BST December 2018

BULK MATERIALS CONVEYING • SIEVES, SIFTERS, SEPARATORS • VALVES BULK MATERIALS HANDLING HANDLING ••POWDER HANDLING • QUARRYING • RECYCLING&&SCREENING WASTE MANAGEMENT

DECEMBER FEBRUARY 2018 2017

DOOSAN SHOWS POPULAR EXCAVATORS AT THE RENTAL SHOW

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HIGHLIGHTS:

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Hosokawa Viblette VBL-F

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SICK Extends LMS Bulkscan Non-Contact Belt Measurement

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Titan Slide Gate provides a solution

The Smart Way to Unload, Convey, Weigh & Mix ®

MODU-KLEEN BIN VENT FILTER

SWITCH RECEIVER

CONVEYING LINE

®

BLENDCON SILO BLENDER

TM

BULKBUSTER BULK BAG UNLOADER

STORAGE SILO

STORAGE SILO

STORAGE SILO

TM

VIBRA-JET BIN AERATOR

BULK BAG

®

GYRO BIN ACTIVATING FEEDER TM

DYNA-SLIDE HIGH PRECISION AIR-ACTIVATED FEEDER

WEIGH HOPPER

®

BAGBUSTER BAG BREAKER ®

BELLA TWIN SHAFT FLUIDIZED ZONE MIXER

®

BLENDCON AIR BLENDING HEAD

TRANSPORTER MANUAL HOSE SWITCH

Less degradation

Cost effective

Move your dry granular materials gently, reliably and with significant reductions in product degradation and/or system wear.

Our high material-to-air ratios reduce energy and compressed air requirements. Our low conveying velocities provide significant process savings in both operation and maintenance. Initial cost is surprisingly affordable too, thanks to our modular design concept and ease of installation.

Proven capability Dynamic Air dense phase pneumatic conveying systems have been proven in over 15,000 installations worldwide. They handle a wide range of materials and bulk densities at rates from less than a hundred kilograms per hour to 400 tonnes per hour, over distances exceeding 1500 metres.

Sixteen concepts Each Dynamic Air system is custom designed from one of our sixteen different conveying concepts. So you get a conveying solution that fits your process perfectly, without compromises.

BellaTM Twin Shaft Fluidized Zone Mixer

GYRO EXTM Bin Activating Feeder

Dynamic Air Ltd. Milton Keynes United Kingdom Phone: +44 (0) 1908 622344 E-mail: sales@dynamicair.co.uk

www.dynamicair.com

Dense Phase Transporter, J-Series

BulkBusterTM Bulk Bag Unloader

Issue 129

CONTENTS 4

NEWS

10 CONVEYING BST TEAM Sales Director: James Scrivens Production: Sarah Daviner Accounts Manager: Katie Brehm Office Manager: Susan Daley BULK SOLIDS TODAY is published 6 times a year by Abbey Publishing Ltd ADVERTISING & EDITORIAL Please contact us at: Tel: 01933 316931 Email: editorial@bulksolidstoday.co.uk

advertising@bulksolidstoday.co.uk Web: www.bulksolidstoday.co.uk Twitter: www.twitter.com/BulkSolidsToday

12 VALVES 16

BULK MATERIALS HANDLING

20

SIEVES, SIFTERS SEPARATORS & SCREENING

24

BUYERS GUIDE

CIRCULATION To receive a copy free of charge, please send your details to subs@bulksolidstoday.co.uk SUBSCRIPTIONS Subscriptions are available via www.bulksolidstoday.co.uk/subscribe No part of this publication may be reproduced by any means without prior permission from the publishers. The publishers do not accept any responsibility for, or necessarily agree with, any views expressed in articles, letters or supplied advertisements.

SOME MANUFACTURERS & SUPPLIERS HAVE MADE A CONTRIBUTION TOWARD THE COST OF REPRODUCING SOME PHOTOGRAPHS IN BST.

ISSN: 1365/7119 All contents © Abbey Publishing Ltd 2018

www.bulksolidstoday.co.uk Bulk Solids Today

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COMPANY NEWS

HOSOKAWA VIBLETTE VBL-F, THE NEW STANDARD FOR PARTICLE SIZE MEASUREMENT OF COHESIVE POWDERS

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he new, Hosokawa Viblette VBL-F, wet sieve analyzer is launched this month and is seen as the modern standard to replace conventional wet sieving methods in dry particle size analysis.

The simple to use Viblette VBL-F offers sieving times a third less than conventional sieving methods whilst using only 1/6th the liquid to produce accurate and reproducible particle size analysis required in quality control operations. The unit offers a 5 micron, non-filming screen wet sieving capability.

Wet sieving is an established method where cohesive or highly electrostatic powders are to be analysed and where small amounts of coarse powders are to be isolated – which is difficult to detect by laser diffractionscattering methods or dry sieving.

Enhanced vibration allows rapid analysis and unique shower nozzles

deliver effective powder wetting with little liquid waste. Liquid is sprayed through shower nozzles onto the powdery sample on the sieve. The sprinkler is rotated by liquid pressure evenly wetting the powder. The problem of fine screen filming that can occur in wet sieving is avoided using enhanced vibration force, allowing both fine particles and liquid to pass through the screen and shortening the measuring time. Manual intervention is not required during sieving.

Options are available for ultrasonic operation for high cohesive, superfine powders; for organic solvents as well as a series of control options of spray timing, flow volume, rotational speed of sprinkler, process time and vibration on/off timing.

Typical powder applications include, carbon black, calcium carbonate, graphite, silica,

plastic, food, abrasives, ceramic fine powders.

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

SUMMIT SYSTEMS ACQUIRES NEW TEMPERATURE CONTROL DIVISION

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ummit Systems, leaders in the plastic automation sector, are delighted to announce the purchase of ‘Total Process Cooling Ltd, a specialist in chilled water and process cooling.

Summit are working very successfully with leading Italian temperature control suppliers Frigel.

Summit are now expanding this division adding a wider range to suit almost any application with a bespoke solution.

TPC offer a full range of temperature control equipment and have over 25 years of experience in the cooling industry. When coupled with Frigel’s equipment and design capabilities, this boosts Summit ability in this area dramatically. An added benefit is TPC’s extensive knowledge of the plastics industry which is a solid source of expansion.

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Bulk Solids Today

Summit’s operations director Ian Lowe states “This is a really exciting development which advances us in the “Chilled” market and will help secure our continued growth.”

Richard Smith, Total Process Cooling comments “This is an exciting move for TPC giving us a broader range of cooling solutions and even greater support and service to our customers. Our expanded product range and infrastructure combining with Summit Systems means TPC will always have the appropriate cooler for a given water cooling application whilst maintaining quality build and competitive edge over others in the market place”.

The combined portfolio keeps Summit’s nose out in front with proven incredible accuracy, energy efficiency and production savings.

Mike Jordan states “we have

been patiently waiting to establish a process cooling solution with a real difference and we’re delighted that we have achieved our aim.”

To contact Summit Systems regarding their range of process cooling equipment, please email info@summitchilled. co.uk or call 01827 265800.

