November 2023 - Volume 20
Process Plant Digitalization Seen Holistically Page 8
10 SAFETY: Cutting, Dosing and ISSN : 2031-9177
Packing with Safety Drives
VALVES & 16 PUMPS, COMPRESSORS:
Efficient and Reliable Bulk Solids Handling
Freshness Protection for Natural Mineral Water
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Dear Reader, Like every journey since time immemorial, the digital transformation journey also requires a number of pitfalls to be navigated and mistakes to be avoided in order to reach the destination as quickly and smoothly as possible. Companies that take on this complex of topics are faced with a large number of very different areas that need to be reviewed and adapted. New topics have to be explored and it may be necessary to say goodbye to cherished habits in order to arrive at a new, sustainable business model. To be successful, companies must have a clear vision, take a holistic approach and be ready for continuous learning and improvement processes.
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So, there's a lot to plan for even before the launch. But like any journey, this one starts with the first step, and it's always beneficial to not have to go alone, even if your are less than 9 companions. The cover story on page 8 gives an example of what digital transformation can look like. Further interesting articles on the subject of water are presented on page 12, and on page 18 you can find out how old pumps for water supply can be made fit for reliable operation through maintenance and overhaul.
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N° 11 - NOVEMBER 2023
Volume 20 - Issue 11
March 2024 Digital Transformation: Analytics, Engineering, Simulation Explosion Protection & Safety Special Food & Beverage
Process Plant Digitalization Seen Holistically
SAFETY & EXPLOSION PROTECTION: Cutting, Dosing and Packing with Safety Drives
SPECIAL FOCUS WATER
Pure and Affordable Drinking Water for a Whole Region
PUMPS; VALVES & COMPRESSORS: Efficient and Reliable Bulk Solids Handling
PUMPS; VALVES & COMPRESSORS: Maintaining Water Supplies. Repair expertise supports reliability of water utilities with large-scale pump refurbishment project in Africa.
Sustainable Freshness Protection for Natural Mineral Water
ENERGY & SUSTAINABILITY
Steel Mill's Compressors Revived to Enhance Sustainability
Heat Recovery System Helps to Reduce Carbon Footprint in Soft Drink Production
Pushing the Limits of Technical Feasibility. Optimization of material transport in mining operations.
N° 11 - NOVEMBER 2023
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5 Feasibility Study for Optimization of Efficient Energy Use The Port of Rotterdam Authority and Yokogawa Electric Corporation announce that they have initiated a feasibility study into increasing cross-industry integration for the efficient use of energy and utilities in the Rotterdam industrial cluster to contribute to ambitious regional decarbonization goals. Individual companies in the petrochemical industry have generally highly optimized their own operations. But concerns about exposing confidential information often hamper them from looking ‘beyond the fence’ to work with other companies in an industrial cluster. The Port of Rotterdam and Yokogawa aim to break through this barrier by facilitating confidential sharing of data and deeper integration within the cluster to unlock the large potential efficiency gains of optimizing production across entire industrial clusters. Through integration of multiple utilities such as heat, electricity, and hydrogen, industrial flexibility can be increased, which leads to new efficiencies. Overall, this multi-utility approach could make a relevant contribution to energy savings and emissions reduction. The first results of the feasibility study are expected by the end of 2023. If sufficiently positive, the next step will be to develop plans for carrying out field trials with cooperating companies in the port from 2024.
FDT Group, an international, non-profit industry association supporting the evolution of the FDT® technology standard for industrial device management, announced that André Uhl, vice president of technology and architecture for Schneider Electric’s Industrial Automation Business, has received a unanimous vote to serve as the Chairman of the FDT Board of Directors. The Chairman's primary role is to ensure that the Board of Directors effectively sets and implements the organization’s strategy and governance of the standard. The IEC 62453 standard directly benefits global manufacturing industries with a unified environment for industrial device management supporting brownfield, greenfield and new smart manufacturing initiatives in the process, hybrid, and discrete markets. Mr. Uhl replaced Lee Lane from Rockwell Automation as chairman due to his departure to a new role. Other board members include Shinji Oda, Yokogawa; Ed Silva, Flowserve Corporation; Rolf Birkhofer, Endress+Hauser; Paul Brooks, Rockwell Automation and Michael Kessler, PACTware. Mr. Uhl has over 20 years of industry experience managing Research & Development (R&D) centers in the process, hybrid, and machine builder markets.
Refocusing on Core Areas of Business The long-established German-based company Schenck Process is moving into a more sustainable future after the carve-out of its food solutions to Hillenbrand/ Coperion. The expert for process-critical bulk solids applications is now focusing 100% on its core competencies of weighing and feeding technology with over 300 patents as well as further developed digital applications. New and green process technologies are to contribute to a climate-neutral circular economy in the target industries of chemicals, high-performance materials, cement, steel, and energy - with further optimised customer service. Under the leadership of the new CEO Dr Jörg Ulrich, the company is ushering in a new era following the carve-out of the food division. "The business units in Europe, China, and India will benefit greatly from the new size of the company, which has changed from 2,500 to 1,100 employees," says Jörg Ulrich confidently. "We combine our premium products, our bulk solids expertise, our advanced digital solutions, and our global reach with the advantages of a medium-sized company in terms of focus, agility, reliability, highperforming teams, and proximity to our customers."
©Schenck Process Holding GmbH
André Uhl Appointed as New Chairman for the FDT Group Board of Directors
ABB Invests $280 Million Into European Robotics Hub ABB announced an investment of $280 million to expand its manufacturing footprint in Europe and build a new state-of-the-art ABB Robotics European Campus in Västerås, Sweden. The Campus will serve as the hub for ABB Robotics’ offering in Europe, providing customers with AI-enabled collaborative and industrial robots, as well as digital solutions to support flexible automation as part of the company’s “local for local” production strategy. Replacing the existing robotics facilities at the site, the new Campus is planned to open in late 2026. “The investment in our new Campus is driven by customer demand and projected market growth,” said Björn Rosengren, ABB CEO. “Following important investments in China and the U.S, the new facility in Sweden will strengthen our capabilities in serving our customers in Europe with locally manufactured products in a growing market. Already today, around 95 percent of the robots ABB sells in the region are manufactured here. This is a strong commitment not only to our “local for local” strategy, but to all our robotics customers across Europe.” With the facility, ABB will expand production capacity by 50 percent and strengthen its capabilities to supply the European market, which is expected to grow at seven percent CAGR through 2027. FREE DIGITAL SUBSCRIPTION
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N° 11 - NOVEMBER 2023
6 IO-LINK MASTER FOR PNEUMATIC VALVES
VERSATILE ULTRASONIC FLOWMETER
Possible reduction of hardware costs on the G3 fieldbus
With ASCII Flow Streaming for direct monitoring
Emerson has introduced a new Class A, IO-Link master that provides customers with a cost-effective solution for smart and analog sensor connectivity on the AVENTICS Series G3 Fieldbus platform. The G3 IO-Link Master is suitable for machine architectures with many sensors and pneumatic valves, and where it's important to have reliable digital data communication between field devices, such as sensors and the machine controller. The IO-Link master provides pneumatic valve control through direct digital data communication with the machine controller. It offers event-based and I/O mapped diagnostics - both important predictive maintenance requirements for Industry 4.0 and IIoT. By adding the IO-Link capabilities to the valve systems, customers can include multiple IO-Link masters on only one G3 Fieldbus platform, saving hardware costs, thus enabling customers to be future-proof and positioned for Industry 4.0/IIoT application requirements. Costs can be cut by reducing the number of communication nodes. G3 IO-Link master is optimized for sensor-rich applications with eight Class A ports per module to support multiple IO-Link smart and standard analog sensors. The IO-Link master can be distributed up to 30 meters away from G3. Together with the 20-meter IO-Link cable length maximum, the sensors can be located up to 50 total m in total from the G3 Fieldbus platform.
Titan's versatile Atrato® line of ultrasonic inline flowmeters now has ASCII flow streaming capability via USB and is reverse flow enabled, enhancing its capacity to be optimised for the user's application, in addition to its datalogging and diagnostic features. The device's USB connection gives the Atrato® flowmeter computer interface capability, enabling the user to directly monitor the flow rate being measured and alter the operating parameters using a laptop PC. The additional ASCII flow streaming means the measured liquid flow is output at 10-20 times per second in human-readable text form (ASCII encoded). This stream of data can then be interpreted and processed by software running on the USB host. This means that flow measurements are streamed directly over the USB connection to the PC and are configured directly to the user's software system such as LabVIEW. Titan's Atrato® ultrasonic flow devices are ideal for low flow applications and precision process control, laboratory processes and chemical dosing. Ultrasonic flow meters are also becoming an important flow metering sensor within petrochemical process applications. With the patented 'time-of-flight' ultrasonic technology, the Atrato® flow meters operate with unmatched accuracy over a flow range of 2ml/min to 20l/min.
