cpp – Process technology for the chemical industry 01.2019

01-2019 

16 COVER 

EXPLOSION SAFETY IN 

BULK SOLIDS PROCESSING 

28 HEAT RECOVERY 

ECONOMICAL BENEFITS 

OF AIR COMPRESSION 

38 SPECIAL 

HANNOVER MESSE 

PREVIEW 

60 TUBULAR REACTORS 

SAFE SCALE-UP WITH 

EXOTHERMIC REACTION 

PROCESS TECHNOLOGY FOR THE CHEMICAL INDUSTRY 

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VISIT US AT 

POWTECH 

09–11 APRIL 

HALL 3 / 3-249

cpp 

EDITORIAL 

Industrie 

Spotlight Hannover 

Messe and Powtech 

Hannover Messe is booming. From 1 to 5 April, an anticipated 6500 

companies from 75 nations will be exhibiting at the world’s leading 

trade fair for industrial technology. Automation, robotics, industrial 

software, drive systems & fluid power, energy technologies, subcontracting 

and research & development will be taking centre stage at 

the 2019 show. Throughout the first week of April, this pivotal confluence 

of technologies will be clustered at Integrated Automation, 

Motion & Drives (IAMD) spanning 14 exhibition halls. Smart sensors, 

intelligent drives, modular production and holistic solutions 

for intelligent manufacturing – the close integration of automation, 

drive systems & fluid power and software & IT will be the focus of 

the upcoming event, which will also serve as a forum for presentations 

and debates under the motto “Integrated Industry – Industrial 

Intelligence”. Comvac, the leading international trade show for industrial 

compressed air and vacuum technology, is likewise continuing 

to grow. The organisers are expecting 15 % more exhibitors 

at Comvac in comparison to 2017. Industry 4.0 will be the top 

theme, for instance in the area of predictive maintenance. Our 

Special Subject section on Hannover Messe, in which we cast a spotlight 

on several of the above-mentioned topics, begins on page 40. 

From 9 to 11 April, the week following Hannover Messe, Nuremberg 

Exhibition Centre will open its doors for experts from all over 

the world – both established and aspiring – in powder and bulk 

solids technology. Around 800 exhibitors will showcase their latest 

developments for mechanical processes like size reduction, agglomeration, 

separation, screening, mixing, storage and conveying in six 

exhibition halls. You can learn more about the new products and 

solutions awaiting you in Nuremberg starting on page 16. 

The 

network of 

expertise 

for industry 

18 media brands for all major 

sectors of industry 

Information, inspiration and 

networking for professionals 

and industry executives 

Practical knowledge spanning 

all media channels: Trade journals, 

websites, events, newsletters, 

whitepapers, webinars 

Günter Eckhardt, Editor-in-Chief 

Discover the appropriate 

media for your specific 

industry sector: 

konradin.de/industrie 

media.industrie.de 

cpp 01-2019 3

cpp CONTENTS 01-2019 

16 Cover Professional explosion 

safety has its price, yet unprofessional 

over-engineering or poor protection 

can be much more expensive in the 

long run. Explosion safety for several 

bulk material handling and processing 

steps is considered in this article. 

10 PCK Raffinerie 

GmbH replaced its old 

control room with a 

highly modern, roughly 

1000 m 2 control room 

with a virtual sky. 

30 The Centripurge 

inerting system for 

centrifuges & Co. has a 

modular design which 

enables individually 

tailored safety solutions. 

INSTRUMENTATION, CONTROL, AUTOMATION 

8 Harvesting data in the field: making it do more 

Vega on the road to Industry 4.0 

10 Up to 1000 views connected to one console 

Europe’s most modern refinery control room 

successfully starts operation 

SPECIAL POWTECH 

14 No cloud, no danger 

Powder incorporation under dust and gas explosion 

conditions 

16 COVER Explosion protection in bulk solids processing 

Operators benefit from integrated concept 

23 Filling containers in a closed nitrogen loop 

Safe transport of BHET 

24 PRODUCTS 

28 Heat recovery in process air generation 

Solutions for new construction and retrofitting 

30 Customised inerting concepts 

Explosion protection for centrifuges and dryers 

32 Oil-free compressed air with 35 % less energy 

Permanent magnet motors make it possible 

SPECIAL HANNOVER MESSE 

38 Easy migration to the Ethernet World 

The digitalisation of Profibus-PA in the process industry 

40 More safety worldwide 

Purge and pressurisation system with global approval 

42 Next level of automation 

Electric actuators for anti-surge valves 

44 The curtain is raised – but only a little 

Focus on process control system at Hannover Messe 

46 PRODUCTS 

50 Efficient dry runners 

Oil-free screw pumps for industrial use 

52 Guaranteed clean and germ-free 

Combination of compressed air treatment and 

continuous monitoring 

PLANTS, APPARATUS, COMPONENTS 

54 Scalable vacuum supply 

Chemical resistant diaphragm pumps for scale-up in 

chemical process technology 

56 Strong performance 

Highly fluorinated materials for chemical processing 

facilities 

SAFETY, SECURITY 

34 Cleanliness and safety in hazardous areas 

Enclosed filter system with protective bag 

36 Seamless data flow 

Safety controller with OPC UA connection 

PROCESS ENGINEERING 

60 Safe scale-up with exothermic reactions 

Safety concept for continuous tubular reactors 

4 cpp 01-2019

44 At this year’s Hannover 

Messe pre-press 

conference, Siemens 

raised the curtain on a 

new process control 

system – though only a 

little. 

54 From small to large: 

The modular VAC 

24seven system with 

pumping speeds up to 

120 m 3 /h allow a stable 

scale-up of processes. 

Visit us! 

POWTECH, Nuremberg, 

Germany 

April 09 - 11, 2019 

Hall 1, stand 1-627 

COLUMNS 

3 The Third Page 

4 Contents 

6 News 

59 PRODUCTS 

62 Contact the Editors 

62 Imprint 

62 List of Advertisers 

WWW.CPP-NET.COM 

More news, facts, products and 

solutions for the process technology 

in the chemical industry can be found 

on our internet page! 

www.cpp-net.com 

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NEWS 

Company anniversary 

GERICKE CELEBRATES 125TH BIRTHDAY 

Picture: Gericke 

Soder mill built by Gericke in 1945 

In the year 1894 Walther H. Gericke started 

his machine factory and mill construction 

company in Zurich. The engineer quickly 

gained an excellent reputation as a specialist 

and supplier of milling equipment. He sold 

roller mills of the prestigious company Seck 

from Dresden. Other important process 

steps included grain cleaning, storageing, 

conveying, sifting and mixing of grain and 

flour. At the beginning of the 20th century 

Gericke designed the first vertical mixers 

and celebrated great success with the 

patented Soder mill. In the 1940s, pneumatic 

conveying systems, vibrating feeders 

and steel belt conveyors for the chocolate 

industry followed. During this time, Otto 

and Walter Gericke managed the prospering 

family business. From the 1960s onwards, 

Dr. Hermann Gericke and Willi Gericke 

pushed the internationalisation of business. 

The focus also remained on new technologies, 

with the introduction of less common 

machine types in Europe via licence 

agreements with US companies. These included 

differential weigh feeders, bag compactors 

and continuous granulators. 

Today, Markus Gericke is the fourth generation 

to head the group. The company‘s engineering 

and plant construction expertise 

has since been expanded to include new locations 

in Asia, North and South America. 

The Gericke Group employs more than 300 

people worldwide. Gericke‘s traditional customers 

include the chemical and food industries. 

Increased capabilities as complete automation solutions provider 

EMERSON ACQUIRES INTELLIGENT PLATFORMS 

Emerson has agreed to acquire Intelligent 

Platforms, a division of General Electric. Intelligent 

Platforms’ programmable logic 

controller (PLC) technologies will enable 

Emerson, a leader in automation for process 

and industrial applications, to provide its 

customers broader control and management 

of their operations. Terms of the deal were 

not disclosed. The acquisition expands opportunities 

for Emerson in machine control 

and discrete applications across process industries 

and target hybrid markets, such as 

metals & mining, life sciences, food & beverage 

and packaging. By interfacing Intelligent 

Platforms’ PLC technology with Emerson’s 

leading distributed control systems, 

customers will be able to connect “islands 

of automation” within the plant to further 

enhance operational performance, safety 

and reliability. Both Emerson and Intelligent 

Platforms are focused on leveraging automation 

technologies to drive digital transformation 

in their end markets. Intelligent 

Platforms recently developed a new family 

of cloud-connected controllers and devices 

to enable smarter plants, a strong complement 

to Emerson’s focus on digital transformation 

and the Industrial Internet of 

Things through its Plantweb digital ecosystem. 

Intelligent Platforms is based in 

Charlottesville, Virginia, with approximately 

650 employees worldwide and 2017 sales 

of 210 million US$. 

cpp NEWS TICKER 

Picture: Comtrol 

Pepperl+Fuchs acquires 

Comtrol 

Pepperl+Fuchs acquired the 

business of Comtrol Corporation. 

Comtrol is an US-based pioneer 

in industrial Ethernet communication 

and IO-Link gateway 

products known for its Rocketport 

product family, among 

others. 

Comtrol’s technologies will complement 

Pepperl+Fuchs’ portfolio 

of Sensorik4.0 sensor so - 

lutions and interface technol- 

ogies that includes AS-Interface, 

IO-Link masters, and industrial 

connectivity. 

Kemira and Valmet 

collaborate 

Kemira and Valmet have signed a 

partnership agreement in Europe 

for collaboration in the water 

and sludge treatment customer 

applications. The agreement aims 

at combining Kemira‘s strong 

chemistry and smart process 

optimisation expertise in the 

municipal and industrial water 

treatment space with Valmet‘s 

analyser and measurement technology 

know-how as well as onsite 

service network. 

Picture: Hosokawa Alpine 

Hosokawa Alpine opens 

Alpine Campus 

The Alpine Campus is open to 

everyone and offers exactly the 

right seminar for every Hosokawa 

Alpine system. The individual 

modules are structured to match 

applications and systems, and are 

directed to system operators as 

well as automation engineers. 

Besides the theoretical basic 

principles, the spotlight is also on 

practical exercises. 

Bilfinger modernises 

Saudi Aramco gas plant 

Bilfinger Middle East has been 

awarded the contract by Saudi 

Aramco to modernise the airpressure 

system at the Berri Gas 

Plant on the Gulf Coast in Saudi 

Arabia. The contract provides for 

the engineering, procurement, 

and construction of the system. 

Berri Gas Plant has a production 

capacity of app. 41 million m 3 per 

day. The new air-pressure system 

of the facility, to be completed 

turnkey-ready by the end of 

2019, is intended to enhance the 

reliability of the plant through a 

combination of system retrofits 

and technology upgrades. 


Picture: Siemens 

Modular production 

GEA AND SIEMENS JOINTLY USE MTP 

AUTOMATION STANDARD 

Automation specialists from Siemens and 

GEA have formed a project group working 

on MTP. In the image: Matthias Wiemann 

(left), GEA, and Christoph Schröder, 

Siemens 

The GEA and Siemens technology 

groups announced their cooperation 

on a Module Type 

Package (MTP) digitalisation 

project. MTPs functionally describe 

the properties of process 

modules independent of manufacturer 

and technology. The 

MTP project adds an important 

process perspective to the 

theore tical preparations achieved 

so far by working groups 

such as Namur, ZVEI and VDMA. 

For this, Siemens is providing 

both a superior process control 

system and modular automation system, whereas GEA is acting as the practice 

partner. “We have been producing modular products for more than 20 years, 

because every single component – be it a separator, a homogeniser, a pasteuriser 

or drying system – has to be integrated into the higher-level automation 

system of the entire facility,” explains Matthias Wiemann, Head of Automation 

and Controls for GEA separators. “If both the control system and the components 

to be connected were talking the same language, it would run as 

smoothly as a printer connected to a PC using a printer driver.” The common 

language for this should be the MTP information protocol. 

Largest crude-to-chemicals complex 

ZHEJIANG PETROCHEMICAL 

SELECTS HONEYWELL 

Zhejiang Petrochemical Co. Ltd. (ZPC) will 

use a range of process technology from 

Honeywell UOP for the second phase of an 

integrated refining and petrochemical complex 

in Zhoushan, Zhejiang Province. The 

complex is one of several new large industrial 

sites that are part of China’s current 

national economic development plan. For 

this second phase of the project, Honeywell 

UOP will supply a wide range of technology 

licenses, engineering design, key equipment, 

and state-of-the-art catalysts and adsorbents, 

more than doubling the plant’s 

aromatics capacity. In addition, the Honeywell 

Experion Process Knowledge System 

will provide process controls and automation 

systems for the complex. “This 

second phase of the complex by itself will 

process 20 million t/a of crude oil and 

produce another 6 million t/a of aromatics 

when completed,” said Bryan Glover, Vice 

President and General Manager, Process 

Technology and Equipment, at Honeywell 

UOP. “ 

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Vega on the road to Industry 4.0 

Harvesting data in the 

field: making it do more 

Optimal networking of data and its users varies from one industrial process to 

another. Whereas encrypted, wireless data transmission might be a perfect fit for 

one application, the Vega Inventory System – or in future APL – is the solution of 

choice for others. The communication requirements are fundamentally different, 

yet the goal is always to avoid leaving valuable sensor data unused in the field any 

longer. 

Pictures: Vega 

The term IIoT (Industrial Internet of 

Things) refers to networked machines or 

production facilities, including the associated 

measurement technology. Among its 

most important benefits are the prospect of 

being able to react faster to inefficient processes 

or problems, save time and use smart 

machine data to enable more efficient control 

of production and operating processes 

as well as entire value chains. All this should 

be possible in nearly real time, with the 

help of intelligent monitoring and decisionmaking 

processes. That’s the theory, but 

what does the actual implementation look 

like – from the perspective of a field instrument 

manufacturer like Vega? 

Using the wheel in a new way 

When it comes to measuring and monitoring 

level and pressure, Vega is ready to meet 

Bluetooth allows Vega to respond to a wide variety of security requirements 

the individual requirements of the process 

industry. “We are consistently modular. This 

is a big advantage because it means we can 

get started at any time”, explains product 

manager Stefan Kaspar. “We don’t have to 

reinvent the wheel to meet our customers’ 

newest requirements.” Vega relies on bridging 

technologies such as Bluetooth. These 

are future-oriented, scalable solutions that 

can be integrated into existing systems. They 

can also provide new systems with a tailormade 

basic security configuration that continues 

to grow with new capabilities. “It’s 

important”, says Kaspar, “that users do not 

have to invest large sums upfront and that 

the solution can be seamlessly integrated 

into their existing set-up without compromising 

security”. 

Vega has a comprehensive range of Bluetooth 

technology covering almost its entire 

sensor portfolio on the basis of a well 

thought-out, multi-level concept. The company 

wants to react flexibly to different security 

requirements in this way. Plicscom, 

the universal display and adjustment module, 

is accordingly available either with or 

without Bluetooth. In the Bluetooth version, 

this function can be switched on or off at 

any time by means of a hardware switch. 

When used with multiple sensors, the wireless 

function is optional. Bluetooth is already 

securely encrypted at the interface 

level via a PC, laptop, smartphone or tablet. 

What’s more, sensor access via Bluetooth 

requires an access code. Wireless technology 

can also be applied to older devices: 

Plicscom is backward compatible for the 

majority of Vega sensors already in the field 

– as far back as 2002. 

Secure through a second data channel 

Plicscom, the display and adjustment module, 

is a convenient and economical solution 

wherever existing systems – which usually 

only have analogue 4 to 20 mA interfaces – 

need to be upgraded to digital, step by step 

in a sustainable fashion. Kaspar is keen to 

emphasise that “the range meets the Namur 

requirements for open architecture”. The association 

demands that the IT components 

be quickly and flexibly integrated, since 

they are generally shorter-lived than the industrial 

process components. This is vital if 

process engineering is to keep pace with the 

4.0 development. “This is the starting point 

for Vega’s initiatives: optimal system availability, 

security and lean solutions that can 

be easily upgraded if required”. 


Easy access to live data around the clock with the Vega Inventory System 

Bluetooth offers a form of communication 

that runs via a separate, second data channel, 

making it independent of the user 

channel. Field devices can thus be analysed 

parallel to the existing process control without 

interfering with plant security and 

availability. In the future, this local Bluetooth 

communication will be expandable to 

a complete diagnostic network, allowing 

diagnostic access from the control room 

down to the field level, also for existing 

analogue field devices from Vega. Plant operators 

will then be able to react to errors 

faster and in a more targeted manner, and 

detect deviations in the process early by recording 

the extensive information which is 

available in the field device and taking appropriate 

countermeasures. 

No more empty bins 

Just as flexible in use, although a big step 

ahead in terms of digital intelligence, is the 

Vega Inventory System. It offers seamless 

status monitoring, providing (or potentially 

providing) a database for efficient process 

supply and automatic re-ordering. The functions 

of the Vega Inventory System always 

follow the application. Should the supplier 

be notified automatically as soon as minimum 

stock levels are reached? Is the system 

“only” meant to visualise the course of production 

cycles reliably across different periods, 

locations and media in order to provide 

the user with a basis for further action? 

Should it “simply” shorten supply chains to 

remote bins and allow query data to be utilised 

over long distances? Or is it instead 

about integrating inventory directly into an 

ERP system? The options and possibilities are 

many and varied, and they can be added to at 

any time. The free choice of network host is 

an advantage for security. This task can either 

be carried out locally by the users themselves 

or transferred to the protected, always up-todate 

Vega cloud. “We want to make life easier 

for our customers, which is why our 

measuring instruments function according 

to the principle of simplicity”, Kaspar continues. 

The Vega Inventory System stands for 

minimum effort and maximum compatibility 

– with modularity a top priority. 

Future standard 

It is anything but easy to network field devices 

via digital fieldbuses, such as Profibus 

PA or Foundation Fieldbus, and then make 

the analysis and evaluation data available to 

the control level. Several decades after they 

were first introduced, these technologies 

have still not succeeded in replacing the 

analogue 4 to 20 mA process signal as the 

most widely used interface for level and 

pressure measurement technology due to 

their high complexity and costs. Bluetooth 

is a bridging technology that points in the 

right direction within this gap. It mediates 

between the analogue current interface of a 

field device and the Ethernet-based IT networks 

that are standard at almost all companies 

today. But why have field devices in 

the process industry not yet been upgraded 

for direct connection to the existing IT infrastructure, 

for example with an Ethernet 

interface? The existing two-wire technology, 

based on the 4 to 20 mA interface, has a 

decisive point in its favour here: the 

measured value and supply voltage can be 

provided simultaneously via just two wires. 

In addition, they conform to the “intrinsically 

safe” type of protection and are also 

explosion-proof for use in hazardous areas. 

The new Advanced Physical Layer (APL) 

makes a good alternative. Based on industrial 

Ethernet technology, this intrinsically 

safe, two-wire Ethernet communication 

standard will in future be able to handle demanding 

applications in process automation. 

The idea is to design it for a range 

of up to 200 m and a bandwidth of 

10 Mbit/s – including the power supply. 

Eleven well-known industry partners are 

currently involved under the umbrella of 

Profibus International, with Vega as well as 

the FieldComm and ODVA organisations 

among them. Their common goal is to eliminate 

the communication bottleneck between 

field devices and the control level. 

Even if several years elapse before the first 

APL devices become available in the market, 

if it is possible to radically simplify the setup 

and administration of such networks, 

this technology has the potential to become 

the future standard for process automation. 