COMPANY NEWS

VORTEX APPOINTS ÉFREN SHAYD CARMONA LOYA AS REGIONAL SALES MANAGER FOR MEXICO

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ortex is pleased to announce the appointment of Efrén Shayd Carmona Loya as Regional Sales Manager for Mexico.

Shayd has joined the team at Vortex Latinoamérica, a division of Salina Vortex Corporation located in Querétaro. In this role, Shayd is responsible for working directly with original equipment manufacturers (OEMs), end users, and industry specialists to further expand Vortex sales throughout Latin America.

Shayd brings with him more than 12 years of industrial sales experience. Previously, he worked as a market administrator for Cemex.

“I really like the work I do; my experiences have been so rewarding,” Shayd explained.

“Above all, I enjoy interacting with customers helpAd them Size Reductionto (2016) (134x178)_Layout 1

improve their processes.”

Of his excitement to be joining the Vortex team, Shayd continued, “I am very happy and proud to now be a part of the Vortex family!

I believe this is just the beginning of something much bigger.

“I hope to positively impact Vortex sales growth with my personal sales philosophy. I believe that if you give clients quality attention and promptly attend to their needs with respect and cordiality, client expectations will be fulfilled. By showing great effort, attitude and persistence in those areas, the sales indicators often follow and goals are achieved.

“Vortex has ample opportunities for growth throughout Mexico and Latin America, and I’m poised to be a part of it.”

For more thanPage 40 1years, Vortex 27/09/2016 11:53

has provided slide gates, diverter valves and loading solutions specifically designed for the handling of dry bulk solids in gravity, vacuum, dilute or dense phase applications. Vortex products are engineered for quality, dependability, durability, and ease of maintenance, making them proven material handling solutions for issues in process efficiency. Through the expertise of Vortex engineers, valves can be completely customized for individual applications or special installations.

Email: ventas@vortexglobal.com vortex.mx@vortexglobal.com Web: es.vortexglobal.com

Experience the

difference… …in innovative size reduction We have one of the largest ranges of size reduction equipment on the market and provide a single source supply of comminution equipment and expertise: from <1g to multi-tonne.

• From lump crushing and coarse grinding to micronizing, fine grinding and nano-milling

• Wet and dry milling equipment and systems • Unique equipment for small batch milling <1g • Accurate, repeatable particle size reduction Milling systems contained within an isolator/glovebox can operate to meet OEB 6. Hosokawa Micron size reduction equipment can be designed specifically for installation within an isolator for a more bespoke solution.

Tel: +44 (0) 1928 755100 • E.mail: info@hmluk.hosokawa.com • www.hosokawa.co.uk

Bulk Solids Today

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COMPANY NEWS

REPLACEMENT AUGER SCREWS FOR ALL TYPES OF MACHINE - OUR 21ST CENTURY CONTRIBUTION TO THE BULK SOLIDS HANDLING INDUSTRY. The Archimedes screw has been around for many years and represents a deceptively simple way to move materials. From liquids to solids and everything in between, a rotating helix can propel a product and deliver the accuracy demanded by many Bulk Solids Handling machinery.

For over 21 years, Trantec Solids Handling Ltd, based in Clayton-le-Moors, Lancashire has been producing just such machines, taking the humble “auger” and putting it to work moving fine powders, granules, flakes and pellets with consistency and precision in their Metering Screw Feeders.

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odays powder handling applications are demanding even greater efficiency and accuracy. Food and Pharmaceutical machinery has its own requirements for hygienic design and the cost of many process ingredients means over-feeding, or wasted product must be minimised. Machine reliability also takes centre stage, with active components such as Auger Screws needing to have a full and long productive life.

Original Trantec machines used augers manufactured by others. Whilst these screws were fully functional, Trantec craved a more accurate and consistent product which had tight tolerances and maximum life.

In the early years of the new millennium, Trantec had developed a new range of Metering Feeders, which included many Quick-release, Easy-clean features.

This new range demanded augers of high build quality at sensible prices and the decision was taken to begin development of our own Auger manufacture.

In more recent times, Trantec have focussed their auger manufacture at the “High Tech” end and have embraced the latest computer-controlled 6

Bulk Solids Today

machine tools combined with modern design and manufacturing software. This investment has given Trantec unique knowledge of auger production methods and has put Trantec at the cutting edge of worldwide auger manufacture for the process industry.

Trantec’s policy of continuous development pushes the boundaries of current engineering manufacture and produces augers of better quality and finish than ever before, whilst driving down costs at the same time. An improved quality product at a lower price is everyone’s target (of course) and Trantec believe they have done just that.

Five years ago, Trantec brought their Auger Screw manufacturing capabilities to the market place and now manufacture augers for use in any type of machinery. We now specialise in supplying full flight augers for all industries to very high precision.

Our customer base includes many global players in the Food, Pharmaceutical and Chemical industries, providing new augers, replacement/interchangeable augers, hygienic augers or exotic development augers for the latest solids handling machinery.

COMPANY NEWS

Not all metering feeder manufacturers however use a full flight auger screw, with some suppliers opting for the simpler spiral/spring type augers. To ensure Trantec cover the full range of replacement spares, earlier this year a development program was established to manufacture spring-type augers at their Clayton-le-Moors production facility.

Augers of this type are usually formed by winding a wire form onto a mandrel. The wire can be square, round or rectangular and of stainless or carbon steel.

The bar or wire stock must be accurately moved as the mandrel rotates to form the correct pitch of the helix.

Trantec modified existing machinery to accomplish this task with accuracy and consistency being at the forefront of the process. Stock in-feed can have a significant effect on how the spiral is formed and careful consideration was given to the wire guide method. The angle of application, tension, speed of application and distance between the mandrel and the in-feed guide all play a part in the quality of the spiral produced.

Spring type Bulk Solids feed screws come in many shapes and sizes. All too often the wire form can be difficult to obtain, especially if only one auger screw is required. There are many established companies who can manufacture whatever wire form is needed but their minimum order quantities can be hundreds of kilos making one-off spirals prohibitively expensive.

Trantec have added to their development program by including the manufacture of custom bar and wire forms by cold drawing. This well-established method of manufacture has many advantages and will allow very small quantities of custom wire shapes to be produced.

Easily obtainable standard bar can be formed into custom shapes and sizes before being rolled into a helix.

The key element of Trantec’s manufacture remains their ability to produce tooling in-house using the latest CAD/CAM software and advanced computer guided machine tools. Custom draw tooling and custom forming mandrels can be manufactured quickly and cost effectively, allowing small quantity production runs. Larger quantities offer the economies of scale and make the process even easier on your budget.

Trantec continue to grow and develop new auger making facilities and methods, challenging their customers to set ever more complex helix configurations for them to make. A real commitment to continuous development will keep Trantec ahead in auger manufacture.

For more information please contact: +44 (0)1282 777566 I sales@trantec.info I www.augers-uk.com

UKWA CELEBRATES 75TH ANNIVERSARY MILESTONE The United Kingdom Warehousing Association (UKWA) will celebrate the 75th anniversary of its inception in 2019.

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he Association was launched in 1944 when representatives from warehousing companies formed a Committee to discuss the storage and distribution of food and materials in wartime Britain. Originally known as the National Association of Inland Warehouse Keepers (NAWK), the Association changed its name to the United Kingdom Warehousing Association in 1994.

