SOLIDS HANDLING PROCESSING
AND
including SHAPA News
JAN/FEB 2014
THE BIGGER PICTURE
Collective expertise Clearly no single person or even company can be expert at everything, but within the manufacture and use of solids handling equipment a vast range of expertise is needed. SHAPA offers valuable resources to enable to enable all members to widen their knowledge and experience. Within any major processing enterprise, the supplier of each element of the flow process system will be both a supplier and a receiver – or “customer”. Each supplier will need to know the characteristics, mass and volume flow of the material delivered to their part of the equipment. Similarly, they will need to pass on appropriate data about the discharge of their product to the next part of the plant. Such communication is essential. Coincidentally, many SHAPA member companies are either suppliers to or customers of each other, often within the same project.
experts from member companies as well as key figures from organisations such as HSE and standards institutions. Development of new skills for upcoming engineers is always high on the SHAPA wish list. To this end special seminars with an educational technical theme followed by an entertaining event, such as kart racing, are arranged from time to time. Continuity is important. Our industries need new blood keen to learn from “old hands” to enable clearly driven progress.
Steady evolution drives quality In many areas, development in solids handling industries is steady rather than revolutionary; step changes in control technology may be an exception. Notwithstanding the desirability of steady progress, from time to time new regulations and standards, perhaps at national level or from the EU, impose changes. Health and safety issues or moves towards the mythical “level playing field” may instigate these. SHAPA members collectively have access to all such changes, with the Association having good links with HSE and key engineering institutions. Quarterly general meetings, in addition to fostering the earlier mentioned networking opportunities, also provide forums for new knowledge and ideas. These are fed to the two main sub-committees dealing with marketing and technical issues and as appropriate become agenda items for the General Council. Thus SHAPA is able to develop and present cogent events and papers to meet new challenges head on.
Incisive technical seminars... A recent example of SHAPA’s listen and learn approach is the valuable co-operation between HSE and our Association to promote good practice in the design, installation and subsequent regular inspection and testing of local exhaust ventilation (LEV) – or dust control – equipment. A number of member companies design, manufacture and install dust control, whilst several others specify and make provision for this in their own equipment. Examples of such equipment include conveyors, vibratory feeders, sieves and many others. HSE requirements, guidance notes and principles of good LEV practice were
Communicating for success This is just one facet of the SHAPA community that leads to profitable networking between members at the regular Association general meetings. In fact, the high level of attendance at these gatherings is almost unique amongst engineering trade associations. By their own enthusiasm and efforts individual members have willingly contributed to the success of SHAPA, secure in the knowledge that this application will help their own companies as well as other members and little by little improve the quality and reliability of all projects offered to end user clients. It has been mooted that solids handling and processing was originally a “black art” – maybethis was true in the misty past. But not now. The cooperative work of technical research institutions and associations such as SHAPA, through the commitment of skilled engineers and other professionals has ensured that knowledge based progress has prevailed. Disseminating expertise So how is this nectar spread? The Association is well known for holding regular interactive seminars for members and increasingly, for other industry professionals. Speakers include
WESTINGHOUSE
the subjects of a very successful seminar held at the end of 2013 during which a number of incisive papers were presented to SHAPA members and other key players from industry. More seminars on equally important themes are, of course, being planned.
...and commercial and marketing ones too Whilst technical development reflects solid worthy progress, to underpin installations that are efficient, reliable, long lasting and cost effective, the world of marketing changes at a much faster pace. In particular, marketing is moving more and more towards the internet, with a huge presence possible at minimal cost to the savvy marketeer. Of course, whilst face to face communication and the printed word remain vital and accessible tools, marketing via the internet is becoming an essential adjunct. SHAPA has held a series of seminars to keep delegates up to date with the latest methods together with the relative merits of each. Professional speakers have offered training and valuable tips in these exciting areas. Again, this subject will recur in SHAPA seminars as new internet marketing possibilities emerge. A browse through the pages of this supplement will demonstrate the comprehensive expertise available to industry from companies who have chosen to become part of the SHAPA family.
Commitment to the future So, SHAPA may well have celebrated more than thirty years’ valuable service to our industries, but our keen members will ensure that the future is assured and therefore any company involved in the supply of solids handling equipment and services should really consider membership. Clearly, we thank those companies who have joined us over the years – today’s membership stands at over 110 companies! They have already tapped into these benefits. Vitally, however, companies and consultants involved with new projects or updating existing process plant should head first for the Product Finder on our website – just a click or two away at www.shapa.co.uk, or email to info@shapa.co.uk.
ss e c o r p r u o y d e e F
Hygienic Rotary Valves
Hygienic Diverter Valves
• Drop through and Blow through versions available • All product contact parts Stainless Steel and grit polish versions available • Clean in place (CIP) suitable • Explosion containment up to bar • Standard Easy Detachable rotor, MZC rail system option available • Enlarged inlet option available • RID (Rotor Interference Detection) option available
• • • • •
SOLIDS HANDLING AND PROCESSING
All product contact parts Stainless Steel and grit polish Tube diverters from to ports Clean in place (CIP) suitable plug diverter Ability to diverge or converge product Explosion shock resistant DMN UK Ltd. T +44 1249 818 400 dmn@dmnuk.com
COMPONENTS FOR BULK SOLIDS HANDLING
Last year was very much a year of consolidation and subtle change – at least for many parts of the UK economy, and indeed for many at an individual level. Trends such as “on-shoring” – or the reverse of “off-shoring” - started to emerge. Many “low cost” economies had begun to lose their pricing advantage in manufacturing. As an example, labour rates in industrial parts of China were beginning to chase those of USA. Furthermore, increasing transport costs from far flung places were allowing home grown industry to compete more robustly on the home market. An example of this “balancing” comes from the automobile industry, where net exports are now close to matching the value of imports. Now, almost everything that is manufactured or is a “processed” product, for example foodstuffs, has some materials that are supplied and used in bulk solids form, which is where SHAPA plays its part in this thankfully improving situation. Indeed, the Solids Handling & Processing Association was initially set up to help like minded companies share knowledge and increase their sales and marketing effort. For more than thirty years a wealth of knowledge and experience has been accumulating within the Association, offering technical standards and legislation data as well as sound commercial and marketing advice. Of course, all of this vital material is updated as and when new intelligence comes along.