64068 at www.pcne.eu
64123 at www.pcne.eu
USER-FRIENDLY MACHINE CONTROLLER
IE5-MOTOR FOR USE IN HAZARDOUS AREAS
Easy-to-use control solution with IIoT functions
Saving Energy in potentially explosive environments
The latest Mitsubishi Electric addition to the's MELSEC iQ-F series of compact, high-performance PLCs is ideal for simple, straightforward applications in the food and beverage, water and machining industries, for example. It offers Industrial Internet of Things (IIoT) functions for effective entry-level industrial automation applications. The FX5S is easy to configure and use, streamlining deployment and enabling users to quickly set up installations. This intuitive system also delivers the level of highspeed performance required by accurate positioning applications. End users and machine builders can leverage the FX5S to develop and implement cost-effective machines with up to 60 I/O points. In particular, when looking at IIoT capabilities, the solution offers data logging and data flow analysis functions to speed up and enhance troubleshooting and root cause analysis. As the PLC features a built-in web server, operators can also remotely access these functions and monitor operations at any time, further improving responsiveness and flexibility. Thanks to its compatibility with CC-Link IE Field Basic, an open industrial Ethernet technology, the controller can be seamlessly linked with other automation devices such as HMIs, drives and remote I/O. This ensures reliable communications and facilitates the creation of interconnected shop floors.
ABB has extended its awardwinning IE5 SynRM (synchronous reluctance motor) series with a brand-new addition: the IE5 SynRM Increased Safety motor. The new version has been developed for use in potentially explosive atmospheres across a wide range of demanding variable speed industrial applications. It offers accurate control and high efficiency throughout the whole speed range, even at partial loads. This makes it the ideal upgrade choice for standard induction motors in pumps, fans and compressors for industries where explosive gas, vapor or dust might be present, such as oil and gas, chemicals, wood processing and flour milling. In addition to energy savings, the new SynRM Increased Safety motors can help customers specify a more cost-effective installation. For example, in Zone 1, the cooler running design could allow the use of an increased safety motor where a flameproof motor with a special enclosure would be the traditional choice. While in Zone 2, the improved loadability of SynRM motors, that enables more power to be delivered from the same size as an induction motor, is important. A key benefit of IE5 SynRM Increased Safety motors is that they run cooler than standard designs and therefore live longer. IE5 SynRM Increased Safety motors are available with output power of 5.5 to 315 kW in frame sizes IEC 132-315.
64124 at www.pcne.eu
64070 at www.pcne.eu N° 11 - NOVEMBER 2023
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7 COLOR SENSOR FOR LABEL INSPECTIONS
HUMIDITY AND TEMPERATURE SENSOR
Reliable inspection for pharmaceutical packages
Heatable sensing element guarantees long-term stability
Medication packaging must be properly labelled. Imprinted are serialization data, the bar code and additional information. The correct positioning of the label is also important. Therefore, smart colorSENSOR CFO100 sensors from Micro-Epsilon are used for absolutely reliable label inspection. The colorSENSOR CFO enable 100% quality control and ensure smooth processes in the labeling of pharmaceutical packaging. For this measurement task, the sensor is positioned at a distance of 5 mm above the boxes in the labeling machine. The sensor receives the light and passes it on to the controller of the color measuring system via the optical fiber where the signal is evaluated. The digital switching output of the controller passes the OK/NOK value directly to the machine control system. If labels are missing or in the wrong position, the medication packaging is immediately sorted out by the machine and relabeled. The advantages of Micro-Epsilon color sensors are their high color accuracy and repeatability. Therefore, they are ideal for 100% inline control. Even at high belt speeds, they measure precisely and allow rework during operation. Up to 320 colors in 254 color groups can be taught. Operation is easy via the web-based interface. The sensor system also offers an attractive price-performance ratio.
The HTS801 is particularly well suited to use in applications with high humidity and chemical exposure. The base is E+E's sensing element with monolithic structure. An integrated heater enables targeted heating of the sensing element to prevent condensation and its negative impacts on the measurement results. Depending on the requirements, two type-specific operating modes are available. The "Condensation Guard" in case of a short-term risk of condensation and "High Humidity Guard" for permanent exposure to high humidity. In addition to this, all HTS801 models have an Automatic ReCovery (ARC) function. ARC removes chemical impurities and eliminates possible drift effects through short-term intensive heating of the sensing element. Furthermore, the tried and trusted E+E sensor coating protects the sensing element and its leads against corrosion or deposits. This coating extends the sensor's service life, ensuring accurate measurement results and improved long-term stability in harsh or corrosive environments. Thanks to its wide operating range from -80 °C to 180 °C and 300 bar, the HTS801 is suitable for a variety of applications. The rugged polycarbonate or stainless-steel enclosure, featuring IP65 / NEMA 4X protection, supports easy mounting and maintenance of the HTS801. The HTS801 offers the option of smart, pluggable sensing probes.
64119 at www.pcne.eu
64092 at www.pcne.eu
ONE-CABLE POWER AND SIGNAL INTERFACE
IO-LINK RADAR SENSOR
IP67-connector with quick locking for high power density
For level measurement in a hygienic environment
binder presents the Power Bayonet Connector PBC15. Its size corresponds to an M15 thread. Thus, in the field of power supply connectors, the PBC15 bridges the gap between the widely used M12 and M23 designs. The compact, yet robust connector is suitable for power supply particularly to three-phase motors or frequency converters. It features 3 power pins, for example to supply the 3 live phases of a 3-phase motor, 2 additional pins for signal transmission, as well as a Protective Earth (PE) contact. The PBC15 design is specified within the DIN EN IEC 61076-2-116 standard. The quick-lock ensures simple, fast, and reliable locking by means of a quarter turn. Termination is provided by screw clamps. The PBC15 is initially available from binder as wireable female or male cable connectors, in each case as an unshielded or shieldable variant. Thanks to the rated values of 630 V and 16 A for the power interface, the circular connector is suitable for the power supply of small to medium-sized drives. With rated values of 63 V and 10 A, the signal pins can be used, for example, to control brakes or to query operating parameters such as temperatures. The shieldable variants of the Power Bayonet Connector are prepared for use in environments exposed to electromagnetic interference.
Equipped with IO-Link and versatile hygienic adapters, the new VEGAPULS 42 radar level sensor meets the key requirements of modern industry: to perform complex measuring tasks faster, be simple to use and more cost-effective. VEGA has launched a new radar level sensor especially for highly automated processes with stringent demands on hygiene and capable of following fast level changes. Since the various automation technologies in many factory environments are increasingly converging. The device is designed specifically for medium measuring distances of up to 15 metres and temperatures of up to max. 150 °C. The instrument is geared to circulation systems in production, dosing processes and downstream processes, like those found in conveying and filling systems. It ensures a smooth-running process wherever a level changes quickly and requires continuous monitoring. VEGAPULS 42 is based on a radar chip with the widest dynamic range, which offers excellent performance and application versatility. The IO-Link communication technology offers, which is common in factory automation, enabling bidirectional data transmission together with extensive diagnostics and parameterisation. For IO-Link sensor VEGAPULS 42 this means: maximum signal quality at minimal cost and complexity
64113 at www.pcne.eu FREE DIGITAL SUBSCRIPTION
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64125 at www.pcne.eu N° 11 - NOVEMBER 2023
8 cover story Process Plant Digitalization Seen Holistically A digital twin is not only the basis for a holistic view of the system and the individual processes. It is also the basis for automatic routines that react autonomously to changes in the process. It helps applications identify unwanted situations and the countermeasures to be taken often long before the plant comes to a standstill. Predictive maintenance is a key to the efficient operation of a process plant. However, digital processes are not a question of individual products or components, but require the seamless interaction of people and systems. Authors: Andreas Hennecke & Yannick Klein, both Pepperl+Fuchs SE, Andreas Wick Neoception
The vital step is a complete digital image of the process plant within the process control system. For this purpose, the system must be aware of the entire process instrumentation. Every sensor and actuator not only needs to permanently reveal its current operating status. It must also provide information about signs of wear or if an imminent failure is to be expected. The result is a digital twin of the entire system that represents exactly what is currently happening out in the field. “Ethernet-APL brings networking right down to each and every field device, even in potentially explosive areas. Thanks to this technology, nothing prevents the fully digital process plant, which exploits the full potential of IIoT and Big Data for operation, maintenance and optimization," says Michael Kessler, Vice President of Components and Technology at Pepperl+Fuchs. Manufacturers like Pepperl+Fuchs no longer just think in terms of individual products and technical features. They are in the process of changing from a pure product provider to a developer of complete solutions. The focus is on the customer's problem, and it is about a seamless migration path that protects existing investments in the communication infrastructure and at the same time supports the change to a fully digital process plant. BETTER INFORMATION FOR FASTER REACTION An illustrative example of this development are digitally controlled processes for maintenance and troubleshooting, which can be made much more targeted and time-saving with the help of real-time information from
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Digital transparency and efficiency: The explosion-proof mobile device for targeted on-site service. the digital twin. The time of simply reacting to technical failures is definitely a thing of the past. The goal is predictive maintenance: Any change in the behavior of a field device is detected at an early stage. Foreseeable issues will be addressed during the next scheduled maintenance. Service technicians can react faster and more specifically. System failures will turn into an absolute exception. We are talking about intelligent systems that not only monitor the physical condition of individual field devices and system components. They also use historical data and knowledge about past wear characteristics to make problematic developments visible long before a system failure can occur.