Today the organisation is the leading trade body dedicated to serving the needs of the UK’s logistics industry and has over 700 member companies – including third party logistics operators together with leading retailers and manufacturers – who, between them, control nearly 100 million square feet of warehousing space from nearly 1300 locations across the UK. www.ukwa.org.uk

High Efficiency Drying or Cooling of Bulk Solids The Bella dryer/cooler offers thermal efficiencies to 80 percent or better because air flows around material while it is suspended in the weightless zone.

The result is a more consistent material.

Dynamic Air Ltd. • +44 (0)1908 622344

www.dynamicair.com Bulk Solids Today

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COMPANY NEWS

HYSTER EUROPE SHOWCASES INNOVATIVE WAREHOUSE AND LOGISTICS SOLUTIONS AT LOGIMAT 2019 At LogiMAT 2019, which takes place from 19th to 21st February in Stuttgart, Germany, Hyster Europe will present 360-degree solutions for warehouse and logistics applications, including a focus on innovative robotics solutions.

In addition, a Reach Truck with tilting mast, particularly suited for use in confined spaces, will be on show.

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isitors to the Hyster Europe stand will be able to find out about robust and reliable Hyster® lift trucks, as well as solutions for warehousing and logistics. For example, the R1.0E1.4E Reach Truck series, which offers better manoeuvrability and is particularly suited to use in tight spaces. The compact chassis and mast, which can be tilted backwards, save valuable centimetres so that the lift truck can reach the top shelves even in narrow aisles.

Overall, the full Hyster product portfolio includes a comprehensive range of more than 140 models of counterbalance trucks, warehouse trucks and container handlers.

At stand B15 in hall 10, Hyster Europe will also be informing visitors to the show about its innovative, truck-based robotics solutions.

“Our robotics technology uses Balyo navigation technology, which does not require complex infrastructure changes in order to automate logistics processes,” says Timo Antony, Area Business Director Central Europe, Hyster.

“Instead, the truck-based solution maps the environment using natural features in the building.”

At LogiMAT, Hyster Europe will also show electric forklifts featuring lithium-ion batteries. These batteries are often used in the food industry where operations are mostly indoors and there is a priority to reduce 8

Bulk Solids Today

contamination. Lithium-ion has no acid which could spill and no fumes - hydrogen and other gases can be produced by lead acid, which are unwelcome in clean food production and storage areas.

With no equalising, watering or cleaning required, lithium-ion batteries do not need the high levels of maintenance that their lead acid counterparts require. Lower maintenance helps to reduce cost.

“Another advantage is the ability to opportunity charge lithium-ion batteries during breaks,” says Antony. “This ‘top up’ approach can simplify operations, as you only need one battery, not two.

In addition, over a period of years, lithium-ion may work out cheaper in the right application, with lower total battery costs.“ In certain applications with the right infrastructure, fuel cells may be the best power option.

For example, Hyster is currently developing a zero-emission container handler for a customer in the Port of Los Angeles. The Hyster® electric laden container handler entering development is intended to be powered by a Nuvera® fuel cell combined with a lithium-ion battery. The model in development is expected to utilise fully integrated wireless fast charging.

“Where the requirements to power a fleet of electric Big Trucks is likely to exceed power capabilities of the grid, hydrogen may provide ports with readily available energy without a requirement for a high capacity electric charging infrastructure,” says Antony.

To enhance the tough range of 2-3.5 tonne capacity Hyster® Fortens™ ICE trucks, a wide variety of solutions and customisations tailored to specific application needs are now available for 2019 models.

“For instance, to alert pedestrians of an approaching vehicle in busy warehouses with blind intersections or high noise environments, for example, Pedestrian Awareness Lights can be fitted to the front, rear, or both, of Hyster® Fortens™ trucks,” says Antony.

Automatically activated when the truck moves, one option projects a blue beam of light on the floor indicating presence and travel direction of the truck.

Other additional options include red zoning lights on either side of the truck to help indicate to pedestrians the distance they should keep from the truck.

Visit Hyster Europe at LogiMAT in Stuttgart, Germany: Hall 10 | Stand B15 For more information or to find your local Hyster® dealer, visit www.hyster.eu

COMPANY NEWS

BONFIGLIOLI INAUGURATES ITS NEW ELECTROMOBILITY PRODUCTION LINE IN ITALY

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onfiglioli – a global leading manufacturer of gearboxes, gearmotors and drive systems – has launched its new electromobility production line in Forlì, Italy. The new unit – covering an area of about 10,000 square meters – was built in 12 months, and is entirely dedicated to the production of electrical axles for powertrain and wheel drives of different sizes. In this case as well, Bonfiglioli has built this new facility with an environmentally-friendly approach, by implementing energy saving and generation measures, such as an A2 energy class building, full led lighting, a roof-top PV plant (self-consumption mode), as well as a compressors/heat recovery system, all together contributing to yearly savings of approx. 1 MWh, equivalent to over 300 TCO2 The additional building is completely integrated into the existing plant, which already produces approx. 300,000 products per year. With a total of 39,000 square meters dedicated to production, this facility already serves 200 customers in the construction, wind, agriculture, marine and logistics & intralogistics industries, with a wide product portfolio including yaw and pitch drives, wheel drives, track drives, slew drives and winch drives.

“This new and innovative unit looks to the future and consolidates one of our main strategic pillars – the development of electromobility solutions – by leveraging the existing decade-old competence center we have in Forlì, focused on mobile equipment”, says Fausto Carboni, Bonfiglioli Group CEO. “This expansion gives us the opportunity to better support our customers with innovative solutions for electrical and hybrid industrial and commercial vehicles. We decided to put the best of Industry 4.0 technology at our service, in order to create flexible processes, enhancing quality and productivity standards.” adds Marco Cesari, Mobility & Wind Industries Business Unit General Manager.

The implementation of Industry 4.0 technologies developed through collaborative robots, AGV, sensors, machine vision systems, interactive working instruction systems, and full data connection systems, allows an extreme optimization of the entire production process. Innovative testing benches – such as the double vibration test – guarantee high quality product consistency.

Flexibility has also been one of the main criteria the assembly line was conceived with, resulting into the capability to manage 25,000 products per year, from 70 kg to 1,200 kg with reduced machine set-up times.

More information available at www.bonfiglioli.com

Tuf-Lok ring grip pipe and tube couplings are rugged, heavy duty, self-aligning and self-grounded couplings with a high end pull. They can be used for almost any application where pipe or tube ends need to be connected. The Tuf-Lok self-aligning couplings install quickly and easily with little effort.