By Gus Bishop – Solids Handling & Processing Association
www.dmn-shop.co.uk
www.dmnwestinghouse.co.uk
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SPIROFLOW SHOWCASING AT FOODEX, MARCH 24-26, NEC BIRMINGHAM, STAND Q340
Shifting millions of tons of ingredients is part and parcel of the production process for many food sectors, which is why Spiroflow Ltd will be showcasing the latest in bulk handling and conveying equipment during the FoodEx Show. Transferring food powders and granules from one area of a factory to another for packaging and distribution requires a system that is fast, easy to route, has few moving parts, empties the system of product with minimum residue and provides a dust-tight operation -– essential when dealing with potentially combustible material. Flexibility and totally secure handling is required if products have to be conveyed dust-free over long distances and complex routes within an operating plant. Spiroflow, a world-leading manufacturer of ATEX approved conveying and bulk handling systems, will be demonstrating a range of solutions for food materials where the most rigid standards in hygiene and containment need to be met and maintained. Sure to attract visitors will be a working flexible screw conveyor along with a bulk bag discharger, ideal for the totally hygienic discharging and distribution of food ingredients, including sugar, flour and spices, within a factory environment. This exceptional equipment fulfils the very highest levels of hygiene and dust control, whatever strict operating parameters are in place. The main advantage of Spiroflow’s flexible screw conveyor is its simplicity, which results in short installation times and low maintenance – the whole system can be stripped down for cleaning in minutes. It can transport powdered, granular and flaked materials with a bulk density up to 2.5kg/1 and carry material to a maximum distance of 20 metres, although
multiple units can extend to greater distances as required. All of Spiroflow’s conveying and bulk handling equipment 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. Food manufacturers and processors visiting FoodEx - possibly agonising over which conveyor not only best suits their product but also meets the stringent regulatory safety requirements - need look no further than Spiroflow’s stand Q340, says the company’s Marketing Manager, Ben Ayrton. He said: “Sourcing the right conveyor can be a daunting task for the buyer, who may not be aware of the advantages of the individual systems available on the market, which is why we are delighted to be showcasing flexible and totally secure handling systems at FoodEx. It is the ideal stage for demonstrating to food professionals the proven advances Spiroflow has made in bulk bag discharging and conveying systems.” Finding the right conveyor will depend a lot on finding the right supplier. The key for food companies is to find a conveyor provider that understands your business, proves it can meet your requirements and who will give a performance guarantee – just like Spiroflow. Visitors to FoodEx at the NEC in Birmingham on March 24-26 will be able to see for themselves some of the high-quality conveying and bulk handling equipment on offer from Spiroflow on stand Q340, but if you can’t get there or would like more information on the company’s products and services visit www.spiroflow.com or call +44 (0) 1200 422525.
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for
PROCESS TECHNOLOGIES FOR TOMORROW SM
PRECIA-MOLEN LAUNCH NEW 20TPH HOPPER SCALE WITH ATEX CERTIFICATION Weighing specialist Precia-Molen has extended its range of hopper scales to include the ABS-X00 available in capacities from 5 to 20tph. Designed to fit into factory process areas the new addition to the range comes complete with EC certification to meet the requirements of the applicable machinery standard, and includes EX certification allowing installation within ATEX areas. The new ABS-X00 range offers potential precision of +/- 0.1% and is designed for internal use, sheltered from the effects of wind with an operating temperature range from -10C to +40C. The ABS-X00 can also be used to weigh a wide range of free flowing granular products which can be adapted to individual requirements, including cereals, cake, wood pellets, waste and many derived products. Built to last, being robust and reliable the ABSX00 is manufactured using ISO components ensuring long life, with all main parts surface mounted and requiring little maintenance. The entire electronic I400 ABS range can also offer functionalities enabling the use of the new ABS-X00 hopper scale with local or remote operation by computerised or automatic control systems. The I400 ABS terminal enables up to four hopper scales to be connected to supervision software via a dedicated PC which can be installed either locally or remotely. Further more information contact Precia-Molen UK Ltd, Redditch, Worcestershire. Tel: 01527 590320 Fax: 01527 590301 E-mail: sales@preciamolen.co.uk Web: www.preciamolen.co.uk
WINKWORTH MACHINERY MAKES A MOVE... Lindor’s Owner and Managing Director, Bastiaan Soeteman, acquires a controlling shareholding in Winkworth, the UK’s largest industrial mixer manufacturer. In acquiring the shareholding from James Winkworth, grandson of the founder Frank Winkworth, the exchange ends 90 years and three generations of control and share ownership by the Winkworth family. Lindor, producer of gentle touch rotating drum blenders, and Winkworth will remain operating as two separate entities, each with their own factories and management. The two companies offer complementary product ranges, which will be beneficial and available globally throughout their respective worldwide sales and distribution channels. Grant Jamieson, who remains a shareholder and Managing Director of Winkworth, is delighted with the transaction adding “The Winkworth family has given a great legacy and opportunity to many people past and present, including me. My role now is to take the new era and opportunity to the next level with the support and vision offered by Bastiaan.” “Winkworth is a company that has a proven track record in the industry for nearly 90 years and is a great example of solid and thorough British engineering. We are very much looking forward to working together and sharing learning and insights to further develop the best process solutions for our current and future customers.” Bastiaan Soeteman For more information contact Winkworth Machinery Ltd, Reading, Berkshire. Tel: +44 (0) 118 988 3551 E-mail: info@mixer.co.uk Web: mixer.co.uk
SOLIDS HANDLING AND PROCESSING
SPARE CENTRIFUGAL SIFTER SCREENS AND FILTER BAGS Process Components Ltd (PCL) has its own in-house sewing facility where it manufactures and supplies a wide range of sifter screens for a number of centrifugal sifter machines, as well as filter bags. New investment in sewing machinery and personnel has meant that Process Components Ltd has not only increased its production capacity and capabilities, but also offers its customers an improved level of service. Benefits of working with Process Components Ltd; • Quality products produced from and OEM manufacturer • Competitive prices • Quick response to customer requirements • Process and application knowhow / expertise Nylon Screens PCL has a large and varied catalogue of screen dimensions and micron sizes that can be utilised to suit applications in many diverse industries. In addition, custom screen modifications can be requested. For example; • Sewn seam for oil based ingredients • Both ends of the screen can be ‘corded’ to allow easy mounting and fitting of the screen to the basket. • Double skin screens offer increased screen longevity in fine sieving applications. • Sifter screen aperture sizes are available from 53 – 5000 micron • FDA approved coloured nylon screens are available for efficient traceability and visible checks. Filter Sock / Bags PCL is able to produce a range of Filter Socks / Bags for Centrifugal Sifters and Mixers in a range of materials to suit a wide variety of applications. All PCL products are manufactured to customer specifications to ensure maximum filtration efficiency for each and every application requirement. Engineering Capabilities In addition to the manufacture of spare parts for Centrifugal Sifters and Mixers. PCL engineers are available to provide CAD support in order to design non-standard customer specific filters and screen templates. For more information contact Process Components, Macclesfield, Cheshire Tel: +44 (0) 1625 412000 E-mail: sales@pro-components.com Web: www.pro-components.com www.mucon.com
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
SOLIDS HANDLING AND PROCESSING
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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Getting to Grips with ‘Waste’ By Richard Farnish – Mphil CEng MIMechE – Consultant Engineer – The Wolfson Centre of Bulk Solids Handling Technology
many types of materials can be diverted for use in other applications. Such applications may work directly with the reprocessing of plastics and cardboard, or take material for combustion in order to generate heat and power. A common issue to most types of scheme to extract value from waste is that the materials to be worked with are invariably defined by their particle irregularity and ‘difficulty’ in handling.
