased efficiency, weighbridge controls may be integrated into a stand-alone console that facilitates unattended weighing operations. These terminals enable drivers to complete weighing transactions 24/7, without leaving their cab. The result is that your weighbridge can run smoothly without a dedicated operator, reducing operating costs, extending hours of availability and improving health and safety by allowing drivers to stay within their vehicles.
Integrate weighing into your processes Once goods have arrived on-site, the ability to transport and weigh materials in one simple step can result in tremendous time savings and a speedy return on investment. A forklift scale can expedite operations by enabling forklift drivers to take raw ingredients directly to storage upon delivery or packaged goods to dispatch, while tracking the weight, origin and storage location during transport. This process results in real-time data acquisition, which can be used for billing and inventory management. In-cab instruments such as bar code scanners allow forklift operators can be used to instantly capture all necessary freight data available and then transmit this information with weight data wirelessly via Bluetooth® or radio to supervisory computer systems. Also used mainly when shipping or receiving, or when sorting inventory, bench and floor scales provide an alternative way of weighing goods with very high accuracy, reducing the likelihood for revenue loss. Often found within a warehouse or ingredient store, both bench and floor scales are available in stainless steel for environments where heavy washdown and strict sanitation is required. The scales also come in mild steel for warehousing or goods in/out applications where an operator might set palletised loads on to a floor scale using a forklift.
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Reduce giveaway and maintain quality When it comes to quality control and average weight legislation, employing a fast and accurate checkweigher can make a big difference to a company’s bottom line. Underweight packages can lead to unhappy customers, while overweight packages lead to costly giveaway and overweight shipments. Whether you need to spot check raw materials or finished goods, or to ensure adequate quality control, checkweighers can provide visibility of weighing data and statistics which can help to maximise performance and profitability. When selecting a checkweigher, or indeed any weighing system, ensure that the construction is suitable for your environment. If working in the food or chemical environments, ensure that the equipment has been specifically designed to meet the stringent requirements of the industry. Products with an IP69K rating are proven for use in heavy washdown environments and can withstand even the most rigorous cleaning regime, while scales with an ATEX badge are deemed suitable for us in potentially explosive environments such as mixing and batching volatile chemicals, or bulk solids that produce explosive dust mixtures.
Inventory control and ingredient mixing Retrofitting bins, tanks or hoppers with load cells can easily turn your into existing equipment into an accurate, dependable scale with minimal interruption to your operation. By adding a weight sensor to your existing storage bins, you can keep a close eye on inventory at a basic level, or pair with a sophisticated weight indicator and software to automate mixing of your raw ingredients. Stainless steel, watertight and explosion-proof (ATEX) models make these ideal for use in a variety of processing applications.
Intelligent data for process control and traceability On a basic level, weight indicators collect, store and communicate data. By integrating more advanced digital indicators into your operations, you can use wireless communications to transmit data to back office systems, improving management information and control and producing instant, accurate invoices for all materials weighed. Indicators can also be linked to printers, bar code scanners, computers and other peripherals for integration into existing networks, allowing effortless data transfer and management from anywhere in the operation. Many scales can also be paired with sophisticated software and indicators to provide additional data collection, tracking
and analysis, from integrated management systems which monitor operations and inventory in real-time, to solutions which can automate batch and recipe control. Software innovations help to facilitate efficient documentation and management of key weight, commodity and scale data, all of which can be absolutely vital for traceability.
Legal-for-trade weighing A scale system capable of legal-for-trade weighing is an invaluable asset in the process industry as revenue is commonly based upon the weight of commodities purchased or shipped. Legal-for-trade accuracy is required for business transactions where goods are bought or sold by weight, but the benefits of a legal-for-trade system extend beyond legality. The legal-for-trade approval can also be seen as a badge of reliability - proof that your scale can provide repeatable weighing of goods, ensuring customer satisfaction, precise billing and accurate inventory records.
Selecting a supplier Having acknowledged the importance of weight data, some organisations fail to see the importance of regular service and calibration from a reputable provider. Focusing on regular preventative maintenance keeps your equipment working at maximum efficiency and reduces the likelihood of costly emergency breakdowns which can halt production. The cost of planned maintenance, particularly as part of a regular service regime is always more cost effective than an emergency repair. If, for example, a checkweigher breaks down, then you may need to close an entire production line. The cost of this downtime can run into several thousands of pounds a day in lost hours, causing production back logs and customer orders not fulfilled. If you trade by weight then regular service and calibration of weighing equipment, with all of the appropriate documentation, is a legal requirement. If a piece of equipment is repaired and this involves replacing weighing parts, it will need to be re-verified for trade by a trained verification officer. Not verifying for trade can result in criminal proceedings by the NMO trading standards officers and could also mean that you’re breaking Weights and Measures legislation and the quality standards requirements of ISO 9001:2008 which demand that you have properly calibrated scales. Without proper servicing, the advantages of incorporating weighing equipment into your production line are diluted.