Online search: cpp0119vega 

AUTHOR: 

CLAUDIA HOMBURG 

Marketing, 

Vega Grieshaber 




Pictures: Jungmann Systemtechnik 

Since windows in the control room had to be omitted, the “Virtual Sky” was installed as an alternative. 

Europe’s most modern refinery control room successfully starts operation 

Up to 1000 views 

connected to one console 

PCK Raffinerie GmbH processes about 12 million tons of crude oil annually into 

mineral oil and petrochemical products. Up until 2016, all production facilities were 

monitored and controlled via a central control room dating back to 1993. However, 

this room had become too small over time, which is why the management decided 

to replace it with a highly modern, roughly 1000 m 2 control room and develop an 

in-house concept geared towards the company’s special requirements. 

The fine tuning and implementation of the 

new control room at PCK Raffinerie GmbH 

in Schwedt took place in cooperation with 

various partners. Jungmann Systemtechnik 

(JST), for instance, was entrusted with the 

interior design and technical equipment: in 

addition to six control consoles with a total 

of 25 operator stations and 78 monitors, 

the control room experts also installed 

video walls with 100 displays for proactive 

control of the plants. 

“PCK has been striving towards centralised 

control rooms since as long ago as the 

1990s, when we consolidated eleven satellite 

control rooms in the old, central control 

room. We’re now taking the next step by replacing 

this control room with a more 

modern one. During the next three years it 

will gradually take on the tasks of four other 

satellites”, explains Thomas Taube, division 

engineer for maintenance services and project 

coordinator at PCK. The company still 

has a total of seven control rooms at present 

– including the new 1000 m 2 main control 

room, which is at the heart of the refinery. 

The entire process chain is monitored and 

controlled here – from the arrival of crude 

oil via a pipeline from Russia through the 

various steps in the production facilities to 

the finished, ready-to-ship product. The 

control room consists of six control consoles 

which are acoustically separated from 

one another by non-reflective glass walls 


High flexibility 

“It was also crucial for us to increase the 

availability of the process technology and 

achieve a high level of flexibility while 

using the control system”, Taube continues. 

“At the same time, the objective was for 

every point in the plant to ideally be acand 

equipped for regular operation with 

three operator stations each as well as one 

reserve station. The control room is big 

enough for 24 people at once. Since PCK 

works in four shifts, there are normally 125 

plant operators including standby personnel. 

This will presumably be the case in May 

2019, when all six control consoles are fully 

staffed. 

Implemented with partners 

PCK developed the concept for this control 

room itself and subsequently implemented 

it together with partners. “For example, we 

had a very clear idea from the outset of how 

the production facilities should be controlled 

in the future”, says Taube. “The fundamental 

requirement was that the plant 

should be operated via the video wall in 

combination with smaller monitors.” Comprehensive 

research and market analysis was 

undertaken in the search for a suitable so - 

lution. Following an extensive trial with a 

test workplace, PCK opted for a holistic so - 

lution from Jungmann Systemtechnik. 

Amongst other things, this covered the 

layout concept, furnishings, video systems 

and multi-consoling hardware and software. 

Virtual sky 

The control room equipment from JST is 

now located in a new, windowless bunker 

building, which was constructed using 

3200 m 3 of concrete and 520 tons of steel. 

The building is protected against pressure 

and explosion. Since windows had to be 

dispensed with in the control room, the virtual 

sky was installed as an alternative. This 

is a 105 m 2 illuminated ceiling which PCK 

developed together with the Fraunhofer Institute 

for Industrial Engineering (IAO) in 

Stuttgart. It simulates the sky at any time of 

the day or night and thus ensures a pleasant 

working atmosphere. 

cessible from every workstation.” Apart 

from the process control technology, this 

is mainly the responsibility of the hardware 

and software developed by JST for 

controlling the workstations and video 

systems: “Multi-consoling correlates 

monitors, in other words each plant operator 

always sees precisely the information 

they need at any given time on one of 

their monitors”, explains Jungmann. “Up 

to 1000 different process images can be 

connected to one workstation in this way.” 

The number of monitors per workstation 

was reduced as a result. The visualisation 

surface on which a plant can be represented 

was simultaneously increased fivefold. 

Moreover, only one keyboard and mouse 

are required for the different views on 

each workstation. “In the past we had four 

keyboards per workstation and were 

forever jumping back and forth between 

them”, Taube adds. That was not only inefficient 

and inconvenient; the control room 

operator also found it difficult to see at a 

glance which monitor belonged to which 

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device – a potential source of error which 

has now been eliminated. So-called mouse 

hopping, another multi-consoling function, 

helps too: “For example, operators 

can drag the cursor across all monitors at 

their workstation as well as up the monitor 

wall using the mouse”, Jungmann reports. 

All in all, this special console concept enables 

a comprehensive overview of all key 

processes in the plant. 

Video walls provide an overview 

To ensure optimal control of the process 

graphics, PCK creates an overview display of 

each operating area and then projects these 

three views onto the video wall, so that together 

they provide an overall view. Taube: 

“In practice, the overview of each operating 

area is normally always displayed in the top 

row of the video wall. As a result, you can 

see instantly what is going on in the plant at 

a particular moment in time and determine 

where a fault has occurred or where intervention 

is necessary.” Operation of the plant 

is generally controlled using the monitors at 

the bottom of the video wall, where – in 

contrast to the top row – the focus is on a 

specific plant section where work is being 

performed. Detailed descriptions or the 

consequences of alarms are usually connected 

to the monitors on the control room 

console. In the event of an alarm, the special 

lighting for the control room workstations 

and video walls further emphasises the 

acoustic warning and supports the control 

room operator. The JST “AlarmLight” which 

is used for this purpose can be activated by 

the monitoring system and blinks or 

changes colour if an error message is received. 

Multi-consoling correlates monitors, that is to say the system operator always gets the readout on one 

of the monitors which they need at the moment 

Full redundancy 

The entire solution at the Schwedt refinery 

is additionally designed to ensure reliable 

plant control in critical situations. The 

multi-consoling system at PCK is used in 

the maximum configuration level, that is 

with full redundancy. The multi-consoling 

system of each control console is laid out so 

that if one system module fails, a second 

cluster takes over within a few seconds. This 

second cluster runs in hot standby parallel 

to the first. “We must remember that all 

four operator stations of a control console 

converge in one system. It is therefore crucial 

that this component is failsafe. If it were 

to fail, the entire control room would no 

longer be able to see what was going on 

and the operators would have no more information 

about the plant”, Taube comments. 

“That is why it was a fundamental 

requirement for us that the heart of the system 

should be one-hundred-percent redundant.” 

Redundant inputs and outputs are likewise 

available for all signal sources and outputs – 

in other words, for every control station 

from the process control system as well as 

for every monitor that needs to output 

something. Each monitor has two connections 

to the overall system. If one channel 

malfunctions, nothing happens. The redundant 

body ensures that communication is 

maintained as far as possible. The highest 

level – the complete system – moreover has 

a fully redundant design, so that the control 

room always provides maximum safety. 


Online search: cpp0119jungmann 

The number of monitors at the workplace can be reduced by means of multi-consoling 


GLASS FILTERS 

High quality material for demanding 

tasks: VitraPOR® glassfilter apparatuses 

made from pure borosilicate glass 3.3 

fulfill many requirements in chemical 

and pharmaceutical labs as well as for 

industrial, biological and environmental 

technology applications. 

Properties such as heat resistance to 

over 500 °C and resistance to most 

acids, alkalis and solvents make our 

VitraPOR® glassfilters, which conform to 

international standards, suitable for use 

in many chemical, pharmaceutical and 

technical procedures. 

Custom VitraPOR® sintered elements 

according to your specifications are 

characterized by their neutral properties 

and open-pore structure. They are 

suitable for even the most unusual 

applications. 

VitraPOR® glassfilter apparatuses can 

be supplied in different pore size classes, 

from smaller than 1 micron to over 500 

micron and as custom-made solutions in 

many shapes and sizes. 

ROBU Glasfilter-Geräte GmbH 

Schützenstrasse 13 

57644 Hattert 

Germany 

Made in Germany 

www.robuglas.com 



SPECIAL 

Powder incorporation under dust and gas explosion conditions 

No cloud, no danger 

Preventing dust when powders and liquids are mixed together makes work safer. 

No cloud, no risk of a dust explosion. The Conti TDS and TDS Induction Mixer solve 

this problem by incorporating the powder into the liquid underneath the liquid 

surface, meaning no dust is produced. 

Wherever powders are used in industrial 

manufacturing dust is created. This is a 

safety problem in many industries because, 

with all organic or organic-coated powders 

and some metal powders, this dust will generally 

be combustible or explosive. Whether 

or not an explosion may occur in practice 

depends on the dust concentration in the 

air. If this concentration is between the 

upper and lower explosion limits, then it 

creates an ignitable dust-air mixture. An ignitable 

mixture can even be created with 

non-combustible and non-explosive 

powders if the powder is processed in a hybrid 

mixture with flammable gases and vapours 

present. In this case, the inflammable 

gas atmosphere between the powder particles 

is the source of the risk. Things get especially 

dangerous when powders are poured 

into a process tank containing inflammable 

liquids with ignitable vapours above: 

the powder must pass through the critical 

zone where the mixture is easily ignitable. 

Ultimately, all it takes to trigger a dust explosion 

is an ignition source with a sufficient 

amount of ignition energy. 

One underestimated – and often overlooked 

– danger is the risk of electrical discharge in 

the flowing powder. Powder becomes 

charged when it flows out of a sack or 

hopper or simply through a pipeline. 

Hence, even conveying and pouring 

powders is risky. What many users and even 

valve manufacturers don’t understand is the 

risk caused by valves through which 

powder is flowing, since the internal ball or 

disc is typically mounted electrically isolated 

from the pipeline. Flowing powder 

charges these components differently, creating 

sparks. 

Consequently, even simple manual valves 

through which powder flows must fulfil all 

requirements to prevent dust explosions and 

have to be certified, even if they don‘t contain 

any electrical part. 

Pictures: Ystral 

The TDS Induction Mixer generates a vacuum in the mixing head, which 

it uses to suction the powder directly under the surface of the liquid 

Avoiding dust clouds 

To ensure safety in production, therefore, 

any dust must be avoided. Outside of 

powder processing systems, critical dust 

concentrations can be reliably prevented 

with a suitable dust extraction system. 

However, when powders are conveyed into 

a process tank or sacks emptied onto a 

liquid, the dust-air concentration is always 

critical. The explosive volume depends on 

the rate at which material is added and the 

amount of dust created by the powder – 

factors which cannot be reliably controlled. 

With Ystral’s TDS systems, powders are inducted 

into the liquid in a dust-free 

manner. The induction vacuum is generated 

directly in the liquid itself. Once the combustible 

powder has been mixed into the 

liquid, there is no risk of dust explosion 

anymore. A TDS Induction Mixer installed 

inside the process vessel. It creates a vacuum 

in the mixing head, which inducts and 

mixes the powder directly below the surface 

of the liquid. 

The Conti-TDS is much more universal. It is 


The ContiTDS is set up outside of the container. It moves the liquid in a 

cycle and suctions the powder in a dust-free manner. 

Process plant for processing dust-Ex powders 

installed outside the process tank, recirculates 

the liquid in a loop and inducts it dustfree. 

The machine can work with significantly 

higher viscosities, different batch 

sizes and variable liquid levels in the tank. It 

can be set up separately from the process 

tank or connected to multiple tanks. 

Both machines are designed and certified in 

accordance with the relevant dust and gas 

explosion directives; they use only certified 

components and are suitable for both dust 

and gas explosive atmospheres. The systems 

are available with different Atex classifications 

as well as with IEC Ex and NEC certifications. 

Processing in non-explosive areas 

One unique variation is designed for users 

who need to process dust explosive 

powders in non-ex-classified zones. This application 

is rare in the chemical industry 

but common in food, cosmetics and pharmaceutical 

production, where a large 

number of organic powders with the potential 

to form explosive dusts are processed. 

Dust explosion risks outside the processing 

systems can be prevented by taking suitable 

precautions. Inside the system, however, 

critical explosive dust atmospheres may be 

created shortly before the powder enters the 

liquid. Suitable TDS machines are available 

for here; they are internally fully dust-explosion 

safe and classified. But externally 

they are designed for installation in non-ex 

areas. A typical Ex classification is II 2D/ – 

cT200 °C, where the zone specification before 

the dash applies to the interior zone 

and execution, and the specification after 

the dash for exterior zone. These machines 

can be used to process dust explosive 

powders in non-ex classified areas. 

Hoods can’t solve the problem 

Stainless steel covers for electric motors or 

even entire machines which are very popular 

in the food and pharmaceutical industries 

are extremely dangerous in explosive 

applications. Atex permits for motors and 

other electrical operating devices generally 

apply to temperatures between -20 and 

+40 °C. Measurements on pumps and other 

aggregates have shown that, even if the 

hood over a motor has a relatively open design, 

temperatures of 60 or 80 °C are not 

uncommon. The temperature inside the 

cover must therefore be monitored and 

must not exceed 40 °C during operation; 

otherwise, the ex-certification for any electrical 

components inside is no longer valid. 

The same is basically true for noise insulation 

hoods, although these are significantly 

better insulated and sealed than 

simple cover hoods. 

In order to use hygienic covers and sound 

insulation in explosive areas, the hoods 

must have interior cooling. Internal cooling 

systems are often insufficient due to the limited 

cooling surface. In this case, a temperature-controlled 

ventilation is the only 

alternative. 


Online search: cpp0119ystral 

Hall 3, Booth 431 

AUTHOR: 

DR. ING. HANS- 

JOACHIM JACOB 

Process and Application 

Engineering, 

Ystral 



SPECIAL 

Pictures: Rembe 

Operators benefit from integrated concepts 

EXPLOSION SAFETY IN 

BULK SOLIDS PROCESSING 

Each facility has its own special features regarding bulk material 

processing. However, usually comparable standard equipments and 

machines are installed, such as equipment for bulk material un - 

loading, conveyors, elevators, silos, screens, mills and filters. 

Suitable explosion prevention and protection measures must be 

provided individually for each equipment. 


The Q-Ball E is a flameless explosion vent specifically for 

elevators 

The Q-Box protects screens by providing flameless 

explosion pressure relief 

Professional explosion safety has its price, but unprofessional overengineering 

or poor protection can be much more expensive in the 

long run. In the worst case, people will pay with their lives. Therefore, 

it is recommended to work with experienced professionals who 

establish a holistic view of the situation, and create a comprehensive, 

individual protection concept for the facility. Even the purchase of 

turnkey plants never relieves the future operator from the duty to implement 

a sufficient explosion safety. Initially, experts always assess 

the neces sity of explosion safety. Because not every facility or every 

part of a facility must be equipped with constructive actions without 

an assessment. In the following we will have a closer look at several 

stations of bulk material handling and processing. 

End-of-the-Line-Powder-Mixing 

KoneSlid®-Mixer (patented) 

A symbiosis of excellent hygienic 

and ergonomic design. 

✓ Extremely gentle mixing process 

with short cycle times 

✓ Virtually complete discharge 

in a few seconds 

✓ Ideal mixture qualities 

✓ 

✓ 

✓ 

✓ 

✓ 

✓ 

Filling levels can vary from 

10%- 100%. 

High flexibility for the production 

of stabilizers, nanoparticle 

agents, pigments, plant protection 

chemicals and medicine 

Several large, hygienically 

designed inspection doors 

On request with type-examination 

Ex II 1D (for Zone 20) 

Optionally, the mixer is 

manufactured as a pressure-shock-resistant, 

pressure-resistant and 

vacuum-proof version. 

All components of the 

amixon®-mixers are 

made in Germany. The 

production of the 

machines takes place 

exclusively in the 

amixon® factory 

in Paderborn. 

Unloading bulk material 

The respective bulk material is usually transferred into bulk containers 

from a truck or freight wagon. This is where organisational/preventive 

actions are mostly sufficient: The risk of combustion from hot 

brakes or exhaust systems is effectively countered through a wait and 

cooling time of 15 min before the discharge. Grounding systems additionally 

protect against spark discharges. For moving objects such as 

trucks or wagons, the staff must work carefully and have received the 

appropriate training. In addition, agreements should be made with 

suppliers to ensure that the raw material is delivered without any 

glowing embers. 

Virtually complete discharge 

in a few seconds 

Flow principle in the amixon® 

KoneSlid®-Mixer 

Mechanical conveyors 

There is no standard concept for explosion safety on conveyors, as 

the designs and functions are highly diverse. However, there are actions 

that avoid explosions – without the need to install protective 

amixon ® GmbH 

Paderborn, Germany 

sales@amixon.com · www.amixon.com 



SPECIAL 

The Q-Rohr enables 

explosion pressure relief 

in closed rooms without 

flame and dust propagation 

The risk of explosion is particularly high in filter systems. If driveways or traffic routes are in the area of explosion 

pressure relief, add-on modules for bursting discs such as the Targo-Vent are used. 

systems. These include limited conveying speeds, suitable material 

pairings and safety-compliant designs. Open belt conveyors are 

relatively uncritical. The material is not swirled up and does not come 

into contact with hot surfaces. This is different with chain and screw 

conveyors: depending on the degree of fineness, moisture content 

and dust formation probability of the bulk material, the conveying 

principle and conveying speed of the connected system parts, there 

could be a need to implement explosion protective systems such as 

explosion pressure venting devices. It must be ensured that explosions 

that occur in neighbouring parts of the system, are prevented 

from propagating through other connected conveyors. For this 

purpose, isolation systems such as Atex-certified rotary valves, chemical 

barriers, quench valves or quick-acting slide valves are used. 

Explosion safety for bucket elevators 

Bucket elevators represent a special source of risk, because they 

facilitate the negative explosion prerequisites (explosive mixture 

and ignition sources) through their function and design. 

Additionally, pressure waves and flames can propagate across several 

floors through unprotected elevators, and cause severe damages. 

VDI Guideline 2263, Sheet 8 (8.1 and 8.2), describes explosion 

safety measures and provides information on the dimensioning 

of explosion venting devices and the design of explosion suppression 

systems. The particular challenge with elevators is that the protective 

systems installed must be as light as possible and at the same 

time achieve the maximum venting efficiency. 

The Q-Ball E (E stands for elevator) from Rembe is an example of a 

flameless explosion vent designed specifically for elevators. At 25 to 

50 kg, depending on its size, the Q-Ball is very light compared to 

other available systems that easily weigh 100 kg and more. This 

does not just make the installation easier, but also reduces the demands 

regarding the attachment and strength of the elevator. 

Risk of an ignition source entry into silos 

Silos do not usually contain any kind of their own ignition sources. 

This eliminates a decisive parameter that can trigger a dust explosion. 

However, there is a danger of combustion which is caused 

by a possible ignition source entry from upstream facility components. 

Outdoor silos must therefore be protected with explosion 

vents, and silos inside buildings with flameless venting devices or 

explosion suppression systems. Depending on the type of bulk material, 

preventive actions can also be implemented, such as the installation 

of spark detectors in combination with spark extinguishing 

systems or quench valves. 

Screens and mills 

Screens can often be extremely endangered, especially in combination 

with upstream dryers. Glowing embers in bulk materials 

which have survived in mechanical conveyors without igniting may 

subsequently be broken open by tumbling or vibrating movements 

and subsequently trigger an explosion. Explosion protection is 

therefore necessary, but not always easy to implement indoors. The 

solution: mostly individual, vibration-isolated systems based on a 

flameless explosion venting device. For the explosion protection of 

grinding systems several manufacturers have devices which offer an 

explosion pressure-resistant design (up to 10 bar). Depending on 

the size of the facility, this represents a cost-intensive investment. , 

Explosion isolation should always be provided above and below the 

mill in order to protect other facility components. The Q-Rohr LF is 

designed for the mill's suction opening. It is a version of the 

Q-Rohr where the usually existing rupture disc is missing. The mill 

thus can suck in air during the normal operation, which is routed 

through the stainless steel mesh filter without any problems. If an 

explosion occurs, the stainless steel mesh filter protects the environment 

from flames and pressure by removing the heat. 