If a component gets into a critical state during operation or even threatens to fail, the predictive maintenance system not only ensures that a warning is triggered immediately. This warning is also enriched with specific information about the type of problem detected and with specific recommendations for action. As a result, in many cases, the service technician already knows in advance where the problem lies. He doesn't has to start troubleshooting on site, but ideally, he already has the required spare part with him when he gets active in the field. This means that he can correct the error right away (1st-time fix), which significantly increases the efficiency of the service deployment.
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another aspect of a digitally supported maintenance system comes into play: Since the digital twin can provide all information about the system down to each individual field device, the crucial technical know-how about the system is not only in the head of the employee, but also stays with the Company. Once the know-how is an integrated part of the system, new service technicians can be easily guided via on-the-job training without compromising service quality. In the event of vacation or illness, due maintenance work can also be carried out by less experienced employees.
Display and operate processes in the field – according to GMP and with explosion protection up to Zone 2/22. The communication technologies used are Ethernet-APL, WLAN and 4G/5G mobile communications, comprising a self-sufficient campus network. This is a private 5G network that provides highly secure wireless communication across the entire plant, allowing access to the information of the digital twin from anywhere within the plant. Each device in the field is provided with a Digital Name Plate. This is a QR code that is used
Infrastructure for process automation: Remote I/O and Ethernet-APL switch. FREE DIGITAL SUBSCRIPTION
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to uniquely identify the device in question. Pepperl+Fuchs uses its intrinsically safe smartphones, tablets or even smart glasses to communicate with both the hardware in the field and the plant control system. When a fault is reported, the QR code is first read with the mobile device in order to precisely verify which field device has reported a problem. The digital twin then provides a graphic representation of the component in question, which is displayed on the handheld display and clearly visualizes where the error is and which procedures are required to replace the component in question. Not only configuration and device data can be called up via the mobile device. It is also possible to directly trigger a repeat order if the defective component is not in stock. In addition, the worker uses the mobile device after completing maintenance work to verify the function and for direct and digital paperless documentation of the entire process. KNOW-HOW MIGRATES INTO THE SYSTEM Service technicians are valuable knowledge carriers for the company. If such an employee leaves the company, a lot of routine and background knowledge is lost. That is where
But that's not all: Using a suitable headset with smart glasses, the service technician can not only display specific device drawings, illustrations and assembly instructions for the component to be serviced. To solve specific problems, he can also trigger a video call directly on site and contact specialists from within or outside the company to be instructed verbally. Running processes can also be displayed and operated via stationary operating stations that are distributed throughout the plant. To operate them, employees can authenticate themselves with their personal access data for example quickly, easily and securely using RFID data carriers. Operating stations with thin clients – socalled remote monitors – allow access to virtual machines on which the applications are running. This means that expensive hardware can be dispensed with, since only the user interface is executed, which saves on computing processes in the hazardous area. Devices such as thin clients and remote monitors can be managed remotely. Service technicians or administrators can maintain and update all devices centrally by connecting to the server, to which the thin clients and remote monitors in turn connect. For this purpose, Pepperl+Fuchs offers innovative software tools (Control Center for central management and VisuNet RM Shell 6 as firmware for the devices) that minimize maintenance efforts and increase efficiency. 63318 at www.pcne.eu
N° 11 - NOVEMBER 2023
10 safety&explosionprotection Cutting, Dosing and Packing with Safety Drives Food and packaging machinery pose special challenges for drive and automation solutions. Functional safety concepts are of particular importance to overcome these challenges. Food and packaging applications are characterised by harsh environmental conditions. In many cases, the machines are cleaned with aggressive washing substances and high pressure. Motors, frequency inverters and controllers must therefore be robust and hard-wearing. The circuit boards in the current series of drive controllers from KEB Automation are equipped with a protective lacquer specially developed for these environments. HMI control panels from KEB are made from stainless steel and are protected to IP69K. High pressure cleaning and even temperatures up to 50°C do not affect the devices. Performance is also important: food and packaging machines must ensure precise cutting, dosing, mixing and filling in the shortest of cycle times. For this purpose, KEB offers compact, energy-saving, dynamic drives with high overloads and precise control. FUNCTIONAL SAFETY FROM DRIVES Up to now, safety technology was often set up decentrally with external safety modules.
These were expensive, complex to wire and required space in the control cabinet. KEB builds functional safety concepts in a smart way. Functions such as “Safe Torque Off” (STO) or “Safely-Limited Speed” (SLS) are integrated in the COMBIVERT range of drive controllers and can be selected on a modular basis. Wiring is not required if a safety controller with, for example, Safety over EtherCAT or PROFIsafe is used. With many speed-based safety functions, the safe encoder can even be eliminated. With KEB’s integrated safety function “Safe Door-Lock Control” (SDLC) door switches on food processing machines with knife drives, for example, are only released when the knife has come to a standstill. An external module for monitoring is not necessary. COMPLETE SYSTEM SOLUTIONS From HMIs, controls and drives, to motors, brakes and clutches, KEB implements drive solutions from a single source. Individual
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components are optimally matched to each other, resulting in maximum machine efficiency. As, for example, the motor and drive controller harmonise perfectly, KEB also complies with the new IE2 energy efficiency label according to the EN 61800-9-2 standard. Another advantage for the machine builder is that there is only one contact person required for all matters concerning the drive. The flexibility of interfaces to components from thirdparty suppliers is retained in all this, in order to integrate components effortlessly into existing systems. Headquartered in Barntrup, Germany, KEB is a medium-sized global business with a workforce in excess of 1,400 worldwide, with more than 10% of these working in research and development. KEB group consists of 10 subsidiary companies worldwide, and Sales & Service Centres in a further 23 countries to support its growing customer base. 64114 at www.pcne.eu
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SAFETY LOGIC SOLVER AND ALARM Certified for Safety Instrumented Systems up to SIL 3 Moore Industries releases the SLA Multiloop and Multifunction Safety Logic Solver and Alarm, designed and built from the ground up to IEC 61508:2010 standards and is exida certified for use in Safety Instrumented Systems (SIS) for systematic integrity up to SIL 3 and for random integrity up to SIL 2. The SLA performs as a multiloop logic solver with built-in voting and enhanced math capability typically found in costly and complex safety PLCs. This allows the SLA to handle everything from simple alarming to more complex schemes, enabling it to act on potentially hazardous process conditions, warn of unwanted process conditions, provide emergency shutdown, or provide on/off control in Safety Instrumented Systems and traditional alarm trip applications. The 4-wire (line/mains powered) SLA accepts up to four discrete and six analog inputs from a wide array of devices and sensors. HART data from connected field devices is passed through the SLA to its analog outputs enabling connected hosts and bi-directional communication for continuous monitoring and programming. Its four relay outputs and up to four discrete contact closure outputs can be driven by any of 16 internally configured alarms, where individual or multiple alarms can be assigned to each relay or discrete output. 64057 at www.pcne.eu
IIOT POWER SUPPLY FOR EXCOM I/O SYSTEM
ASME VIII Approved US Patent Technology 100% Italian Design
Monitoring for high availability applications up to ATEX 2 Turck has upgraded the power supply modules of its excom high availability system with two variants for IIoT data. The PSM243G.1 supplies power to excom systems in Zone 2/22 while the PSM24-N.1 supplies power to excom systems in the safe area (N system). Compatibility with previous power supply modules is retained. Power supply redundancies can be made from a combination of old and new modules. The additional IIoT data of the new modules is also transferred via the Ethernet gateway modules. Turck's new power supply modules ensure the long term operational capability of the I/O system. Compatibility with previous power supply modules and excom systems allows existing excom installations to be upgraded with IIoT functions. The systems output diagnostic data in accordance with NAMUR NE107 via the Ethernet gateway. Process data can also be accessed via a parallel read access without affecting the integrity of process communication. This data can be used for predictive maintenance systems or monitoring and optimization measures (M+O). excom is the most compact I/O system of the redundant systems for high availability applications and Ex areas. Another feature that distinguishes excom from comparable systems is the closed system approval.