The impact of weighing processes With today’s fierce market competition, ensuring customer satisfaction without impacting productivity is crucial. Now, operators can implement weighing solutions with customisable features and functions in order to tailor their performance to exact specifications. This not only improves production with data acquisition and inventory management capabilities, but also improves a company’s bottom line and product quality. ITW Limited trading as Avery Weigh-Tronix, Smethwick, West Midlands Can be contacted via: Tel: +44 (0)845 307 0314 Fax: +44 (0)870 90 50085 E-mail: info@awtxglobal.com Web: www.averyweigh-tronix.com/uk
SOLIDS HANDLING AND PROCESSING
MUCON SERIES H IRIS VALVE – THE IDEAL SOLUTION FOR IBC DISCHARGE AND FLOW CONTROL The Series H Iris valve is able to offer the end user a choice of either a bolted or a quick release adaptor, so that they can be easily and quickly fitted to the bottom of any rigid IBC. The Series H Iris valve offers the end user an economical, gentle and easy to operate discharge valve. Should the application require frequent washing of the IBC, the Series H Iris valve with the quick release option. This allows the Iris valve to be effortlessly removed from the IBC for cleaning in between product batches. Where cross contamination could be an issue, the Series H has the ability to offer two different kinds of adaptor. 1. The Plain adaptor allows the end user to include a simple polythene liner to the inside of the Iris valve. As and when the material being processed is changed, the liner can be quickly disposed of and replaced with another clean liner. This is a very simple and inexpensive way of ensuring that cross contamination is avoided. 2. For materials that are more abrasive a grooved adaptor can be supplied with the Series H Iris valve to accommodate a robust liner. The Mucon Iris valve is often used to control the discharge of powders and tablets. Its gentle opening and closing of the diaphragm acts to prevent tablet damage. This not only means that cleaning of the IBC is reduced to a minimum, but also product wastage is reduced. The Iris valve has FDA approved contact parts. The Series H also has an additional Transit Cover option. Transit covers can improve product safety and minimise moisture absorption while the IBC is in storage or transit. The Series H valve has been on the market since 1992. Since then thousands have been supplied all over the world to IBC manufacturers and IBC end users. Customers include Bayer Pharmaceutical, Mc Neil Pharmaceutical, Merck and Novartis. For more information please contact Process Components Ltd, Macclesfield, Cheshire. Tel: +44 (0) 1625 412000 E-mail: sales@mucon.com Web: www.mucon.com
LARGEST BARTON SILO CONTRACT COMMISSIONED BY CARR’S FLOUR SCOTLAND Barton Fabrications has completed its largest ever silo installation project. As part of a multi-million pound investment to automate and upgrade its Kirkcaldy site, 26 aluminium silos have been commissioned by Carr’s Flour Scotland. The silos supplied range in size from 12 to 100 tonnes and are up to 19 metres tall. Barton’s silos are used for a number of different applications at the Kirkcaldy plant, including flour storage, out-loading and ingredient containment. Commenting on the benefits of Barton Fabrications’ products and service, Tim Hall, Operations Director at Carr’s Flour Scotland said: “Barton Fabrications’ reputation for build quality and installation expertise were key reasons in the selection of the company to manufacture and install the silos at our Kirkcaldy site. “Apart from Barton’s established track record and technical competency, the company has been easy to deal with, highly responsive and extremely flexible in accommodating prog-ramme adjustments.” The majority of the storage vessels include Barton’s half penthouse design: this provides indoor housing protection for operators during filter maintenance and easy venting for explosion panels which are part of the silos ATEX compliant design. A number of special features have also been incorporated into the plant including measures to avoid condensation and a unique double door arrangement fitted to twelve finished flour storage silos. This provides easy access for maintenance to the motors and discharge equipment located at the base of the silos. For more details on Barton Fabrications’ silo solutions, contact Barton Fabrications Ltd, Portishead, Bristol Tel: +44 (0) 1275 845901 E-mail: sales@bartonfabs.co.uk Web: www.bartonfabs.co.uk
SOLIDS HANDLING AND PROCESSING
The Serious Pipe* *No side splitting comedy guaranteed High-volume manufacture means high-quality pipework that’s reliable, flexible and easy-to-maintain but costs less than custom-built sheetmetal ductwork.
Jacob (UK) Ltd T: +44 (0) 1694 722841 E: sales@jacob-uk.com W: Jacob-uk.com
DID YOU KNOW
?
Which ONE company prevented approximately
20
potential dust explosions in the UK last year.
Keep reading to the answer...
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SELF CLEANING ECO FILTER DOES THE ITALIAN JOB… Consorzio Latterie Virgilio is an Italian consortium that is associated with 70 dairies and more than 2,000 farmers. Working with the members of the consortium, the company primarily focuses on the production of dairy products, including butter, fresh cream and aged cheeses. However, with increasing uses for animal fat, the company recognized the opportunity to expand their product range. Sourcing fat from their slaughter plant, the company sought to produce two key animal fat by-products – an animal fat spread (an Italian delicacy) and biodiesel.
The processing of these animal fat by-products required a new processing line to be built, and therefore Virgilio approached a well known engineering house to provide a processing solution. The proposed system required the meat fat to be minced before it is steam heated into a liquid form at just under 100oC. As the meat fat contains skins and cartilages that are difficult to break down, the liquid product is then fed to a filtration system to remove any oversize contamination. Having worked with Russell Finex previously, the engineering house did not think twice about supplying the SelfCleaning Russell Eco Filter® to Virgilio for this stage of the process. The unique design of the Self-Cleaning Russell Eco Filter® ensures that material passes through the filter screen whilst the screen is automatically cleaned using a rotating wiper inside the element. “The Eco Filter wiper system works on a continuous basis, cleaning the filter element surface at all times, providing a consistent throughput rate and differential pressure” states Andrea Bozzellini, Area Responsible. The units were customized to meet the exact requirements of the application. As the filter was
required to remove oversize above 100 micron which is then returned to the pulverizer for rework, the oversize outlet was reduced in size from 2” to 1” and attached to a pump. The pump constantly feeds the oversize back into the main line. “Russell Finex were happy to facilitate the necessary adjustments to the machine to suit the process better”, continues Bozzellini. Due to the nature of the product being processed, the pipework needed to be cleaned on a regular basis. Therefore, a second Russell Eco Filter® was supplied, acting as a Clean-in-Place system circulating water with cleaning solution around the pipework. Russell Finex has over 75 years of experience manufacturing and supplying separators, screeners and filters to enhance productivity and ensure product quality. The company serves a variety of industries in over 100 countries with applications that include adhesives, ceramics, chemicals, colors, enamels, explosives, food, inks, latex, metal powders, paint, paper coatings, pharmaceuticals, plastisols, powder coating, and waste oils. For more information contact Russell Finex Ltd, Feltham, Middlesex. Tel: +44 (0) 208 818 2000 E-mail: enquiries@russellfinex.com Web: www.russellfinex.com
DEMAG CRANES PROVIDE LIFTING POWER FOR THE OIL AND GAS SECTOR • Demag open winch wire rope units fit the bill • Precision movement and positioning of large and heavy loads • Strong Demag regional service support Terex Material Handling has installed two Demag overhead travelling cranes at Dril-Quip Europe’s production facility in Aberdeen. A division of the multinational operator, DrilQuip Inc of Houston, Texas, the company designs, manufactures and services a wide variety of hardware for the oil and gas industry. Dril-Quip’s product range includes sub-sea and surface trees and tubular components, which are distributed to major oil and gas operators worldwide. Dril-Quip specified the Demag cranes as part of an expansion programme at its 400,000 sq ft production facility. The investment was driven by the need to handle increasingly large and heavy components, between manufacturing and assembly processes. Terex Material Handling supplied a Demag 50 t SWL, 17.6 m span ZKKW double girder overhead travelling crane and a 30 t SWL, 17.6 m span ZKKW double girder overhead travelling crane. Both cranes incorporate Demag MPW open winch wire rope lifting units, which are particularly suited to Dril-Quip’s manufacturing processes. Both cranes have variable cross and long travel speeds of 0 - 20 m/min. The 50 t SWL crane has variable hoisting speeds of 0 – 8.8 m/min for loads up 30 t and 0 – 5.5 m/min for loads above 30 t, whilst the 30 t SWL crane has variable hoisting speeds of 0 – 8.8 m/min for loads up 18 t and 0 – 5.5 m/min for loads above 18 t. Safety features include fast to slow and slow to stop functions at cross travel and long travel limits, with an optical crane to crane anti-collision feature.