Filter: Increased danger during the pulse-cleaning 

The risk of explosion is particularly high in filter systems. Many 

manufacturers therefore offer products with integrated explosion 

safety devices. It becomes particularly critical when the filter 

elements are pulse-cleaned. The very fine dust can then spread evenly 

in the filter, and in combination with a present ignition source, lead 

to an explosion. Indoor area filters are therefore protected with 

flameless venting devices, outdoor filters with explosion vents. If 

transport or traffic routes are located in the vicinity of the explosion 

venting, add-on modules for explosion vents such as Targo-Vent are 

used to deflect the flames and pressure wave into non-critical areas. 


Online search: cpp0119rembe 


AUTHOR: 

DR.-ING. JOHANNES 

LOTTERMANN 

Director Explosion Safety, 

Rembe 



SPECIAL 

Safe transport of BHET 

Filling containers in a 

closed nitrogen loop 

Conveying and handling are critical steps in any production process. Together with 

Ioniqa, Dinnissen has developed a closed-loop pneumatic transport system for BHET, 

an intermediate in the production of PET. To solve the problems of product degradation 

and particulate matter explosion, nitrogen is used as the transport medium. 

Bis(2-Hydroxyethyl) terephthalate 

(BHET) is the ester of ethylene glycol and 

terephthalic acid. Together with 2-hydroxyethyl 

terephthalic acid, BHET is an intermediate 

in the production of PET. Ioniqa 

manufactures BHET, the raw material for 

manufacturing PET products, by chemically 

recycling PET flows. The question that arose 

was how this product – solid particulate 

matter consisting of small pellets as well 

as somewhat smaller particles – could be 

safely blown by dryers into 20 ft containers 

to fill the liner? This question was quickly 

answered thanks to Dinnissen’s experience 

and expertise. Together with Ioniqa, 

Dinnissen developed a closed-loop 

pneumatic transport system for BHET. 

It is well known that using nitrogen can 

eliminate the risk of product degradation 

and particulate matter explosion. To solve 

the problems, therefore, it was decided to 

use nitrogen as the transport medium for 

the BHET. The system that has now been 

developed monitors the critical oxygen 

level continuously. It includes a nitrogen 

balancing system which ensures that the 

complete system is constantly filled with 

the correct nitrogen atmosphere at a 

predetermined overpressure. 

The entire closed-loop system is enclosed 

and in line with Ioniqa’s vision of a circular 

economy. Only a minimum amount of 

nitrogen is used. Moreover, the system 

offers 100 % safety in the event of an electrical 

discharge in the liner of the 20 ft 

container, because the product is transported 

and the liner filled in a completely 

inert environment. 

Controlled speed of the product flow 

An additional advantage of the closed-loop 

pneumatic conveying system is that it is 

possible to fill the container optimally by 

controlling the speed of the product flow. 

This volume control is relatively simple to 

realise by using a frequency regulator to 

adjust the gas volume moved by the blower. 

The final point to be considered was gastight 

sealing of the transport line to the 

liner of the container. It was decided to use 

a special, proven clamp adapter with an inflatable 

seal. The return gas is fed via this 

adapter to a filter unit, then compressed 

and cooled before being reused as a carrier 

gas. 


Online search: cpp0119dinnissen 


Picture: Dinnissen 

The closed-loop pneumatic transport system for BHET uses nitrogen as the transport medium 



SPECIAL 

Grinding down to the nano range 

Operator interface for feeder control 

Picture: Fritsch 

Picture: IEP Technologies 

The Fritsch Pulverisette 5 premium 

line is the ideal mill for 

fast wet and dry grinding of 

hard, medium-hard, soft, brittle 

and moist samples as well as for 

mechanical alloying, mixing 

and homogenising down into 

the nano range. The mill is 

equipped with an extra strong 

2.2 kW drive and reaches high 

centrifugal acceleration up to 

Explosion isolation flap valves 

64 g and 800 min -1 . Sample 

quantities up to 450 ml and 

feed size up to 10 mm are possible. 

With the Servolock clamping 

of the grinding bowls and 

the automatic check of the fastening 

of the bowls inside the 

mill, man and machine are optimally 

protected. In the event 

of impermissible operating 

states, the machine blocks the 

start of a grinding – and if an 

imbalance occurs it automatically 

shuts off. The mill comprises 

two grinding stations for 

grinding bowls from 125 to 

500 ml volume. 


Online search: cpp0119fritsch 


IEP Technologies' IFV and IFV-M isolation flap valves are 

typically required where two or more process vessels are 

linked by ductwork and an explosion hazard exists. An 

isolation flap valve installed in the duct is closed rapidly 

by the pressure wave from the downstream explosion 

ahead of the flame front arrival. 

The IFV flap valve is compliant to the Atex Directive and 

certified by a third party as a dust explosion protection 

system. The IFV-M model adds integrated monitoring of 

the flap position and dust accumulation in the valve 

body, meeting the requirements of the Osha Combustible 

Dust Directive, NFPA 654, and NFPA 69. Both models 

feature a durable carbon steel body and a stainless 

steel flap. In normal operation, process airflow holds the 

lightweight flap open with minimal pressure drop. The 

cylindrical housing design minimises the risk of product 

buildup, while the blade axle is mounted entirely within 

the housing to ensure leak-tightness. A hinged inspection 

cover provides easy access. The isolation flap valves 

are available in sizes from DN 100 to DN 710 for dust 

class ST1 for reduced explosion pressures up to 1 bar. 

For ST2 dusts they are available in sizes up to DN 200. 


Online search: cpp0119iep 


Picture: Coperion 

Coperion K-Tron has added new 

features to its proven K-Vision 

software. The K-Vision controller 

is a graphical operator 

interface for controlling multiple 

devices such as feeders or 

feeder refill (vacuum receivers) 

in a process. With the release of 

K-Vision Software version 2.0, 

the K-Vision is now able to 

handle a total of 24 devices (e.g. 

KCM feeder controls or MPC refill 

controls) in one or two 

lines. This is a major upgrade 

over the previous version which 

managed a maximum of 16 

feeder controllers in a single 

line. K-Vision uses a 12.1 inch 

color LCD display together with 

a touchscreen as the primary 

operator input mechanism. It 

offers a quad screen display 

mode for viewing multiple 

pages on one feeder or a single 

page on multiple feeders. Support 

for over a dozen languages, 

even Chinese and Japanese, is 

included, and additional languages 

can be added on request. 

Designed for simple operation 

and fast and easy start up, K-Vision 

offers graphic visualisation 

of process information, utilising 

flexible, easy to use trend 

graphs. This feeder interface 

offers event logging and supports 

all of the different feeding 

control types for both continuous 

and batch operation. Easy to 

maintain, K-Vision software updates 

are possible by updating 

files on a compact flash card or 

by using a USB flash drive. 


Online search: 

cpp0119coperion 


Process data worldwide under control 

The cloud based Dinnissen productivity 

platform is designed 

to reduce downtime, boost productivity 

and gain insight using 

a computer, smartphone or tablet 

to stay up-to-date on the 

performance of production processes. 

It offers a user-friendly 

way to connect to machines 

around the world, with very 

high levels of security. 

The productivity platform ensures 

fast and troubleless service 

and troubleshooting from Dinnissen. 

Amongst the functions 

are remote service, machine 

monitoring, custom alerts and 

high-end data dashboards. 

It guarantees security, as it is 

realised in accordance with 

Picture: Dinnissen 

widely recognized guidelines. 

With production and maintenance 

data stored on high-availability 

database clusters hosted 

in certified data centers, automatic 

updates and redundant 

DPP services, you can be confident 

that your data is safe. 



cpp0119dinnissen 



ComVac, Hannover 

April 1 – 5, 2019 

Please visit us: 

Hall 26, Booth D16 

YOUR PARTNER FOR VACUUM 

SOLUTIONS IN FREEZE DRYING 

Design, consulting and optimization of your vacuum application in freeze drying 

Vacuum generation with CombiLine Roots pumping systems 

This modular pumping system is the optimal solution for production freeze drying. In addition to the wide variety of standard pump 

combinations – both wet and dry – customizations can be implemented for reduced footprint or high reliability. 

Pressure measurement with CLR capacitance gauges 

Monitor your process pressure with our CLR capacitance gauges, specially designed for freeze drying processes. They can be 

heated up to 160 °C and have a rugged design, which extends their lifetime in SIP processes. 

Detection of silicone oil with PrismaPro mass spectrometers 

Do you want to prevent silicone oil leaks from contaminating your batch? Are you looking for a PAT tool to monitor your process 

and endpoint detection? Then the latest generation PrismaPro mass spectrometer is your solution! It completes these tasks with the 

highest accuracy and is also available as a ready-to-go solution tailored to your needs. 

Are you looking for a perfect vacuum solution? Please contact us: 

Pfeiffer Vacuum GmbH · Headquarters/Germany · T +49 6441 802-0 · www.pfeiffer-vacuum.com 



SPECIAL 

Picture: Hosokawa Alpine 

Twin screw dosing unit 

Powders with poor flow properties pose a 

particular challenge for the production of 

pharmaceutical products. With the Alpine 

twin screw dosing unit PDD 14, Hosokawa 

Alpine has launched a solution which guarantees 

the continuous dosing of even critical 

powders into production systems such 

as mills or mixers. It complies with the 

highest GMP requirements. With a screw 

diameter of only 14 mm, the twin screw 

dosing unit PDD 14 is the smallest screw in 

the PDD product line. It can convey between 

0.5 and 50 l/h. The dosing unit is in monobloc 

design. This results in two advantages: 

On the one hand, the product-contact parts 

can be dismantled and assembled quickly 

and easily. And on the other hand, the geometry 

of the unit was designed so that there 

are neither dead spaces, gaps nor welds. This 

saves time when cleaning. 


Online search: cpp0119hosokawaalpine 

Hall 4A, Booth 233 

Efficient mixing and drying processes 

Hosokawa Micron developed 

the Conical Paddle Mixer/Conical 

Paddle Dryer (CPM/CPD) 

which can be used for mixing, 

drying and reaction processes. It 

is compact, quick, efficient and 

suitable for many applications 

in a diverse range of industries. 

The central rotor creates a combination 

of vertical, axial and 

radial 3D motion in the vessel. 

The paddles gently guide the 

product along the vessel wall to 

the surface of the batch, where 

it is dispersed before being 

forced back down by the gravitational 

pull at the centre of the 

mixer. This creates continuous 

motion throughout the complete 

batch during the entire 

mixing cycle, even at low speed. 

The CPM/CPD combines rapid 

drying rates with a compact design 

developed to enable vacuum, 

atmospheric and pres - 

surised processing of a variety 

of materials such as powders, 

filter cakes, viscous slurries and 

especially brittle materials. 

Continuous powder synthesis 

Picture: Hosokawa Micron 

Capable of combining several 

processes in one vessel, the 

paddle mixer/dryer has proved 

successful in a range of applications, 

including sterilisation 

and pasteurisation, high-temperature 

processing of powders, 

vacuum drying at low temperatures 

with liquid recovery, alkalisation 

and crystallisation. 




cpp0119hosokawamicron 

Picture: Haver & Boecker 

Ultrasonic screening solutions 

Ultrasonic screening solutions 

from Haver & Boecker can be 

used for cut sizes of approx. 

1000 to 25 μm. Existing screening 

units with pre-tensioned 

screen frames can be retrofitted 

with this innovative technology. 

Haver & Boecker is collaborating 

with Artech Ultrasonic Systems, 

an international leader in 

ultrasound technology, to provide 

custom-made ultrasonic 

screening systems with innovative 

frequency variation. 

The system comprises all 

required components from the 

pre-tensioned screen frame with 

waveguide-system over the 

ultrasonic converter and the 

generator to the support elements, 

if needed. With their 

Plug’n’Sieve concept, ultrasonic 

screen frames with Artech frequency 

variation offer great user 

convenience: Simply install the 

screen frame, connect the components, 

and immediately start 

screening with higher throughput. 



cpp0119haverboecker 


Picture: Glatt 

Glatt presents the continuous 

powder synthesis method Apptec. 

Using spray calcination in a 

pulsating hot gas stream at temperatures 

of 200 to 900 °C, 

powders with particularly narrow 

particle size distributions 

can be produced from a wide 

range of starting materials. The 

easily controllable thermodynamic 

process conditions make 

it possible to precisely adjust the 

product properties — for 

example with regard to chemical 

composition, morphology, 

phase structure and coating or 

surface chemistry. In addition to 

the joint development of Apptec-based 

powders and contract 

production, Glatt also offers 

reactors of the Proapp series in 

various sizes – such as for laboratory 

scale production. 


Online search: cpp0119glatt 



The effective way to suppress explosions 

Sterile mixing-dryer and reactor 

IPD, the system for suppressing 

and isolating dust explosions 

from BS&B Safety Systems, detects 

critical rises in pressure to 

the millibar and reacts at lightning 

speed. The highly effective 

extinguishing agent smothers 

any flame in an accumulating 

explosion in a fraction of a second, 

long before the explosive 

pressure is unleashed. When 

used for isolation, the IPD system 

stops the explosion spreading 

to connected parts of the facility. 

To make sure the IPD system 

is ready for use again 

quickly after being triggered, 

the designers developed a 

modular design that allows for 

immediate resetting on site. 

The extinguishing unit consists 

of an unpressurised, easily replaceable 

extinguishing agent 

cartridge and a pressurised container 

that is filled with nitrogen 

during installation or reset. The 

Picture: BS&B Safety Systems 

lack of a pyrotechnic trigger 

means that none of the individual 

components or the completed 

system are classified as 

hazardous goods. This makes 

both handling and management 

much easier. Furthermore, the 

extinguishing unit requires no 

extra discharge nozzle for the 

agent. Instead, the integrated 

rupture disc becomes an aerodynamic 

outlet when activated. The 

design avoids the use of plumbing 

that can become blocked. 


Online search: cpp0119bs&b 


Amixon‘s VMT series vertical 

mixers produce sterile materials 

and active pharmaceutical substances. 

Their working volumes 

vary between 0.2 and 2 m³. So 

ideal mixing quality can be 

achieved when the device is filled 

to a level anywhere between 

about 10 and 100 %. 

Components that come in contact 

with the product are made 

of Alloy 59. The various stages 

of the drying process are carried 

out in between 30 and 180 min, 

under vacuums down to 10 to 

2 mbar. Because the mixing device 

only has bearings and seals 

at the top, operation of the mixing-dryer 

calls for almost no 

servicing. Liquid additives can, 

at the same time, be distributed 

very precisely with the aid of a 

novel wetting technique. A 

further feature worth emphasising 

is that amixon mixers automatically 

empty themselves, 

Picture: Amixon 

leaving very little residue. Regardless 

of the velocity of removal, 

no tendency to separate 

occurs, even if the ingredients 

are highly heterogeneous. 

The energy-saving method of 

automatic cleaning and the 

chemical-free sterilisation are 

further advantages. Manhole 

openings, nozzles and flanges 

are designed in accordance with 

EHEDG recommendations. 


Online search: cpp0119amixon 


See us at: 

POWTECH 


April 9–11, 2019 

PROCESS 

TECHNOLOGY 

PELLETING FOR 

ECONOMIC 

COMPACTING 

AND SHAPING 

We constantly encounter bulk 

products and powdery materials in 

everyday life. They come in various 

particle sizes – from lumpy to powdery. 

Bulk products are processed in many 

industries, for example in the chemical 

and pharmaceutical industry. 

AMANDUS KAHL GmbH & Co. KG 

Dieselstrasse 5–9 · 21465 Reinbek 

Hamburg, Germany 

+49 (0) 40 72 77 10 

info@akahl.de · akahl.de


SPECIAL 

Solutions for new construction and retrofitting 

Heat recovery in process 

air generation 

Process or compressed air is the most expensive form of energy for physical 

reasons. There is no compressed air without heat. In view of the long operating 

times of compressors, it is particularly important to recover these costs for 

two reasons: firstly the environment and secondly good business management. 

Appropriate solutions for new construction and retrofitting are now an integral 

part of the Aerzen portfolio. 

Compressed air is a hot topic from the 

energy point of view. Limited resources, 

strict environmental regulations, restrictions 

on CO 2 

emissions, rising energy costs 

and increasing price pressure are the 

driving forces behind energy efficiency 

projects. 

On the one hand, these are based on precise 

design, so that systems can operate around 

the clock and as close as possible to the optimum 

operating point, using frequency inverters 

for speed control. It is therefore important 

to say goodbye to well-meant 

power reserves without endangering operating 

safety. On the other hand, for physical 

reasons, compressors offer enormous potential 

for utilising the inevitable rise in air 

temperature as the pressure increases. In 

view of the growing interest in ecological 

sustainability and economic cost awareness, 

plant operators are increasingly considering 

heat recovery. This development is accelerating, 

not least due to the attractive return on 

investment, which is often less than two 

years. What are the reasons for this easily 

accessible potential? 

Laws of thermodynamics 

According to the laws of thermodynamics, 

air heats up in an enclosed space as soon as 

the pressure rises. The reason for this is that 

the air molecules must move closer together 

because there is less space, leading to increased 

friction. The law of ideal gases is applied 

for further analyses at typical process 

air pressures. The air temperature can be calculated 

downstream of compression together 

with the efficiency of the compressor 

at the respective operating point. This 

mainly depends on the pressure ratio. At an 

Pictures: Aerzen 

Air compression generates heat. Large parts of this heat can be recovered using tube 

bundle heat exchangers. 

Cooling water flows around the 

tubes in counter-flow. The fins 

ensure effective heat transfer.

The compact, flow-optimised tube bundle 

heat exchangers are located immediately 

downstream of the assembly on the 

discharge side 

intake temperature of 20 °C, a pressure ratio 

of three and an isentropic compressor efficiency 

of 74 %, the air is heated to approximately 

166 °C during compression. The 

higher the temperature, the wider the range 

of applications for waste heat recovery. 

Thermodynamically, the quality of the heat 

is described by the so-called Carnot factor, 

which includes the ratio of the absolute 

waste heat and heat sink temperatures, i.e. 

the use of waste heat. The amount of heat 

contained in the process air typically accounts 

for about 85 % of the total that can 

potentially be recovered in plants. The remaining 

15 % are distributed more or less 

equally between losses from the drive 

motor, the mechanics and radiation from 

the hot compressor stage underneath the 

acoustic hood. 

Waste heat for heating rooms 

However these 15 % can also be used to heat 

adjacent office or production areas in connection 

with heat recovery measures. Aerzen 

equips the exhaust air louvres of the Delta 

Blower positive displacement blower, the 

Delta Hybrid rotary lobe compressor and the 

Delta Screw compressor with an exhaust air 

duct. The heated air which previously cooled 

the compressor stage, the silencer, and the 

piping system underneath the acoustic hood 

escapes from this duct. The return flow in 

the central exhaust air duct, from which 

branching ducts supply the rooms to be 

heated, has a temperature of between 30 

and 60 °C. Regulated flaps are used in this 

system for individual temperature control. 