64069 at www.pcne.eu FREE DIGITAL SUBSCRIPTION
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63056 at www.pcne.eu
Pure and Affordable Drinking Water for a Whole Region Veolia Water Technologies has built an ultra-modern plant to produce drinking water in Ostend, Belgium. In a multi-stage filtration process, the water supplier is now producing drinking water of excellent quality – far above the statutory requirements. At critical points of the process – during reverse osmosis, filtration with activated carbon and remineralisation of the water – sliding gate valves made by Schubert & Salzer Control Systems are responsible for regulating pressure and flow rate. The water supplier, FARYS, produces drinking water for the city of Ostend and its surrounding area from the brackish water in the Bruges-Ostend Canal. In the current development stage of the waterworks built by Veolia Water Technologies, up to 1,200 cubic metres of drinking water per hour can be fed directly into the pipe network. The plant constructed by the leading specialist for water treatment is the largest Belgian
drinking water production facility using Reverse Osmosis (RO) technology and the production speed is among the fastest in the world. It is also unique that the installation can be used very flexibly within a variety of canal water qualities and that the entire process is done within considerably reduced energy costs. Frederik Debaillie, project manager of Veolia Water Technologies Belgium, describes the pro-
One DN125 and one DN50 sliding gate valve are used in each of the twelve reverse osmosis units.
In the multi-stage filter process, up to 1,200 cubic metres of drinking water per hour can be extracted from the brackish channel water.
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cess as follows: “The canal water is treated in eight stages. First, in coarse, fine and microfiltration, all suspended particles, microbiological substances and pathogenic microorganisms are removed. During the subsequent reverse osmosis, fine-pored, semipermeable membranes filter microcontaminants up to particle sizes of 0.1 nanometre as well as minerals and salts.” Only water molecules remain. This water is
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13 Size comparison between a normal seat valve and a Schubert & Salzer sliding gate valve. In the example, the nominal size of both valves is identical.
sent through activated carbon filters and after injection with carbon dioxide, remineralised with limestone. Finally the water is disinfected with UV light and then chlorinated. The result – drinking water of the highest quality – is fed into the pipe network via buffer storage tanks. “The operator of the waterworks wanted a facility that works cost-effectively. Maximum energy efficiency was required everywhere – even at the control valves”, explains Tristan Lejeune, International Sales Manager at Schubert & Salzer. “Equally, reverse osmosis and the subsequent process stages are demanding applications. There are special requirements here in terms of the control accuracy and reaction speed of the valves used.”
The decisive factor for the high precision and extremely short response time of the sliding gate valves is their special design principle. The sliding gate technology controls the flow rate in milliseconds, by two slotted sealing discs arranged vertically to the direction of flow moving on top of each other. The pneumatic actuator only has to overcome the sliding friction between the two discs. This means that the required actuating force is up to 90 per cent less than on other types of valves. The actuators can be dimensioned considerably smaller and the need for control air can be reduced. Simultaneously, the short strokes of only a few millimetres and the reduced kinetic masses of the throttle element protect the actuator and the spindle seal.
SLIDING GATE VALVES PROVIDE EFFECTIVE PROTECTION AGAINST DAMAGE “During the reverse osmosis process, precise and fast pressure regulation is very important”, emphasises Debaillie, the Veolia engineer. “The highly sensitive filtration layers are rolled up in pressure pipes. Pressure shocks and excessive flow quantities have to be reliably prevented. Even the slightest overshoots in the control process could damage the expensive membranes. That is why we use one DN125 and one DN50 sliding gate valve produced by Schubert & Salzer in each of the twelve reverse osmosis units. They ensure the exact regulation of the high process pressures that are necessary to compensate for the osmotic pressure of the brackish water and keep the reverse osmosis going.
MATERIAL AND ENERGY EFFICIENCY HELP OVERALL COST-EFFECTIVENESS “The special design principle of the sliding gate valves has a double positive effect on the weight and dimensions. On the one hand, the valves are smaller and lighter due to the intermediate flange design and the smaller actuators. On the other hand, the significantly better flow properties due to the particularly high KVS values also allow the use of smaller nominal sizes, which makes these valves even more compact and lighter than common alternative solutions”, explains Lejeune. Hence the 45 sliding gate valves in the plant weigh just 1,100 kilograms altogether. Seat valves in comparison would weigh in at around 5 tonnes. This differ-
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ence is considerable and, due to the savings on resources and CO2, has positive effects over the valve’s entire life cycle – from manufacture to transport through to its operation in the plant. The maintenance and hence the operating costs are also reduced because of the more compact dimensions and low weight. “The long service lives of the sliding gate valves were also a decisive point. These result, among other things, from the fact that they neutralise the damaging effects of cavitation”, says Lejeune. In alternative globe valves, imploding cavitation bubbles often cause cost-intensive wear due to erosion. “Due to the special design of the sliding gate valves without flow deflection, the cavitation bubbles implode one to two metres behind the valve in the pipeline. This can easily be designed so that no damaging effect arises from the cavitation. For this purpose, it is sufficient to run the pipe straight for a short distance after the valve”, adds Lejeune. EVEN UTILISATION DUE TO HIGH-PRECISION POSITIONERS “Before the treated water is fed into the region’s pipe network, we use DN150 sliding gate valves during the activated carbon filtration and remineralisation with limestone and CO2”, adds Debaillie. Here too, the high-precision Schubert & Salzer positioners, combined with the sliding gate valves, guarantee extremely accurate flow control, such that the eight activated carbon filters and 13 remineralisation tanks are evenly utilised. In this application, a linear flow characteristic curve proves to be particularly suitable for the regulation of the flow quantities to keep the process stable. RELIABLE, REGIONAL WATER SUPPLY GUARANTEED With an average output of 24,000 cubic metres per day, the plant makes an important contribution to the reliable and cost-effective supply of drinking water to the people in the Ostend region. Periods of water shortage - as Belgium has experienced in the past summers and which will become even more frequent due to climate change - will be avoided in the future. For this reason, FARYS is already planning a second similar plant in Nieuwpoort. 64116 at www.pcne.eu
Sustainable Freshness Protection for Natural Mineral Water To date, the KHS coating of wafer-thin, chemically pure glass on the inside wall of PET bottles was primarily applied to improve the quality and shelf life of sensitive soft drinks and juice. VILSA-BRUNNEN Otto Rodekohr GmbH is now the first mineral water bottling plant to profit from Plasmax technology. The family business is consistently investing in its product quality and the long-lasting freshness protection of its premium beverages – and in doing so is setting standards on the market. The mineral water VILSA extracts from deep underground in Bruchhausen-Vilsen in the German federal state of Lower Saxony is over a thousand years old and naturally pure. For Henning Rodekohr, CEO of the VILSA Group and a representative of the fourth generation of the family firm, the long-term protection of his spring is a fundamental concern. All varieties of VILSA mineral water have been organically certified since 2021 and are thus subject to the strictest threshold values and highest sustainability standards commonly applied on the German mineral water market. The bottler has also been provably climate-neutral since 2021. By actively promoting various sustainability measures in agriculture, in coopera-
tion with local farmers VILSA helps to maintain a high quality of the soil and groundwater in the vicinity of its spring. This striving to protect the local environment ultimately triggered the bottler’s decision to switch over to KHS Plasmax coating technology for all non-returnable containers used to fill the VILSA brand. FROM THE SPRING TO NATURAL ENJOYMENT – PERFECTLY CONVEYED TASTE The advantages are obvious: FreshSafe PET combines the low weight and robustness of the plastic container with the much better barrier properties of the glass bottle. The triedand-tested system protects the bottle against oxygen pickup and carbon dioxide loss, which
Picture: Frank Reinhold
At VILSA a latest-generation InnoPET Blomax stretch blow molder was first installed that was then combined with the barrier unit to form an InnoPET FreshSafe block during the later development process. N° 11 - NOVEMBER 2023
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both extends the shelf life and increases flavor stability. Moreover, FreshSafe PET also provides a number of key positives when it comes to establishing closed recycling loops. Unlike PET bottles that contain additives to improve the barrier effect and shelf life, the KHS equipment permits full bottle-to-bottle reuse as the interior coating is completely washed off during the recycling process. OPTIMUM PRODUCT PROTECTION Characteristic for VILSA mineral water are its pH, natural ingredients and gentle mineral content. This makes it a sensorily demanding product, however, that reacts extremely sensitively to off-flavors or sunlight. Thanks to the wafer-thin barrier of chemically pure glass in the containers, VILSA’s natural taste is now protected against oxygen pickup and loss of flavor and CO2 for a considerably longer period of time. The PET material also loses none of its proven benefits, meaning that consumers profit from top product quality. PROVED SUSTAINABLE AND SAFE Back in 2019 the Lower Saxon mineral water bottling plant switched the material of all of its non-returnable bottles over to [r]PET. In adding coating technology to its plant engineering setup, the company is now continuing its drive for sustainability. Both the EPBP (European PET Bottle Platform) and North America’s APR (Association of Plastic Recyclers) have confirmed that FreshSafe PET is fully recyclable. The container’s suitability for use with foods has also been officially established by the US Food and Drug Administration or FDA, among other institutions. As the interior glass coating is less than 0.1 FREE DIGITAL SUBSCRIPTION
micrometers thick and chemically bonded to the inside wall, it is flexible. It cannot be accidentally removed or flake off when force is applied to the bottle, with the coating only separating off during the recycling process.