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The crane systems feature AC inverter controls for smooth movement, precision positioning accuracy and minimisation of load sway. The cranes are operated via a Demag DRC-J joystick radio remote control, allowing the operator to be excluded from the lifting area for safety, ergonomic efficiency and comfort. Dril-Quip Europe’s Lifting Equipment Supervisor, Arty Matheson, reported that the company now has several Demag cranes at its Aberdeen production facility: “We have been impressed by the productivity and reliability of our existing Demag cranes. This latest investment was prompted by the necessity to handle increasingly large and heavy loads. Terex Material Handling was able to help us meet these objectives with an engineered solution, tailored to our specific requirements, incorporating the Demag MPW open winch wire rope lifting units.” He added: “Demag’s regional after sales network was also an important factor in the specification process. Demag service has a strong presence in the north east of Scotland, providing us with total peace of mind in terms of technical support.” For more information please contact Demag Cranes & Components Ltd, Banbury, Oxfordshire. Telephone enquiries to: 01295 676100 · Fax enquiries to: 01295 271408 E-mail enquiries to: bnb-help@demagcranes. com or visit Web: www.demagcranes.co.uk
SOLIDS HANDLING AND PROCESSING
VACUUM CONVEYING IS AS SIMPLE AS IT IS INGENIOUS Piab are an innovative designer and manufacturer of vacuum pumps, suction cups and vacuum conveyors. The growing reliance on vacuum conveying is not hard to understand, once you consider its myriad advantages. It is enclosed, hygienic and safe, which is recommended when transferring ingredients and finished products in the food processing applications. Powder and granules are ideal for vacuum conveying as well as a number of other materials. Even those materials that are sensitive to humidity and contamination can be safely conveyed. The piFLOW® range of vacuum conveyors can be configured or tailor made to transfer powder or granular products with volumes from 250g up to 10 tons p/hr and distances up to around 50 metres total vertical/horizontal. Visit us at the PPMA show STAND E06 where will be exhibiting the piFLOW®p conveying plastic granules. Tel: 01509 857010 E-mail: info-uk@piab.com Web: www.piab.com
Up, down and around For clean, safe, cost effective and dust free bulk handling of products turn to UniTrak Powderflight’s range of reliable equipment: • Bucket elevators • Aeromechanical conveyors
• Flexible screw conveyors • Bulk bag dischargers
UniTrak Powderflight always moving in the right direction! Featured product: Powderflight Aeromechanical Conveyor
Trust the experts. (0)1457 865038 www.unitrak.co.uk
Which statistic would you prefer to be part of for
2014?
In 2013 Fike EPACO® systems prevented 21 potential dust explosions from occurring in UK factories alone. In the UK the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) require employers to control the risks to safety from fire and explosions.
Fike offers: ■ Conventional & Flameless explosion vents ■ Full range of passive isolation devices ■ Active explosion isolation & suppression systems ■ Full-scale explosibility testing facilities
SOLIDS HANDLING AND PROCESSING
Fike UK, 35 Earl Street, Maidstone, Kent, ME14 1PF, United Kingdom T: +44 (0) 1622 677081 E: info@fike.co.uk www.fike.co.uk
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Spherical D
for Solids Process Solids and slurries have completely different flow characteristics than liquid and gases, so it’s important to choose a valve for powder applications carefully.
Taking the GEMCO spherical disc valve as an example: Related to a full-port ball valve, the spherical disc valve design uses a spherical disc section (segmented ball) to provide shutoff. Mounting arms are added to provide a pivot on shafts through the center axis of the original ball. A section of the spherical disc seals against the identical spherical radius of the seat while the rest of the shut-off surface is under-cut below the spherical radius.
Advantages of the spherical disc valve design: • The spherical disc wipes the material away from the matching radius of the seat to provide sanitary sealing and longer seat life. • The spherical disc rotates 90 degrees out of the material flow, to allow mass-flow through its full port. • The under-cut disc segment provides clearance that prevents powder jamming between the disc and housing.
Factors to consider when choosing your spherical disc valve: Materials of construction The powders and/or solvents to be processed determine the product contact material. While cast iron, carbon steels, and aluminum can be used for many industrial applications; corrosive processes require the use of stainless steel. In some cases, material laden with solvents justify the extra expense of using Hastelloy or other high-nickel alloys to prolong valve life. Seat materials: Very abrasive material tend to dictate the use of metal seats versus the commonly used reinforced Teflon seats (RPTFE). The metal seat is typical stainless steel coated with a Carbide in a Cobalt favorable environments (WC/CO) and will give longer life and can be used at higher temperatures than Teflon.
Cleanability The sanitary requirements of a particular process govern surface finishes and other sanitary options. No surface finish specified: Also referred to as “mill finish” or “as cast”. Fabricated valves will only have the internal welds ground smooth and flush. This finish is most often used in general industrial applications where cross contamination
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or cleanability are not a concern. #2 finish - Ra 33 to 65 microinch - 150 to 180 grit: Also referred to as “buffed, blended or uniform appearance finish.” This finish is usually specified for the outside of equipment which will be washed down. #4 polish - Ra 16 to 32 microinch - 180 to 240 grit: All fabrication and handling marks are removed and the surface is buffed to a uniform satin finish. The #4 polish is typical for the interior of equipment that needs to be cleaned between batches to prevent cross contamination. #7 polish - Ra 10 to 15 microinch - 240 to 320 grit: All surface imperfections are repaired. Often referred to as “pit free” and “mirror finish.” Used for high purity applications such as processing potent pharmaceutical actives. This finish is also used for products that tend to adhere to surfaces. Spray balls or jets should be considered for automatic cleaning. Another option is a valve that can be dismantled by hand for inspection and cleaning. For safety reasons, the size of such valves are typically limited to a 10” port diameter due to the weight of individual components.
Weight The weight of a valve is especially important for mobile or rotating equipment. High performance and heavy- duty valve models will be heavier than regular duty valves. A valve that is dust tight, full vacuum, and 1 bar service, is considered to be regular duty service. Valves that can handle 90 PSI (6bar) to 150 PSI (10bar) are high performance. A higher performance valve can weigh four times as much as its regular-duty counterpart.