Glassware
Broken Bottles
The impact of handling problems is compounded by the low value nature of the materials being processed – any stoppage in the process operation frequently translates very rapidly into a direct impact on the profitability of the plant. For this reason there is a very strong impetus to adopt best practice when designing plant for these ‘difficult’ materials. Many types of recyclable bulk materials tend to exhibit a very strong ‘nesting’ behaviour which can result in flow stoppages caused by material forming self-supporting bridges over quite substantial distances. This is particularly an issue where such materials are being handled through bunker or silos that were originally conceived for more uniform particle types or freer flowing bulk materials. Generally, the use of convergences or reductions in cross-sectional area for bulk storage vessels or bunkers should be avoided – this will compound the inherent bridging behaviour. By virtue of the irregularity of particle shapes and sizes found in many ‘waste’ materials the packing of these particles (and subsequent load transfer when stress is applied – i.e. head of material) results in substantial gains in strength. This is partially where the pronounced ‘bridging’ characteristic originates from, which is compounded by the effect of geometry and internal construction features of the storage equipment.
Take account of the distinguishing features of the material… If the extraction system used to draw material out of storage is not capable of activating the entire cross-sectional area of the outlet (assuming at this point that no convergent sections or ledges are present) then it is highly likely that the discharge of material will be both erratic and head dependant. A common example of such a discharge arrangement would be the use of multiple screw sets, which typically utilise constant pitch and shaft diameters. The use of a design (as described) will result in an active draw down of material only at the far end of the screw set – which will drag material underneath material ahead of the flow channel. This will lead to extended storage time (indefinitely, if the bunker is never totally emptied) and give rise to the potential for bio activity or selfheating – depending upon the nature of the material being handled. Some installations of screw sets will attempt to introduce additional draw down capacity along the length of the screw through either an increase in pitch spacing or a reduction in shaft diameter.
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The use of a ‘shuffling’ floor has the potential to achieve a full cross-sectional activation for a bunker – but even with this approach it is important to take into account the size/shapes of the material to be extracted and also, critically, the elasticity/compressibility of the bulk. The latter bulk characteristics should be used to inform on the slat spacing and stroke length – such that the combination of the two aspects can capture and drag the bulk material beyond the point that it shears from the bed of material above and transports forwards. Failure to achieve this effect can result in very poor extraction rates and some rather large ‘nests’ of material! In summary, this article can only hope to highlight a few issues to consider in troubleshooting or designing plant. The key to success lies in taking the time to fully understand the bulk characteristics of the material being handled and to translate this knowledge into practical design options. The Wolfson Centre for Bulk Solids Handling Technology, University of Greenwich, Central Avenue, Chatham, Kent Can be contacted on: Tel: +44 (0) 208 331 8646 E-mail: r.j.farnish@gre.ac.uk Web: www. bulksolids.com
Broken Steel
of what actually constitutes ‘waste’ – with the effect that
Varying Shapes
conserve land fill resources has driven a broad reassessment
Recycled Materials
in a consumer orientated society. Increasingly the need to
Although, in principle, such designs have the potential to provide an increase in transport capacity along their length, the inclusion of these design details must take into account the bulk characteristics of the material to be extracted. If the pitch spacing is too close relative to the size/length of the particles to be handled ‘logging’ of the screw may occur which will result in a lack of capacity at that point in the screw (potentially supporting a static region above). If the change in shaft diameter does not fully take into account the gain in capacity achieved through the change in pitch spacing, then extra capacity may be too great too early in the screw volume progression – resulting in poor draw down or high contact stress/wear on the face of the flights.
Pet Bottle Flake
The reference to ‘waste’ is, as many are aware, a relative term
SOLIDS HANDLING AND PROCESSING
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. 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
VRIECO NAUTA DRYER DELIVERS MULTI PURPOSE PROCESSING FLEXIBILITY IN ONE MACHINE Now developed to be more than just a dryer, the Vrieco Nauta Vacuum Dryer, available from Hosokawa Micron Ltd is capable of performing a range of processes including filtration, high temperature and vacuum sterilisation, steam stripping, chemical and crystallisation reactions and vacuum drying – all in one machine. This additional flexibility can be further enhanced to include mechanical dewatering, prior to drying with the installation of a filter directly on top of the dryer or even inside the vessel. Developments of this well respected piece of equipment offers maximum flexibility with minimum operator intervention. Using smart process engineering methods the original multi-purpose sequences have been rearranged to deliver a 50% reduction in processing times which also delivers potential energy savings too. Process time is reduced by mechanical watering, prior to drying then by heating the extracted water which is then recirculated back to the dryer, reducing the process heating time. Alternatively the heated water is available to other processes. Crystallisation can also be carried out in the vacuum dryer where the reactants can be first dissolved and reacted. The efficient mixing within the dryer accelerates dissolution and temperature control. Cooling of the liquid then initiates the crystallisation process. The crystals formed can be dried under vacuum, all in one machine. Chemical reactions including those where solids react with gases or liquids can be handled very effectively with the high efficiency of the mixer ensuring an homogenous result in product conversion, while the reaction energy is efficiently removed or supplied by the efficient heat transfer within the dryer unit. For more information please contact: Hosokawa Micron Ltd, Runcorn, Cheshire. Tel: (01928) 755100 Fax: (01928) 714325 E-mail: info@hmluk.hosokawa.com Web:www.hosokawa.co.uk
SOLIDS HANDLING AND PROCESSING
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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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Keep up with ATEX and stop dust fires Most of us are aware that devastating explosions and fires can be caused by explosive gases and vapours but are perhaps not so aware that fires caused by dust can be equally as destructive. This has now been addressed by the recently defined ATEX zone 20 to 22 dust conditions. To avoid liability, companies are advised to use suppliers and repairers who correctly certify machines to comply with the new legislation, says ERIKS. The trend for many years now has been to tighten up Health & Safety in the workplace. Engineering companies have a responsibility to their employees, and engineers themselves have a responsibility for their own safety and those around them. Statistics at a recent H&S course illustrated the point that over 90% of all industrial accidents are attributed to complacency. At H&S courses, attendees are encouraged to think about what they would miss most if they lost their sight or the ability to walk, even temporarily, and suddenly the wearing of safety glasses
doesn’t seem such a chore. Understanding and appreciating the risks to workers and establishing the most effective and efficient practices by which to minimise them can be a complex task but one that looks set to become more urgent than ever. A new Health and Safety Executive (HSE) cost recovery scheme for inspections and interventions is now in force under the Health and Safety (Fees) Regulations 2012. These Regulations put a duty on HSE to recover its costs for carrying out its regulatory functions from those found to be in material breach of health and safety law. A material breach is defined by the HSE as a contravention of health and safety law that is serious enough to require them to notify the person in material breach of that opinion in writing. When it comes to machine safety, legislation is particularly thorough and far reaching. Since moving machinery is capable of causing fire in hazardous environments, designers and engineers have invested a lot of time and energy in trying to minimise the problem. The fact that so much is at stake as a consequence of failure has driven the development of a range of tools and practices to defend the workforce from such hazards and their consequences, and routine maintenance procedures have enabled engineers to minimise the development of faults. Indeed, components themselves are continually being refined and upgraded to prevent, or offer greater resistance to, hazardous environments. To achieve a consistent and efficient management of plant safety, an awareness of ATEX-approved components is vital and, in many process and manufacturing applications, plays a major part in enabling operators and maintenance engineers to ensure that plant is observing all current legislation. Compliance with ATEX has always been a challenging, step-by-step process. Even in traditional ATEX industries, such as petrochemical processing facilities, there have been some challenges that have proved particularly hard to surmount, such as providing sensors that can perform reliably in the presence of the high pressures found within applications such as wellhead automation, gas distribution and gas compressors. In these applications, safety is critical and component failure could result in a serious accident. These hazardous conditions present complications to engineers, not only in ensuring safety but also in carrying out installation and replacement of components, which can be extremely difficult. However, solutions have been developed and engineers in these applications are now well used to conformity. Now maintenance operatives in a much wider section of industry need to make sure that repairs and maintenance meet the latest ATEX dust regulations.