PERFECTLY ADAPTED RECIPE ENSURES HIGH QUALITY “We ran extensive simulations to effect an optimum separation behavior of the reaction gas in the coating process and thus achieve perfect distribution of the wafer-thin glass coating in the bottle,” explains Stefan Knappmann, head of Sales for Germany and Switzerland at KHS. “Our Bottles and Shapes specialists defined the exact recipe for each container size, product and carbon dioxide level.” “Our investment and trust in KHS thus take us a big step forward,” claims Henning Rodekohr. “We’re setting new standards on the market with respect to quality and sustainability.” MOST INNOVATIVE PART OF THE SYSTEM To start with, a latest-generation InnoPET Blomax stretch blow molder was installed
Picture: Frank Reinhold
INTENSIVE DEVELOPMENT PROCESS The first coated bottles are now being distributed to retailers, with more and more consumers able to purchase the new style of packaging and test the noticeably longer fresh taste of VILSA beverages for themselves. The market launch was preceded by an intensive development process. Although a number of well-known bottlers of challenging sensitive products such as juice or carbonated soft drinks have relied on environmentallyfriendly Plasmax barrier technology for years, its use for natural organic mineral water was new to the specialists from Dortmund. At a series of workshops on site the experts from KHS steadily worked to meet requirements in
the runup to the launch of FreshSafe PET for all container sizes from 0.5 to 1.5 liters.
The designs of the 0.25-, 0.5-, 0.75 and 1-liter bottles were already suitable for coating; only the largest and thus most challenging container holding 1.5 liters had to undergo minor changes. FREE DIGITAL SUBSCRIPTION
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that was combined with the barrier unit to form an InnoPET FreshSafe block during the later development process. Following preform infeed, stretch blow molding, cooling and transfer, the PET bottles are coated according to the PICVD (Plasma Impulse Chemical Vapor Deposition) method, a process first used in the pharmaceutical industry. Here, the containers are turned upside down and passed on to the coating chamber where a reaction gas mixture is introduced into the bottle in a fine vacuum and this subsequently transformed into a plasma state by microwaves. In this state silicon oxide – the chemically pure glass commonly found in most households – is deposited on the inside of the container. At VILSA bottles are stretch blow molded and coated at a maximum rate of 24,500 containers per hour. The most popular non-returnable format is the 0.75-liter bottle. PIONEERING ACHIEVEMENT FOR PREMIUM BEVERAGES “With the new InnoPET FreshSafe block from KHS we’re now the first mineral water bottling plant to have the most innovative barrier technology available on the market – and thus the optimum packaging system for our valuable products,” smiles Henning Rodekohr. “We collect our water from its protected source deep under the ground in a way that’s sustainable and pass it on to our consumers in a perfectly preserved state.” The plant’s personnel are still being trained and instructed by KHS employees on site, yet VILSA’s head of Production and Technology Joachim Weippert can already say that “The partnership with our colleagues from KHS has been and still is marked by a very high level of expertise and has proved extremely cooperative. The entire team got along very well throughout the entire development period, which is an important factor. 64121 at www.pcne.eu
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Efficient and Reliable Bulk Solids Handling Pneumatic conveying processes have a key function in the material flow of many industrial companies and place correspondingly high demands on blower technology, with efficiency, reliability and purity of the conveying air particularly in focus. The pneumatic conveying has established itself as the ideal solution for transporting large quantities of bulk materials - whether for loading and unloading vehicles and ships or for transfer within the production process. High-performance technologies are needed to get materials and products from A to B quickly, gently and with the lowest possible energy consumption. The oil-free compression Positive displacement blowers, Screw blowers, Screw compressors and Turbo blowers from AERZEN set standards on the market and solve every transport task - efficiently, safely and smartly. ENERGY SAVINGS OF UP TO 30 % With the aid of intelligent control systems, the combination of different technologies and sizes as well as options for heat recovery, solutions that are equally economical as they are resource-saving and environmentally friendly can be implemented. The screw and turbo blowers in particular are unbeatable in terms of energy and achieve significant energy savings compared to conventional positive displacement blowers. Up to 30 % are possible. AERZEN's application engineers know the industry-specific processes and develop bespoke product concepts that are precisely tailored to the customer's individual application. With its worldwide sales and service network, the compressor specialist ensures short distances to the customer and guarantees fast and reliable onsite support. SAFETY IS THE MOST ESSENTIAL THING The packages provide absolutely oil- and absorption material free air (oil-free opera-
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tion according to ISO 8573-1, class 0), meet the ISO 22000 standard and the current the current ATEX product directive 2014/34/ EU and can be used in highly critical, explosive working environments (e.g. flour dust) without any problems. The use of silencers without absorption material increases process reliability, guarantees the highest compressed air quality and increases energy efficiency through reduced pressure losses. A spark arrester integrated into the silencer further increases safety: it prevents sparks, which could emanate from blowers and compressors in the event of a malfunction, from entering the conveying pipe or the silo. The process air is guaranteed free of contaminations such as oil or abrasion.
DIGITAL SOLUTIONS FOR BLOWERS AND COMPRESSORS AERZEN focuses on the data-driven consideration of the entire life cycle of its machines and provides bespoke cloud-based digital services which combine long experience in mechanical engineering with the latest technology from the information processing and artificial intelligence ranges. The recording of all relevant operating data provides information about the processes involved in the compression process. In this way, malfunctions can be reduced and downtimes minimised. The result: more energy efficiency, process safety, transparency and reliability.
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64127 at www.pcne.eu
17 ROTARY VANE VACUUM PUMPS
AFLAS-SEALING FOR THE FOOD INDUSTRY
High efficient and low wear dry pumps
FDA approved compound for use in CIP and SIP processes
Atlas Copco has developed the new oil-free, dry rotary vane DVS vacuum pump series that guarantee emission-free, quiet operation and do not contaminate processes. They deliver high efficiency at competitive costs and suit for a wide range of packaging and pneumatic conveying processes as well as pick and place solutions. They are predestined for applications in which high efficiency must be achieved at competitive costs. This is achieved on the one hand by the proven functional principle of the rotary vane pump and on the other hand by the use of robust materials. For example, a rotor with graphite blades rotates inside the DVS pumps. The centrifugal forces press the vanes against the inside of the housing wall and hermetically seal the chamber for a safe, uninterrupted operating vacuum. The efficient pump mechanism and the design ensure minimal wear - and this in turn leads to long maintenance intervals and easy servicing of the DVS. In addition, the vacuum pumps are thus designed for maximum operating times. The temperature management also contributes to this: To reduce the temperature of the discharged air, the exhaust air is passed through an air cooler. Pumps of the DVS series are available with a nominal suction volume flow of 5 m³/h to 140 m³/h and an ultimate vacuum of up to 120-150 mbar(a).
With the newly developed "AF 680", the independent seal manufacturer C. Otto Gehrckens is expanding its product range with an FEPM material for critical fields of application in food production and related industries. An especially devised AFLAS® base polymer was used for the innovative formulation. The important FDA 21 CFR 177.2600 approval, which is pertinent for the industry, is a novel feature of the special sealing material compounded by COG. What's more, it is absolutely reliable in applications with SIP and CIP processes. Unlike peroxidecured FKM high-performance materials, this new FEPM compound is also fully compatible with the increasingly required, more aggressive cleaning cycles with brine (base) flushing at high tempeNovember ratures (approx. 140 °C). Even in high-temperature SIP processes at approximately 150 °C, the volume swelling of the new FEPM sealing material is extremely low. That makes this compound ideal for use in the tight installation spaces of the sterile threaded connections in accordance with hygienic design. As an AFLAS® series high-performance elastomer, AF 680 is highly resistant to many different chemicals as well as flavouring agents and essential oils. The very attractive price level as well as compatibility with operating temperatures up to +230 °C complete the performance profile of AF 680.