Tube bundle heat exchangers 

The first method of heat recovery is to exploit 

the 85 % share of thermal energy, i.e. 

the compressor air itself. Aerzen already successfully 

uses flow-optimised tube bundle 

heat exchangers for a large number of applications. 

These compact units are located 

immediately downstream of the assembly 

on the discharge side and are simple to install. 

Consequently, this technology is also 

recommended for retrofitting, as a way to 

noticeably improve the energy efficiency of 

existing plants as well as the CO 2 balance. 

The tube bundle heat exchangers used by 

Aerzen are designed such that the perfor - 

mance loss due to the increased duct pressure 

(less than 2 to 3 %, depending on the 

application and requirements) is negligible 

– at least in terms of the savings as a result 

of heat recovery. 

While the thermal energy from the pure exhaust 

air can be utilised most effectively for 

direct room heating, tube bundle heat exchangers 

represent an energy source with 

significantly higher temperatures, opening 

up a multitude of potential uses. Supporting 

heating systems, preparing hot water for 

showers and washrooms or heating service 

water in industrial environments are typical 

applications. In wastewater technology, the 

heat is used to dry sewage sludge. When 

planning these systems, they must always be 

sized to match the base load. This can easily 

be read off using long-term characteristic 

curves. 

The starting point for optimum waste heat 

utilisation is to determine the usable heat. 

This obviously depends on the usable temperature 

difference, the prevailing volume 

flow (i.e. the quantity available over a period 

of time) and the degree of simultaneity 

of supply and use. In view of these interdependencies, 

Aerzen offers smart heat recovery 

solutions for each application, so 

that the available energy is effectively channelled 

into production processes, hot water 

preparation or heating systems. 

Summary 

Compressed air generation is automatically 

linked to waste heat due to the law of 

thermodynamics. Since this law cannot be 

repealed, solutions are needed to integrate 

previously unused heat into a plant’s own 

energy demand. Plant operators often fail to 

recognise the full extent of the potential 

savings. In practice, however, this technology 

pays for itself quickly and also reduces 

CO 2 emissions. 


Online search: cpp0119aerzen 


AUTHOR: 

THORSTEN SIENK 

Freelancer


SPECIAL 

Explosion protection for centrifuges and dryers 

Customised inerting 

concepts 

Wherever explosive substances are handled, plant owners in the chemical 

and pharmaceutical industries are responsible for operator and environmental 

safety and for taking suitable precautions. The Heinkel Group’s 

know-how and experience help them implement appropriate safety 

measures and inerting concepts – from SIL 1 to SIL 3. 

Various risks arise in manufacturing processes 

such as filtering, sieving, agitating 

and separating from the type of substances 

and media used, for example solvents or 

flammable hazardous materials. Handling 

and processing can also be dangerous, as 

can the processes themselves. Since these 

risk factors often vary considerably in practice, 

a specific solution has to be developed 

and implemented for risk avoidance. The 

Heinkel Drying and Separation Group supports 

users with many years of practical 

know-how backed up by a specially developed, 

TÜV-tested inerting system. Heinkel 

Centripurge is suitable for all machine models 

in the Heinkel Group’s portfolio as well 

as for third-party makes. The inerting system 

has a modular design which enables individually 

tailored safety solutions based on 

advanced technologies and conforming to 

current guidelines and regulations. 

Individual explosion safety 

When a specific inerting solution is developed, 

the approach is always the same. The 

first step is to take stock of the situation and 

carry out an overall assessment using the 

hazop (hazard and operability) method 

which is commonly applied for risk management. 

The customer’s explosion protection 

documentation is decisive for the risk 

assessment. The process components to be 

inerted, such as centrifuges or dryers, are 

then analysed comprehensively with regard 

to the actual processes. Potential hazards – 

not only of individual components but also 

of the whole system – are revealed in this 

way. Thus, even though each individual 

component is considered safe, the system as 

a whole could nevertheless show safety 

deficits. Each system is ultimately only as 

secure as its weakest part. If this part is not 

inerted because there was no explosion risk 

initially, the explosion zone could be “carried 

over”, with impacts on the entire system. 

Picture: Heinkel 

Centrifuge with attached Centripurge inerting system 

Plant safety concept 

In the second step, Heinkel specialists develop 

a safety concept for the overall system. 

Heinkel Centripurge, the Heinkel inerting 

system, is used as technical apparatus; due 

to its modular design, control components 

and the associated peripheral systems are 

easy to replace. The motto: as simple as 

possible and as much as necessary. SIL 3, the 

highest safety integrity level, can also be 

achieved with Heinkel Centripurge if 

required. The inerting system has been 

tested and approved by TÜV Süd and is in 

conformity with TRGS 725. The concept is 

ideal whenever pharmaceutical and chemi- 


® 

Innovations for heating 

Flexible 

electical 

heating technology 

• Chemical heated hoses 

• Transfer- / delivery hoses 

• Ex-heated hoses 

• Barrel heaters 

All instruments needed for the autonomous inerting unit are installed in a stainless steel 

cabinet close to the process component 

• Pipe trace heaters 

• Heating plates 

cal applications demand the highest levels 

of quality and safety, for example the manufacture 

of active pharmaceutical ingredients, 

agrochemicals or dietary supplements. As a 

standardised system, it minimises the effort 

for validation because the complete documentation 

is already approved. In addition, 

the modular design enables individual 

inerting systems tailored to actual needs, 

which can be upgraded at any time without 

difficulty. 

Safe inerting in three phases 

The SIL level is determined by analysing the 

failure behaviour of the components concerned 

and checking them for redundancies, 

continuity and errors. The Heinkel 

inerting concept is based on the principle of 

flow-through inerting. As soon as the process 

component is switched on, the nitrogen 

inerting system is activated. During 

the first, diagnostic phase, the leak-tightness 

of the process housing as well as of the connecting 

pipework between the inerting 

cabinet and the process component is tested 

by charging with a predefined inert gas 

flow, where a set increase in pressure has to 

be achieved. This test is time-controlled and 

safely monitored by means of a pressure 

transmitter. If it is successful, the second, 

rinsing phase introduces a large amount of 

nitrogen into the process housing. During 

this initial inerting, the oxygen content is 

reduced below the process-specific requirement. 

The rinsing phase is likewise timecontrolled 

and monitored by a flowmeter. 

In the final phase, a continuous supply of 

inert gas compensates plant-specific or operational 

leakage flows and pressure variations. 

Single or redundant monitoring of 

the pressure housing is possible depending 

on the SIL level. All instruments needed for 

the autonomous inerting unit are installed 

in a stainless steel cabinet close to the process 

component. 


Online search: cpp0119heinkel 


AUTHOR: 

TOBIAS HÄNLE 

Manager Automation, 

Heinkel Process Technology 

AUTHOR: 

HELGE FIEDLER 

Product Manager, 

Heinkel Process Technology 

• Special solutions 

We exhibit! 

Nuremberg 

9.- 11.04 2019 

hall 4, booth 4-197 

Hillesheim GmbH 

Am Haltepunkt 12 

D-68753 Waghäusel • Germany 

Phone.: +49 72 54 / 92 56-0 

E-Mail: info@hillesheim-gmbh.de 

www.hillesheim-gmbh.com 



SPECIAL 

Permanent magnet motors make it possible 

Oil-free compressed air 

with 35 % less energy 

The variable-speed drive compressors in the ZR 90-160 VSD+ series generate oilfree 

compressed air up to 35 % more efficiently than compressors with full load/idle 

control. They are suitable for use in the food and beverage as well as pharmaceutical 

industry and for all applications with a high demand for compressed air. 

Atlas Copco first presented the ZR 90–160 

VSD+ series of water-cooled screw compressors 

at the Frankfurt Achema in 2018. 

According to the manufacturer, these oilfree 

compressors with a variable speed drive 

allow energy savings of up to 35 % compared 

to compressors with full load/idle 

control. Generally speaking, the feature 

which attracts customers most is probably 

not oil-free compression but the compressors’ 

very high efficiency, especially compared 

to oil-injected compressors of similar 

sizes. Machines of that type have relatively 

large quantities of oil in circulation. Removing 

this oil from the air cycle calls for complex 

systems. As a result, the specific power 

requirements of large, oil-lubricated compressors 

are higher than for dry models. Put 

simply, they need more energy to deliver 

the same amount of compressed air. Above a 

power rating of about 400 kW, oil-free ZR 

compressors are always more efficient. Particularly 

with new compressors, this makes 

a difference of between 10 and 15 %. As 

filters become fouled and clogged over the 

course of time, the compressor requires 

more and more energy to overcome the 

growing resistance, maintain the set pres - 

sure and keep the volume flow rate stable. 

Many features designed in-house 

The new series of compressors have a large 

number of design features that contribute to 

their high efficiency, notably the compressor 

elements, the new cooler design and the 

improved controller. All elements are installed 

in a compact, acoustically insulated 

housing. The ZR merely needs to be connected 

to the power, compressed air and 

cooling water systems. 

The compressors are driven by two highperformance 

permanent magnet electric 

motors, which are already in accordance 

with the future IE5 efficiency class and are 

shipped complete with Neos-VSD+ variable-speed 

drive technology for the first 

time in this series. This means that the two 

compressor elements can be operated at different 

speeds, further improving efficiency. 

Adjusting the compressor power to actual 

requirements considerably reduces the energy 

consumption of the ZR 90-160 VSD+ 

as well as the associated costs and environmental 

impacts. The water-cooled IP 66 permanent 

magnet motors are designed for 

high efficiency and reliability. This also 

applies to the converters; like the permanent 

magnet motors themselves, these were developed 

in-house by Atlas Copco. The new 

converters are intended specifically for use 

Pictures: Atlas Copco 

Example installation of the new ZR 160 VSD+ series of variable-speed drive compressors at the front together with 

the higher-level Atlas Copco controller on the wall 


The ZR VSD+ compressors compress the air in two stages. Each stage has its own permanent magnet motor (T), which can be separately controlled 

and operated at variable speeds, and an efficient compressor element (C, J). 

with compressors. This is highly relevant in 

large sections of the process industry where 

fine dust collects on machine components. 

Integrated rotary drum dryer 

In the full-feature version (ZR 90-160 VSD+ 

FF), the compressors are equipped with an 

integrated MDG rotary drum dryer. This 

unit was developed for a stable discharge 

dew point of -40 °C. As far as residual 

moisture is concerned, the MDG produces 

high-quality compressed air much more efficiently 

than other dryers. As a heat-ofcompression 

dryer, the MDG only needs 

about 0.2 kW of electric power to operate 

the dryer motor in addition to the heat of 

compression. As with all rotary drum dryers 

from Atlas Copco, the additional energy 

requirement is therefore very low because 

the MDG manages without additional heating 

elements and a blower, and it does not 

operate with purge air to reach low dew 

points. In addition, the MDG, as an integrated 

dryer, saves considerable space compared 

to an external absorption dryer with 

the same performance. There is no external 

piping, no electrical wiring, no hot air intake 

system and no condensate line. 

Class 0 oil-free compressed air 

All components in the compressor element 

of the new ZR compressors, especially the 

profiles, bearings and rotor coatings, have 

been redesigned for outstanding efficiency 

and durability. The design and sealing of the 

compressed air chamber maintain the 

physical separation between the oil and air 

systems, ensuring that no oil can enter the 

chamber and that the air delivered is absolutely 

oil-free, corresponding to Class 0 in 

accordance with ISO 8573-1:2010. 

The newly designed coolers are fitted with 

stainless steel tubes with an enlarged exchange 

surface to further improve cooling 

performance. The coolers additionally feature 

special water separators that improve 

the efficiency of the unit. 

Visualisation of machine status data 

The Neos converter communicates directly 

with the new, user-friendly Elektronikon- 

Mk5 Touch controller. The controller issues 

warnings, is programmed with information 

on maintenance intervals and visualises the 

actual condition of the compressor unit online. 

The Smartlink data monitoring programme 

is a standard feature of the controller. 

This remote monitoring function 

allows the entire compressed air system to 

be analysed with a view to planning preventive 

maintenance. 

Compressors in the ZR 90-160 VSD+ series 

work with Optimizer 4.0, Atlas Copco’s 

new higher-level controller. This controller 

selects the most efficient combination from 

among the compressors installed at a compressed 

air station. That way, all equipment 

requiring compressed air is supplied with 

air at the required pressure and with maximum 

efficiency at all times; the operating 

hours of the compressors are simultaneously 

balanced. Optimizer 4.0 can also 

operate air dryers. Via the intuitive user interface, 

users can inspect the output and 

energy consumption of each compressor as 

well as the entire system. Optimizer 4.0 can 

moreover be monitored on the customer’s 

PC. In addition, the new ZR compressors 

can be included in a premium maintenance 

contract, in which case Atlas Copco assumes 

responsibility for all maintenance work, upgrades, 

repairs and possible failures. 


Online search: cpp0119atlascopco 


AUTHOR: 

JÖRG SCHWITTEK 

Business Line Manager 

Oil-Free Air, 

Atlas Copco 




Enclosed filter system with protective bag 

Cleanliness and safety 

in hazardous areas 

The Wolftechnik QP-Quick-Pack is a special filter unit with a protective bag that 

offers a number of advantages with regard to product quality, servicing and maintenance. 

It is designed for quick filter changes and reduced downtime. Both the 

filter and the housing meet the requirements of Atex Directive 2014/34/EU for use 

in potentially explosive atmospheres. 

The QP-Quick-Pack filter system from 

Wolftechnik is suitable for all applications 

where an enclosed, ready-to-use unit is preferred 

for reasons of cleanliness, hygiene 

and toxicity. QP-Quick-Packs are installed in 

matching WTQP stainless steel housings and 

sealed with special unions at the inlet and 

outlet ports. They bear the Ex II 2GD mark, 

which certifies that the filter systems meet 

the requirements of Atex Directive 

2014/34/EU for use in potentially explosive 

atmospheres (hazardous areas). They are 

also approved for processing products containing 

solvents. 

The QP-Quick-Pack filter system consists of 

a sturdy PP adapter with a manifold, inlet 

and outlet ports and a double-layered protective 

bag containing the filter cartridges. 

QP-Quick-Packs are available with 1, 3 or 7 

filter elements and in lengths from 5” to 

30”. Various filter elements are possible. The 

design offers special advantages in terms of 

product quality. As the protective bag prevents 

direct contact between the liquid to be 

filtered and the housing, there is no contamination 

of the latter. This also eliminates 

the risk of cross-contamination between 

different product series due to residual deposits 

in the filter housing. At the same 

time, the filter system provides greater 

safety for workers as direct contact with the 

medium is avoided during filter changes 

and servicing. In addition, there is no need 

for time-consuming cleaning of the housing. 

The filter is changed simply by removing 

the spent QP-Quick-Pack filter system 

from the housing and inserting a new one – 

that’s all! 

Pictures: Wolftechnik 

QP-Quick-Pack filter cartridges with a protective bag 

Preventing electrostatic discharge 

If the QP-Quick-Pack is used in hazardous 

areas, the Technical Rules for Industrial 

Safety and Health (TRBS) must be observed 

regarding electrostatic charging of components. 

Such charges are also known as electrical 

potential differences and are generally 

caused by friction. Under certain circumstances, 

electrostatic discharge might cause 

sparks that can ignite substances and cause 

an explosion. That is why the installation 

and operation of mechanical devices in hazardous 

areas are subject to stringent safety 

regulations. 

To prevent electrostatic discharge at the 

filter system while changing, servicing or 

inspecting the filter, users have to make sure 

that the bottom part and the cover of the 

WTQP housing are properly earthed at their 

earth tabs. Friction, and thus static electricity, 

might also occur when the liquid flows 


Technical data of the QP-Quick-Pack filter cartridge 

Installation diagram – WTQP housing for a QP-Quick-Pack 

with a purging bypass 

through the housing. With conventional 

filter cartridges, this electrostatic charge of 

the filter medium is discharged through the 

housing. The protective bag of the QP- 

Quick-Pack, however, insulates the filter 

medium from the housing. To prevent excessive 

charging, it is made from conductive 

polyethylene or polyamide. Before opening 

the housing, adequate relaxation time must 

be allowed in order to dissipate the charge. 

This is the time required for a system to 

achieve a near-equilibrium state. In the case 

of the filter, it is the time after which the 

electrostatic charge is fully dissipated. The 

relaxation time is determined by the conductivity 

of the medium and varies greatly 

from one liquid to another. For solventbased 

paints and varnishes, for instance, 

Wolftechnik recommends waiting 20 to 30 

seconds before opening the housing. 


Online search: cpp0119wolftechnik 

AUTHOR: 

PETER KRAUSE 

Managing Director, 

Wolftechnik 

PATENTED 

MULTI-TASKING 

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01-2019 35



Safety controller with OPC UA connection 

Seamless data flow 

Many experts believe that OPC UA will establish itself as the new communication 

standard for digital production – and chemistry and process engineering are no 

exception. The latest generation of safety controllers from Schmersal is therefore 

shipped with an OPC UA server, paving the way for a seamless data flow from 

(safety) sensors to the top levels of corporate IT. 

From the sensor in the machine to the top 

management levels of the central IT systems 

such as ERP, PPS and MES, seamless data exchange 

is one of the most important features 

of digital production structured in accordance 

with Industry 4.0 principles. 

This also applies to safety switchgear and 

hence the safety of machines and equipment 

in chemical and process engineering, 

including the downstream processes of filling 

and packaging. Two data worlds, which 

fulfil different requirements and have different 

design bases, always need to be taken 

into consideration. 

At the functional safety level are the requirements 

of the Machinery Directive and the 

standards and regulations assigned to it. 

Amongst other things, they deal with the 

ability to switch machines off safely and 

stop hazardous movements when the operator 

opens a guard door or enters an area 

secured by opto-electronic safety devices. 

At the same time, the safety switchgear 

generates operational data, i. e. non-safety 

related. This is of interest to users, for 

example, because it allows maintenance to 

be optimised and system productivity improved. 

The number of switching cycles provides an 

indication of when safety sensors and actuators 

are reaching the end of their service 

life and need replacing. For electro-mechanical 

switchgear which is prone to wear, this 

number can be derived from the MTTFd 

(mean time to dangerous failure), which 

according to EN 13849-1 must be calculated 

based on the B10d value (nominal service 

life to dangerous failure). This, in turn, 

is based on T10d, which defines the time 

for preventative replacement, namely 10 % 

of the MTTFd. Here, too, the service life can 

be determined very accurately if the switching 

cycles are counted at the same time. In 

practice, the safety switchgear can then 

normally be used for longer and does not 

need to be replaced on a preemptive basis at 

the end of a calculated service life. 

These and similar functions are currently 

the subject of fierce debates under the 

banner of predictive maintenance. In many 

companies in the chemical and process industries, 

they are the first real-life applications 

for digitalisation and Industry 4.0. 

Pictures: Schmersal 

If the signals from the safety switchgear, e. g. in packaging lines, are comprehensively 

evaluated, there are real benefits, including maintenance. The connection via an 

OPC UA server provides the prerequisite. 

Networking opportunities 

For some time now, there have been various 

ways of networking the information generated 

by safety sensors. In terms of functional 

safety, there are safety instrumented 

bus systems such as AS-Interface Safety at 

Work (ASi SaW). To enable operational signals 

such as threshold range warnings to be 

transmitted and evaluated, Schmersal developed 

the SD bus which, if required, can also 

send this data to any cloud via the SD gateway. 