Newly defined regulations determine the need to select suppliers more carefully… The recently defined ATEX zone 20 to 22 dust conditions present a new challenge and companies are advised to use suppliers and repairers who correctly certify machines, if they are to avoid liability. Most of us are aware that devastating explosions and fires can be caused by explosive gases and vapours but are perhaps not so aware that fires caused by dust can be equally as destructive, and this is reflected by the new legislation. The regulations have
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been influenced by the fact that there have been several large explosions investigated in recent years, in areas such as crop storage, food processing, coal processing and plastics that have been attributed to dust, either atmospheric or settled. So, with both these dust conditions covered by the regulations, and with the dangerous substances and explosive atmospheres regulations (DSEAR) 2002 also requiring employers to control the risks from fire and explosions, it is time for engineers to be sure that they understand what constitutes a risk to safety and consider carefully how to address it. Key to achieving conformity is to consult a leading supplier with expertise in a wide range of parts and components such as motors, belt drives and couplings – all of which are included in the regulations. Any party with responsibility for certification of supplied equipment, including product manufacturers, can be held legally responsible for accidents due to non-conformity with the new directives. The newly defined zones will affect many new operations, so if you are in any doubt about your responsibilities, conformity or the best way to achieve it, you should talk to a supplier who understands your industry, the legislation, and the machinery to which it applies. ATEX compliance – indeed, plant safety at large – has thankfully become an established part of the business processes for most industrial and manufacturing companies. It has moved beyond a simple assessment of risk to comply with and exceed the requirements of legislation and the welcome growth of this more responsible culture will make it easier for most firms to adjust. Indeed, the more enlightened companies are already recognising that by getting in line with legislation as early as possible, they can both comply with legislation and improve their productivity and profitability, while also presenting an impressive set of credentials to their customers.
Don’t take chances… Understanding and appreciating the risks to workers and establishing the most effective and efficient practices by which to minimise them can be a complex task. So, it may be advisable to work with a partner such as ERIKS that can help you to cost-effectively and efficiently review and renew your plant to comply with the regulations. Take, for example, the requirements for motors that operate in hazardous areas. The ATEX labelling scheme provides a vital indication of the level of protection offered and the zones in which the motor is suitable for use but the judgement as to whether a repaired motor remains ATEX-compliant is more complex and may require help from a specialist. To maintain safety, operators must be sure that a repaired motor is as safe as a new one, so it is important to enlist the help of a partner that offers an accredited repair service. The recently defined ATEX zone 20 to 22 dust conditions present a new challenge but also an opportunity to maximise safety and minimise plant shutdown, which will benefit people as well as profitability. ERIKS UK, Halesowen, West Midlands Can be contacted on: Tel: 0121 508 6000 Fax: 0121 508 6255 E-mail: marketing@eriks.co.uk Web: www.eriks.co.uk
SOLIDS HANDLING AND PROCESSING
LATEST DEVELOPMENTS IN CONCRETE MIXING TECHNOLOGY Mixer manufacturer EIRICH are well known in many sectors of the concrete industry such as roof tiles and block paving. Their high shear intensive pan mixers have become synonymous with high quality end products. Since their originally invented rotating pan mixer design of the 1920’s, EIRICH have continuously developed their products according to customer demand. At the UK Concrete Show (2728th Feb 2014 – NEC, Birmingham) EIRICH and Orthos Engineering, their UK partner of almost 60 years, will exhibit examples of the latest developments in concrete mixing technology, designed to achieve mix quality superior than other styles of mixer. During the show’s seminar program, Dirk Heuer from EIRICH will make a presentation on Mixing Technology for high grade concrete. EIRICH and Orthos are on stand A13. Read more at www.eirichmixers.co.uk or contact Orthos Engineering Ltd, Market Harborough, Leics. Tel: 01858 464246 Fax: 01858 434480 E-mail: sales@orthos.uk.com Web: www.orthos.uk.com
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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Chain Conveyors are an essential part of many bulk handling systems, where they are used to convey bulk materials such as powders, grains, flakes, pellets … etc. Many of these conveyors use drop forged chains with flights as a means of conveying the material being handled. This “en-masse” conveying system is very popular as it is a simple but highly efficient system of moving material. When it comes to purchasing a chain conveyor, it is easy to look just at the one-time purchasing cost and the quality of the components. The problem with conveyors is that they are exposed to a lot of wear and tear, and even the best chains can fail after a certain period of time. But this can be many years depending on the conveyor use and maintenance. If we look at the lifetime cost of an en-masse chain conveyor, we’ll find that a big part of this is the maintenance: the cost of replacement chains and links, the cost of the labour and finally the cost of the downtime. For each and every user of chain conveyors, it is of vital importance to have the conveyor running to full capacity for as long as the equipment can allow it. Maintenance and repair can cost a lot of money and time, usually requiring the services of a team of engineers and considerable amount of resources. So how does the en-masse conveying system work, and where does the chain failure occur?
The True Cost of En-Masse Chain Conveyors By Cedric Tchatchouang, Sales Engineer at 4B Braime Elevator Components In the case of a minor incident, such as the flights breaking, although the chain does not require to be changed, it is still necessary to order new chain links with flights welded or grind the sides of the failing links and weld new flights onsite. In both cases, a lot of resources and time are needed to complete the maintenance procedure. Having new links with flights welded is only the first step of the maintenance process: the chain needs to be slackened, the circlips must be broken in order to take out the links where the flights have failed, new links with welded flights need to be put in, and finally the chain has to be tensioned again before the conveyor is at last operational or the whole chain removed from the conveyor. One of the other major causes for concern with this traditional assembly is the fact that the circlips can sometimes come loose due to poor installation, not only causing the chain to collapse therefore again stopping the conveyor, but also contaminating the product that was being conveyed and risking pollution and obstructions in the plant process. Engineers have been working hard at suppressing and minimising the different problems encountered within a chain conveyor as much as possible with solutions such as more frequent maintenance checks, metal detectors… etc. - Whilst this has helped to reduce the number of unexpected break-downs, it hasn’t removed the need for conveyor shut downs when the chains or flights need to be replaced.