Features • Self-aligning • Self-grounding • High pressure rated • Full vacuum rated • Stainless or mild steel • Usable on thin or thick wall pipe or tube • Low cost • Reusable • Absorbs vibration • Externally leakproof

Tuf-Lok (UK) Tel: +44 (0) 1706 822512 Email: sales@tuflok.co.uk • www.tuflok.com

Bulk Solids Today

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CONVEYING

CUSTOM DESIGNED PNEUMATIC CONVEYING SYSTEMS

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ry, granular materials can be moved gently, reliably and with significant reduction in product degradation and/or system wear with a Dynamic Air pneumatic conveying system. Each Dynamic Air pneumatic conveying system is custom-designed to achieve the optimum performance characteristics at the highest efficiencies. Dynamic Air has developed 16 different pneumatic conveying concepts, utilizing both pressure and vacuum, for handling a wide variety of dry bulk solids to provide a conveying solution that fits the process perfectly. Because each and every material to be conveyed reacts differently under a given set of operating conditions, it is extremely 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 Airâ&#x20AC;&#x2122;s 16 different pneumatic conveying concepts have the ability to convey at almost any conveying velocity desired to suit a given material to be conveyed. Dynamic Air pneumatic conveying systems improve efficiency and reliability and significantly reduce operating costs. http://www.dynamicair.com/systems.html Phone: 44 1908 622344 E-mail: sales@dynamicair.co.uk www.dynamicair.com

ABRASION-RESISTANT LUMP BREAKER

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new model RDC-2424MS De-Clumperâ&#x201E;˘ Rotary Lump Breaker from Munson Machinery breaks chunks of agglomerated abrasive or friable materials that have compacted during storage or shipment, conditioning them for downstream processing or conveying.

Material entering the 610 mm square inlet is reduced in size by dual rotors with threepoint, single-piece, AR-235 abrasion-resistant steel breaking heads rotating with minimum clearance above a curved, perforated bedscreen.

On-size material exits through 25 mmdiameter apertures in the bedscreen. Other bedscreens are available with apertures ranging from 25 to 64 mm in diameter.

Powered by a 5.6 kW motor with gear reducer and a rugged chain and sprocket drive, the synchronised shafts rotate at approximately 120 RPM, offering high throughput rates with minimal heat generation.

A side mounted bedscreen can be rapidly removed for cleaning, replacement or maintenance.

The compact, low-profile design allows inline placement in restricted spaces between upstream and downstream processing, packaging or bulk storage equipment. With an optional feed hopper 10

Bulk Solids Today

and support structure, it can also operate as a stand-alone unit.

The unit is recommended for breaking lumps in product flows of bulk materials such as cement powders, sodium or calcium carbonates, fertilisers, and bulk chemicals of all types.

According to the manufacturer, it is built to withstand heavy usage and is simple to maintain; bearings can be lubricated through external fittings and are isolated from the product processing area with air purged shaft seals.

Suitable for industrial and chemical applications, it is also offered in 304/316 stainless steel, finished to sanitary standards for food, dairy, pharmaceutical or industrial applications.

The company also manufacture higher capacity models with square or rectangular inlet openings up to 1220 mm, and up to four rotors driven by motors up to 30 kW. Other size reduction machinery offered by the company includes Screen Classifying Cutters, Pin Mills, Attrition Mills, Rotary Knife Cutters, Hammer Mills and Shredders. Blending equipment includes Ribbon/ Paddle/Plow Blenders, Rotary Batch Mixers, Rotary Continuous Mixers, Fluidised Bed Mixers and Variable Intensity Blenders. www.munsonmachinery.com

CONVEYING

SICK EXTENDS LMS BULKSCAN NON-CONTACT BELT MEASUREMENT TO MORE USERS SICK has extended its LMS Bulkscan laser scanner offering, so that more users can benefit from noncontact, continuous measurement of volume and mass throughput of bulk materials on conveyor belts.

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he SICK LMS111 Bulkscan provides highlyaccurate, delay-free volume and mass flow measurements to maximise throughput of a wide range of bulk materials including waste, crops, fertilisers, building materials and food ingredients. Compact, and easy-to-integrate, the LMS111 Bulkscan can be designed into new lines or easily retrofitted onto existing conveyors.

The SICK LMS111 Bulkscan is a cost-effective alternative to a conventional beltweigher that offers the wear-free, low-maintenance advantages of non-contact, real-time measurement. The multi-echo, time-of-flight laser scanning technology enables a reliable output of the material’s volume and mass flow. In addition, the material’s centre of gravity is continuously monitored to help avoid uneven loading and resulting belt wear.

“The new SICK LMS111 Bulkscan presents a value-added alternative to a standard belt scale and is a robust and consistent performer even in dusty production environments or when mounted behind glass,” explains Darren Pratt SICK UK’s National Product Manager for Industrial Instrumentation.

“By measuring the load height profile every 20 milliseconds, the LMS111 Bulkscan delivers an accurate, continuous profile measurement. It then works out the volume of the material using the belt speed which can be provided as a fixed value or input via an encoder in the case of a variable speed belt. The mass is computed from the volume and a known density of the material.

“Volume is more important than mass for many production processes, making Bulkscan an ideal alternative to beltweighers in conditions where the density of material changes significantly. Asymmetrical belt filling or unequal bulk distribution can cause offtrack running. The load height and centre of gravity also have important wear, energy efficiency and safety implications in bulk conveying. As it’s noncontact, there is nothing to wear out with the LMS

Bulkscan and it remains accurate without the regular recalibration needed for conventional scales.”

The LMS111 Bulkscan is easy to install and set up in a vertical (nom. 5°) alignment for accurate profile measurement. Using the pulsed, time-of-flight laser measurement system with a 190° wide field of view, the unit can be applied to the narrowest and widest conveyors. The instrument outputs three analogue signals via the BAM100 processing unit accessory, or delivers three digital signals that can be assigned to a bulk quota or for condition monitoring. A TCP/ IP interface ensures easy connectivity with a PC, factory SCADA and PLC communications networks.

The SICK LMS111 unit is compact, measuring only 152mm x 102mm x 105mm, so is easy to install in a wide variety of locations. It can be mounted up to 10 metres above the conveyor, ambient operating conditions range from +50°C to -30°C, and environmental protection is rated at IP67.

The SICK LMS111 complements the LMS511 Bulkscan PRO which provides additional measurements and is designed for operation in more challenging dusty and dirty conditions, including the most arduous ambient conditions.

For more information on the SICK range of products, please contact Andrea Hornby on 01727 831121 or email andrea.hornby@sick.co.uk.

Bulk Solids Today

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VALVES

TITAN SLIDE GATE (TSG) PROVIDES A SOLUTION FOR WASTE MANAGEMENT A waste and recycling company’s process includes bulk storage, discharge and transfer of a variety of residues, which are the byproduct of incinerating chemical, clinical and municipal wastes.

These are solids and residues from flue gas treatment, APC, FTG and fly ash.

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he company had experienced problems with the existing valves located on the outlet of their bulk storage silos. Due to the aggressive and varying nature of the materials being handled, the existing valves had difficulties opening and closing through a standing column of material.

The Vortex® Titan Slide Gate™ (TSG) was identified as the ideal solution for this application. The TSG is designed for handling heavy-duty, abrasive dry materials in gravity flow applications. Beneficial features of the TSG include a positive material shut-off and dust-tight sealing capabilities.