Schmersal offers users of the Protect PSC1 

more extensive options for networking and 

integration. This safety instrumented controller 

can be fitted with a universal communication 

interface for connection to numerous 

fieldbus protocols such as Profibus, 

Profinet, Ethercat, Ethernet/IP, CANopen, 


An integrated OPC UA connection is 

now available for the Protect PSC1 safety 

controller 

SD Interface gateways can be used for the 

transfer of non-secure data 

etc. The user can simply select the relevant 

fieldbus via the software, meaning that all 

fieldbus versions can be covered with two 

different hardware components. 

Communication via OPC UA server 

The latest version of the Protect PSC1 comes 

with a built-in OPC UA server in the communication 

interface. Apart from HMI access 

as well as commissioning and support 

services, this interface also allows digital 

asset management (DAM) services. 

This mode of communication via the OPC 

UA server offers added options and benefits. 

Comprehensive data records from all safety 

sensors in the Schmersal range can now be 

accessed in machine-readable format, with 

semantic descriptions via the M2M communications 

protocol, for example status 

data of safety outputs, safety parameters, 

sensor lifecycle information, order details, 

datasheets or CAD data and pictures. 

As one specific example, users can specify 

the target service life, i. e. the maximum 

number of switching cycles per item of 

safety switchgear, with the SafePLC2 programming 

software. The controller records 

the actual number of switching cycles and 

notifies the user when this number is 

reached. The device in question can then be 

replaced at exactly the desired time. 

Safety sensors with a connection to the 

above-mentioned SD bus can also transmit 

information, e. g. about the actuator, as well 

as error messages such as cross-wire short, 

overtemperature, internal device error, communication 

error, output Y1/Y2, etc. 

The integration of OPC UA into the Protect 

PSC1 communication interface is likewise 

an important condition if actual data from 

Schmersal safety switching systems (and 

therefore their digital twins) is to be exchangeable 

regardless of the manufacturer, 

for instance from one machine to another 

or for communication between factories. 

Industry 4.0 compliant 

The use of the global OPC UA standard (IEC 

62541) ensures interoperability between 

products from different manufacturers and 

offers real added value for users of machines 

and equipment. They have access to 

additional information, for example in 

order to lay the foundation for improved 

production control or more efficient maintenance 

planning. Moreover, product 

parameters can be consulted and their 

documentation or operating instructions 

uploaded. 

Provided this data is used intelligently and 

evaluated by higher-level CRM, MES or ERP 

systems, it can also open the door to new 

business models. This applies not only to the 

users of machines and equipment but also 

to the manufacturers, who can then supply 

new services based on this data. For these 

reasons, OPC UA is the first choice for 

Schmersal when it comes to making its 

product portfolio Industry 4.0 compliant. 

Standard also for the process industry 

As yet, OPC UA is not that widespread in 

process engineering equipment and controllers. 

However, this integrated interface 

gives Protect PSC1 users peace of mind 

when planning and developing next-generation 

machines. It is not hard to imagine 

that networks of machines will rapidly become 

established in the same way as the 

generation and transmission of data from 

machines and systems or the use of such 

data for predictive maintenance. These are 

just some of the reasons why large production 

companies are jostling to introduce 

OPC UA as a binding, non-proprietary 

standard. 

The discussion on Industry 4.0 is providing 

additional impetus. For example, fifteen 

working groups at the German Mechanical 

Engineering Industry Association (VDMA) 

are currently working on application-specific 

OPC Companion Specifications, i. e. 

standardised data and interfaces for individual 

applications such as robotics or industrial 

image processing. The OPC Foundation 

also recently set up its own working group 

on Functional Safety. 

Thus, all the signs are that OPC UA will 

soon become established as the communication 

standard for digital production – and 

the process industry, with its interlinked 

production and packaging lines, is no exception. 

There are major benefits here for 

comprehensive M2M communication. 


Online search: cpp0119schmersal 

AUTHOR: 

ULRICH BERNHARDT 

Head of Controller Sales, 

K.A. Schmersal 



SPECIAL 

The digitalisation of Profibus-PA in the process industry 

Easy migration to the 

Ethernet World 

Process automation is in a constant state of change – also in the field of communication 

technology. The analogue 4…20 mA loop was followed by fieldbus systems. 

Today, many companies rely on Ethernet communication. Phoenix Contact has therefore 

developed a solution with which Profibus-PA segments can be directly connected 

to the Profinet protocol. 

Some 50 years ago, the birth of electronics 

helped make the analogue 4…20 mA loop 

the leading global method for measuring 

and controlling industrial processes. Industrial 

field devices designed with electronics 

were connected via a shielded twisted-pair 

cable and supplied with 24 V DC. The intervening 

decades have seen major advances in 

terms of miniaturisation and increased signal 

wiring density, creating the standard for 

the global industry we still know today. The 

change from the previous pneumatic technology 

to a 4…20 mA signal was also 

fuelled by the incorporation of microprocessors 

into controllers in both factory and 

process automation. 

As electronic and communication technologies 

continued to improve and evolve, 

various process-oriented fieldbus systems 

were developed that worked either in “hybrid” 

tandem with the 4…20 mA analogue 

signal like Hart or as purely digital fieldbus 

systems like Foundation Fieldbus and Profibus-PA. 

The rapid deployment and introduction 

of Ethernet on the plant and factory 

floor has now led to a new wave of networked 

and digitalised process applications 

in the oil and gas, pharmaceutical, food and 

flavourings, beverages and brewing, water, 

mining, power and chemical industries – 

resulting in additional customer demand for 

Ethernet connectivity which is very easily 

met with Profinet. 

Converting Profibus-PA into DP 

The Foundation Fieldbus and Profibus-PA 

technologies share the same physical layer 

Pictures: Phoenix Contact 

Profibus-PA protocol converters (addressed as PA devices) also support Modbus-RTU 

and Hart devices in the topology 


These pluggable modules offer segments a choice of simplex 

or redundant power, providing an on-board indication 

as well as data access via the Profinet link 

All Profinet redundancy structures (S2, R1 & R2) are possible 

using two bus couplers; the modular design results in 

a very small footprint depending on the application 

in IEC 61158, allowing customers to use 

the same twisted-pair wiring as when 

4…20 mA signals are transferred from the 

field layer to the control level. Fieldbus 

topology will ultimately enable up to 

32 field devices to be powered using the 

existing wiring of one 4…20 mA device 

and 28 V DC (instead of 24 V DC) in a 

15 W power trunk. Depending on the field 

devices – from simple temperature to 

complex flow or valve control – it will 

then be possible to transmit far more data 

between the controller and the field layer. 

Owing to the additional digital data, 

plants can quickly identify anomalies and 

respond with predictive maintenance 

methods to ensure maximum system uptime, 

increased plant availability and improved 

efficiency. Ultimately, all plant assets 

can be used with optimum effectiveness 

and profitability. 

Profibus-PA has been deployed in plant 

across the globe for the past 25 years. Over 

eleven million Profibus-PA field devices are 

now installed worldwide, yet a linking device 

that converts Profibus-PA into Profibus- 

DP has always been required to connect 

them to a PLC (programmable logic controller) 

or DCS (distributed control system). 

Based on a regular office and consumer environment, 

but without the ruggedness and 

high temperature capability needed on the 

factory floor or outdoors, industrial-grade 

Ethernet only became possible with the invention 

of Profinet, which in the last two 

decades has become the global standard in 

factory automation. 

In 2015, standardisation efforts resulted in 

the gradual elimination of the intermediate 

Profibus-DP step, facilitating a direct connection 

between Profinet and Profibus-PA (as 

well as all field devices). 

Proxy for eight Profibus-PA segments 

At last year’s Achema exhibition, Phoenix 

Contact provided a sneak preview of a 

modular system that connects the existing 

and installed world of Profibus-PA segments 

directly to the Profinet protocol. Each Profibus-PA 

segment receives power in either 

simplex or redundant mode and outputs 

14 W to a PA segment featuring a highpower 

trunk and being just 35 mm wide. A 

fully expanded proxy can be connected to a 

maximum of eight Profibus-PA segments 

and has a Profinet coupler with eight parallel 

connections that convert to Profinet at 

10/100 Ethernet speeds. 

The Profinet coupler – only 45 mm wide – 

can either have a simple S1 connection or 

be connected to two Profinet controllers via 

an S2 redundant mode. Furthermore, an R1 

or R2 redundant system can be configured 

using a second Profinet coupler. 

To enable easier installation and commissioning 

of the proxy, Phoenix Contact 

engineers also developed a GSDML 

composer that creates the GSD (general 

station description) in XML file format; this 

is needed by the Profinet controller to address 

the Profibus-PA segments connected 

to the proxy. The system can be modified 

when needed, with resulting edits of the 

GSDML file. 

Profinet switches with gigabit option 

Over the years, Phoenix Contact has developed 

a comprehensive range of products for 

the process industry including power 

supplies, cyber security, overvoltage protection 

and the well-known terminal blocks. 

The company also offers numerous media 

methods for Profibus-DP as well as other 

process automation (PA) infrastructure 

products such as modular and block field 

couplers for installation in zones 1 and 2. 

Only recently, Phoenix Contact launched a 

series of Conformance Class B Profinet 

switches with both 10/100 and gigabit options 

in its new 2200 and 2300 series of 

Ethernet switches. A plethora of products 

with IECEx, Atex and North American Hazloc 

certification are available in the extensive 

portfolio. 

In summary, the digitalisation of the process 

industry is well under way and in the next 

few years many more new and exciting announcements 

will further underline Phoenix 

Contact’s commitment to industry needs 

regarding process automation. 


Online search: cpp0119phoenixcontact 

Hall 9, Booth F40 

AUTHOR: 

ARNOLD OFFNER 

Strategic Marketing Manager 

Process Infrastructure, 

Phoenix Contact 



SPECIAL 

Picture: Aleksej Filatov – Fotolia.com 

The Bebco EPS 7500 series is ideal for applications in the international process industry where a less practical and more expensive form of 

explosion protection was previously unavoidable 

Purge and pressurisation system with global approval 

More safety worldwide 

With the Bebco EPS 7500 series, Pepperl+Fuchs has developed a purge and 

pressurisation system for Zones 2/22 and Classes I/II, Division 2 that can be put to 

universal use. The solution combines all essential functions for reliable explosion 

protection in an extremely compact housing. 

Companies operating on a global scale 

place high demands on the explosion protection 

components installed at their subsidiaries. 

This is particularly true of OEMs 

who cater for clients around the world. Take 

the case of a manufacturer of agitator systems, 

for example, whose customers needed 

to be provided with universal solutions for 

Zones 2/22. These agitators are used to mix 

substances for the pharmaceutical industry, 

for instance, in processes where hazardous 

dust or gas atmosphere is formed. The 

switch boxes required for these hazardous 

areas had to house devices with high power 

loss, such as frequency converters. Using 

Ex-d enclosures was out of the question. 

What’s more, the customer wanted to be 

able to operate the system directly on site at 

the plant, meaning the switch boxes could 

not be positioned outside the hazardous 

areas. Another crucial requirement was suitability 

for clients anywhere in the world. 

When it came to implementing the switch 

boxes, therefore, the choice was clear: the 

manufacturer opted for the Bebco EPS 7500 

series purge and pressurisation system, 

which was specifically developed by Pepperl+Fuchs 

with these and similar market 

and customer requirements in mind. 

Compact, universal, efficient 

The purge and pressurisation system is approved 

for Zones 2/22 and Classes I/II, 

Division 2 and can be used universally in 

process plants the world over. It comprises a 

robust, ultra-compact control unit, an enclosure 

protection vent and a valve. The innovative 

purge system is designed for enclosures 

measuring up to 12.7 m³ and thus 

covers most potential requirements for 

purge and pressurisation systems or switch 

cabinet solutions in the field of process 

automation. The compact 7500 series is easy 

to operate and incredibly reliable and efficient. 

It offers excellent – and fully automatic 

– protection for electrical devices 

such as motors, drives, control panels or 

cabinets and gas analysers. Whether for gas 

or dust protection in the oil and gas, chemical, 

shipping or offshore sectors, the Bebco 

EPS 7500 series is ideal for applications in 

the international process industry – applications 

where a less practical and more expensive 

form of explosion protection was 

previously unavoidable. 

One crucial advantage for global use is the 

fact that the 7500 series is operated with a 

universal AC/DC power supply unit, so that 

any voltage from 90 to 253 V(AC) or 18 to 

33 V(DC) is possible. It also has all the 

necessary international certifications from 

independent testing authorities such as 

Atex, IECEx, NEC and CEC. For OEMs and 

other companies with subsidiaries around 

the world, this solution provides a single 

system that can be installed on any continent 

– a major advantage. This greatly reduces 

the logistical and technical planning 

effort for global players and adds up to universal 

explosion protection that meets the 

requirements of different regions. 

The purge and pressurisation system can be 


operated both fully automatically and manually. 

It prevents dangerous gases and dusts 

from entering the enclosure, and monitors 

– or rather controls – the pressure through 

dilution as well as by maintaining a continuous 

flow. That way, the classification inside 

a protected switch cabinet is reduced to 

that of a non-hazardous area. Users can set 

up to four pressure points in five selectable 

programs. As soon as the pressure falls 

below a defined limit, the system sounds an 

alarm. If it drops due to a fault, the plant 

will automatically disconnect from the network 

with no need for manual intervention, 

thus avoiding potentially dangerous situations. 

If defective cable glands or seals are 

the cause of a pressure drop in the switch 

cabinet, not only is an alarm triggered but 

the pressure can also be temporarily compensated 

due to the built-in leakage compensation 

technology. The operator can then 

take appropriate action before the fault leads 

to a failure or a dangerous scenario. 

Touch display with status LEDs 

The extremely compact housing of the control 

unit is just 150 x 100 x 50 mm in size 

and made of powder-coated aluminium. 

This robust device is built to withstand the 

harsh conditions in the process industry and 

is equally suitable for both panel and external 

mounting. Despite its small outer dimensions, 

the unit boasts an extra-large 

touch screen, ensuring that the status indicator 

is easy to view and that operations be 

completed quickly and easily. The conditions 

in the enclosure to be purged can be monitored 

using a combination of bar charts 

showing the pressure levels and various default 

programs, enabling rapid adjustment 

to any situation. Four status LEDs next to the 

display provide quick information, e. g. by 

indicating whether the exact pressure 

required for operation is present or only the 

bare minimum, too little or too much. They 

are visible from a distance of more than 

20 m, so that the status of the purge and 

pressurisation system can be recognised 

without having to approach the enclosure. 


Online search: cpp0119pepperl 


Picture: Pepperl+Fuchs 

Bebco EPS 7500 control unit with touch 

display in a compact housing 

AUTHOR: 

ALEXANDER AUST 

Product Manager 

EPE & Solutions, 

Pepperl+Fuchs 

Intelligently combined 

www.bosch-industrial.com 

Three good reasons for combined energy systems from Bosch: 

Reduced energy costs for higher competitiveness 

Cost-saving own power generation and maximum waste heat recovery 

Eligible energy management (EN 50001) 

Visit us! 

HANNOVER 

MESSE 

Germany 

1–5 April 2019 

Hall 27, Booth 42(1) 



SPECIAL 

Electric actuators for anti-surge valves 

Next level of automation 

An electric servo actuator for anti-surge control valves (ASCV) developed by Festo 

in cooperation with Shell Global Solutions (SGSI) offers clear benefits compared 

to traditional pneumatic solutions. The actuator integrates a mechanical fail-safe 

function, has a modular design and is easy to install and maintain. A prototype was 

presented at Valve World 2018 in Dusseldorf. 

Anti-surge control valves (ASCV) are utilised 

mainly – though not only – in the 

O&G industry to protect compressors. According 

to Shell, the control requirements 

for ASCVs are more complex than for any 

other area of process valve automation in 

the O&G industry. The ASCV is located in the 

compressor bypass and closed under optimal 

operating conditions, when the full 

compressor power is used to supply a gas 

distribution network, for example. If a failure 

occurs in the network, the ASCV must 

open the bypass at the compressor as fast as 

possible to avoid damage due to a change in 

the flow direction. In an efficient plant the 

ASCV is closed for more than 80 % of the 

entire operating time. During the remaining 

period, precise control of the plant is essential 

to ensure that the compressor works at 

the ideal operating points and minimise 

losses. The key requirements are therefore 

firstly precise control of the ASCV and secondly 

rapid opening of the valve in case of a 

disturbance. 

Pictures: Festo 

New concept for automating different anti-surge control valves based on 

electric actuators 

A novel solution 

Willem van Rijs, Senior Automation Engi - 

neer SME Automated Valves at SGSI, came up 

with the idea for this innovative application 

for electric actuators during a visit to a robotics 

and mechatronics fair. SGSI – always 

on the lookout for novel technologies that 

simultaneously reduce plant complexity and 

save lifecycle costs – launched the project 

with Festo, bringing it to its present level of 

maturity. 

The use of electric actuators to automate 

ASCVs is a change that has also taken place 

in other areas of automation. Pneumatic actuators 

have clear advantages in many applications. 

If the requirements are complex, 

pneumatic actuation has limitations, for in- 


Typical compressor map: electric actuators enlarge the operating area 

Advantages of electric actuation vs. pneumatic actuation in terms of speed 

and control accuracy 

stance if precise control must be reconciled 

with speed. Driven by a desire to satisfy all 

possible requirements, Festo extended its 

product portfolio for factory automation 

from pneumatic components and solutions 

to also include electric automation. 

The requirements of the O&G industry must 

likewise be met by all new products, namely 

operational reliability and of course fail-safe 

behaviour, in other words if all auxiliary 

power breaks down, the valve must move to 

a predefined position if it is relevant for system 

safety. The prototype is essentially based 

on standard components with all the 

necessary certifications. The fail-safe component 

integrated into the prototype is currently 

a mechanical system that is traditionally 

based on normally biased springs, 

which relax in the event of a malfunction 

and open the valve. The spring is stretched 

once initially and then mechanically 

blocked, so that continuous consumption of 

electrical energy is prevented during normal 

operation. 

Advantages in operation 

One major advantage of electric actuators is 

the ability to operate systems closer to the 

design limits. Measurements have shown 

that electric actuators open an ASCV much 

faster in case of failure compared to pneumatic 

solutions. As a result of this, systems 

can be operated closer to the surge limit 

and operating states that would normally 

cause the ASCV to open in a pneumatic application 

are no longer a problem. The 

avoidance of disturbance-related downtime 

results in increased productivity and greater 

economic efficiency. The control speed and 

accuracy are also significantly higher with 

electric actuators as opposed to pneumatic, 

enabling near-optimal plant operation. 

Another advantage of electric drive technology 

over pneumatic concerns the simplified 

diagnostics. Changing conditions in the system, 

such as increased friction in specific 

positions over the entire opening path of 

the valve, are detected in addition to the 

usual operating parameters of individual 

components. This data can be transmitted 

using standard protocols such as HART and 

transferred to a higher-level asset management 

system, where it forms the basis for 

condition monitoring and predictive maintenance 

concepts. The elimination of unplanned 

downtime due to failures and the 

proactive maintenance of anomalous components 

during planned shutdowns extend 

the life of the plant and result in higher 

productivity. 

Outlook 

Each compressor generally has a separate 

controller, which is independent of the 

higher-level DCS, to enable fast and direct 

control in the field and rule out signal delays 

via DCS bus structures. The integration 

of the above-mentioned advanced diagnostic 

capabilities and parameters linked to 

the plant operating status in dedicated compressor 

controls can provide even more 

benefits. The goal here is to detect an impending 

surge even earlier than is possible 

today and allow operation even closer to the 

design limits. In the future, AI functionalities 

will further support this objective. At 

present, though, these are still in the early 

stages. The fail-safe function, which is currently 

mechanical, could also be implemented 

with the help of electrical storage 

technologies, meaning that the complete 

unit would have to be evaluated according 

to SIL requirements. In the search for ways 

to reduce plant complexity and hence operating 

costs, this is where the future lies. 