Mounting arrangements The typical ANSI 150 # drilling is used as an industry standard for heavy duty and high performance models valves. Quick clamps can also be used for applications up to 15PSI (1bar) and port sizes up to 10". Some valves will include blind tapped holes, which might present a problem if the valve is mating with existing blind tapped holes. Another option is to choose oversized flanges, which allows for through holes. DIN and special drilling are engineered to order. However, for regular duty service valves, ANSI and DIN bolting can be overkill.
Actuation When selecting an actuator one must consider the materials being processed, available air supply and
SOLIDS HANDLING AND PROCESSING
Disc Valves
sing Applications failsafe operation. As with other quarter turn valves; levers, gear drives or chain operators are all options to consider. Pneumatic and hydraulic, operators are available in double acting or failsafe modes. For price, reliability, and speed, pneumatic operation should be the first choice. When handling solids, a higher factor of safety is used to calculate seat torque requirements. The factor is typically 1.5 instead of the more commonly used 1.25 safety factor used for liquid and gas valve calculations. For solids that “set-up” or harden, an oversized actuator and specially designed discs that can be incorporated to break through the hardened cake when the valve opens or closes is recommended. Actuators are typically sized for 5.3bar (80-PSI) pressure. If the available supply air pressure is dependably higher 6.7 bar to 8 bar (100 to 120PSI) or lower 2.6 bar to 4 bar (40 to 60 PSI), you will need to consider this factor when sizing the valves actuator. For fail-safe operation, spring return actuators are the norm. When a spring return type actuator is used, it is oversized to compensate for the spring as well as the unseating, run, and seating torque required for valve operation. This can lead to weight and space problems as well as extra cost. Another fail-safe option to consider is to use a double-acting actuator in conjunction with a pneumatic accumulator sufficiently sized to close the valve. When there is a loss of pneumatic pressure, a pressure switch activates the accumulator and closes the valve.
a concern. The valve is offered as dust tight, full vacuum, and low-pressure (1 bar) services. Common installations of the TLD valve include inlet/ outlet ports on rotating or stationary blenders and Intermediate Bulk Containers (IBC’s).
and efficiently. Options for retractable sleeves can include inflatable seals for hazardous environment, spring-return air cylinders for fail-safe operation, metal bellows for high-pressure applications, and “clean-in- place” fittings.
Sanitary Valve: The sanitary K valve is designed to USDA and FDA guidelines, which eliminate threads, keyways, and crevices. The split body design means it can be completely disassembled by hand to allow for quick and easy inspection and cleaning. It is used for charging/discharging, commonly in food and pharmaceutical industries where cleanability is required.
Diverter Valves: The diverter valve places the spherical disc valve in a ‘Y’ junction. This allows the valve to select a product feed stream from one of the two inputs, or to direct one incoming stream of material to either of the two outlets. Diverter valve use varies greatly from rock crushers to food processing.
Heavy Duty Valve: The T valve is designed for heavy-duty service and comes with oversized flanges with through holes for mounting to blind flanges. Options include high temperature or pressure (3 bar) designs. This valve is commonly used for charging and discharging of hoppers, tanks, silos, conveying systems, and weighing systems processing slurries, abrasives, and heavy density materials.
Summary
Fast acting (1 to 5 seconds), quarter turn valves are ideal for flow control of solids. A pneumatic (200mbar to 1000 mbar/3 to 15 PSI) or electropneumatic (4 to 20 milli-amp) positioner can take a signal from a manual adjusted pressure regulator, or from a computer controller. The pneumatic positioner is often used in manually-operated filling stations, whereas the electro-pneumatic positioner is typically used for automatic loss-inweight systems.
High Pressure & Corrosion Valve: The P21 valve is specially engineered to meet rigorous demands of pressure and corrosive applications. The valve is designed and built to ASME/PED standards for pressure-assisted sealing from full vacuum to 10 bar (150PSI), and at temperatures up to 230 Celsius (450F). This valve is often used for reactor feed valve or as an isolation valve.
Spherical Disc Valve Examples:
Other Valve Combinations and Options:
Flow Control
Light Weight Valve: The versatile TLD valve is most often chosen for processing light density materials such as foods and pharmaceuticals, and on rotating and mobile equipment where weight is
Retractable Sleeves: Retractable sleeves are designed for the dustless transfer of solids from one process to another. They are usually interlocked with the valve. A mobile vessel or container is located so the retractable sleeve engages and seals automatically. Once the seal is confirmed, the valve opens to allow material transfer safely
SOLIDS HANDLING AND PROCESSING
Airlocks: Airlocks are designed to control the flow of material between two atmospheres. They typically consist of two valves connected by an intermediate chamber. Airlocks are often used instead of rotary feeders, which are prone to high maintenance and leakage of material and gases,
Choosing the best valve for your powder application results in many benefits including: better performance, lower maintenance costs, and better product quality over the life of the processing equipment. For more detailed information visit the “Design Principles” page at Gemco Valve Company.
Gemco Valve Company, 301 Smalley Ave, Middlesex, NJ 08846, USA Can be contacted via: Telephone: 800-654-3626 or +1 732-733-1142 Fax: 732-424-2483 Web: Gemco Valve Company http://gemcovalve.com/contact/ Induchem UK – UK distributor, Congleton, Cheshire Can be contacted via: Tel: +44 1260 295413 Fax: +44 1260 295075 E-mail: Sales Inquiries to: sales@induchem.biz Web: www.induchem.biz/
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EFFICIENT PARTICLE CAPTURE? – THE ANSWER SHOULDN’T BE BLOWING IN THE WIND The removal of particles from gas flows can be achieved through a variety of equipment types. A major challenge for many industries when a plant is subject to expansion or re-design, is that it is often the case that the dry particle filtration system is unlikely to be adequately assessed for its capability to operate with either higher transfer rates or radically different bulk particle properties. Failure to take these factors into account can lead to an increased tendency for filter blinding or more frequent cleaning cycles. In either case the end result can cause interruption to process efficiency and hence loss of profits. The Wolfson Centre for Bulk Solids Handling Technology has developed a comprehensive suite of pilot plant scale equipment for evaluating filter performance and the effects of changes in bulk particulates on filter life. For more information The Wolfson Centre for Bulk Solids Handling Technology, Chatham Maritime, Kent. Tel: +44 (0) 20 8331 8646 E-mail: Wolfson-enquiries@gre.ac.uk Web: www.bulksolids.com
BESPOKE PADDLE BLADE MIXERS FROM JR BOONE PERFECT FOR CLAN CERAMICS John R Boone have developed a bespoke mixer solution for investment casting specialists Clan Ceramics for their global ceramic core process and material supply business, including high-temperature, multi-stage mixing with vacuum processing.