63736 at www.pcne.eu
64101 at www.pcne.eu
DIAPHRAGM METERING PUMP For applications with flow rates up to 2000 l/h LEWA is now expanding its product range with the new, powerful LCD variant. The model is designed for a flow rate of up to 2000 l/h. The maximum permissible operating pressure is 50 bar or 60 0 lbs. The stringent use of similar components within the ecosmart range keeps production costs and therefore, the final price, low. It can be used in many applications in the chemical, food and the oil and gas industry. For this model, too, LEWA engineers were able to successfully implement the equal parts strategy they have often practiced. This considerably simplifies the spare parts inventory for users. At the same time, the modular principle also allows individual adjustments to the respective application. For example, stroke frequencies or plunger diameters can be selected individually. The basis for this is the M900 pump head, which is already used in the LCA and LCC variants, as well as in the ecoflow program. The ecosmart pump can be aligned either vertically or horizontally, making it easier to integrate the unit into systems with a very small footprint. In addition, the pump head of the new LCD variant is aligned at right angles to the plunger axis, resulting in a particularly compact format. The LCD complies with the U.S. metering pump API industry standard 675, so it can be used for numerous complex processes in a wide range of industries. 64102 at www.pcne.eu FREE DIGITAL SUBSCRIPTION
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63139 at www.pcne.eu N° 11 - NOVEMBER 2023
Maintaining Water Supplies Sulzer’s repair expertise supports reliability of water utilities with large-scale pump refurbishment project in Africa. Water is a precious resource, especially in Africa, and maintaining the infrastructure that delivers it to homes and businesses is a complex task. Pumping stations are the heart of this system, transferring huge volumes of water between reservoirs and water towers as well as across the wider network. Sulzer is using its local facilities to deliver planned refurbishments to 11 pumps sets as the first part of an essential maintenance plan. Large parts of the local water infrastructure were installed around 50 years ago and since then the reliability of the pumps has been assured by their quality of the design and construction. Now, Sulzer is working with water utility companies to identify the pumps most in need of refurbishment to en-
able them to continue operating without unplanned downtime. INDEPENDENT OEM QUALITY PUMP MAINTENANCE Many of the municipal companies in Africa have been in business for decades, and they will have many brands of legacy pumps where the original equipment manufacturer (OEM) has merged with another or ceased to exist. In these cases, although the pumping stations contain pumps manufactured by several brands, they can all be maintained by Sulzer. The water supply network also consists of many reservoirs and water towers, all connected by large pumping stations that ensure water is delivered to the local population. However,
Sulzer is working with water utility companies to identify the pumps most set in need of refurbishment. N° 11 - NOVEMBER 2023
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supply and demand are finely balanced, so any downtime can cause significant problems. A recent power cut at one of the pumping stations showed just how the importance of these large pumps cannot be underestimated. The event resulted in considerable water shortages for several weeks while the pumps tried to refill the water storage system. SUPPORTING ANY MUNICIPALITY LOCALLY Sulzer has worked closely with the plant management team to create an overview of the most critical pumps that need repairs to ensure the continued reliability of the water network. The network contains hundreds of pumps, and it was important to the utility to engage a leading service provider with OEM knowledge that had local facilities and expertise to complete the work. The team responsible for operating and maintaining the pumps recognized the need for many of the assets to be overhauled before any significant issues occurred. Finding a maintenance provider with the expertise and facilities to handle the various brands and vintages of pumps was made easy after a meeting with Sulzer. However, projects such as this that involve municipalities have to pass through numerous committees, with each one requiring more information before a decision can be taken. Additionally, to ensure the best outcome and provide transparency, a rigorous competitive tender process is undertaken. Having successfully outperformed the competition, the contract was awarded to Sulzer and the two teams developed a comprehensive list of pumps and the spare parts that would be required. FREE DIGITAL SUBSCRIPTION
Sulzer is working with water utility companies to identify the pumps most set in need of refurbishment.
widescale program of planned maintenance can be completed. In these situations, a proactive approach is by far the best course of action. Unplanned downtime can have a huge impact, especially if more than one asset is out of commission while repairs are being planned. Large pumps require specialist facilities and knowledge to achieve an efficient turnaround, a service that Sulzer has delivered for decades. Pump operators in Africa can benefit from Sulzer’s leading design and repair capabilities and access them via the facilities located within the region. This localized approach aligns with government initiatives that encourage local manufacturing and maintenance of a country’s infrastructure wherever possible. RETURNING LEGACY PUMPS TO BETTER THAN NEW In the first part of this project, a total of 22 pumps (11 pump sets), will be refurbished. Each pump set consists of a booster and a main pump operating in series. Although the longest serving of these assets is 45 years old, the average age of the pumps in this program is around 20 years. The majority of the pumps will be repaired with the wearing parts such as seals and bearings being replaced. However, the oldest of the machines uses an antiquated lubrication system that will be upgraded as part of the repair process. All the old coatings inside the pumps will be removed and replaced with more modern equivalents. For example, the old ceramic coatings used on the internal sleeves are being replaced with
a tungsten coating. The first pump has already been removed and its overhaul is underway. To avoid any disruption to the water delivery, each pump set will be refurbished, reinstalled and run for a month before the next one is removed. Throughout the process, the utility’s management team will be kept fully informed on progress, with Sulzer coordinating logistics and field services personnel to ensure the project is delivered smoothly.
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PROACTIVE PLANNING FOR WATER SECURITY Large parts of the water infrastructure in Africa are of a similar age, which means that significant volumes of equipment are reaching the end of their serviceable lives around the same time. This situation has the potential to develop into a serious issue unless a
PUMPING UP INFRASTRUCTURE IN AFRICA Water utilities aim to make the most of their existing facilities and equipment to optimize operational efficiency and expenses. As part of this drive, refurbishment projects are vital to increasing engineering resilience and extending the effective service life of pumps. To obtain project approval, it is necessary to demonstrate technical expertise and capabilities to deliver the repairs on time and within budget. Sulzer is supporting utility companies in Africa with maintenance contracts that ensure spare parts availability as well as engineering support at the point it is needed. This minimizes any downtime and ensures the continued reliability of the water infrastructure. 64129 at www.pcne.eu
20 energy&sustainability Steel Mill's Compressors Revived to Enhance Sustainability Before purchasing something new, it is worthwhile to take a look at the stock and think about possible reuse and upgrading, as this example shows. Burckhardt Compression, a pioneer in compression solutions, recently partnered with one of Europe's leading steelmaking mills undergoing a significant transformation. The mill aimed to convert one of its plants into a sustainable facility in compliance with stringent environmental guidelines. The project's critical aspect involved reviving four non-Burckhardt compressors that had been inactive for a decade. Acknowledging the crucial role of the compressors, the mill sought for expertise. Addressing the challenges posed by the steel mill’s transformation, Burckhardt Compression offered a comprehensive range of services, from major inspection and revamping to supplying necessary spare parts. Its efforts didn't stop at the compressors. The expert team from Burckhardt Compression also revamped auxiliary equipment such as motors and coolers. Its commitment to delivering a turnkey solution within a tight schedule and budget demonstrates its leadership in the realm of compressor technology. The task at hand required expert knowledge and precise execution within a tight schedule and budget. Alongside the overhaul of the compressors, auxiliary equipment such as motors and coolers also needed an upgrade. A fullservice solution was required, and Burckhardt Compression was well-positioned to deliver.
MISSION: RELIABLE OPERATION The company’s expert team dived into the project, conducting a major inspection, revamp, and upgrade of all four compressors. It inspected the electrical motors and refurbished the lube oil coolers. The team also updated the instrumentation, performed calculations for increasing discharge presN° 11 - NOVEMBER 2023
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sure, and supplied necessary spare parts. The project's success was due to the broad expertise of Burckhardt Compression’s team and the company's ability to provide comprehensive, customized solutions. Despite the challenging nature of the project, Burckhardt Compression maintained its commitment to quality and safety. The result was a set of revitalized compressors optimized for improved performance, ensuring their reliable operation. The client acknowledged Burckhardt Compression's technical acumen, quick response to challenges, and commitment to safety. A spokesperson for the steel manufacturing facility stated, "Burckhardt Compression has been a crucial partner in our journey towards sustainable steelmaking. Its dedication and skill ensured our compressors were not only revived but also optimized for enhanced performance." The expertise and commitment to quality demonstrated by Burckhardt Compression continue to be a vital asset to its customers. As the steel mill transitions to greener operations, the company's revived and optimized compressors are set to play an integral role in its sustainable journey. 64131 at www.pcne.eu FREE DIGITAL SUBSCRIPTION
21 Heat Recovery System Helps to Reduce Carbon Footprint in Soft Drink Production GEA supplies Britvic, one of UK’s leading soft drinks manufacturers, with a heat recovery system at its Beckton site, in London. The installation begins this summer and will result in cutting the factory’s carbon emissions by an estimated 1,200 tons annually – equivalent to the annual energy usage of around 500 UK homes. At its Beckton site, Britvic produces 2,000 drinks every minute, including many of the UK's most popular beverages such as Robinsons, Tango and Pepsi MAX. GEA is supplying two industrial ammonia heat pumps and a large thermal storage tank. For Britvic, the project is a major step toward its goal of reducing direct carbon emissions by 50 percent by 2025 and achieving net zero by 2050. “The challenge with this brownfield project was how the improvements support us on our journey to reduce our Scope 1 and Scope 2 emissions as part of our science-based targets and our Healthier People, Healthier Planet sustainability strategy”, says Sarah Webster, Director of Sustainable Business at Britvic. “We’re excited to be working with GEA to make our much-loved London factory sustainable for the future.”