Online search: cpp0119festo 


AUTHOR: 

FOLKERT HETTINGA 

International Key Account 

Manager O&G and Turbine 

Industry, 

Festo NL 

AUTHOR: 

DR. ECKHARD ROOS 

Head of Global Industry and 

KA Management Process 

Industries, 

Festo 



SPECIAL 

Focus on process control system at Hannover Messe 

The curtain is raised – but 

only a little 

At this year’s Hannover Messe pre-press conference, Siemens raised the curtain on a 

new process control system – though only a little. Eckard Eberle, CEO of the Process 

Automation Business Unit, gave first insights into this PCS, but its name remains a 

secret and will not be revealed until Hannover Messe finally opens its doors. Under 

the motto “Digital Enterprise – Thinking industry further!” the company recently 

presented its trade fair innovations for the process industry in Herzogenaurach. 

Siemens will be placing smart solutions 

for the industry-specific implementation of 

Industry 4.0 at the heart of its Hannover 

Messe 2019 exhibit under the banner “Digital 

Enterprise – Thinking industry further!”. 

On around 4000 m² of exhibition space in 

Hall 9, Siemens will be showcasing these 

solutions with an array of new additions to 

its Digital Enterprise offering, which is designed 

to enable the digital transformation 

of the discrete and process industries. By integrating 

future technologies into its portfolio, 

Siemens provides users with new and 

far more extensive scopes for leveraging the 

exponential growth in industrial data. The 

spectrum covers everything from the use of 

artificial intelligence and edge computing 

through to factory and process automation 

of the future. 

Siemens will be illustrating its vision for the 

industry-specific implementation of Digital 

Enterprise and the use of future technologies 

with a range of exhibits, including 

two especially notable highlights. One of 

these is the chemical industry showcase 

featuring a fully virtual representation of a 

greenfield plant complete with laboratory, 

automation and control technology to facilitate 

the sustainable and environmentally 

responsible production of polyamide made 

from biomass. 

Picture: Bernd Rademacher 

Eckard Eberle, CEO of the Siemens Process Automation Business Unit, gave first insights 

into the manufacturer’s new process control system 

New process control system 

The Simatic PCS7 process control system 

was developed by Siemens more than 20 

years ago as an effective tool consisting of 

powerful hardware, an extensive set of 

stand ards and numerous libraries. Responding 

to new issues such as “modular plants”, 

“global engineering” and “scalability of 

plants”, Siemens decided to launch a novel, 

web-based process control system on the 

market. “The new system focuses on continuous 

processes like those found in the 

petrochemical or water and wastewater industries”, 

explains Process Automation Business 

Unit CEO Eckard Eberle. “The totally 

web-based new system and the multi-user 

concept for engineering and operation will 

open up radically new and efficient ways of 

working for our customers.” Up to 30 experts 

worldwide can log in simultaneously 

and work on the system collision-free. “We 

attached particular importance to manage- 



Siemens has expanded its Digital Enterprise portfolio to include a new digital service for optimising plant maintenance 

ability and user-friendliness”, Eberle continues. 

“The process industry also thinks in 

terms of process engineering objects. We 

mapped this in the new control system and 

thus created integrated workflows.” 

Besides this, customers will benefit from 

Plantsight, a system which draws data from 

several different sources to permit rapid access 

to previously unobtainable information. 

By synchronising the physical 

plant with the relevant engineering data, it 

is possible to create a digital twin of the 

manufacturing process. Plant operators are 

ensured a high level of trustworthiness and 

information quality, enabling continuous 

operational readiness and greater reliability. 

Digital service optimises maintenance 

Siemens has expanded its Digital Enterprise 

portfolio to include a new digital service for 

optimising plant maintenance. The Lifecycle 

Management Suite paves the way for consistent 

planning, execution and documentation 

of all service activities. This cloudbased 

system can even be used from mobile 

terminals in order to immediately document 

activities in the plant. Furthermore, 

those responsible for maintenance always 

have a transparent and up-to-date overview 

of all service activities and plant states, 

allowing maintenance to be planned even 

more efficiently and cutting maintenance 

costs. 

This comprehensive and consistent database 

has benefits for the maintenance and asset 

managers of industrial plants. They can store 

all planned and performed service activities 

in a single system, even on-site on a mobile 

terminal, so that absolute consistency is 

guaranteed. Maintenance managers can take 

advantage of the Lifecycle Management 

Suite to schedule service activities, create 

job orders and monitor performance, so as 

to make maximum use of resources and 

streamline maintenance costs. Plant asset 

managers are permanently aware of the current 

lifecycle status of all products and systems 

in use, for example through extensive 

information on obsolete hardware and software 

components. Field service engineers 

working in the plant can view their jobs directly 

on a mobile device. 

The pre-configured system is based on 

Comos MRO (Maintenance, Repair and 

Overhauls) and provides standard operating 

procedures (SOP) in the form of checkpoints 

for lifecycle services, which are assigned 

to components of the Simatic PCS7 

process control system. The system can be 

upgraded at any time with additional maintenance 

objects. Thanks to the modular 

portfolio, plant operators everywhere can 

take sound decisions on a site’s service 

requirements. 

An annual subscription scheme lets users 

access the various modules in the portfolios 

from a cloud without having to purchase 

any supplementary hardware or software. 

Siemens offers comprehensive software support, 

including updates. 


Online search: cpp0119siemens 


DR. BERND RADEMACHER 

Editor 



SPECIAL 

Picture: Sick 

Reliable safety light curtain 

The Twinox4 safety light curtain was specially developed 

to protect aseptic filling and sealing machines 

used in the pharmaceutical and cosmetic industries. Its 

housing design enables it to be integrated seamlessly 

into machines or systems. The safety light curtain also 

boasts a full high-resolution protective field, ensuring 

maximum safety and high availability of the machine or 

system. The housing of the safety light curtain, along 

with all brackets and end caps, is manufactured in stainless 

steel 1.4404/316L. Aggressive cleaning agents and 

disinfectants such as hydrogen peroxide require mediaresistant 

materials. The stainless-steel housing of the 

Twinox4 meets this criterion, making it compatible 

with all common decontamination processes. Thanks to 

its easy-to-clean housing, all residue can be removed 

from the light curtain quickly and efficiently. With 

rounded edges and no indentations, the design is ideal 

for use in areas with stringent hygiene requirements. 

Multi-colored LEDs indicate the operational readiness 

and status of the Twinox4 safety light curtain across the 

entire protective field height. 


Online search: cpp0119sick 

Hall 9, Booth F18 

Picture: Wika 


Digital float switch with PNP/NPN signal 

Wika has launched a float switch 

with a PNP/NPN output signal. 

The model GLS-1000 detects the 

level of liquids with an accuracy 

of ≤ 1 mm. The digitised float 

measuring principle of the level 

switch is implemented using 

semiconductor sensors. These 

enable an unlimited number of 

switching cycles. Users can define 

up to four switch points 

with a minimum distance of 

only 2.5 mm. Thus the instrument 

reacts to even the smallest 

changes in level. At the same 

time, the GLS-1000 can monitor 

the temperature of the medium 

via a temperature output with a 

Pt100/Pt1000 resistance. 


Online search: cpp0119wika 

Hall 11, Booth C56 

Powerful network management system 

Sinec NMS enables users to 

master the growing demands 

placed upon industrial communication 

networks, such as 

the increasing degree of networking, 

larger quantities of 

data, and the complexity of network 

structures. Networks with 

between 50 and 12,500 participants 

can be centrally configured, 

managed and monitored 

round-the-clock. This facilitates 

forward-looking planning and a 

quick response time to prevent 

possible failures and so increases 

productivity. The software can 

be used across all industries. 


Online search: cpp0119siemens 


01. – 05.04.19 

Hall 9 · D76 

Automating functions. 

Simplifying operations. 

Modernizing protection. 

Bebco EPS ® 7500 Series 

Globally certified Type Z/Ex pzc system for 

Zone 2/22 and Div. 2 applications 

Fully automatic control and pressure compensation 

in a low-cost, compact housing 

Touch screen display and pre-set purge programs 

for easy system setup 

www.pepperl-fuchs.com/purge7500 


Profinet data in OPC UA 

Picture: Profibus Nutzerorganisation 

In close cooperation, and within 

the framework of a joint working 

group, experts from Profibus 

& Profinet International (PI) 

and the OPC Foundation have 

specified a solution for presenting 

Profinet data in the OPC UA 

object model. Profinet’s OPC UA 

companion specification is set 

to be reviewed soon. 

According to extensive coordination 

talks with users, the most 

significant content of Profinet’s 

OPC UA companion specification 

includes the collection 

and display of asset management 

and diagnostic data. This 

information can be displayed 

flexibly in specific ways on various 

devices, based on the 

requirements and possibilities. 

Asset and diagnostic data from 

the devices employed today can 

be collected in a system controller 

through existing mandatory 

Profinet services and delivered 

to higher-level entities 

by means of OPC UA. This service 

can also be offered by an 

edge gateway, which can additionally 

be added to the system. 

The advantage here is that no 

changes have to be carried out 

on the controller. These use 

cases are predestined for innovating 

characteristic brownfield 

systems. It is also possible to directly 

integrate the OPC mapping 

in a Profinet field device. 



cpp0119profibus 


Mass flow meters and controllers for gases 

Mass-Stream instruments operate 

on the basis of direct 

through-flow measurement in 

accordance with the constant 

temperature anemometer principle. 

They contain no moving 

parts and the measured gases 

pass the two stainless steel sensor 

probes directly, without bypass. 

As a result, the gases are 

entirely unhindered on their 

flow path, making the series 

particularly suitable for applications 

with low pressure loss as 

well as less sensitive to moisture 

Picture: Bronkhorst 

and particulate contamination 

than thermal mass flow instruments 

with a bypass sensor. The 

electronics casing has a robust 

design with an IP 65 level of 

protection (dustproof and 

splash waterproof). The mass 

flow meters and controllers can 

be supplied with an optional integrated 

multifunctional display. 

On the new developed D-6390 

model, the maximum measuring 

range has been expanded to 

10 000 l n /min air equivalent. 

Analogue I/O signals as well as 

an RS232 interface are provided 

by default. In addition, an interface 

with DeviceNet, Profibus 

DP, Modbus or Flow-Bus protocols 

can be integrated. 



cpp0119bronkhorst 

Hall 11, Booth A50 

943 km³ 

municipal and industrial 

waste water is released 

globally per year into the 

environment. 

IP68 Solutions 

Energy Efficient Technology 

for the Waste Water Industry 

Your benefit 

• Motor effi ciencies IE2 / IE3 and IE4 

• IP68 submersible designs 

• High axial and radial loading capacity 

• ATEX certifi ed 

• Customised sealing solutions 

• Advanced coating systems 

• Leakage sensors and detectors 

• Stainless steel shafts 

Bauer Gear Motor GmbH 

Eberhard-Bauer-Strasse 37 • 73734 Esslingen am Neckar • Germany 

Tel: +49 711 3518 0 • Fax: +49 711 3518 381 • info@bauergears.com 

www.BauerGears.com 



SPECIAL 

Multi-stage pumps 

Upgrade to distributed control system 

Picture: Spx Flow 

The Spx Flow Clyde Union 

Pumps (CUP) brand is known 

for its provision of reliable, long 

life pumping solutions. From 

this range, its CUP-BB3 and 

CUP-BB5HP pumps, both 

comply with the latest editions 

of API 610 standards. 

Meeting the needs of heavy 

duty, medium and high-pressure 

applications, the flexible CUP- 

BB3 axially split, multi-stage, 

double volute heavy-duty 

pumps offer high speed service, 

good reliability and efficiency 

in applications varying from 

standard water, oil and chemical 

flows through to advanced 

water flood and boiler feed processes. 

Designed for longer wear 

life and low static deflection, 

the CUP-BB5HP are heavy-duty 

multi-stage, radially split barrel 

pumps available with inline or 

back-to-back impeller arrangements. 

As well as offering high 

speed and reliability, the range 

includes features such as a pioneering 

Shear Ring cartridge 

locking system which enables 

rapid withdrawal of all the 

pump internals as a cartridge 

without disturbing pump alignment 

or pipework. These pumps 

are well-proven in areas such as 

produced water/seawater injection, 

flow line displacement and 

main oil line applications. 


Online search: cpp0119spxflow 


ABB announced an update to its 

Freelance distributed control 

system (DCS), which it originally 

launched in 1994. The Freelance 

suite of solutions comprises 

an operator level, a scaleable 

process level option, and an 

engineering application, which 

is used to configure and commission 

the system including 

the operator interface. 

Freelance 2019 includes advanced 

navigation, filter and 

sort functionality. The user experience 

has been improved 

with a new, very modern UI. A 

new controller, PM 904F, expands 

the Freelance AC 900F 

controller family in the upper 

range, supporting four communication 

interfaces. It also 

provides more application 

memory and enables the reservation 

of specific memory. As 

for all Freelance controllers user 

applications are 100 % runtimecompatible 

which also enables 

Picture: ABB 

smooth upgrade opportunities. 

Freelance provides an additional 

alternative to its user management 

capabilities known as Security 

Lock by a solution called 

Extended User Management. 

This new option makes use of 

Windows user accounts, supporting 

both local and domain 

accounts. As a result typical requests 

for options such as central 

password management, 

rules for password complexity 

or password aging can be fulfilled. 

The update is available now. 


Online search: cpp0119abb 


Residual gas analyses in vacuum 

Leybold introduced its Leyspec 

Series residual gas analysers for 

use in high and ultra-high vacuum 

systems. These compact residual 

gas analysers are available 

in six variants, each featuring an 

integrated display that shows 

the partial pressures of the relevant 

gases at any time. The 

user can assign a separate channel 

to analyse additional gases 

in the process. The accompanying 

software supports simple 

operations to complex analyses. 

The software always displays the 

total pressure, with additional 

test procedures and functionalities 

pre-installed, such as the 

helium leak test or the setting of 

warnings and error limits for 

certain gases. Simple gas analyses 

can be performed without 

connecting the Leyspec to a 

computer. 

These analysers can be used in 

mass spectrometry applications 

for 100, 200 or 300 amu 

(atomic mass units), depending 

on process requirements. 


Online search: cpp0119leybold 

Hall 26, Booth E10 

Picture: Bürkert 

Versatile digital device platform 

Bürkert Fluid Control Systems' 

Efficient Device Integration Platform 

EDIP opens up the possibility 

of customised solutions 

that can function as a standalone 

or autonomous subsystem. 

The platform is now being expanded. 

With the I/O module 

ME44, various sensors and actuators 

can be integrated into 

the EDIP environment. The fieldbus 

gateway ME43 allows simple 

integration at process control 

level with the help of standard 

fieldbuses and Industrial Ethernet. 

Intuitive graphical programming 

allows autonomous subsystems 

to be realised quickly. 


Online search: cpp0119buerkert 

Hall 9, Booth G16 

Oil-free compressors up to 450 barg 

Picture: Sauer 

Sauer Compressors introduces 

the Haug.Sirius Nanoloc. The 

compressor offers a final pressure 

of up to 450 barg and operates 

completely oil-free. The 

Sirius Nanoloc combines a high 

final pressure, a hermetic gastightness 

and a wear-free drive 

via magnetic coupling and can 

compress nearly all gases. 

Sauer Compressors' range of accessories 

includes compressor 

controls as well as solutions for 

gas and air treatment, storage 

and distribution. These technologies 

are available for medium 

and high-pressure applications 

and for wet and dry gases. 


Online search: cpp0119sauer 

Hall 26, Booth B41 


IO-Link master modules in IP 20 and IP67 

IO-Link is considered key technology 

for the implementation 

of Industry 4.0/IIoT concepts. 

For this technology Weidmüller 

provides IO-Link master modules 

in IP20 and IP67 degree of 

protection. Plug-in connectors 

and pre-assembled lines for the 

bus connection as well as the 

sensor/actuator wiring complement 

the product portfolio. The 

parametrisation and configuration 

of IO-Link devices can be 

performed with the web-based 

configuration tool. The configuration 

tool with its intuitively 

operable interface connects 

to the new, central, crossmanufacturer 

database for description 

files of IO-Link devices 

(IODDs). The IODD finder database 

unites the entire IO-Link 

world under one roof and enables 

central access to all available 

IO-Link devices. 



cpp0119weidmueller 

Hall 11, Booth B58 

LET US FILL YOUR 

REQUIREMENTS, TOO! 

Picture: Weidmüller 

Rapid delivery 

Made in Germany 

ISO 9001 

Listen, evaluate and analyse 

Together with the update of the 

Sonochek apps Sonolevel and 

Sonoleak, Prüftechnik launches 

the Sonolevel Dataviewer, a visualisation 

PC-software for leak 

analysis. Sonochek is a digital 

leak inspection device used to 

localise leaks in compressed air, 

gas and vacuum systems. The 

device includes automatic leak 

classification and its broad 

bandwidth of 20 to 100 kHz 

allows detecting leaks even at an 

early stage. Sonochek is also 

used effectively for electrical inspection 

and monitoring of 

bearing lubrication. 

In the age of digitalisation, data 

must be transferred seamlessly 

from one device to the next. 

With Sonochek 1.1, maintenance 

and service engineers can 

now fully integrate leak inspection 

into their maintenance activities 

by transferring the Sonolevel 

measurement data via 

micro USB into the Dataviewer 

PC-software for central leak 

visualisation and analysis. 

The Sonolevel Dataviewer en- 

Picture: Prüftechnik 

ables analysts to save time by 

identifying defects at first sight 

through the clear visualisation 

of data in level graphs and spectrograms 

showing ultrasound 

phenomena such as the status of 

steam traps or the type of partial 

electrical discharge. Users can 

also easily compare reports e. g. 

of identical bearings. The Dataviewer 

software can be installed 

easily on a PC or a tablet for onsite 

evaluation. Export to CSV 

format is fully supported for 

data archiving and trending. 



cpp0119prueftechnik 

Hall 15, Booth G42 

Multi-purpose 

laboratory pump 

The compact, standardized Gather gear pump is designed 

for metering and recirculation from 0 °C to 85 °C against 

10 bar. Proven Gather quality at budget prices. 

• For lubricating and non-lubricating liquids 

• Pulsation-free pumping action (0.6 to 180 l/h) 

• CIP capability (cleaning in place) 

www.gather-industrie.de · pumpe@gather-industrie.de · +49 2058 89381-23 

cpp 01-2019 49 

Pump Technology · Metering Technology · Coupling Technology


SPECIAL 

Oil-free screw pumps for industrial use 

Efficient dry runners 

Contamination, particles, outgassings or vapours which are introduced into the 

pump cannot harm a Varodry. These one-hundred-percent oil-free, dry-compressing 

screw pumps also tolerate disruptive factors which occur when processes are not 

stable. They have a number of other advantages too. 

completely resistant to repeated shock 

ventilation. Any number of cycles are possible 

without overloading. 

Pictures: Leybold 

The Varodry vacuum pump (the VD100 version is shown here) excels with its simple design 

and low maintenance requirements 

Screw pumps, currently the state of the 

art in the field of industrial vacuum 

pumps, are predestined for demanding 

tasks. Their functional principle can be 

compared to that of an extruder, which 

simply pushes out disturbing particles. In 

addition, these pumps are very good at 

handling fumes. The Varodry series is initially 

available in sizes VD65 (65 m³/h) and 

VD100 (100 m³/h), with VD160 and 

VD200 already in preparation. 