Nerak Wiese Ltd
Other bucket conveyors pale in comparison
If you handle bulk, you may already know that Nerak conveyors – which are manufactured in our state-of-the-art factory in Brecon, Wales – have a proven track record for quality, speed and reliability. We're delighted to announce that, having been appointed sole UK distributors, we now exclusively offer the market-leading range of bucket conveyor solutions from Wiese. Whether you're handling food, chemicals, aggregates, pharmaceuticals or waste, bucket conveyors from either the Nerak or Wiese ranges will provide rapid, quiet and safe handling around the clock. Driven by the grease-free, non-slip and ever-taut Wiese rubber chain technology, both the continuous bucket conveyor and the pendulum bucket conveyor systems from Wiese offer spill-free operation, gentle handling and a long service life – even in the harshest of applications.
Continuous bucket conveyors
Featuring an ingeniously shaped and interlocking bucket design, the Wiese continuous bucket conveyor operates horizontally, vertically and at any angle in between without spillage. Offering high conveying speeds and capacities, this solution is ideal for operation in tight spaces in applications requiring only one discharge point.
Pendulum bucket conveyors
With individual buckets that swing freely and overlap when in horizontal operation, the design of the Wiese pendulum bucket conveyor ensures no-spill handling, yet makes multiple discharge points and more complex layouts possible. Tool-free removal of the buckets facilitates cleaning outside of the casing, as well as simplifying maintenance.
A whole host of options
Both the Nerak and Wiese conveyor ranges are available in a wide choice of sizes, layouts and finishes. Casing options include a hygienic and easy-clean coating that meets FDA standards, as well as mild steel or stainless steel finishes. Bucket materials are selected to suit the application, with options available to suit all types of bulk – from sticky goods to abrasive items, at temperatures from -40°C to 130°C – with food-grade metal detectable buckets also available.
Find out more Visit the Nerak Wiese website for full details of the bucket conveyor range or contact Simon Musgrave for more information on 01874 612 900 or via e-mail: simon.musgrave@nerak-uk.com Nerak Wiese Ltd, Ffrwdgrech Industrial Estate, Brecon, Powys, LD3 8LA
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In such a technical arena, the choice of machinery is critical. Clan needed a partner with whom they could work, and whom they could trust to supply equipment to fit their production lines globally. JR Boone produced a horizontal paddle blade mixer (HPBM) for Clan. The mixing process is complex, forming a paste at high temperature (140ºC) over a number of stages, finally de aerating and discharging under vacuum to make sure that a homogenous, bubble-free ceramic material is produced for the casting process. JR Boone produced a variation on their standard HPBM, incorporating an insulated jacket, heating system and a vacuum pump for the final part of the process. John Morris, Clan’s Technical Director, said: ‘The amount of testing we were able to do with JR Boone helped tremendously. We have been able to reduce mixing time by 25%, for example. We also found that the profile of the Boone paddles means that, despite the very abrasive materials we use, they wear far less than other mixers we have tried; improving product quality and ultimately reducing cost.’ The Control System was designed specifically for Clan, with temperature, speed and time all being selectable and monitored parameters within the easily operated menu system on the HMI. Boone mixers are specified to third party manufacturers, so JR Boone have manufactured them to be as far as possible ‘plug and play’, easily installed and operated so that operators worldwide can produce the very high quality ceramic cores that have rightly built Clan Ceramics’ reputation. For more information contact John R. Boone Limited, Congleton, Cheshire. Tel: 01260 272894 Fax: 01260 281128 E-mail: sales@jrboone.com Web: www.jrboone.com
SOLIDS HANDLING AND PROCESSING
MATERIALS PROCESSING & HANDLING SOLUTIONS FROM EXPERTS GAME Engineering Ltd is a privately owned company based in Lincoln, and founded in 1986. We are materials processing and handling engineers providing processing, packaging, handling, storage and bespoke solutions to clients. We have a unique and proven ability to deliver innovative, imaginative and real world solutions to our customers and have built our hard earned reputation by consistently completing successful projects while at the same time developing excellent working relationships with our clients. Services: “Our Experience is your Guarantee.” • Complete Turnkey Engineering Solutions • Process Design and Engineering, Layouts & Flow Diagrams • Project Management • Principal Contractor • Site Installation and Construction • Risk Analysis, Health & Safety and CDM Safety Management • Machinery Manufacture • Home Office approved Subcontract Fabrication • Bespoke Manufacture Products: “Why Compromise? Your Special is Our Standard.” • Conveyors • Elevators • Ribbon blade mixers • Paddle blade mixers • Valves • Diverters • Weighing systems • Cyclones • Feeders • Storage Systems (silos, bunkers & hoppers) • Self-clean elevator boot • Micro-ingredients weighment systems • Rotary sifters • Robotic palletising • Slides • Materials recycling facilities (MRFs) • WEEE process lines • Bio-fuel storage and handling systems • Extruder plants • Pelletising plants For more information contact GAME Engineering Limited, Lincoln, Lincolnshire. Tel: +44 (0) 1522 868021 Fax: +44 (0) 1522 868027 E-mail: sales@game-engineering.com Web: www.game-engineering.com
Protecting Your Plant Before Things Start To Go Wrong
Motion Sensors for Every Application PE 4000
Speed Relays or PLC
SR4000
AUE400
OST! LOW C ATION IFIC C E P S DY HIGH EN E B O ROPYL POLYP VY DUTY HEA
Speed Standard Units
End of shaft mounted
Safety MAE 1000
Rotation
Interlocking
Bespoke Units
Tailored to suit individual requirements
Rotech Motion Sensors units are used for monitoring of:
•Stop/Slip •Distance/Direction Protects: •Underspeed/Overspeed •Rotation Control • Conveyors •Interlocking/Sequencing •Belt Weighers • Crushers
• Valves & Pumps • Bucket Elevators •And many more!