In En-Masse conveying, the flight height can be as low as 12.5% of the material being transported in the chain conveyor. The material is fed into the conveyor from the top and falls through the moving chain to the bottom of the box. Because the particles interlock, the material moves as a single stream at the same speed as the chain. This highly efficient conveying process allows nearly the entire conveyor cross section to move as bulk. Traditionally, the flights are made of steel and welded onto the links. The links with flights are then assembled in many different arrangements using pins and circlips, headed pins and circlips or headed pins with collars and a roll pins. The whole assembly is very robust and works well until general wear, operational errors, material build up and many other reasons can cause maintenance shut down.
A new system represents a solution to this problem: it is a new flight assembly system that gets rid of the need for welded flights and pins and circlips assemblies which are quite costly and time consuming in terms of manufacturing. The system minimises conveyor maintenance downtimes and overcomes a lot of the problems encountered when using drag chain conveyors. The system includes: A set of Nylon flights that can be cut to accurate lengths depending on the desired overall width. These nylon flights are very strong and wear resistant but remain light- weight, therefore reducing the amount of power required to drive the chain.
no longer required to take the tension out of the chain and take the chain out of the conveyor before changing the flights; the old flights can be taken out and new ones fitted while the chain is still tensioned inside the conveyor. Since a shorter amount of time is required to assemble the Nylon flights rather than welding steel flights onto links, all the flights can be delivered very quickly thus eliminating the need to stock a lot of spare parts; or they can be kept in stock on site at low cost, since they are not welded to the chain. It will also enable the full use of the links since it is not necessary to change the links every time new flights are needed. Once again this represents a major saving for facilities using this system. This system has been used successfully in many facilities across the world, in a wide range of applications including agricultural, wood chips, sugar, animal feeds, etc. All these products have been used in conveyors of various length, angles and high capacity applications.
A hollow pin made of alloy steel (the same material as the link) and case hardened to C57 - C62. This pin will take the load in the assembly. It is very strong and can be supplied in stainless steel for applications in a corrosive environment. Bolts, nuts and washers are used to hold the flights onto the link and assemble the links together. Lock nuts are used to secure the whole system. At no point does the bolt take the load or is in contact with the pin. It merely holds and secures the flights. The system uses 4B drop forged chain links that have special lugs on the sides onto which the flights are fastened, giving the assembly extra stability. The system is extremely easy to install, yet very robust and has a long lifespan It will save a precious amount of time and money when conducting maintenance work. With this system, it is
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4B Braime Elevator Components Leeds, West Yorkshire. Can be contacted on: Tel: +44 (0) 113 246 1800 E-mail: 4b-uk@go4b.com Web: www.go4b.com
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AMBROSIA DESSERTS KEEP FLOWING For Premier Foods it was no longer feasible to maintain the existing ingredient vacuum transfer system due to its age and excessive down time compromising critical production line performance. Piab’s involvement consisted of completing vacuum conveying trials of the six ingredients at our East Leake facility, witnessed by Premier Foods to vacuum transfer these product ingredients from 1 tonne FIBC bags. The decision was made to replace the existing complete mechanical pump powered system with a more efficient Piab Premium Conveyor which provided Premier Foods with the following benefits:
• 10-25% transfer rate performance gain • 50% reduction of maintenance downtime • 14-36% reduced energy consumption • A simple maintenance regime For more information contact PIAB Ltd, East Leake, Nottinghamshire Tel: 01509 857010 E-mail: info-uk@piab.com or visit our website www.piab.com
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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
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The UK’s largest manufacturer of aluminium silos • 30 years supplying the food and plastics industries • Fully ATEX compliant • Aluminium or stainless steel silo construction • Dual tower silo manufacturing facility
GLOBAL FLOORING MANUFACTURER USE RUSSELL COMPACT SIEVES® TO GUARANTEE CONSISTENT PRODUCT QUALITY A close relationship between Russell Finex and Altro helped ensure that six Russell Compact Sieves® were supplied and fitted to safeguard the quality of their final product.
Founded in 1919 Altro is a family owned manufacturer that supplies safety flooring and wall cladding solutions worldwide. Altro pioneered the world’s first safety flooring recycling system, and with sales subsidiaries across the globe, produce over 5.4 million square metres of safety flooring each year. Altro have been expanding their Hertfordshire operations for a number of years, allowing them to increase the manufacturing capacity of their flooring T: 01275 845901 production. With a new product range of safety flooring being developed a new sieving machine was required. E: sales@bartonfabs.co.uk Having worked with them previously, Russell Finex W: www.bartonfabs.co.uk provided Altro with a sieving solution to meet their exact requirements. Altro pride themselves on providing high quality, high wear flooring materials which maximize durability and life bartonFabAdvert86x124.indd 1 11/07/2013 10:46 of the flooring. Recycled glass granules are one of the materials used to increase the hardness of the flooring whilst adding to its robust safety features. In addition, the use of recycled glass conforms to Altro’s sustainability plans to remove fewer resources from the Earth. Before the glass is fed into the flooring, it is passed through a sieving system via a hopper where oversize particles are removed, leaving the fine material needed. The material of the correct particle size is then added to the product line. Having purchased two Finex Separators™ from Russell Finex 8 years previously, Altro have formed a strong relationship with Russell Finex and therefore when a new sieving solution was required it was the natural choice. After a short consultation, an onsite trial was arranged for a 600mm diameter Russell Compact Sieve® to be installed within the new processing line where staff could monitor the effectiveness and suitability of the machine. Sieving recycled glass during the trial proved very successful and it was decided that the Compact Sieve was the machine needed to meet the production demand. “It was important for us to be able to trial the sieve at our facility prior to purchase. It allowed us to put the machine through the toughest conditions and it needed to succeed to ensure that product quality would not be compromised,” says Richard Holt, Manufacturing Shift Team Leader. The Russell Compact Sieve® is a versatile check screener ideal for high capacity screening of a wide range of materials. One of its key features important to Altro is the ease of dismantling the machine. “We needed a system that would allow our operators to easily dis-assemble the machine for cleaning,” explains Holt. The slim-line straight through design of the Compact Sieve enabled Altro to mount the sieve below the hopper, with material passing straight through to storage once sieved. Deblinding discs were also fitted underneath the mesh of the sieve to eliminate blocking of the sieve mesh which has also prolonged the mesh life. “Our long relationship with Russell Finex has been cemented with excellent high quality machinery and aftermarket support they provide. We would certainly recommend them to others in the industry” concludes Holt. For more information contact Russell Finex Limited, Feltham, Middlesex. Tel: +44 (0) 20 8818 2000 Fax: +44 (0) 20 8818 2060 Malvern, Worcs WR14 1JJ, UK E-mail: sales@russellfinex.com Tel: +44 (0) 1684 891371 Web: www.russellfinex.com
PULSAR GUARD 2010 PROCESS PROTECTION MONITOR
Senses changes in flowrates of bulk solids in pipes, chutes and supply lines to ensure accurate process protection of foodstuffs, cement, powder, plastic pellets or animal feeds in flight. l IP68 ingress protection l ATEX I.S. option l Non invasive l -40 to +125°C
info@pulsar-pm.com www.pulsar-pm.com