HERE'S HOW THE NEW HEAT RECOVERY SYSTEM WORKS AT BRITVIC Britvic will convert much of its process heating from natural gas steam boilers to a carbon-free heat recovery systems driven by heat pumps. The new heat recovery system, designed and supplied by GEA, reuses low temperature waste heat from the existing production system. This waste heat was previously released into the atmosphere and will now be used to heat hot water to 92°C, which will be distributed throughout the plant. Britvic says this will decarbonize 50 percent of the site's heat demand by using less gas in the traditional steam boilers, shifting the heat source away from fossil fuels. A valved connection is provided for up to 750 kW of heat which will be recovered in the future from other sources.
“Upgrading legacy industrial steam heating systems and integrating these with heat pump technology is a challenge. At GEA, we can supply heat pumps and integrated process heat exchanger skids as one solution. This clearly sets us apart from our competition”, says Matthew Hadwen, Beverage Sales Manager at GEA’s Liquid & Powder Technologies Division. Simon Gurr, Sales Manager at GEA’s Heating & Refrigeration Division adds: “This project provides us with a fantastic opportunity to extend our leading role in industry decarbonization. GEA’s expertise in both heat pump technology and process integration bring the right solution to Britvic.”
64130 at www.pcne.eu
GEA RedGenium heat pumps are used for industrial applications where process heat is required for local supply or district heating networks.
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22 energy&sustainability Pushing the Limits of Technical Feasibility How can mining companies make their operations more sustainable to reduce their environmental footprints? One element that can be perfectly adapted to match the conditions is the efficient transport of the mined material. Here overland conveyors that can move large quantities of material over long distances are required. BEUMER Group relies on modern planning and layout tools to support operators at an early stage of the project and design the ideal conveying solution together with the customer. BEUMER Group installed the first overland conveyor with horizontal curves as early as 1969. Since then, calculation methods and components such as idlers, belts and drives have undergone constant development, resulting in the implementation of increasingly efficient conveying systems for routes that are often complex. Mine operators can use BEUMER curved troughed belt and pipe belt conveyors to transport raw materials over routes with steep inclines and narrow curve radii. “We can exactly match our systems to the required conveying task and topography,” says Dr. Kilian Neubert, Global Head of Mining at BEUMER Group. “We rely on state-of-theart planning tools to provide our customers with an efficient, sustainable and cost-effective material flow.” SUSTAINABILITY IN MINING Raw materials are needed to produce almost all industrial and consumer goods; however, extracting them has far-reaching effects on the environment and society. This is why mining companies constantly strive to make their extraction and processing operations even more efficient and sustainable, and such efforts are called for in the planning of a new mine. Mine operators must ensure that the population generally approves of the planned project. This approval can be obtained through extensive approval procedures, environmental impact studies, geo-monitoring, and the implementation of suitable risk management systems. “Mining companies need to build trust with the public,” Neubert explains. “For example, they need to involve the public and key stakeholders at an early stage of proj-
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Photo credits: BEUMER Group GmbH & Co. KG
The topography of the existing terrain has a significant influence on the design of the conveying system.
THE FUNDAMENTALS AND CAPABILITIES OF MODERN CONVEYING SYSTEMS No two conveying systems are alike, even if the primary task of transporting bulk material from A to B appears comparable. “We must adapt the components and the system to the material to be conveyed,” says Neubert. “The mass flow to be conveyed and height differences that need to be overcome over the length of the conveyor line are important fac-
tors that we must address when designing a system.” The energy consumption of long, horizontal belt conveyors is primarily determined by the main resistance in the upper and return strand in stationary operating conditions. This resistance consists of the running resistance of the idlers, the indentation rolling resistance, and the flexing resistance of both the conveyed material and the belt as they run over the idlers. The forces required to overcome these resistances depend on various operational and design parameters; however, they can be determined using the ‘single resistance method.’ If components with low running resistances are used, such as belts with reduced indentation rolling resistance or running-optimised idlers, the calculations of the systems nowadays show considerably
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ects.” This is why operators need to integrate the issue of sustainability into all aspects of planning a mine and improve the environmental compatibility of the overall system by ensuring the efficient transport of ore and waste rock over longer distances. Optimised routing and the selection of suitable methods achieve these objectives
Photo credits: BEUMER Group GmbH & Co. KG
A 3D model of terrain and conveyor: the advantages of earthworks (cut & fill) or steel structures can be quickly and precisely assessed using graphic representations and mathematical calculations. lower tractive forces of the belt than those of a few years ago. This leads to lower energy costs, and smaller radii can also be selected for the horizontal curves thanks to the lower tractive forces of the conveyor belt. The topography of the existing terrain also has a significant influence on the design of the conveying system. An in-depth analysis of various dynamic load cases and a thorough investigation of the technically feasible horizontal and vertical curve radii must be conducted to design the system in the most efficient and environmentally friendly way. This is especially true for longer and more difficult conveyor lines. Potential obstacles that must be considered during the planning phase include residential areas, roads, and rivers. “Today, we can design curved overland conveyors of up to twenty kilometres or longer without
the need for a transfer tower,” says Neubert. The conveying capacities of a system like this are more than 20,000 tons per hour.
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THE RIGHT LAYOUT “We use our BEUMER Overland Layouting Tool to ascertain the ideal layout for the system,” says Neubert. “It generates a digital 3D model of the conveyor in the virtual landscape during project planning, more or less automatically.” The critical topography data can either be provided by customers, or drones are used to capture terrain data. “These 3D visualisations are also ideal for supporting mining companies in their PR relations work,” explains BEUMER expert Neubert. Important factors such as ‘cut and fill’ volumes, i.e. the necessary excavation work, and the required steel structures for the con-
veyor can be evaluated and illustrated on this basis. “This procedure considerably accelerates the project planning process and enables us to provide project-critical data to the customer at an early stage of the project,” says Neubert. ONGOING DEVELOPMENT IN CONVEYING TECHNOLOGY The 1990s saw BEUMER Group start its development into one of today’s leading suppliers of pipe conveyors. In these systems, the idlers form the belt into a closed pipe that protects the material to be transported against external influences and the environment from emissions such as dust and odours. This conveying solution is therefore ideally suited for fine bulk materials such as ore concentrates. Pipe conveyors also allow tighter curve radii and greater angles of inclination compared to conventional troughed belt conveyors. However, what if bulk material with large grain sizes requires a larger pipe diameter? The rule of thumb here is that the pipe diameter should be about three times the maximum grain size. To solve this problem, the BEUMER Group developed the U-shape conveyor. “This variant combines the advantages of a troughed belt conveyor with those of a pipe conveyor,” says Neubert. The idlers form the belt into a U-shape rather than a pipe. The U-shape conveyor enables tighter curve radii than a troughed belt conveyor and higher mass flows than a pipe conveyor and also protects the conveyed material from environmental influences and the environment from material loss and emissions. 64122 at www.pcne.eu
24 VERSATILE 7-ANGLE MALS DETECTOR
MELT-BLOWN POLYESTER FILTER CARTRIDGES
Simple and accurate determination of molecular weights
High chemical resistance for demanding applications
TESTA Analytical offers the BI-MwA Multi-Angle Light Scattering (MALS) detector with high performance to price ratio for molecular weight determination. It can be used to determine absolute molecular weights of polysaccharides, proteins, and peptides or their aggregates by HPLC or uHPLC quickly and accurately. The Bi-MwA is also a powerful tool that can dramatically increase the capability of any GPC/SEC system enabling the precise and accurate determination of the molecular weights of polymers and nanomaterials in solution. Compact in design, the novel vertical flow path of the BI-MwA avoids trapped bubbles - a problem commonly associated with horizontal light scattering systems. The flow cell inside the BI-MwA has no sharp corners, only conical shapes, meaning previously analyzed samples are easily flushed out eliminating the possibility of contamination from previous samples. The BI-MwA is simple to use but incorporates sophisticated features to help solve challenging light scattering research applications. For use samples are simply injected into the low-volume, 7-angle flow cell. The sample is illuminated by a temperature stabilized, precision power-controlled diode laser. Using the system allows to eliminate column calibration and improves data quality.
Eaton's LOFTOP™ and LOFTREX M™ depth filter cartridges ensure the safe and efficient filtration of demanding media such as process chemicals, fine chemicals, acids, alkalis and solvents, as well as paints, lacquers and resins. The Filtration Division of Eaton is now expanding its range to include filter cartridges that use polyester as the filter material for particularly high chemical resistance. The new melt-blown polyester depth filter cartridges are not only suitable for a variety of aggressive media, but also provide an alternative to filter cartridges that are bonded with phenolic resin. The entire LOFTOP and LOFTREX M filter cartridge range is now available with polypropylene (PP), polyamide 6.6 (PA) or polyester (PES) filter material. The filter cartridges are available in different lengths and with all common adapter configurations and sealing materials so that they can be used safely in a wide range of applications and filter housings. LOFTOP depth filter cartridges offer absolute retention rates from 0.50 to 120 µm with a retention efficiency of 99.98%. LOFTREX M depth filter cartridges offer nominal retention rates from 1 to 150 µm with a retention efficiency of 95%. No matter whether the filter material consists of PP, PA or PES, Eaton's LOFTOP and LOFTREX M depth filter cartridges offer a solution to the many challenges of filtering media safely and reliably.