Proven track history of Simply Choose Reliable and extremely high R TECH FOR RELIABILITY! Quality products with hundreds of Why Accept Anything Less? Applications worldwide
Web: rotechsystems.co.uk Tel: +44 (0)151 356 2322
ULTRASONIC FIRE SUPPRESSION SYSTEMS One of the major issues facing process industries during the manufacturing process is fire. Coltraco Ultrasonics a leading UK OEM of ultrasonic fixed fire suppression systems has a range of products and systems to help negate this risk. The fire suppression system within a facility such as Pharmaceutical manufacturing plant will have many components. One of the most important is the suppression system cylinders. In a high risk high value environment detection is key. Permalevel™ Multiplex is an ultrasonic measuring system that has the ability to monitor up to 700 cylinder points in real time. This gives the operator the ability to call up individual cylinder points and monitor their liquid level. With a complex data logging system it also gives the operator the ability to check historic levels for slow seepage. Permalevel™ Multiplex gives owners the ability to better protect their assets. For more information please contact Coltraco Ltd, 46 Mount Street, Mayfair, London. Tel: +44 207 629 8475 Fax: +44 207 629 8477 E-mail: sales@coltraco.co.uk Web: www.coltraco.com
SOLIDS HANDLING AND PROCESSING
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ENHANCING EFFICIENCY IN
CONVEYORS Today’s bulk conveyors are moving a more punishing
development and production. Drawing on decades of
mix of raw materials, into more places, than ever before.
material handling experience, the designers and engineers
Meanwhile, at the opposite end of the scale, conveyors
behind the components that drive conveyors are helping
in food and beverage must maintain performance while
OEMs to build machines that reduce the high costs of
offering enhanced product safety. To meet these demands,
unplanned downtime, maintenance and energy, says Phil
conveyor OEMs are looking for ways to optimise design,
Burge, Country Communication Manager, SKF.
Heavy duty conveyors Whether transporting raw coal or metals at a mine, or bulk materials and finished goods at a port, heavy (or bulk) conveyors often endure abrasive contaminants under dirty, wet conditions that challenge component reliability. The surging population, rapidly growing economies and burgeoning global development, particularly in areas such as the Asia-Pacific region, are the main drivers behind an ever increasing consumption of mineral commodities and ore bodies. In order to meet the rampant demand, raw material suppliers the world over are now under heightened pressure to ensure that sufficient supply is in place to satisfy the need.
belt damage during the commissioning and training period. Further expected benefits are longer operational life of the idlers and pulleys, as unnecessary stresses have been removed from these components prior to full production operation. Components such as bearings are present in virtually every piece of industrial machinery, so when a breakthrough in bearing technology is made that offers notable energy savings, the benefits can be applied across industry. Improvements made to just one piece of equipment, such as the ubiquitous conveyor, which often incorporates many hundreds of bearings for pulleys and idler rollers and in drive motors, can have a profound impact on energy consumption.
And there is further pressure in the form of tightening regulatory requirements and rising energy, raw material and waste disposal costs that only serve to compound the issue. Consequently, these challenges see many plants being forced to drive down energy consumption and emissions in order to remain environmentally responsible and commercially competitive.
With this in mind, a range of highly efficient, low friction bearings that cut frictional torque has now been developed. The new bearings reduce friction, and thus energy consumption, by as much as 50%, depending on the application. Perhaps as importantly, bearing life can be increased to give a major reduction in total cost of ownership.
Increasing productivity and reducing costs are the keys to success in surviving the sector and, as a result, many organisations are now increasingly looking to contain and reduce costs to sustain profitability, primarily through improvements in machine performance, reliability and efficiency.
Similarly, the latest high performance seals are perhaps more effective than ever at providing protection against the intrinsically harsh operating environments of mining applications, preventing system contamination resulting from the ingress of particulate matter and moisture. Furthermore, a correctly specified seal provides low levels of friction, retains the lubricant and essentially extends bearing service life.
In many cases, the key to achieving these goals lies not just in addressing the performance of larger systems, such as engines and gearboxes, but by taking a holistic view and evaluating the system as a whole. By focussing on the components of the conveyor, operators of mining plant and equipment can realise significant cuts in operating and maintenance costs, while maximising equipment performance and life in service.
Conveyors in food and beverage In proving ovens, high pressure wash-downs and humid operating conditions cause premature failure to conveyor chains and bearings, leading to an increased risk of product contamination and unnecessary maintenance and re-lubrication costs.
Belt alignment tool TMEB 2 B
A range of products and services are now available that optimise conveyor performance and efficiency, including lubrication, alignment and housing solutions. For example, where a conveyor tracks substantially Shaft alignment tool TKSA 80 off course whilst feeding the belt through the idler system, poor tracking is often the result of poor pre-alignment of the pulleys and idlers. In such cases, geometric alignment of the entire conveyor assembly - including drive trains, pulleys and idlers - may be required. Precision conveyor alignment can be achieved using a combination of techniques and several laser alignment tools ranging from advanced geometric alignment to basic belt alignment lasers. As a result of the precision geometric alignment, conveyor belt commissioning times can be reduced considerably when compared to conventional methods of belt tracking where idlers have to be adjusted continuously in order to train the belt along its pathway. The benefit to the customer after the alignment process is an extremely smooth start-up with only minor adjustments needed in order to be fully productive. The precision alignment also results in a greatly reduced risk of