Because this client’s process had high-pressure silo discharge aeration (despite the TSG’s “gravity flow only” design), to prevent leakage of materials and dusts to atmosphere, the TSG was equipped with a Return Pan. A Return Pan is a fabricated metal piece designed to transition the outlet side of a gate. It is angled to create an inverted “ramp” – beginning narrow at the back of the gate and gradually steepening as it approaches the gate’s opening. When using a Return Pan, on the top part of the gate, a solid bonnet cover is used. On the bottom part of the gate, a perforated bonnet cover is used. A Return Pan is installed on the outlet side of the gate, directly beneath the perforated bonnet cover. As materials begin to migrate into the bonnet area, rather than building up, they are deposited down through the perforated bonnet cover and onto the Return Pan, to be reintroduced into the material flow stream.

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Bulk Solids Today

BENEFITS OF A RETURN PAN INCLUDE: • An inexpensive way to prevent dusting to atmosphere. This improves housekeeping and workplace safety, and prevents product loss.

• An effective solution to prevent material build-up in the bonnet area, which could otherwise cause gate actuation issues.

On the closing stroke, the TSG is designed so that the blade enters into a recessed area with a displacement pocket. Upon gate closure, the displacement pocket prevents materials from packing, as they would into an end seal. The displacement pocket also allows any materials remaining at the leading edge of the blade to fall away into the process line below, even after gate closure. This feature is essential when handling packable materials, as is the case in this client’s process.

Otherwise, material packing can cause seal wear, actuation issues and material leakage past the gate.

For ease of maintenance, the TSG features milled access slots on each side of the gate’s frame so that bonnet seals can be quickly and easily replaced whilst the gate remains in-line. www.vortexglobal.com

VALVES

LEADING, DEPENDABLE VALVES FOR CRITICAL OILGAS & POWER APPLICATIONS

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ncorporating the M&J Valve® and Copes-Vulcan® brands, SPX FLOW has long served the oil, gas and power industries with a huge range of valves designed to offer reliable, safe performance in even the most critical of applications. Our valves portfolio includes Danflo Surge Relief Valves for pipeline protection against surge, Slab and Expanding Gate valves for pipeline isolation, 4-way diverter valves for Bi-Direction Provers, Turbine Bypass Valves, Desuperheaters, general and severe duty control valves for power plants. All are precisely engineered and incorporate innovative features to help address challenges faced in the oil, gas and power industries.

Offering high flow capacities and exceptionally fast response times, the M&J Valve DANFLO surge relief valves are engineered to track unabated surge-wave pressure transients, opening quickly and then closing without slamming shut. The valves can be gas-loaded or Pilot Operated. Both types of Surge Relief valves actuate in 100 mille-second and completely open in 250 milliseconds, thus diverting the required flow fast enough to keep the pipeline pressure well below the set point.

Proven in a wide range of demanding isolation applications, M&J expanding gate (EG) valves provide a superior bi-directional mechanical seal by using a twopiece gate assembly which expands against the seating areas in the open or closed position. The seal becomes tighter with increasing torque, resulting in reliable, heat resistant sealing independent of line pressure or vibration.

M&J EG valves have double block and bleed capabilities and seal at low and high line pressure. They offer long, leak-free service with a protected seat design to extend valve life. The valves have a full bore through conduit to minimize pressure drop and turbulence in the line. They are specifically engineered for easy operation, with low operating torque and visual position indication.

Straight forward maintenance is also assured as the stem packing does not require lubrication, the valve can be overhauled in-line, and top entry access to all internals is provided. They are ideal for use in applications such as meter bypass, pig launch/receiver traps, hot tap, manifolds, tanks, stations and as mainline block valves.

The M&J Valve M-303 is an advance fabricated body Slab Gate Valve for pipeline isolation, manufactured and tested as per API 6D specification. The fabricated body allows wider selection of material choices. Available in sizes from 2” to 84” with pressure class from 150 to 2500. Ease of Maintenance and versatility makes the 14

Bulk Solids Today

M-303 a preferred choice of Slab Gate valve in the market.

The advanced CopesVulcan RAVEN™ trim Control Valves are uniquely designed to rapidly reduce flow velocities and are proven to provide true velocity control in severe service applications.

Engineered to prevent erosion, vibration, poor control and cavitation, problems typically associated with high velocity applications, the RAVEN trims limit fluid velocities at the exit of the trim. The valves are available as general service or severe duty models and are suited for a wide range of power, petrochemical, boiler feed, pipeline and gas transportation applications and offer users reduced noise, resistance to the effects of blockage and long, reliable, high velocity performance.

The low velocity achieved by the RAVEN trim is achieved using a trim cage which is made from a series of individual discs that have been bonded together.

Every trim is custom designed to meet the needs of the toughest liquid, steam and gas services in the power and process industries. Each of the discs has a precisely manufactured pattern of orifices and channels with a multitude of sharp turns. As the trim’s plug travels with the cage, the fluid is forced to travel this extremely torturous path, with each turn effecting a stage of pressure drop. The precision of the trim manufacture provides extremely accurate pressure drop and its design inherently allows for more stages of pressure drop compared with conventional torturous path trims.

Copes Vulcan DSCV-SA (Direct Steam Converting Valves-Steam Atomisation) is a Turbine By-Pass valve designed for unprecedented operations and reliability, available in ANSI 150 to 4500 pressure class. It eliminates potential risks associated with sub-standard designs during plant start up, shutdown and turbine trips. It is a preferred choice in steam conditioning applications, with variety of trim options for noise control, and repeatable tight class V Shut off.

To learn more about SPX FLOW, please visit www.spxflow.com.

VALVES

POSI-FLATE GATE LOCK ROTORK’S CMA RANGE EXPANDS VALVE ASSEMBLY

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otork has extended its CMA range of compact modulating actuators with new sizes specifically designed for reliable automation of larger linear control valves.

The new actuator is capable of a maximum 4,500 lbf (20 kN) seating thrust. The new sizes increase the CMA range modulating thrust performance to 3,000 lbf (13 kN) with a 114.3 mm (4.5”) stroke length for the automation of larger valves with higher pressure ratings. The combined performance of the CMA and the larger CVA ranges enables Rotork’s innovative electrical control valve actuation technologies to be applied to process control applications of virtually any size and description.

CMAs are robust enough to handle extreme temperature swings, corrosive environments and are also available for explosion-proof areas. The CML1500 and CML-3000 models, including those with hazardous area approvals, are watertight to IP68 for temporary submersion (7 metres, 72 hours).

The optional Reserve Power Pack (RPP) uses supercapacitors to provide the actuator with enough stored energy to perform predetermined action on mains power failure, such as moving to the fully closed position, fully open position or anywhere in between.

Manual operation is available as standard.

The cost-effective electric solution is suitable for a wide variety of applications found in sectors such as power generation, chemicals, petrochemicals and the majority of other process industries. The new sizes are ideal for linear valve control with modulating duty, generally in remote locations, such as oil pipelines and remote gas extraction stations where power supplies are limited. Single-phase or DC electrical power is all that is required for control valve actuation, saving the installation and on-going costs associated with instrument air supplies. Simple cabling replaces cumbersome lines and hoses, eliminating freezing and leaking problems.