In addition to the general advantages of the 

screw pump principle, Varodry pumps are 

characterised by quiet running and an unobtrusive 

noise level. At the same time, 

they can make a significant contribution to 

improving production processes. The variable 

arrangement of the inlet flange allows 

flexible placement of the pump within the 

system. 

Furthermore, the special design of the silencer 

(without any sponge-like damper 

materials) and the mounting of the outlet 

flange at the lowest point on the pump 

allows any liquids or condensed vapours 

that are introduced to be completely discharged, 

thus preventing the formation of a 

“dam”. Rust formation is avoided and process 

safety improved. The pump’s loading 

capacity and efficiency likewise have benefits 

for the process. It can be operated continuously 

at any suction pressure and is 

One-hundred-percent oil-free 

One important differentiator of the Varodry 

is the complete absence of oil. Conventional 

screw vacuum pumps are also dry-compressing 

but have gear compartments in 

which oil is used to lubricate the bearings 

and gearwheels. 

None of this applies to the Varodry. There is 

no possibility of oil migration from the 

drive chamber to the pump chamber. Reactions 

between this oil and process media are 

ruled out, as is back diffusion into the process 

chamber. 

The Varodry has grease-lubricated ball bearings 

and does not require synchronising 

gears. It is driven and synchronised by a 

high-tech toothed belt, which can be 

changed by the user in a few minutes. This 

eliminates the need for oil changes, in other 

words no oil can get into the process or 

drip underneath the pump. These properties 

of the Varodry are fundamental to the reduced 

costs and increased system cleanliness. 

Another advantage is the fact that the 

pump is fully air cooled. This simplifies its 

integration into the system considerably, as 

a potentially complicated water supply can 

be dispensed with. 

In contrast to most conventional products, 

the Varodry has a moderate temperature 

profile. The low internal temperatures, 

which are a maximum of 100 to 130 °C 

depending on the operating point, also 

permit temperature sensitive media to be 

conveyed, since there is no immediate decomposition 

which could cause deposits to 

form. This moderate temperature represents 

the optimum for many applications and 


IN A NUTSHELL: 

FEATURES AND BENEFITS 

The toothed belt can be changed quickly 

and easily 

allows long-term operation with no need to 

clean the pump chamber. 

Wide range of applications 

These features qualify Varodry for a wide 

range of applications. In addition to drying 

processes in industrial cleaning systems, the 

pumps are also used in freeze-drying as well 

as in the pharmaceutical and food industries. 

Drying applications are similarly important 

in lithium-ion battery production 

or in the manufacture of power storage 

units. 

Another target market is the manufacture of 

transformers and other high-voltage components 

containing paper insulating materials 

that must be absolutely dry. The humidity 

is reduced to a few ppm under vacuum. 

Here, too, the high water vapour compatibility 

is decisive. 

In composite applications, on the other 

hand, resins must be degassed before use in 

order to guarantee freedom from bubbles. 

They are then drawn into the pre-evacuated 

tissue during the subsequent infiltration. In 

both process steps, the resins are degassed 

and vapours enter the pump. This is where 

the moderate temperature profile of the Varodry 

pays off, largely preventing the 

formation of deposits and ensuring a long, 

trouble-free life. 

Among the typical plasma applications are 

part cleaning, surface activation and sterilisation, 

in which the bacteria are killed by 

the hot plasma gases without really heating 

the often temperature-sensitive products. In 

this kind of application, the chamber is 

generally pumped out to a pressure of 


SPECIAL 

Combination of compressed air treatment and continuous monitoring 

Guaranteed clean and 

germ-free 

When the aim is to increase process reliability and resource efficiency, attention 

should also be paid to compressed air treatment. The quality of compressed air has 

a decisive influence on processes, costs and the product itself. This is especially 

true for chemical and pharmaceutical companies that use compressed air as a central 

element in their production processes. 

Compressed air is used as a medium in 

numerous applications: for cleaning, ventilation 

and transporting chemical products, 

controlling production lines, manufacturing 

nitrogen or as an air curtain for separating 

safe and clean areas. Since the chemicalpharmaceutical 

industry works with toxic, 

corrosive and changeable substances, high 

quality requirements and safety standards 

are in place there for the compressed air, 

because even the slightest carelessness du - 

ring the production of chemicals can lead to 

reactions and have a decisive influence on 

the manufacturing process. The contamination 

of compressed air by oil particles, for 

example, can cause a great deal of damage 

from increased scrap to machine downtime 

with all the ensuing economic consequences. 

Contamination in the compressed air 

At the start of a compressed air line is a 

compressor. Quite often, the compressor 

itself can be a source of contamination in 

the compressed air, since it is generally oillubricated, 

meaning that aerosols and oil vapours 

can enter the system. Yet, even an oilfree 

compressor is not completely safe, because 

if the intake air is already charged 

with steam, dirt or micro-organisms, it can 

carry those pollutants into the compressed 

air system. Even excessive humidity in the 

compressed air – caused by high humidity 

in the intake air on hot summer days, for 

example – endangers the air quality and has 

impacts on production. 

Insufficiently designed compressed air treatment, 

inappropriate operation and inadequate 

maintenance of compressors and 

treatment components can also lead to contamination 

through dirt particles as well as 

residual humidity or oil vapour. During the 

manufacture of pills, for example, the compressed 

air which is used to transport the 

products comes into direct contact with 

them. The pills can potentially become contaminated 

if the air is not sufficiently 

treated. This can lead to cracking or to fluctuations 

in colour and entails health risks 

for the consumer. 

Pictures: Beko Technologies 

Chemical and pharmaceutical companies use compressed air as a central element in 

their production processes 

Oil-free as a result of treatment 

To avoid this, the compressed air must be 

absolutely oil- and germ-free and also of 

top quality. This is the only way to achieve 

safe, stable processes and products in the 

chemical-pharmaceutical industry. Compressed 

air is hence subject to strict requirements 

and checks. Various regulations such 

as the GMP (Good Manufacturing Practice), 

the implementation of which is regulated 

by rules governing medicinal products and 

active ingredients in the European Union, as 

well as DIN ISO 8573-1 and the European 

Pharmacopoeia define compressed air 

classes which are oriented towards applications. 

For an application to be safe, it is important 

that the compressed air be treated by means 

of filtration, drying and process technology 

(catalysis), as well as by condensation, and 


monitored throughout the process. This permits 

the quality of the air to be checked 

against the specified requirements. The catalytic 

process of a Bekokat by Beko Technologies 

delivers absolutely oil- and germ-free 

compressed air with a scarcely measurable 

maximum residual oil content of 

0.001 mg/m 3 . The process exceeds the 

stringent requirements of ISO 8573-1 (Class 

1 oil content), in other words, with the 

kind of quality that is stipulated in particularly 

demanding production processes. 

Cracking hydrocarbon chains 

In the Bekokat, all oils contained in the air 

after compression are removed, whether in 

gaseous, vapour or aerosol form. These 

problematical substances are completely 

converted into carbon dioxide and water 

during the catalysis by means of total oxidation. 

Following the principle of heat recuperation, 

the compressed air is heated to 

150 °C in the heat exchanger before entering 

the insulated reaction tank. The sheath 

heating of the tank then only has to heat it 

slightly, so that the Bekokat is very energyefficient. 

A granulate which works as a catalyst in 

combination with the heat starts the reaction 

and enables long-chain oil molecules 

(from oil-lubricated compressors, for 

example) to be cracked into ever smaller 

molecules until only H 2 O and CO 2 are left. 

After cooling, these are precipitated as condensate 

and discharged. Thanks to the 

catalysis process, the condensate is oil-free 

and can thus be safely disposed of via the 

sewerage system without any further treatment. 

The exothermic reaction also produces 

thermal energy. A measuring and control 

circuit constantly monitors the temperature, 

ensuring the safety of the process. 

If oil entry, and with it the temperature, increase 

due to a compressor fault, the inlet 

and outlet valves close immediately, so that 

contamination of the downstream compressed 

air systems is ruled out. 

Monitored compressed air quality 

In order to guarantee this compressed air 

quality in the long term, all crucial air pa - 

rameters such as the residual oil vapour content, 

volume flow, pressure, relative humidity 

and dew point can be monitored using 

appropriate measuring systems. Quality is 

always the result of controlled processes. The 

measuring devices deliver a sound data basis 

The Bekokat, a compressed air catalytic converter, produces absolutely oil- and germ-free 

compressed air 

for evaluation. The compressed air measurements 

and checks are generally automated. 

A Metpoint OCV compact, for example, 

measures and monitors the residual oil content. 

Every 4 s, it records and displays a 

value which is a running mean of the past 

80 s. This prevents the results from being 

distorted by outliers owing to unexpected 

internal or external disturbances. 

Increased measuring reliability regardless of 

the operating conditions is ensured by the 

patented reference gas which is produced by 

a catalytic converter. In contrast to other 

measuring devices, the gas from the converter 

is absolutely oil-free zero air. If, on 

the other hand, reference gas is produced 

using activated carbon, there is always a risk 

of residual oil being contained in the compressed 

air in the event of a non-ideal design 

or insufficient maintenance. 

The modular design of the Metpoint OCV 

compact simplifies assembly on site and restricts 

subsequent maintenance to a minimum, 

as all components can be exchanged 

quickly and easily. Servicing and mainte - 

nance cycles are indicated automatically. In 

addition, the measuring device can be 

adapted to different operating pressures 

from 3 to 16 bar via a controller. The operating 

condition and compliance with the ISO 

8573 oil class is shown by red or green 

LEDs. 

Alarm contacts can be configured individually 

to allow instant information if the residual 

oil vapour content increases. Production 

managers can then take appropriate action 

before the compressed air becomes 

contaminated. 

The Metpoint OCV compact measuring 

system allows continuous monitoring of 

compressed air quality 

Thus, industrial companies always work 

with the compressed air quality that is best 

suited for their process. If they combine 

comprehensive compressed air treatment 

with continuous monitoring of the compressed 

air parameters, maximum process 

reliability and resource efficiency will result. 


Online search: cpp0119beko 


AUTHOR: 

RAINER STÜTZEL 

Head of Department Corporate 

Identity & Relations, 

Beko Technologies 




Chemical resistant diaphragm pumps for scale-up in chemical process technology 

Scalable vacuum supply 

We’ve all been there. A process works well in the laboratory, yet issues arise during 

scale-up to production size. Thanks to seamless vacuum technology from Vacuu brand, 

this may very well be a problem of the past. Individual pumps and modular vacuum 

systems with pumping speeds up to 120 m 3 /h allow a stable scale-up process. 

Mini and pilot plants in the chemical industry 

are at the interface between lab and 

production scale. Numerous chemical processes 

such as distillation, evaporation, drying, 

extraction or filtration are performed 

under vacuum. During scale-up, the vacuum 

technology has to be adapted accordingly – 

ideally without sacrificing proven advantages 

from the laboratory like chemical resistance, 

oil-free vacuum, durability or precise 

vacuum control. On the laboratory 

scale, chemical resistant diaphragm pumps 

are established as the go-to technology for 

the aforementioned applications. A lot of 

processes are operated at pressures between 

1 and 500 mbar, falling well into the working 

range of diaphragm pumps. Mini and 

pilot plants usually require significantly 

higher pumping speeds than laboratory 

scale applications, often between 15 and 

100 m 3 /h. The other requirements mostly 

remain unchanged. So, why switch technologies 

when something tried-and-tested is 

available? 

Apart from the obvious parameters like 

pumping speed and ultimate pressure, other 

factors need to be considered in order to 

achieve the optimum layout for a vacuum 

supply in the chemical industry, for 

example chemical resistance, the use of utilities, 

energy and maintenance costs. Taken 

together, in the long run they affect process 

reliability, availability and the total cost of 

ownership. 

Appropriate measuring and control devices, 

which must be designed to be as chemically 

resistant and as robust as possible, are 

necessary to monitor and control the process 

vacuum. Many of the solvents commonly 

used in chemical plants are flammable 

at atmospheric pressure and have 

high vapour pressures, making them prone 

to forming explosive mixtures with air. In 

these cases, explosion protection, too, becomes 

an important factor. 

Pictures: Vacuubrand 

From small to large: chemical resistant vacuum pump with pumping 

speeds all the way up to the modular VAC 24seven system 

Oil-free pumps enable clean vacuum 

In chemical processes, not only air and 

water vapour are pumped but usually also 

aggressive vapours, so that vacuum pumps 

with high chemical resistance are a must. 

Due to the systematic use of fluoropolymers 

in all wetted areas, chemistry diaphragm 

pumps meet this requirement perfectly. 

Further more, these pumps are exceptionally 

tol erant of condensate. Vacuubrand manu - 

factures all heavy-duty components such as 

head covers and diaphragm clamping discs 

with stable metal cores combined with a 

thick, diffusion-tight overmould. 

The proven PTFE sandwich design of these 

diaphragms guarantees high durability and 

long service intervals. Depending on the 

application, the diaphragms typically only 


need to be replaced after 15,000 operating 

hours. 

Many processes and laboratories must be 

kept oil-free to avoid contamination of the 

products – another strong argument in favour 

of chemistry diaphragm pumps. They 

are dry-running and require neither operating 

nor cooling fluids, and they also operate 

completely oil-free without any abrasion. 

This guarantees a dry, clean vacuum and at 

the same time reduces operating costs, since 

no consumption or disposal of consumables 

occurs. 

For protection against particles and condensate 

droplets, chemistry diaphragm vacuum 

pumps can be equipped with an inlet catch 

pot. An emission condenser is used to recondensate 

the vapours at the pump exhaust. 

Solvent recovery rates close to 100 % 

can be realised in this way, keeping both 

production sites and the environment clean. 

Precisely controlled vacuum 

Rotary evaporation and many other processes 

require that the vacuum is controlled 

as precisely as possible. Speed-controlled 

diaphragm pumps like the Vario series 

achieve this precision automatically by adjusting 

the pump’s motor speed. This results 

in fewer strokes per minute, significantly reducing 

wear and tear and extending the service 

intervals accordingly. 

As a result, Vario pumps are nearly mainte - 

nance-free in many applications. Evaporation 

rates are maximised due to the hysteresis-free 

pressure control when compared 

with conventional, two-point control using 

solenoid valves. Process times are consequently 

up to 30 % shorter. Energy consumption 

and thus operating costs can simultaneously 

be reduced by up to 90 % depending 

on the process in question. While 

precise vacuum control is paramount, userfriendliness 

and ease of use are becoming 

more and more important. Vacuu-Select, the 

common controller on all Vario diaphragm 

pumps, sets a benchmark for straightforward 

and efficient operation: simply choose 

and start the desired application on a stateof-the-art 

touch display and let the controller 

execute the vacuum process all the 

way through. In case of solvent evaporation, 

Vacuu-Select automatically detects the boiling 

point and adapts the pressure continuously 

as necessary. Needless to say, the desired 

vacuum and other parameters are 

readily combinable in custom applications. 

Only chemical resistant materials are used 

in the wetted area of chemistry diaphragm 

pumps 

From small to large 

Vacuubrand offers a comprehensive range of 

chemistry diaphragm pumps with Vario 

control. Typical applications such as rotary 

evaporation are covered along with supplies 

to local vacuum networks, kilo labs and 

mini plants. Even high boiling solvents can 

be easily evaporated at low temperatures 

using pumps with ultimate pressures of less 

than 1 mbar. Pumping speeds up to 30 m 3 /h 

are possible with large chemistry diaphragm 

pumps (maximum pumping speed: 

20 m 3 /h) and Duo pumping units. In the 

latter case, the speed of two individual 

pumps is synchronously controlled and precisely 

adjusted to the vacuum requirement. 

For many applications – especially in mini 

or pilot plants – 100 % system uptime is essential. 

Any interruption due to mainte - 

nance, even when carried out at regular intervals, 

costs valuable process time. 

VAC 24seven, the modular process pump 

series providing pumping speeds of up to 

120 m 3 /h, addresses this issue. At the heart 

of every pump module are two variable 

speed pumps. Up to three pump modules 

can be combined with one control module. 

Individual pumps may be uncoupled for 

servicing, while the speed of the other 

pump(s) is automatically adjusted in order 

to maintain the correct process vacuum. 

This opens up totally new options for process 

technology. 

Atex chemistry vacuum pumping unit MV 

10C EX Vario +AK+EK 

The pump modules are available in two different 

versions with an ultimate vacuum of 

5 or 70 mbar. The control module provides 

synchronous vacuum control of the individual 

pumps, determines the required pumping 

speed and ensures an optimal process 

due to the demand-based speed control. 

Energy consumption is minimised and 

maintenance intervals extended. 

No sparks please 

Almost all Vacuubrand diaphragm pumps 

and measuring instruments are approved for 

Atex category 3. If this category is not sufficient, 

chemical diaphragm pumps and 

pumping units conforming to Atex category 

2 (e.g. for Zone 1) are also available. These 

pumps can be controlled in combination 

with the Vacuu-Select controller and corresponding 

system accessories, allowing fully 

automatic operation of the vacuum process 

without complex programming. 


Online search: cpp0119vacuubrand 

AUTHOR: 

DR. BARBARA 

RICHARZ 

Product Manager, 

Vacuubrand 




Picture: Mulderphoto – Fotolia.com 

Fig. 1: The Chem XP material family should meet the high requirements in process plants 

Highly fluorinated materials for chemical processing facilities 

Strong performance 

Fluoro rubber (FKM) is considered the standard material for seals in processing 

facilities, yet it offers only limited resistance to acids, bases and solvents. For 

demanding applications, perfluoro rubber (FFKM) has been used until now, although 

it is significantly more expensive than FKM. Freudenberg Sealing Technologies has 

developed a new family of materials called Chem XP, which fills the gap with a good 

balance between performance and cost. 

The seals used for equipment in the 

chemical process industry today are mainly 

made of fluorinated materials (Figure 1). 

The amount of fluorine and the composition 

of the formulation affect the cost of the 

material on one hand and the resistance of 

the various fluoro elastomers to acids, bases 

and solvents on the other. Fluoro rubber 

(FKM) is widely employed as a standard 

material in chemical processes. In many applications, 

this material is a suitable choice 

for O-rings, formed parts and diaphragms. 

For example, standard FKM is distinguished 

by its high resistance to mineral oils and 

other hydrocarbons. However, its resistance 

to certain acids, bases and organic solvents 

is comparatively low. If FKM comes into 

contact with increased concentrations of 

these media, they can attack it chemically 

and cause it to swell, leading to significant 

changes in its mechanical qualities. In this 

event, the material foundation must be selected 

and combined differently, so that it 

can withstand chemical attack. In especially 

demanding applications, perfluoro rubber 

(FFKM) is the preferred material because it 

offers excellent media resistance due to its 

complete fluorination. Unfortunately, in the 

light of factors like its elaborate production 

process, FFKM is very costly and the extremely 

high level of performance it 

achieves is not necessarily a requirement. 

Good balance 

With this in mind, Freudenberg Sealing 

Technologies has developed a new line of 

materials called Chem XP, which fills the 

gap and creates a good balance between 

performance and cost. Its characteristics in- 


clude resistance to temperatures between 

–20 and +200 °C as well as better chemical 

stability than FKM in contact with many 

acids and organic solvents. Chem XP is also 

highly resistant to ultraviolet light and 

ozone and has very good aging behaviour. 

In June 2018, this innovation was presented 

to industry professionals for the first time at 

Achema. Figure 2 shows a schematic comparison 

of the price levels and resistances 

for standard FKM, the premium material 

FFKM and the newly developed Chem XP 

material family. 