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Under these conditions, moisture, water and cleaning fluid will creep into bearings, resulting in reduced lubrication. This is because the bearing grease will absorb the water and emulsify, changing the consistency of the grease and allowing it to wash out. Along with corrosion accelerated by the humid environment, this can cause the guide wheel bearings of proving oven conveyors to fail. Prompted by customers that have experienced similar difficulties the designers and engineers of conveyor components have worked with OEMs to review the system and minimise such maintenance issues in the future. An efficient solution that has emerged from this collaboration is the use of air-assisted oil projection lubrication systems to address issues connected to manual chain lubrication. An air-assisted oil projection lubrication system enables reliable and effective lubrication of the conveyor chain, eliminates related downtime and reduces maintenance costs. Through accurate oil projection, the system prevents lubricant waste and reduces environmental and operator safety issues created by excess oil. Volumetric piston pumps precisely deliver a metered volume of lubricant to the points of friction while the chain is in operation, while a control unit can be preset to the preferred timing for lubricant application. Because the projection nozzles have no mechanical contact with the chains, dirt accumulation and applicator wear are prevented. The chain does not need to be stopped for re-lubrication, so productivity is increased, while longer service life is achieved due to decreased chain wear and reduced friction lowers energy consumption. In food and beverage applications such as this, an air-assisted oil projection lubrication system also helps support the HACCP process in producing safe food by preventing contamination from the lubricant. SKF (UK) Limited, Luton, Bedfordshire Can be contact via: Tel: 01582 490049 E-mail: marketing.uk@skf.com Web: www.skf.com/uk/
SOLIDS HANDLING AND PROCESSING
ERIEZ RARE EARTH MAGNETIC DRUM PRODUCES THE HIGHEST LEVEL OF PURITY A world authority in separation technologies, Eriez Magnetics Europe Ltd demonstrates the efficiency of its rare earth magnetic drum separation system to help produce the highest levels of purity in fine powdery material. Société Européenne Produits Réfractaires (SEPR) in France, part of the Saint Gobain Group required reducing the ferrous contamination of its very fine (> 0.5mm particle size) refractory cullet to less than 120ppm of Fe whilst maintaining a throughput of 1,000 kg per hour by using a self-cleaning system. The solution was to use rare earth magnets, which produce magnetic fields up to twenty-five times stronger than ferrite magnets without any increase in size. They remove low mass particles that may have been generated during the grinding process and weakly magnetic materials, such as rust and stainless steel particles rendered paramagnetic through work-hardening. Tests were carried out at Eriez’s laboratory in South Wales using SEPR material samples. Various drums types and feeder systems were trialled to establish the
GEARBOX IMPROVES RELIABILITY AND PRODUCTION CAPACITY The new ABB Dodge® Torque Arm II is a highly efficient helical bevel shaft mounted gearbox suitable for conveyors carrying sand, crushed rock, gravel, recycled and artificial aggregates. The modular design of the gearbox is ideal for use in shaft mount, screw conveyor or vertical and flange mounted applications. The twin tapered bushing system provides concentric grip on the shaft eliminating fretting corrosion that can often occur on these types of gearbox applications. The integrated oil seals in the Torque Arm II offer up to six times the wear resistance and a good level of resistance to both synthetic and mineral lubricants. The gearbox has a minimum operating life of 25,000 hours giving end users a more reliable gearbox capable of running longer between maintenance intervals. Reducing the number and frequency of outages and maintenance intervals allows manufacturing companies to realise the full potential of their production machinery. For more information contact ABB Limited MPT, Warrington, Cheshire Tel: 01925 741 111 Fax: 01925 741 212 E-mail: energy@gb.abb.com Web: www.abb.co.uk/energy
best equipment for the application. It was found that a high performance, double stage Rare Earth Magnetic Drum model RRS in a vertical housing produced the best results. This two-stage approach achieved the high level of purity SEPR required. The drums consist of a permanent, rare earth, high strength and high gradient fixed magnetic arc element and a rotating stainless steel shell. Material is fed onto the drum shell surface by an Eriez electromagnetic HS42 vibratory feeder, which ensures an even, controlled feed of material. As the rotating shell carries the fine powder through the magnetic field any fine magnetic particles are attracted and held to the surface of the drum. Once they reach the end of the magnetic arc they are then discharged by gravity into a separate chute. The fine clean feed material simply falls via its normal trajectory from the drum into the clean product discharge chute. Eriez Europe Sales Director Gareth Meese comments: “The main benefits of our magnetic drum separators are that they allow high volumes of material to be processed, are self-cleaning and require very low maintenance and spare parts. Our vast experience in this sector enables us to
specify equipment to very strict constraints of quality and installation. By using different types of separators with different feeders and configurations we expand significantly the potential applications of Eriez permanent magnetic drum separators in the food, ceramics, and mineral processing industries when high quality of the end-product is paramount, as well as in the recycling industry for the removal of ferrous material. They provide cost-effective solutions to the fine and weakly magnetic iron contamination problems. Eriez’ Rare Earth Drum Separators are available up to 1220mm in diameter and up to 3m wide in a variety of configurations. For more information contact ERIEZ Magnetics Europe Ltd, Bedwas, Caerphilly, Tel: +44 (0)29 2086 8501 E-mail: info@eriezeurope.co.uk Web: www.eriez.com More information is available from the brochure on our website. www.eriez.com/magnetic_drum_separator.
Revolutionary Odour Neutralisation Without Power or Water For some industrial processes, creating unpleasant odours is a natural part of the process. Industrial and waste processors are under pressure to reduce odours to improve industrial relations and avoid litigation or fines for nuisance odour.
Bespoke Odour Control Specific granules neutralise specific odours, enabling us to customise Neutrapak to your odour problem.
Introducing Neutrapak Effective indoors and outdoors, with low running costs as no power or water is required - ideal for limited access sites, waste sites, animal processing or biowaste sites. Effective Odour Neutralisation Some odour control systems attempt to mask odours. Others filter huge amounts of air; filtering is often impractical and impossible outdoors. Instead of masking odours, Neutrapak neutralises odour by bonding odour molecules to odour absorbing plant-oil extracts. Discreet, easily attached pouches of granules are positioned at 2m intervals, 2m from the ground. Neutrapak works upon exposure to air and releases at a slow, steady rate.
Renby Limited, Tarvin Mill, Barrow Lane, Tarvin, CHESTER CH3 8JF Tel: 01829 740913 www.renby.co.uk info@renby.co.uk
SOLIDS HANDLING AND PROCESSING
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PRODUCT AND SERVICES DIRECTORY ABRASIVE RESISTANT LININGS
EXPLOSION PROTECTION
CONSULTING
The Wolfson Centre for Bulk Solids Handling Technology
Bulk Solids Short courses and consultancy for handling
Solutions Contact the experts +44 (0)20 8331 8646 bulksolids.com
AUTOMATED IRIS VALVES
LIQUID RING VACUUM PUMPS
Total Process Protection ■ Conventional Bursting Discs ■ Engineered Bursting Discs ■ Explosion Venting
One Thousand Pumps, One Distributor.
■ Flameless Venting ■ Explosion Suppression ■ Explosion Isolation
www.tomlinson-hall.co.uk Tel: +44 (0)1642 379500 Email: enquiries@tomlinson-hall.co.uk
Fike UK, 35 Earl Street, Maidstone, Kent, ME14 1PF, United Kingdom T: +44 (0) 1622 677081 E: info@fike.co.uk W: www.fike.co.uk
Tomlinson Hall & Co Ltd, TS23 4JA
MIXERS & BLENDERS
CONTINUOUS PARTICULATE EMISSION MONITORING FOR REGULATORY COMPLIANCE AND PROCESS CONTROL
MIXERS & CRUSHERS
FEEDERS
GENESIS
BIG BAG HANDLING
Spiroflow Wall Planner Ads_Layout 1 19/10/2011 09:11 Page 1
WHAT’S IN YOUR BULK BAGS IS YOUR BUSINESS...