The CMA is a low power consumption solution (less than 1 Watt at standby) for automation in established or remote installations such as oil installations and offshore facilities where there are pneumatic limitations. The design allows for solar powered and battery back-up supplies in remote locations where electric energy consumption is a concern and power is often provided through solar collection for the operation of remote automated critical systems such as wellheads. www.rotork.com

T

he Gate Lock Valve Assembly

by Posi-flate is a low cost and low maintenance alternative to the traditional rotary airlock feeder and provides a positive seal that can accommodate either full vacuum or pressure up to 100 PSIG. The air-operated seat inflates to provide a long-lasting high integrity seal and easily handles high cycling of dry granular or fine powdered materials. The seat automatically compensates for wear when it inflates against the disc, extending valve life considerably. The Posi-flate Gate Lock Assembly is available in carbon steel and stainless steel in sizes from 2 inch (50mm) to 30 inch (750mm) diameter and in any length desired. Other materials of construction are available upon request. http://www.posiflate.com /products.html Tel: +44-1908-622366 E-mail: sales@posiflate.co.uk

Other Valves Fight Friction, We Designed it Out Unlike other valves that seal with friction, Posi-flate’s unique butterfly valve uses an inflatable seat to seal with air pressure. Thus it requires less torque and a smaller actuator, resulting in lower cost.

Plus, the seat automatically compensates for wear, providing longer life. Some users have reported over six million cycles and the valves are still going strong.

• • • • • •

Less friction Low torque Low maintenance Lower actuator costs Longer valve life More reliable Tel: +44 (0) 1908 622366

www.posiflate.com

Bulk Solids Today

15

BULK MATERIALS HANDLING

JCB TELETRUK JOINS THE FRONT LINE AT STAFFORDSHIRE FIRE AND RESCUE Staffordshire Fire and Rescue Service has added a JCB Teletruk to its range of front line fire fighting and emergency rescue equipment.

T

he Teletruk is deployed at waste and rural fires where it is used to move bailed and bulky items to support improved firefighting tactics, reduce the risk of fire spread, improve firefighter and public safety and limit the potential for environmental impact during the firefighting process.

It will also be used at fire scenes during the clean up and ‘dampening down’ phase of an operation, where there is a need to disturb smouldering debris to allow fire crews to direct water at deep seated fires to ensure that a blaze is fully extinguished in the fastest possible time.

The Teletruk is transported to the scene of an emergency using a transport mechanism specially developed by JCB in partnership with Staffordshire Fire and Rescue Service. In simple terms, the Teletruk is driven on to a skid plate and elevated using a clever hydraulic system on to the back of a standard flat-bed trailer. The system is quick, safe and simple and complies with all relevant regulations.

Staffordshire Fire and Rescue Service’s Newcastle Station Commander, Mark Walchester, said: “Before we had the Teletruk, in many instances firefighters had to use shovels to move materials to expose the base of the fire when ‘dampening down’. This process not only put personnel at unnecessary risk, but delayed the time it took to fully put out a blaze and resulted

16

Bulk Solids Today

in greater use of water than was often needed.”

“Using the Teletruk means we can aggressively attack a deep seated fire and buildings can be made safe far more quickly which is good news for their occupiers – members of the public or businesses – who are able to recover goods earlier than was previously possible.”

The 3500 KG capacity Teletruk supplied is a 4-wheel drive model from JCB’s Wastemaster range. It is fitted with puncture-proof tyres and its cab features rollover and falling object protection systems to ensure that operator safety is maximized when the truck enters a building.

The introduction of the Teletruk is also delivering significant cost efficiency benefits to Staffordshire Fire and Rescue Service. In one incident alone the ability to deploy the Teletruk saved an estimated 360 person-hours in the time it took to fully extinguish the fire, which equated to a budget saving of £25,000.

Paul Murray, JCB’s Teletruk general manager, says: “Thanks to its robust build quality, the JCB Teletruk is the ideal choice for a wide range of arduous applications and we are delighted that the invaluable work undertaken by Staffordshire Fire Service is being made easier thanks to Teletruk technology.”

Staffordshire Fire Service’s new Teletruk was supplied by JCB dealer, Gunn JCB. www.jcb.com

BULK MATERIALS HANDLING

LOADEX 100

ON-BOARD EXCAVATOR WEIGHING SYSTEM

WHAT’S NEXT FOR GOPLASTICPALLETS.COM?

C

elebrating its 25th year of business this year, Goplasticpallets.com has recorded sales in excess of one million plastic pallets, pallet boxes and containers in the last 20 years alone, which reinforces its position as the UK’s largest plastic pallet supplier.

Goplasticpallets.com has further strengthened its relationships with leading European plastic pallet and box manufacturers this year. First saw the signing of the company’s fifth partnership agreement, this time with Italian manufacturer JCOPLASTIC which secured Goplasticpallets.com sole UK distribution rights for an impressive range of industrial and agricultural rigid pallet boxes. The summer then saw the company consolidate its partnership agreement with Belgiumbased manufacturers Smart-Flow and Gamma-Wopla who have given Goplasticpallets.com exclusivity in the UK for distributing more than 50 of its plastic pallets and small containers.

Another major accomplishment for Goplasticpallets.com this year was becoming an Accredited Exporter of Plastic Packaging Waste. This means that when customers no longer have a need for their plastic pallets or boxes, or they have come to the end of their long working life, Goplasticpallets. com can return them to their recycling plant in Belgium; saving customers both the hassle and cost of disposal and ensuring their products are recycled in a sustainable way.

The rise in automation in the manufacturing sectors is definitely one opportunity given the crucial role plastic pallets play in ensuring a smooth and efficient production line. This year Goplasticpallets.com supplied plastic pallets to one of the UK’s largest supermarkets for use in an automated storage and retrieval system and is working with a number of other large retailers on similar projects.

Sustainability will remain a key area of focus for 2019 both in-house – looking at new ways to reduce waste – and demonstrating the company’s ‘green’ credentials to customers.

What is certain is that Goplasticpallets.com has exciting plans for the year ahead!

Call Goplasticpallets.com on 01323 744057 to find out how we can become your plastic pallet supplier or browse our extensive product range: www.goplasticpallets.com

The benchmark for accuracy in difficult conditions and terrains

T: +44(0)1453 733300 | info@rdstec.com | www.rdstec.com

Bulk Solids Today

17

BULK MATERIALS HANDLING

DOOSAN SHOWS POPULAR EXCAVATORS AT THE RENTAL SHOW Doosan Construction Equipment will display two of the company’s most popular excavator models for the rental industry on its booth – 5301 – at the Anaheim Convention Center during The American Rental Association Show in Anaheim, California, USA from 17-20 February 2019.

T

he Doosan® DX85R-3 and DX140LC-5 excavators will be on-site during the show, and Doosan staff will be available to walk visitors through the capabilities of the machines. As a member of the increasingly popular 8 tonne class of excavators, the DX85R-3 is the perfect rental machine for a contractor who needs a compact excavator but has a job that calls for a slightly heavier piece of equipment that can still be easily towed. The DX140LC-5 is a 14 tonne, conventional tail swing excavator known for its trusted reliability – a chief concern for rental companies.

The DX85R-3 comes standard with rubber tracks to minimize ground disturbance. The DX140LC-5 will be outfitted with rubber pads on its steel tracks, which is an optional feature that enables operators 18

Bulk Solids Today

BULK MATERIALS HANDLING to minimize damage when working on concrete or asphalt. They will also both be equipped with a hydraulic quick coupler, which allows operators to change the excavator attachments without leaving their seats.