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DURABLE ROLLER CRUSHER NOW FULLY CONTROLLABLE USING PLC TECHNOLOGY FOR REMOTE MONITORING Glen Creston - ‘Leaders in Size Reduction’ have improved the design and function of their Roller Crusher. OPERATING PRINCIPLE /CONSTRUCTION The wear resistant steel crushing cams are mounted on the roller shaft in staggered positions, accurately spaced so that they pass between the crushing and stripping combs which are mounted laterally on opposite sides of the inner housing. The roller Crusher Mill is only one machine from our range of laboratory and pilot scale/light industrial equipment. From our Jaw crusher, for primary sample breakage prior to further processing, to the McCrone Mill, which will grind to analytical fineness, these machines can cope with a wide range of materials from rocks to edible grains For preparation of larger laboratory samples or for light
It can be supplied with a new control box with PLC which allows remote monitoring and control of the crusher in process applications. The largest single shaft unit is now 800mm long by 500mm wide internally and designed for crushing lump coal up to 250mm. High temperature versions are available for crushing power station ash at up to 250 degrees centigrade This rugged, slow-running mill is equipped with either a single or double roller shafts fitted with crushing cams which rotate between crushing and stripping combs. Different shaped crushing elements are available depending on material. This machine is particularly suitable for de-agglomeration of materials from sacks or silos, pre-crushing softer minerals and for granulating coarse lumpy, caked or compacted materials. Features include: • Robust construction • Minimal maintenance • Compact design allows retro-fitting into existing process lines. • Parts easily removed for maintenance/repair Suitable for: • Pigments and Resin • Food and Pharmaceutical • Coal • Waste materials and Ash • Minerals
industrial applications, Glen Creston offers a range of machines that can cope with higher throughputs whilst still producing reasonable particle sizes. Glen Creston also manufactures special machines for sample processing production needs. These machines are designed for processing anything from small samples to larger scale continuous flows for industrial applications. For more information contact Glen Creston, London. Tel: +44 (0) 208 545 9140 E-mail: enquiries@glencreston.com Web: www.glencreston.com
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Schenck Process are leaders in providing process solutions utilising their expertise in weighing, feeding, mechanical and pneumatic conveying and air filtration. This combination of process experience and a broad range of product and system technologies provide clients with the effective process solutions they require. Products such as the MoveMaster Vacuum modular conveying system, Proflex loss-in-weight feeders, SacMaster for bulk bag discharging and the Multidos L weigh feeders all use world-class designs that are incorporated into factory systems to save costs, reduce energy consumption and improve productivity.
Schenck Process UK, based in Doncaster, incorporate the brands and technologies of Redler and Clyde Process. For more information on how we can improve your process efficiencies contact: Schenck Process UK Limited Carolina Court, Lakeside Doncaster, South Yorkshire DN4 5RA Tel: +44 (0) 1302 321313 Fax: +44 (0) 1302 554400 enquiries@schenckprocess.co.uk www.schenckprocess.co.uk
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Oldie but By Matthew Hikade, UWT Level Controls, USA
For as long as there has been a need to store material there has been a need to know how much is being stored at any given time. Whether it is for inventory counts, loading out or in, or batching, there is always someone somewhere in a plant needing to know what is in a silo or other holding bin. Because there hasn’t always been the fancy high tech methods of measuring level in a bin we know today or even electricity for that matter yet still a need to know, this need has led to innovative methods of measuring how much material one has in a bin. From hitting the side of a bin with a hammer (or even throwing rocks up the side of a silo) while listening to the type of “bong” the hit creates to waking up extra early to see where the morning dew on the side of vessel begins or ends, there is no shortage of ways people have come up with to measure level. Probably the most tried and true method and maybe even the most common still used today is the plumb bob style or “weight and cable” method. 12 SP
There is evidence of the plumb bob being used for vertical alignment as early as ancient Egyptian times and somewhere along the way someone came up with the idea to use this concept for measuring the vertical depth of empty space in a bin and using that measurement to calculate how much material is in the vessel from the bottom up or percent full. Assuming human error is controlled, this method has proved to be incredibly reliable and repeatable, inexpensive, and easy to execute. This manual method of bin level measurement is still by far the most used today in modern plants by operators who have tied a rock to a tape measuring device and lower the apparatus into a bin while looking at how much tape has paid out when the rock hits something in the bin. The only downside is that someone has to climb to the top of a bin or silo to conduct this measurement which requires valuable resources and introduces a possible safety hazard. It is this issue that drove the development of the electromechanical plumb bob level system several decades ago. Early systems utilised several pulleys and large motors which resulted in bulky, complex machines which, without proper preventative maintenance applied, tended to fail due to a number of reasons. Failures included cables breaking or tangling, fouling of the electronics due to material being drawn up into the housing, motors burning up, and weights being caught under material as it fed into the bin. Measurements were conducted using a counting wheel which generated an electronic pulse with every turn of the wheel relating to a predetermined distance of cable fed out of the unit during the plumbing. These pulses were typically sent to a counter which interpreted each pulse as a distance and displayed the resulting value to the operator. Even with all of these initial challenges, the electromechanical plumb bob device was perceived to be an invaluable tool in the field of inventory management and as technology improved in electronics and materials, so did the plumb bob. We are now seeing fourth and fifth generation designs which employ microprocessor based electronics, simpler pulley designs, high-efficiency motors, and stronger cables (or tape in the case of a few suppliers) which address many of the issues the technology saw with its ancestors. Engineering controls which are built in to the programming of these units monitor cable and motor life and notify users if there is cable, pulley, and motor failure due to any number of reasons. Some manufacturers offer direct analogue 4…20mA outputs, relays, and digital MODBUS or Profibus communications which eliminates the need for an intermediate remote start unit (RSU) thereby eliminating significant cost. Today electromechanical plumb bob devices are the most prolific and widely used inventory measurement systems but they still hold a reputation for being less reliable and more maintenance intensive than the newer technologies such as microwave radar, ultrasonic, and laser. The following are five common arguments (we’ll be bold and refer to them as myths) against electromechanical plumb bob level devices and the industry response to those arguments.
a
Myth #1: Having moving parts makes the electromechanical system maintenance intensive. Yes, electromechanical devices by definition have both electrical and a mechanical components and yes, some of those parts have to move in order to function as designed. However, with advances in motor technology and with simpler pulley designs in use, the reliability and resulting life cycle of these systems has increased to match that expected for devices with no moving parts such as microwave and ultrasonic. It is not unreasonable to expect 3500 running hours with standard motors or unlimited lifetimes for systems that use high efficiency brushless motors. Users may expect at least 100,000 measurement cycles of a cable-based system or over 500,000 measurement cycles for a tape-based plumb bob device. For an operator making 24 measurements per day, that equates to an expected lifetime of 10 years for a cable or over 50 years for a tape-based system. In addition, any supplier worth considering will utilise on-board diagnostics to notify the user as to any potential failure so that it can be addressed before becoming a resource-consuming problem. A quality electromechanical unit will monitor and notify a user of motor/electronics failures, sensor weights being jammed or buried, broken cables/tapes, adequate supply current, and other functions for which the failure of each would cause downtime.