When Chem XP replaces FKM in an application, 

the operating life increases, enabling 

maintenance intervals to be extended and 

production costs reduced. The risks of unplanned 

equipment downtime are simultaneously 

minimised, avoiding the high follow-up 

costs to operators that are associated 

with stoppages. Choosing Chem XP materials 

also helps cut the costs for materials. 

Since Chem XP’s media resistance to selected 

acids and organic solvents is comparable 

to that of FFKM, substitution is 

possible in these cases and the very high 

price of FFKM seals averted. 

Formulation for the elastomer mixture 

When they developed Chem XP, Freudenberg 

Sealing Technologies’ material experts 

devoted particular attention to the broadest 

possible resistance to aggressive media. 

Amongst other things, the Chem XP material 

family has a high fluorine content similar 

to that of FFKM materials. In combination 

with a new formulation for the individual 

components, Chem XP achieves a high degree 

of media resistance, which has been 

successfully demonstrated in comparative 

analyses and lab tests. 

Picture: Freudenberg Sealing Technologies 

Fig. 2: Comparison of resistance and pricing 

for three material families: FKM, Chem XP 

and FFKM 

Lab tests with acids and solvents 

The Chem XP material family was investigated 

in lab tests, in order to identify 

changes in swelling and strength and compare 

it with other materials available in the 

market. As the benchmark for these comparative 

analyses, the material developers at 

Freudenberg Sealing Technologies selected 

three of the most critical representatives of 

each chemical class which is relevant for the 

chemical industry. A 20 % concentration of 

Every child 

is one of a kind and unique. Each child needs 

individual support according to their needs. 

Please help us by donating. Thank you! 

New Industrial 

Coriolis Flow Meter 

Product line extension - expected mid 2019 

Robust mass flow meters for gases and liquids 

Flow ranges from 5 g/h up to 300 kg/h (FS) 


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IBAN DE22 4306 0967 2222 2000 00 

BIC GENO DE M1 GLS 

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2016/1 

www.bronkhorst.com 




acetic acid was chosen to represent the acid 

class at a temperature of 98 °C. Pure methyl 

ethyl ketone (MEK) represented the solvent 

class at a temperature of 80 °C, while pure 

toluene at 40 °C represented the alkylbenzenes. 

Demanding, challenging conditions 

were deliberately created for the materials, 

with storage temperatures very close to 

boiling point in the first two cases. The test 

samples were exposed to acetic acid and 

MEK for three days and immersed in toluene 

for an entire week. 


Fig. 3: Results relating to volume changes in acetic acid, methyl ethyl keton (MEK), and toluene 

Results of the lab tests 

Changes in volume such as swelling or 

shrinkage give an indication whether a material 

absorbs media or gives off components. 

Swelling was the sole relevant criterion 

for the Chem XP lab tests. If swelling 

is not limited to a certain degree, seals can 

lose their functionality and leaks could 

occur. For the purposes of the tests, a maximum 

permissible volume change of +10 % 

was set. A standard FKM, the proven 

75 Simriz 495 and four special, highly 

fluorinated varieties of FKM from competitors 

were used for reference. 

As Figure 3 shows, the standard FKM material 

is not suited for these demanding test 

conditions. Especially in acetic acid and 

MEK, the swelling was far too great; the 

seals would deteriorate in the foreseeable 

future. The tested elastomer mixtures from 

manufacturers 1 and 2 exhibited clear 

weaknesses during the acetic acid test. The 

same was true of the mixtures from manufacturers 

2 and 3 in MEK. Only the material 

from manufacturer 4 could be used with 

certain limitations in the test conditions. In 

acetic acid and toluene, the Chem XP 1 variant 

delivered results that were comparable 

to the very low volume change for 

75 Simriz 495, the FFKM material par - 

ticipating in the test. At temperatures below 

+80 °C, the material also showed outstanding 

stability in MEK. The Chem XP 2 variant 

which was tested in parallel likewise demonstrated 

good resistance to acetic acid and 

toluene, but is only limitedly suited for use 

in MEK at +80 °C. 

Standard FKM also proved to be unsuitable 

during the strength tests (see Figure 4). In 

addition to a high degree of swelling, the 

more than 30 % reduction in strength indicates 

chemical breakdown of cross-linkages 

and polymer chains in the elastomer matrix. 

The materials from manufacturers 1 to 4 

showed an impermissible deterioration in 


Fig. 4: Results relating to strength changes in acetic acid and methyl ethyl ketone (MEK) and toluene 

strength in MEK, similar to the picture for 

manufacturers 3 and 4 in toluene. This puts 

the moderate swelling values of manufacturer 

1 in MEK (Figure 3) into perspective: 

with an up to 60 % loss of strength, it was 

discarded as a potential candidate. In all 

cases, the strength values for Chem XP 1 

were within the tolerance limits and 

comparable to the very good values of 

75 Simriz 495. The excellent volume stability 

of Chem XP 2 in acetic acid and toluene 

was confirmed by the only slightly reduced 

strength in both cases. 

In summary, it can be said that the newly 

developed Chem XP materials rank directly 

below FFKM in terms of media resistance 

and in the future can serve as standard materials 

for the chemical processing industry. 

Lab tests confirmed that they provide a very 

good balance between performance and 

cost. 

The first seals made from Chem XP are expected 

to be ready for serial production in 

early 2019. O-rings and formed parts are 

among the possible varieties of seals suited 

for this material. The exact material types 

and applications will be determined in joint 

tests with customers. Freudenberg’s development 

engineers are simultaneously working 

on other variations of the new material 

family. 


Online search: cpp0119freudenberg 

AUTHOR: 

DR. ROBERT ROTZOLL 

Business Development 

Manager Process Industry, 

Freudenberg Sealing 

Technologies 



PRODUCTS 

Turnaround concept reduces downtimes 

High-efficiency turbocompressor 

The Bilfinger Turnaround Concept 

(BTC) consists of nine 

modules covering various aspects 

such as resource management, 

workplace safety, and materials 

management. These theory-heavy 

modules are supplemented 

by a comprehensive 

handbook that defines all the 

work steps involved in detail, 

along with their respective interdependencies. 

Depending on 

the initial situation at hand, the 

required workflows pre-defined 

as templates in the handbook 

can be individually adjusted to 

the specific dictates of the prevailing 

conditions. This produces 

a complete operational 

flow chart for all the various 

simultaneous and sequential 

work steps, including their cyclical 

timing. This in turn provides 

the wherewithal for the 

exceptionally precise turnaround 

management, particularly 

when it comes to minimising 

project risks and precalculating 

costs with maximum accuracy. 

A further focal point of the BTC 

is on readying and compiling all 

the parts and components 

required for the maintenance of 

a given structural element. In 

this process (also known as kitting), 

all the small parts to be 

replaced are pre-sorted and 

packed in the correct quantities 

for each work step. 

The progress of a turnaround 

project can be tracked using a 

mobile app linked up to a central 

web application. 


Online search: cpp0119bilfinger 

Sulzer's HSR line of high-speed 

turbocompressors is designed 

for the production of oil-free 

pressurised air in applications 

where contamination of the air 

must be avoided. The HSR utilises 

high-performance turbo 

and magnetic bearing technology 

that maximises the efficiency 

and minimises the need for 

maintenance. 

A key benefit is that the HSR 

contains no oil at all. This means 

100 % safe compressed air for 

processes where no contamination 

is allowed, for example 

in the production of fibrous 

materials or pharmaceuticals. 

A key technological choice is 

the use of active magnetic bearings 

that bring the benefit of no 

mechanical friction and no 

mechanical wear. Together with 

Picture: Sulzer 

the almost total absence of vibration, 

this grants the product 

a long lifetime. The HSR is 

cooled by water. The advantage 

is that both the heat generated 

by the compression and driverelated 

losses can be recovered 

as usable energy. Water cooling 

also ensures optimal performance 

and generally extends the 

lifetime of the components. 


Online search: cpp0119sulzer 

Sensors for single-use applications 

Non-seal centrifugal canned motor pumps 

Picture: Hamilton 

Hamilton offers a complete solution 

for cell culture and fermentation. 

The single-use pH 

sensor Oneferm and a disposable 

sensor for optical dissolved 

oxygen measurement are the 

latest developments. The sensors 

are implemented into bags and 

reactors by the manufacturers of 

the single-use equipment and 

delivered gamma-sterilised afterwards. 

This means a minimum of 

preparation time as well as no 

time consuming cleaning validations 

for the users. Oneferm 

pH combines at the same time 

the precision and minimal drift 

of a glass pH sensor with the 

quick use of an optical pH sensor 

without increasing the contamination 

risk. The single-use sensors 

are available as an analogue 

and an Arc version. Along the 

same line, Hamilton released an 

Arcair Software version, which 

allows the user to access all processes 

fast and easy with the app. 

Reading the barcodes printed on 

the pH buffers and conductivity 

standards labels, and documenting 

all settings and changes, is 

one of the innovations of the 

new ArcAir software. 


Online search: cpp0119hamilton 

To even better meet the requirements 

of the European market, 

the reliable Nikkiso non-seal 

centrifugal canned motor 

pumps are available since January 

2019 also in accordance 

with DIN EN ISO 2858. As the 

first step, four sizes, the 25-160, 

32–125, 40-200 and 50-200, 

had been introduced. Another 

four models followed in February 

of 2019, while a total of 12 

pump sizes should be available 

by the end of the 3rd quarter of 

2019. 

The compact and low-vibration 

Nikkiso centrifugal canned 

motor pumps are used mainly 

for the transfer and circulation 

tasks of easily flammable, explosive 

or toxic fluids in the 

Picture Lewa: 

chemical and petrochemical industry. 

They therefore satisfy all 

the requirements of the Atex Directive 

2014/34/EU and are 

able to be customised. Furthermore, 

models in accordance 

with the API 685 standard are 

available. 


Online search: cpp0119lewa 

T +49 2961 7405-0 | info@rembe.de 

Gallbergweg 21 | 59929 Brilon, Germany 

F +49 2961 50714 | www.rembe.de 

Your Specialist for 

EXPLOSION SAFETY 

and PRESSURE RELIEF 

POWTECH 

Hall 5 

Stand 5-410 

Consulting. Engineering. Products. Service. 

© REMBE® | All rights reserved 



PROCESS ENGINEERING 

Safety concept for continuous tubular reactors 

Safe scale-up with 

exothermic reactions 

Fluitec offers a safety concept and all essential equipment for scaling up demanding 

chemical reactions in tubular reactors. The continuous processes are divided into 

safety classes based on their temperature levels, as a starting point for selecting 

and installing suitable safety devices such as a countercurrent safety purge system, 

safety valves or bursting discs. The use of certified assemblies results in significantly 

shorter development times. 

Chemical processes are often developed 

directly today in continuous operation. 

Owing to the small reactor volumes and the 

high surface-to-volume ratio, even fast and 

highly exothermic reactions can be carried 

out safely in millireactors or microreactors. 

However, the question of safety requirements 

generally arises at the latest when 

these reactions are scaled up. Fluitec has developed 

a safety concept for assemblies and 

built a reference plant with a diameter of 

The Fluitec mixer/heat exchanger 

DN 50 for throughputs from 100 to 

300 kg/h. The engineers responsible chose 

Fluitec’s proven, high-performance mixer/ 

heat exchanger as the tubular reactor. 

Safety classification 

Although the reaction mass is only heated 

locally in a continuous process and there is 

a large heat-exchanging area, thermal runaway 

or an excessive pressure rise in the 

Pictures: Fluitec 

tubular reactor cannot be completely ruled 

out. If a hazardous incident of this kind occurs, 

measures must be in place to prevent it 

from propagating to the storage tanks and 

collecting vessels. In practice, these safeguards 

are dependent on the type of chemical 

reaction as well as on the process conditions. 

At the heart of the safety concept, 

therefore, is the division of continuous processes 

into safety classes 1 to 5 based on 

their temperature levels (modified diagram 

taken from F. Stoessel, Thermal Safety of 

Chemical Processes, Wiley-VCH, Weinheim 

2008). This safety classification is determined 

by the relative positions of the following 

temperatures: 

• T P – Process temperature range 

• T m = T 0 + ∆T ad – Maximum temperature 

attainable under adiabatic conditions 

• T S – Maximum allowable temperature of 

the pressure equipment; temperature at response 

pressure of the bursting discs or 

the safety valve 

• T Onset – Onset temperature of the decomposition 

reaction 

Safety classes 1 and 2 are considered to be 

«safe» because if the cooling system fails, 

the maximum attainable temperature (T m ) 

cannot initiate the decomposition reaction. 

In the case of class 3, the above-mentioned 

incident could cause the reactor to burst, 

while with safety classes 4 and 5 even a decomposition 

reaction is conceivable. Eventpreventing 

protective devices such as a 

countercurrent safety purge system (SPS) 

should be installed for the class 3 to 5 reactions 

for this reason in addition to damage- 


limiting protective devices like a safety valve 

or bursting discs. The SPS is tripped if the 

maximum limit temperature which can just 

be handled without risk (T Exo ) is exceeded. 

The difference between the T Onset and T Exo 

temperatures must be sufficiently large for 

enough time still to be available to trip purging 

before the decomposition reaction begins. 

This temperature difference is consequently 

dependent on the response time of 

the temperature sensors. Processes assigned 

to safety classes 4 and 5 are very critical because 

T m is greater than T Onset . They must 

therefore be diluted, either with solvent or 

using a plug flow recycle reactor (PFRR), so 

that T m is reduced to a value below T Onset and 

the safety classification of the reactions 

changes to class 1 or 2. Provided no secondary 

reactions occur with the product, Fluitec’s 

advice is to give preference to PFRR 

mode over dilution with solvent on environmental 

grounds. 

Damage-limiting protective devices like a 

safety valve or bursting discs permit depressurisation 

if significant amounts of gas 

are produced, as is usually the case with decomposition 

reactions. Three pressure rise 

systems are possible: 

• Gas-producing systems form non-condensable 

gases 

• Vapour pressure systems follow the vapour 

pressure curve 

• Hybrid systems are a combination of gassy 

and vaporous systems 

A pressure rise due to vapour production 

can be absorbed to a large extent by the 

pressure equipment. In a gassy or hybrid 

system, the safety valve or the bursting discs 

respond. 

Functional assemblies 

The assemblies for fast and highly exothermic 

reactions are fitted with axial temperature 

sensors, pressure sensors and flow 

meters as standard. Furthermore, Fluitec’s 

experts equipped their reference plant with 

a safety purge system as an event-preventing 

protective device. The safety purge system is 

automatically activated, and the reactor 

emptied immediately, if the allowable temperature, 

pressure or flow limit is exceeded. 

The flow which exits from the plant is fed 

into a quench tank, causing the reaction to 

be instantly quenched. The hot liquid is thus 

prevented from spreading into the storage 

tanks and collecting vessels. Inert gases or 

liquids are particularly suitable for purging. 

The countercurrent safety purge system is 

an integral part of the plant and includes 

both mechanical and electronic components. 

It has SIL certification and can hence 

be used as a SIL protection level. 

The component is equipped with a control 

system and has three SIL protection levels. 

Thanks to this high level of safety, the reactor 

is ideal for numerous liquid-liquid reactions. 

The control system was programmed 

with a standard operating manual and each 

process step is documented. Full traceability 

is ensured in this way. The software can be 

used for any reactor and adapted to meet 

additional process requirements without 

any problems. The following step sequences 

are integrated in the programming: 

• Initial commissioning and recommissioning 

• Start-up and running up (continuous/normal 

operation) 

• Shut-down 

• Removal from service including cleaning 

• Sampling 

The five safety classes where T 0 = start temperature, T P = process temperature, 

T m = maximum temperature attainable under adiabatic conditions, 

T S = maximum allowable temperature of the pressure equipment, 

T Onset = temperature of the decomposition reaction, T DEC MAX = maximum 

attainable decomposition temperature, T Exo = limit temperature 

* The type of decomposition reaction must be taken into account in the 

risk analysis 

Reference plant with two dosing systems, a mixer/heat exchanger unit 

with a safety purge system and a quench tank 

Since operating regulations, certified components 

and risk analyses already exist, the 

process development time can frequently be 

halved. 


Online search: cpp0119fluitec 

AUTHOR: 

MARLIES MOSER 

Project Manager/R&D, 

Fluitec mixing + reaction 

solutions 

AUTHOR: 

ALAIN GEORG 

Head of R&D, 

Fluitec 



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Phone +49 711 7594-300 

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Phone +49 711 7594-415 

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Printed by Konradin Druck GmbH, 

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Printed in Germany 

© 2019 by Konradin-Verlag 

Robert Kohlhammer GmbH, 

Leinfelden-Echterdingen 


LIST OF ADVERTISERS 

amixon GmbH, Paderborn 17 

Bauer Gear Motor GmbH, Esslingen 47 

Beumer Group GmbH & Co.KG, Beckum 5 

Bosch Industriekessel GmbH, 

Gunzenhausen 41 

Bronkhorst High-Tech B.V., NL-Ruurlo 57 

C. Otto Gehrckens GmbH & Co. KG, 

Pinneberg 35 

Fette Compacting GmbH, Schwarzenbek 2 

FREWITT Fabrique de Machines SA, 

CH-Granges-Paccot 35 

GATHER INDUSTRIE GmbH, Wülfrath 49 

Hillesheim GmbH, Waghäusel 31 

Dr. Jeßberger GmbH, Ottobrunn 63 

Amandus Kahl GmbH & Co., Reinbek 27 

KELLER AG für Druckmesstechnik, 

CH-WINTERTHUR 64 

Nürnberg Messe GmbH, Nürnberg 7 

Pepperl + Fuchs GmbH, Mannheim 46 

Pfeiffer Vacuum GmbH, Aßlar 25 

Rembe GmbH Safety + Control, Brilon 59 

Robu Glasfilter-Geräte GmbH, Hattert 13 

VEGA Grieshaber KG, Schiltach 19–22 

ystral GmbH, Ballrechten-Dottingen 11 


& 

robust 

Pumps 

powerful 

www.jesspumpen.de 

Please visit us 

Hannover Messe 

Hannover 

Hall 5 A 35 

POWTECH 

Nuremberg 

Hall 3-147 

Electric and air operated drum pumps 

and container pumps 

Manual hand pumps 

Air operated diaphragm pumps 

Horizontal centrifugal pumps with 

mechanical seal or sealless design 

Vertical centrifugal pumps 

High viscosity dosing pumps 

Horizontal and vertical 

eccentric screw pumps 

Impeller pumps 

Accessories such as 

flowmeters, hoses 

and nozzles 

Filling systems according 

to customer request 

JESSBERGER GmbH 

Jaegerweg 5 -7 

D-85521 Ottobrunn 

Tel.: +49 (0) 89 - 66 666 

33 400 

Fax: +49 (0) 89 - 66 666 

33 411 

info@jesspumpen.de 

www.jesspumpen.dee 

Pumps 

made in 

Germany 



SPECIAL 

KELLER in Space 

International Space Station (ISS) 

welcomes Swiss pressure measurement technology 

Absolute and differential pressure transmitters 

regulate regenerative processes 

in the ISS oxygen supply 

Pressure measurement technology 

for applications under extreme conditions 

Including in the following ranges: 

50 mbar…20 bar 

0…110 °C 

1…9 VDC and RS485 

Joint development with the customer 

Stringent stability and reliability requirements 

End-to-end quality assurance from sales and development 

to specialised production areas 

64 cpp 01-2019 

keller-druck.com

cpp – Process technology for the chemical industry 01.2019

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