DX85R-3 COMPACT EXCAVATOR The Doosan DX85R-3 is a powerful machine which leads the industry in bucket force but is also light enough to be easily moved between worksites by most contractors.

Its reduced tail swing design allows operators to work in tight spaces, and its excellent slew performance makes it an ideal machine for working on slopes.

The DX85R-3 offers best-in-class cycle times due to its cylinders, which are sized precisely to match pump capacities. It offers smooth, predictable operation with fingertip boom swing control via a simple thumb switch on the left joystick. The comfortable joystick controls reduce hand fatigue and include two way auxiliary hydraulic control.

Inside the cab, a multi-language deluxe colour panel displays fuel level, coolant temperature, day/ time, throttle position and engine rpm. Operators can select auxiliary hydraulic flow modes and rates from the panel. For increased security, an integrated password protection system may be used to help prevent theft.

DX140LC-5 CRAWLER EXCAVATOR The Doosan DX140LC-5 excavator is designed for long life with an extra-sturdy frame and reinforced superstructure. The conventional tail swing overhang on LC models gives the operator strength and leverage for general construction and traditional excavating applications. The DX140LC-5 comes standard with permanently sealed and lubricated track links, and the workgroup bushings and hard-wear disks are designed for reliability as well as extended service intervals to increase uptime.

A standard 7-inch liquidcrystal display (LCD) screen allows operators to continue monitoring the excavator parameters while viewing the rear view or side view camera images. Critical machine data appears next to the camera view. With the standard side camera, a split screen allows both camera displays to be viewed at once.

To help save valuable diesel fuel, auto shutdown is standard to help owners save fuel during non-working conditions. Operators can configure the idle time from 3

to 60 minutes. When enabled, the feature will shut down the excavatorâ&#x20AC;&#x2122;s engine when the preset idle time is met.

Doosan hydraulic quick couplers provide a more durable, reliable and convenient means to change attachments and increase overall productivity.

Manufactured using extra high strength steel, the Doosan hydraulic quick coupler has an optimized weight as well as increased durability to enhance the excavator performance and overall productivity.

The simple design has no greasing requirements, which means less maintenance and fewer replacement parts. www.doosanequipment.eu

Bulk Solids Today

19

SIEVES, SIFTERS, SEPARATORS & SCREENING

GERICKE GS CENTRIFUGAL SIFTER: EVOLUTION NOT REVOLUTION

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n commencing his position as General Manager at Gericke UK, Colin Arlott assessed the information and feedback from existing centrifugal sifter installations and decided that a new machine with an evolved design was required to meet todayâ&#x20AC;&#x2122;s productivity demands, a machine with sound engineered solutions fit to bear the Gericke logo.

The project began in earnest in January 2018 with the analysis of sifting machines in operation around the world, identifying the various design features which have proven successful with operators and maintenance engineers alike, and importantly, identifying features which had not performed as expected within process environments. This analysis provided a focus for evaluation and a direction to redesign Gericke sifters to set a new industry standard.

The process of centrifugal sifting remains mostly unchanged from the first machine concepts, whereby a paddle assembly rotating within a static hose is used to create a centrifugal force to push material against the sieve mesh and through pre-determined holes.

Whilst the concept is resolute, the demands of modern processes are ever increasing and the new range of Gericke GS sifters has been specifically designed to remain one-step ahead of these demands.

20

Bulk Solids Today

The new range of sifting machine provides time-proven application technology, yet allows for rapid inspection, cleaning, change-over, repeatability, access and maintenance.

Operational up-time is maximised with features such as improved 360° in-situ basket inspection and timeframes for removing the basket assembly, replacing the sieve hose and basket insertion have been significantly reduced. Additionally; the orientation and location of the basket within the sifter is accurately repeatable and the basket fixing is simple yet robust leading to a more secure and accurately position basket.

All of these features combine to minimise down-time, improve production, increase yield and maximise productivity.

Similarly, Gericke have reviewed the methods for construction, fabrication, part procurement, assembly and testing, taking them back first principles, analysing where commonality of parts, standardised fabrications and dynamic construction can be employed.

The Gericke UK based manufacturing team have been involved from the ground up to ensure all aspects of the machine are manufactured with best engineering practice, repeatability, minimised set-up, and standardised methodology. www.gericke.net

SIEVES, SIFTERS, SEPARATORS & SCREENING

ROQUETTE PROTECTS POWDERED GLUTEN FROM METAL CONTAMINATION WITH BESPOKE SOLUTION FROM ECLIPSE MAGNETICS

R

oquette is ensuring the highest standards of food safety and product quality with a bespoke double row magnet from Eclipse Magnetics. The unit consists of a double row of magnetic bars which has been installed as part of a new sifter installation for powdered gluten at its plant in Corby, Northamptonshire. As a global leader of natural-based ingredients for the Food, Nutrition and Health market, Roquette supplies gluten to a variety of blue chip food manufacturers.

Roquette needed to pass the powdered gluten product over an offset double row magnet with a minimum strength of 8000 Gauss, and approached experts in foreign body removal, Eclipse Magnetics, to meet the highest standards of safety and quality.

Eclipse Magnetics supplied Roquette with a bespoke double row magnetic unit with magnetic bars, which are not only withdrawable, but also easy to clean.

A catchment tray was also included to effectively contain any residual gluten which can be dislodged from the bars as they are withdrawn for cleaning.

The unit has been installed at the end of the process, before the product is filled into tankers or tote bags, and the residual product captured by the magnets is collected in clearly marked bags and disposed of.

Ian Aunger at Roquette said: “The result is an aesthetically pleasing system, which is effective in trapping metal contaminants and is easy to clean. Although the design of the magnet system was not easy because of the limited headroom and space, Eclipse Magnetics were willing and able to meet all of our design criteria.”

Foreign body removal systems from Eclipse Magnetics contain magnetic cores which can be pulled from stainless steel tubes to ensure that contamination falls away. They are extremely efficient at removing fine iron contamination from dry free flowing products such as sugar, grain, flour, granulates and powders.

The magnetic bars require no power and no maintenance (except for cleaning) and are quick and easy to install. Eclipse Magnetics often supplies custom designed and engineered solutions to suit specific requirements, as is the case with Roquette’s application. All product contact parts are manufactured

using food quality 316 grade stainless steel, are fully sealed, and supplied with test certificates.

Roquette is a global leader in plant-based ingredients and a pioneer of new vegetal proteins.

Currently operating in over 100 countries, the company has a turnover of around 3.3 billion euros and employs 8,400 people worldwide. As a commodity ingredient, powdered gluten is often used as an additive in baking to add elasticity to flours that would otherwise be low in gluten, such as whole wheat flour or rye.

As a global leader of natural-based ingredients for the Food, Nutrition and Health market space, Roquette aims to improve the health and well-being of millions of consumers around the world. Working with different stakeholders, Roquette offers the best of nature to respond to an increasing Global demand for Food, Pharmaceutical and Industrial applications. www.eclipsemagnetics.com Bulk Solids Today

21

SIEVES, SIFTERS, SEPARATORS & SCREENING

GKD: PLAYING A KEY ROLE IN THE RETENTION OF MICROPLASTICS ODW 6 stainless steel mesh proves indispensable in both research and real-world applications.