Myth #2: Electromechanical devices are not as reliable or repeatable as newer technologies such as ultrasonic or microwave radar. Aside from devices which provide weight measurements of a bin or silo, electromechanical plumb bob technology is the only inventory management system which is not adversely affected by most conditions one might see in a silo containing a solid material. The performance of
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t Definitely a Goodie ultrasonic, microwave radar, and laser all depends on how amenable the conditions are within the vessel. With each of these technologies, an instrument is projecting a wave and looking for a return signal strong enough to detect and analyse. Dust, steam, foam, high temperatures, low dielectric constant, low bulk density, and angle of repose can all seriously affect the quality and reliability of a noncontacting time-of-flight instrument. Because a plumb bob utilizes a mechanical measurement, all of the conditions just listed do not affect the action by which this instrument generates a measurement thereby improving the chances of a repeatable and reliable measurement. Because a plumb bob is a straight line measurement, each time it is activated it takes a reading from the same spot within the bin every time. There is no worrying about installation angles in order to catch the optimal surface area as would be the case with many of the non-contacting technologies. Accuracies of measurement differ depending on which manufacturer one is considering but it is reasonable to expect a measurement accuracy of 0.25% to 0.5% of measured range.
Myth #3: Electromechanical devices are not directly compatible with current control systems. Before the introduction of modern electronics, this statement held more credence. However, today most brands of electromechanical plumb bob devices will communicate directly with PLC control systems via an analogue 4…20ma signal or for some suppliers even a MODBUS RTU or Profibus digital protocol. If a supplier is still specifying an intermediate remote monitoring unit as standard in order to generate an analogue output, find another supplier.
Myth #4: The use of pulleys and cables is inefficient and makes the device prone to failure. One of the more common questions about this technology regards the perceived high rate of failure due to cables getting tangled in pulley systems. Whether it was a result of constant winding and unwinding or material getting drawn up onto the pulley system and causing interference with the cable setting correctly on the cable, this used to be a legitimate concern. Many plumb bob suppliers have recognised that less is more with pulley systems and have introduced designs which utilise two or less pulleys. One manufacturer has even introduced a single pulley design. Many designs also employ the use of a brush cleaning system or a spring-tensioned tape scraping apparatus which removes material from the cable or tape as it is retracted into the housing. Manufacturers of plumb bob units which use a tape instead of a cable claim to eliminate tangling completely because of the tape’s tendency to lie only on top of itself as it winds onto a pulley. Add to this the qualities of improved materials as previously stated and these improved features have resulted in a reduction of pulley/cable failures and have enhanced the reliability of plumb bob devices.
Writing that this is a myth is a bit of a stretch because this has been known to occur. A weight and cable is intrusive in that it does have to enter the bin in which it is measuring material; however it must be pointed out that most technologies have to intrude in some manner in order to “see” the material it is tasked with measuring. One should remember that the sensor weight and cable is not exposed to the material in the bin except only when it is in the process of taking a measurement, and then it is only touching material for an instant before it is retracted back into the housing of the instrument. A well-designed plumb bob device will seal itself during downtime so as to prevent material from blowing up into the housing. With regard to sensor weights breaking off and causing damage, this may be minimised with the advance of stronger cables and engineering controls designed to prevent conditions which could lead to this issue. Many systems now include minimum travel distances for weights in the case that the silo is empty to prevent weights from getting caught in the bottom of the bin. Many systems also have controls built in to prevent motors from continuously pulling on cables in the case that a sensor weight is buried, which itself is a rare occurrence if care is taken during the installation stage. For those prospects who still worry about sensor weights breaking off, most suppliers now offer breakable “digestible” bags which may be filled with the material which is in the bin so that if the weight does break off it will simply pass through the system. Is the electromechanical plumb bob system perfect for every application? No. Because it is only taking a measurement when asked to do so, it is not a true continuous monitoring device. If one absolutely needs a 24/7 measurement for process control, another technology may be a better choice. Also, as with any device installed at the top of a bin, plumb bob units are measuring linear level and not true volume. Volume or weight of material in a bin must be calculated using bin dimensions and bulk density which may lead to slight inaccuracies. Finally, because power is needed to drive a motor capable of moving a sensor weight and cable, plumb bob devices are not available with twowire 24VDC loop power as is the case with many of the electronic level systems. Inventory management is an important function in any plant environment. Choosing the best solution depends on application considerations, desired output, and of course, cost. When considering which level measurement solution best suits your needs, seek advice from a tank monitoring professional, and remember that sometimes an oldie is still a goodie.
Myth #5: A weight and cable device is intrusive. The weight can get caught in the material and can break off into the silo causing damage to components downstream.
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UWT (UK) Limited, Dorrington, Shropshire Can be contacted on: Tel: 0845 4810463 E-mail: sales@uwtuk.com Web: uwtuk.com
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Assessing the need for dust suppression A new white paper written by Peter Guttridge, Chairman of Guttridge Ltd, and Ian Walton (CEO, DSH Systems Ltd).
Figure 1: The release of dust during bulk outloading can present a major health, safety or environmental hazard which can be addressed by using appropriate dust suppression technology. The dust cloud visible here consists of fine particles that are escaping from the bulk material flow. These may originate from the ‘as manufactured’ product, which may have a defined fines content, or may result from attrition during transit. Many grain feeds may be transported in an ‘as harvested’ state that includes significant quantities of fine dusty dirt. In each case, as the material flows, these fine particles escape from the bulk, spreading into the surrounding environment on air currents induced by the bulk flow, and any prevailing wind. The result is a dust cloud that can present difficulties for a number of reasons:
• Environmental contamination From an environmental perspective the release of dust is, most immediately, an issue of air contamination. This is an important and growing problem as the potential hazards of respirable dust are recognised, and population centres develop around facilities that may, in the past, have been some distance from a community of any size. However, fugitive dust emissions are also a potential source of watercourse degradation and their monitoring is becoming increasingly stringent for this reason too. Tackling environmental issues is becoming critical for facilities anxious to secure good community relationships and an on-going licence to operate in the face of tightening legislation.
flammable materials have explosive potential. The lowest concentration of dust in air that is capable of supporting an explosion1 (the “lower explosive limit”) varies from material to material but typically lies in the range 10 to 500 g/m3. While this figure may seem quite low, it represents a relatively dense fog of particles and so, in practice, is relatively rarely exceeded during routine loading operations.