PROCESS SOLUTIONS Providing solutions for the Plastics, Food, Chemical & Pharmaceutical industries including:
DISCHARGE AIDS
How you put it in or get it out is ours!
Bulk Bag Fillers
• Feeders - Screw, Belt, Vibratory • Volumetric & Gravimetric Systems • Fabric Internal Silos & Storage Hoppers • Refill Systems Unit 5, Springvale Business Centre, Sandbach, Cheshire CW11 3HY Tel: 01270 766300 Fax: 01270 766302 E-mail: phil@genesisps.co.uk www.genesisps.co.uk
Bulk Bag Dischargers
MOTION SENSORS INDUSTRIAL DATACOMMS
www.spiroflow.com Tel: 01200 422525
BUTTERFLY VALVES
INDUSTRIAL DATACOMMS SOLUTIONS
KD420 Modbus Sensor Interface 4-20mA and DC voltage inputs Modbus RTU Slave registers with multiple data formats Modbus Master feature can write data to a Modbus Slave device
Modbus RS422 / 485
Modbus RS485 Slave
Master
4-20mA ±30V
DUST CONTROL
DUSTECH ENGINEERING LTD 162 Chiltern Drive, Surbiton, Surrey KT5 8LS Tel: 0208 399 9991 Fax: 0208 390 2004 www.dustechengineering.com explosionhazards_6x6b.pdf 1 30/10/2012 11:55:26
CONSULTING
EXPLOSION PROTECTION
C
M
Y
CM
MY
CY
CMY
K
KK Systems Ltd
01273 857185 01273 857186
Visit us online
www.kksystems.com
LEVEL MEASUREMENT
NYLON SCREENS & WEDGE WIRE BASKETS
PRODUCT AND SERVICES DIRECTORY PARTICLE ANALYSERS
PROCESS MEASUREMENT
Worldwide Level and Flow Solutions SM
A preferred partner in the global supply of level and flow control solutions
TEMPERATURE MEASUREMENT
VACUUM CONVEYING
- Optris PI Series - Thermal Imaging - From Just £2,690 - Industrial Process & R&D Applications - Fast Moving Processes - Compact & IP67 Rated www.processparameters.co.uk/ thermal-imaging-camera
01628 778688
magnetrol.com • (0)1444 871313 • sales@magnetrol.co.uk
Hosokawa Wall Plan ad 55 x 60_Layout 1 17/10/20
PARTICLE SIZE REDUCTION
QUICK CONNECTOR SOLUTIONS
TRADE ASSOCIATIONS
» WEH® QUICK CONNECTOR SOLUTIONS
WEIGHING SOLUTIONS
PRECIA-MOLEN UK LIMITED
Pressure-tight connections in SECONDS
Unit 30, Walkers Road, North Moons Moat Industrial Estate, Redditch, Worcs B98 9HE Tel: 01527 590300 Fax: 01527 590310 E-mail: sales@preciamolen.co.uk Web: preciamolen.com
» Simplified workflows » Reduced operating times » Increased productivity
s • Systems icroniser ills • M Delivering accurate and M s sher repeatable particle size reduction. • Cru Wet or dry milling equipment and systems for coarse grinding, medium and fine grinding and nano-milling.
www.hosokawa.co.uk • info@hmluk.hosokawa.com
PIPE COUPLINGS
WEH UK T: 01564-825100
enquiries@wehuk.co.uk
» www.weh.com
RISK ASSESSMENT
GexCon has a staff of highly qualified personnel, which can offer safety services for all types of installations. Including: · Expert Witness · Advanced CFD modelling · Hazardous area classifications and DSEAR risk assessments/compliance in accordance with DSEAR / ATEX 137
Tuf-Lok (UK) +44 (0) 1706 822512
www.tuflok.com
www.gexcon.com
01695 726565
TRAINING PIPEWORK SYSTEMS
SERVICE & MAINTENANCE
The Wolfson Centre for Bulk Solids Handling Technology
Bulk Solids Short courses and consultancy for handling
Solutions Contact the experts +44 (0)20 8331 8646 bulksolids.com
PROCESS COOLING
NEED PROCESS COOLING? Chillers · Dry Coolers Cooling Towers · Chilled Air UK distributor for the new JACIR TOPAZ “Dry Cooler on Steroids”
0845 057 3097 appliedthermodynamics.co.uk
SLIDE GATE VALVES
ULTRASONIC FLOWMETERS
To advertise here or within our editorial pages or on our website please call Peter or Guy on 01428 751188
•
40th anniversary
established 1974
an excellence in engineering
2014
comprehensive range of components www.jbj.co.uk
permanent magnetic couplings built to suit your system. external coupling half, motor side (atmosphere)
The rpm of the external half of the coupling is equal to the rpm of the internal half of the coupling.
internal coupling half, pump side (fluid)
containment shroud (does not rotate)
Magnetic couplings capable of transmitting torque from 3 to 600 Nm without mechanical contact between two shafts through magnetic forces that are established between the internal and external rotor. The magnetic coupling is ideal for applications where prevention of leakage from the pump is essential. Magnetic couplings also prevent vibrations and, radial and axial loads to the pump shaft. The magnetic coupling is a synchronous system with a primary function of hermetically separating two areas. There is no need to alter your system as the magnetic coupling will be designed to suit your machinery. These magnetic couplings can be used to connect gear pumps, screw pumps, centrifugal pumps, etc. with all types of electric motor or gear box including U.S.A. standards such as NEMA types. The magnetic coupling works by using the power generated by permanent magnets. No external power supply is needed, as these are permanent magnets not electro-magnets.
» no fluid leakage from pump seals.* (depending on application) » maintenance free. » no transmitted vibration. » management of misalignment between shafts. » hermetic separation between two areas. » ability to limit a maximum torque. Areas of Application; the ability to hermetically seperate two areas whilst continuing to transmit mechanical power from one to the other makes these couplings ideal for applications where prevention of cross contamination is essential. For instance: hydraulic sectors, dosing systems, compressors, sterilizers, industrial ovens, biotechnology, subsea equipment, pharmaceutical industry, chemical industry, food industry, generators, mixers. ATEX compliance (on request) is yet a further advantage for using these excellent power transmission couplings within your system.
www.jbj.co.uk/magnetic-couplings.html
You Tube quality products for mechanical & fluid power
01737 767493 jbj Techniques Limited is ISO certificated, committed to international coordination & unification of industrial standards.
info@jbj.co.uk - registered in England No: 1185469 -
www.jbj.co.uk A range of products ATEX certificated to directive 94/9/E requirements