W

hether by car, on foot, during daily personal grooming, or when doing laundry: plastic microparticles find their way into sewer systems and then into the oceans via rivers and lakes. According to estimates, some 2.5 million tons of microplastics - i.e. plastic particles less than five millimeters in size - are flushed into the oceans every year. In the battle against this global environmental problem, Germany’s Federal Ministry of Education and Research (BMBF) initiated one of the largest research programs in the world with 18 projects on the topic of plastics. The aim is to research the origin, distribution, and effects of the microscopic plastic particles and have solutions developed to avoid their entry into bodies of water by 2021. In several of these projects, optimized dutch weaves (ODW) from GKD - Gebr.

Kufferath AG, technological leader in the field of woven filter media, play a key role in terms of researching microplastics. They are proving to be a highly efficient solution, not just at sewage plant outlets but also for filtration of both mixed water and street runoff water.

60 years after the development of plastic, according to a current study undertaken by the International Union for Conservation of Nature IUCN, some 300 million tons of plastic are being consumed worldwide each year. In Germany alone, the annual per capita quantity of plastic waste is 25 kilograms, some 4 kg of which comprise microplastics. Abrasives in cosmetics, detergents, and cleaning products, as well as the fiber abrasion that occurs during washing and drying synthetic textiles, are also making a significant contribution to this.

The abrasion of shoe soles is another key source of microplastics. However, by far the greatest polluter in Germany is tire abrasion with 110,000 tons per year.

Around a quarter of all microplastics that find their way into the oceans come from the outlets of sewage plants, while two thirds come from street runoff. The TU Berlin, together with a range of project partners, is addressing both of these routes of entry in two research projects. GKD is the only company from the processing industry to be integrated as a development partner in both of these projects. In the project entitled Optimized materials and processes for removing 22

Bulk Solids Today

microplastics from the water cycle (OEMP), GKD is not only technology partner, but also project manager. To improve retention of microplastics in municipal waste water treatment operations, the key was to develop new filter media that can retain particles larger than 5 to 6 µm and also maintain the flow rates required at sewage plants. Due to their characteristics, the plastic media predominantly used here offer a maximum pore fineness of 15 µm - albeit with tolerances from 4 to 5 µm.

REAL-WORLD TEST AT A SEWAGE PLANT OUTLET PASSED WITH FLYING COLORS On the basis of the tried-and-tested stainless steel optimized dutch weaves, which have also been in use in the water industry for quite some time, GKD developed versions of this metallic mesh range with filtration rates in the micro-filtration range that boast apertures of 8 and 6 µm. For example, ODW 6 achieves an absolute pore size of 6 µm with its woven pore structure. This allows system operators to reliably prevent any spherical particles larger than 6 µm from entering surface waters.

Despite the impressive performance on offer, this ultrafine filter medium still guarantees the requisite water flow rate. Following numerous laboratory tests, these innovative high-performance meshes are successfully demonstrating their filtration efficiency for microplastic retention in real-world pilot systems at the Ruhleben sewage treatment plant in Berlin. According to studies, previous systems at modern sewage plants retained 98 percent of plastic particles. However, disc filters with ODW fitted can significantly reduce the remaining proportion. When using the standard mesh ODW 20, the proportion of particulate material in the outlet water is already reduced to two milligrams per liter of dirt load.

The ODW 6 meshes then reduce this by a further 50 percent, while maintaining a comparably high flow rate.

This means that only one milligram of these filterable materials are then contained per liter of dirt load. Similar results were also achieved with measurements taken in combined sewage tanks at the Berlin waterworks, whose mix of street runoff water and untreated household wastewater represents the most demanding type of wastewater. The single-layer mesh design combines this excellent particle retention with a high degree of dirt holding capacity, low clogging tendency, good

SIEVES, SIFTERS, SEPARATORS & SCREENING backwashability, and rugged mechanical strength.

Unlike the plastic filters previously used, the ODW meshes produced from stainless steel wire are also insensitive to process-based abrasion, meaning that they do not cause any contamination due to abrasion.

For GKD the focus of the project is the treatment of waste water in the sewage plant. Despite the already high-tech and sophisticated treatment of waste water, the tiniest of plastic particles are still able to pass through sewage plants and flow into rivers, lakes, and ultimately oceans. To find out how much microplastic can actually pass through a sewage plant, a disc filtration system constructed by Invent Umwelt- und Verfahrenstechnik was installed at the most productive sewage plant in Berlin, the Ruhleben sewage plant, in December 2016. The filter discs are fitted with optimized dutch weaves from GKD. They are used to filter the water from the sewage plant run-off, that is to say water that has already passed through all cleaning stages in the treatment plant.

99 PERCENT PARTICULATE MATTER RETENTION RATE IN STORM SEWERS The engineering and manufacturing expertise demonstrated by GKD in the OEMP project even provided sufficient motivation to incorporate the Dürenbased filtration experts again in the follow-on project entitled Tire abrasion in the environment (RAU). Here, GKD took on the task of developing a sampling basket to facilitate investigation of the formation, nature, and entry of tire abrasion into street runoff thanks to defined fractionation of particulate material. This basket was modeled on the leaf collecting baskets used in standard

street drains, which ensured its universal usability. Using the same dimensions, GKD developed a sampling basket whose core element is an integrated filter cascade. These “sieve stacks”, each comprising up to six sieve pans that employ filter media of various pore sizes, make it possible to automatically record and test the various fractions of a complete rain shower - from a light drizzle, all the way up to real downpours - thanks to integrated online measurement functionality. The ODW 6 mesh plays a key part here as well, as it secures retention of all particulate material larger than 6 µm. In total, GKD is making 40 of these sieve stacks available for the RAU project for testing in Berlin - on a six-lane highway that is used by 30,000 trucks and passenger vehicles every day, as well as on the test circuit of tire manufacturer and project partner Continental or on the runway at Berlin airport.

CROSS-PROJECT EXPERTISE REQUIRED IN RESEARCH AND INDUSTRY Since these sampling baskets allow scientifically substantiated and thereby comparable sampling of the entire street runoff water to be guaranteed for the first time, various other companies and institutions have already turned to their inventor, GKD. With these sieve stacks, the filter specialist is also supporting the project entitled Representative investigation strategies for an integrative understanding of systems used for specific entry of plastics into the environment (RUSEKU) under the leadership of the Federal Institute for Materials Research and Testing (BAM) in Berlin. A well-known household appliance manufacturer also relies on these sieve stacks in its research activities for modification of its own devices and their processes. www.gkd.de

DON’T MISS OUT REGISTER TODAY To receive regular copies of BST please register at www.bulksolidstoday.co.uk

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23

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Bulk Solids Today

Remote Silo Monitoring

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www.ajax.co.uk email: solids@ajax.co.uk

Sieves & Sifters

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Posi-flate Milton Keynes England +44 (0) 1908 622366

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Intermodal dry bulk logistics for polymers, chemicals & minerals Cost effective Environmental savings Reduced C02 emissions

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InterBulk GROUP

Bulk Solids Today

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Global sieving & filtration specialists The Russell Compact SieveÂŽ

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