• Operator safety Certain dusts are known to have a direct effect on health and consequently have well-defined exposure limits. Silicosis, for example, is an occupational lung disease attributed to the inhalation of crystalline silica which, as a result, carries a NIOSH recommended exposure limit of 50 µg/m3 (TWA (time weighted average) for a working day of up to 10 hours, 40 hour working week).[1] More broadly however, even non-toxic dusts may be associated with a decline in lung function [2] making it essential for bulk material handlers to install appropriate control and exposure prevention strategies.
• Damage to machinery Machinery that has to operate in a dusty environment may be prone to low reliability caused by, for example, inhibited lubrication and enhanced wear. The frequent change out of filters designed to protect equipment is also a time-consuming task in dusty environments. One way to prevent such problems, and to simultaneously improve the operating environment, is to adopt an effective clean-up policy, but this too is manually intensive, adding to the overall cost of operation.
• Loss of product Especially for a valuable product, the amount of material lost through fugitive dust emissions can be surprisingly high, and may justify expenditure in superior bulk handling equipment. Most bulk materials are relatively low cost but even with these products the annualised overall cost of losses can be significant. When it comes to tackling a potential dust control problem there are three possible strategies: prevention, isolation and/or control. Conventional technology is typically based on the second and third approaches while more modern, dust suppression systems tackle the problem at source. To read more about these alternative options and the economics driving their adoption, please refer to ‘The practicalities and economics of dust suppression.’, To access the white paper, go to www.guttridge.co.uk
• Explosion hazard:
References
The fine nature of particles present in a dust can, under certain circumstances, promote very rapid reaction/combustion, which is why dust clouds formed from
1. http://www.silicosis.com/niosh/ 2. http://www.iom-world.org/media/93355/ioms_position_on_oels.pdf
Prevention Venting Isolation Suppression
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PNEUMATIC CONVEYING PERFORMANCE Dynamic Air offers 16 different pneumatic conveying concepts: Each system has it own unique set of operating characteristics for pressure, conveying line velocity, efficiency and performance. Because each and every material to be conveyed reacts differently under a given set of operating conditions, it is critical to match the system operating characteristics to the material to be conveyed in order to achieve the most desired conveying performance and to provide the best value. Dynamic Air’s 16 different pneumatic conveying concepts have the ability to convey at almost any conveying velocity desired to
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BARTON SUPPORTS SIX SILO SCHEME Six new aluminium and stainless steel silos have been installed by Barton Fabrications at IKO plc. The major contract awarded by the specialists in roofing waterproofing is part of a £2million+ plant investment. Capability in providing a single source of liquid and powder storage for IKO’s first silo installation, plus technical support provided during silo specification, helped Barton to secure the order. Three stainless steel and three aluminium silos have been installed at IKO’s Chesterfield site. The stainless steel silos each stand 9m tall with a capacity for 100,000 litres of liquid plasticiser. The 12 metre high aluminium silos are used for dry powders: these contain non-flammable materials in the form of PVC resin and calcium carbonate. The silos are all fitted with load cells, ladders and hand-rails for safety and ease of operation. Commenting on what impressed him about Barton’s service, Andrew McArthur Engineering Manager of IKO plc said: “Barton Fabrications were able to provide a single source of silos for both liquid and powder storage. They guided us through the specification process and liaised with our materials handling engineering company to ensure that the specification, installation and commissioning all ran smoothly. “As the site is close to residential housing, a key requirement of the plant design has been to minimise environmental impact. Barton Fabrications worked closely with us to keep the height of the silos to the level of the roofline. The construction quality of the vessels has also been impressive.” Barton Fabrications is the UK’s leading silo manufacturer for the food and plastics industries. The company regularly works closely with all the key European materials handling engineering contractors simplifying the silo specification process and ensuring trouble free installation and commissioning. For more details on Barton Fabrications’ silo solutions, contact Mark Barton:Tel: +44 (0) 1275 845901 E-mail: sales@bartonfabs.co.uk Web: www.bartonfabs.co.uk
SOLIDS HANDLING AND PROCESSING 18.10.13 12:29
woodworking-55,5x255mm.indd 1
suit a given material to be conveyed. We can convey many materials with conveying velocities as low as .25 m/sec. using our HDP 6000 dense phase pneumatic conveying system and, using our LDP 2000 dilute phase pneumatic conveying system, we can convey at velocities well over 35m/sec. Plus our conveying capacities range from just 100 kg of material per hour up to 400 tons per hour and conveying distances exceeding 1500 m in length. For more information contact Dynamic Air Ltd., Milton Keynes, Bucks. Tel: 44 1908 622344 E-mail: sales@dynamicair.co.uk Web: www.dynamicair.com
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KD420 Modbus Sensor Interface
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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
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4-20mA
DUST CONTROL
DUSTECH ENGINEERING LTD Bulk Bag Fillers
Bulk Bag Dischargers
162 Chiltern Drive, Surbiton, Surrey KT5 8LS Tel: 0208 399 9991 Fax: 0208 390 2004 www.dustechengineering.com
www.spiroflow.com Tel: 01200 422525
Modbus RS485 Slave
±30V
KK Systems Ltd
01273 857185 01273 857186
Visit us online
www.kksystems.com
NYLON SCREENS & WEDGE WIRE BASKETS
LEVEL MEASUREMENT
BUTTERFLY VALVES explosionhazards_6x6b.pdf 1 30/10/2012 11:55:26
EXPLOSION PROTECTION
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CM
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LIQUID RING VACUUM PUMPS
CONSULTING
Total Process Protection ■ Conventional Bursting Discs ■ Engineered Bursting Discs ■ Explosion Venting ■ Flameless Venting ■ Explosion Suppression ■ Explosion Isolation
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
One Thousand Pumps, One Distributor. www.tomlinson-hall.co.uk Tel: +44 (0)1642 379500 Email: enquiries@tomlinson-hall.co.uk Tomlinson Hall & Co Ltd, TS23 4JA
PARTICLE ANALYSERS
PRODUCT AND SERVICES DIRECTORY Hosokawa Wall Plan ad 55 x 60_Layout 1 17/10/20
PARTICLE SIZE REDUCTION
QUICK CONNECTOR SOLUTIONS
TRADE ASSOCIATIONS
» WEH® QUICK CONNECTOR SOLUTIONS Pressure-tight connections in SECONDS
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
PIPEWORK SYSTEMS
www.gexcon.com
01695 726565
SERVICE & MAINTENANCE ULTRASONIC FLOWMETERS
PROCESS COOLING
SLIDE GATE VALVES
NEED PROCESS COOLING? VACUUM CONVEYING
Chillers · Dry Coolers Cooling Towers · Chilled Air UK distributor for the new JACIR TOPAZ “Dry Cooler on Steroids”
0845 057 3097 appliedthermodynamics.co.uk
PROCESS MEASUREMENT
TEMPERATURE MEASUREMENT
- 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
WEIGHING SOLUTIONS
PRECIA-MOLEN UK LIMITED
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
To advertise here or within our editorial pages or on our website please call Peter or Guy on 01428 751188
» Simplified workflows » Reduced operating times » Increased productivity