63911 at www.pcne.eu
64045 at www.pcne.eu
ELECTRO-PNEUMATIC PRESSURE REGULATORS
NON-INVASIVE FLOW METERS FOR LOW FLOW
For applications that require a tight pressure tolerance
Compact devices for continuous flow monitoring
ControlAir announced the introduction of the new Type 1000P Electro-Pneumatic Pressure Regulator Series. The series consists of the Type 1000P Precision Pressure Regulator, Type 1005P High Flow Pressure Regulator, and the Type 1010P Economic Pressure Regulator. The Electro-Pneumatic Pressure Regulators are complete closed loop servo systems consisting of two solenoid valves, an internal pressure sensor, and electronic controls. Based on analog signal, the pressure is controlled by two solenoid valves to maintain precise pressure: one valve functions as inlet control, the other as exhaust. The pressure output is measured by an internal or an external feedback pressure sensor that provides a feedback signal to the electronic controls. A typical application for the Type 1000P Electro-Pneumatic Pressure Regulator Series is to control and monitor the pressure in pneumatic systems that drive automated machinery, robotic arms, and assembly line equipment. By maintaining the correct pressure, these regulators ensure consistent performance, accurate positioning, and reliable operation of industrial automation processes. The series is available in 1/8" or 1/4" NPT porting. Input signals are 4-20mA, 0-10V, or RS485 Modbus. Output ranges include 0-2 bar, 0-4 bar, and 0-8 bar.
Biotech Fluidics has expanded its family of non-invasive flowmeters for real-time monitoring of liquid flow. The range now includes four discrete devices optimized to operate from nanoliters per minute right up to 650 milliliters per minute. Operating over the flow range 0.01 to 80 µL per minute, with a resolution of 1nl per minute, the Micro Flow Meter is the perfect tool for precise monitoring of extremely low flow rates such as are encountered in UHPLC, LC/MS and micro-/ nanoscale bioprocessing applications. Designed to operate over the range 1µL to 5mL per minute - the HPLC comes pre-calibrated and can be connected inline to continuously measure inline flow rates of liquids from pumps serving HPLC and GPC/SEC systems as well as flow chemistry reactors. Operating up to liquid flow rates of 650mL per minute, with a resolution of 0.02 mL per minute, the new High Flow Meter is an ideal tool for monitoring preparative chromatographs used to produce larger compound quantities. Compact in size, each Biotech Flow Meter comes with easy-to-use PC software enabling continuous recording, monitoring and storage of measured flow rate data. Operating in real-time, with current flow rate displayed on the integral OLED display, users can spot transient pulsations.
64097 at www.pcne.eu
64066 at www.pcne.eu N° 11 - NOVEMBER 2023
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FREE DIGITAL SUBSCRIPTION
25 RUGGED ANDROID-12-TABLETS
DUAL H2S/CO2 ANALYZER
Mil-Standard devices in 8'' and 10'' size
Two-in-One Analyzer for quality and process control
WEROCK Technologies expands its product portfolio with two rugged tablets with the Android operating system. The Rocktab S508 (8-inch display) and S510 (10-inch display) models from the Rocktab S500 series are now available with either Windows 11 or Android 12. Whether for digitizing operations, accelerating warehouse processes, analyzing machines and vehicles or in manufacturing - the Rocktab series promises reliable performance in all industries. The industrial tablets are certified IP65 water- and dustproof and meet military standard MIL-STD-810H for smooth operation in harsh conditions such as dust, dirt, rain, snow and extreme temperatures from -20°C to +60°C. They can even withstand drops from heights of up to 1.2 meters and strong vibrations in vehicles. The devices feature scratch-resistant screens with gesture-enabled touchscreens that allow intuitive operation. Despite their robustness, the models of the Rocktab S500 series are very compact with a depth of around 2 cm and enable comfortable working. The new models are equipped with an 8-core processor with up to 2.2 GHz, 8 GB RAM and 128 GB integrated storage. Even in the standard configuration, the rugged computers offer full-fledged USB ports, front and rear cameras, mobile 4G LTE Internet, Bluetooth, WLAN and GPS.
With the combination of its standalone H2S and CO2 Analyzers in the CS Hound Dual Analyzer Keco now offers a fast and cost-effective method for measuring H2S and CO2 in natural gas, biogas, and air. Employing microprocessor-based technology, the CS Hound provides continuous online analysis based on NDIR sensor for and electrochemical cell technologies. In operation, gas analyzed for H2S and CO2 is regulated to 10 psi, then controlled to a flow of approximately 1.5 SCFH. The gas is, then, introduced to an electrochemical detection element and NDIR sensor that provides an output proportional to gas concertation. A 4-20mA DC output is analyzed by an advanced microprocessor and related software. A touch-screen LCD provides current and previous readings, historical and real-time charts, alarm conditions, and failure indicators. The CS Hounds offers ppm level measurement of CO2 from 0-500 ppm/v up to 100% by volume and H2S from 0-2000 ppm by volume. The analyzer provides concentration and diagnostic alarms via Modbus and the sensor. The operating temperature range is -10°C to 50°C, with units built for operation in Division 2 (Zone 2) hazardous locations. The CS Hound Online process analyzer is low maintenance, with limited moving parts.
64120 at www.pcne.eu
64115 at www.pcne.eu
STANDARDISED BATCH MIXER SERIES
For increases cost efficiency amd lower lead times
Minimising prog ramming tasks for bulk handling
Lödige's Ploughshare® Batch Mixers of the FKM series are designed for the treatment of powdered, granular or fibrous bulk solids. Their main advantages are short throughput times, excellent mixing quality and high batch reproducibility. Like customised machines, the new FKM mixers of the "Light Series" are manufactured entirely at the Lödige headquarters in Germany. However, they differ from customised solutions due to their standardised design. The reduced workload allows Lödige to charge a significantly lower price. Yet another advantage is the reduction in delivery times for the FKM LS series to three to four months, a significantly shorter period than that for customised special machines. The machines of the new mixer series are available in seven sizes from 130 to 3000 litres and designed for a clearly defined range of functions. At the same time, numerous standardised options permit optimal adaptation to the relevant product and process requirements. For instance, separately driven choppers rotating at high speeds can be used to support the effect of the mixing element. Other equipment options include liquid injectors, a product thermometer, different control systems and an explosion-proof ATEX version.
Gericke is introducing the updated GUC Gericke Universal Controller with the goal for improved accuracy and efficiency. The GUC (Gericke Universal Controller) is equipped with sophisticated algorithms that filter out environmental effects to ensure accuracy even under challenging conditions. Supporting both analogue and digital weighing cells, the GUC allows users to choose weighing technologies tailored to their application and accuracy preferences. It is also capable to control multiple feeders with one electronic. An important element of Gericke's approach is the user-friendly Human-Machine Interface (HMI) featuring a modern and intuitive design. This design promotes efficient operations by enhancing the overall user experience. Gericke's technology arrives preconfigured and tested alongside the loss-in-weight feeder, offering a comprehensive and ready-to-deploy package. Furthermore, Gericke simplifies integration through pre-configured fieldbus communication to frequency inverters, saving time and eliminating the need for additional programming. The GUC empowers users with full local control over essential devices and options, including refilling with volumetric feeding mode, intromitters, agitators, and closing devices for feeding tubes.
64118 at www.pcne.eu FREE DIGITAL SUBSCRIPTION
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64104 at www.pcne.eu N° 11 - NOVEMBER 2023
Red for companies advertising in this issue
H HANS TURCK
ANALYTICAL SYSTEMS KECO
K KEB AUTOMATION
C C. OTTO GEHRCKENS
PEPPERL + FUCHS
SCHUBERT & SALZER CONTROL SYSTEMS
TESTA ANALYTICAL SOLUTIONS
W WEROCK TECHNOLOGIES
G GEA GEBRÜDER LÖDIGE
SPS 14 – 16 Nürnberg www.sps.mesago.com
AUTOMA 27 – 28 Vösendorf www.automacongress.com
1, 8, 9
EMPACK 25 – 26 Zurich www.empack-schweiz.ch
MARCH MECSPE 06 – 08 Bologna www.mecspe.com
N° 11 - NOVEMBER 2023
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Note: Dates and descriptions of events have been obtained from official industrial sources. The publisher, therefore, cannot be held responsible for errors, changes or cancellations. FREE DIGITAL SUBSCRIPTION
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