cpp – Process technology for the chemical industry 03.2019

The journal cpp - Process technology for the chemical industry reports about processes, plants, apparatus and components for the chemical and pharmaceutical industry. Further topics are IT technologies, industry 4.0, digital production, MSR and automation technology and process analysis technology. The content spectrum is rounded off by explosion protection, plant safety, occupational health and safety, maintenance, site management and energy management.

The journal cpp - Process technology for the chemical industry reports about processes, plants, apparatus and components for the chemical and pharmaceutical industry. Further topics are IT technologies, industry 4.0, digital production, MSR and automation technology and process analysis technology. The content spectrum is rounded off by explosion protection, plant safety, occupational health and safety, maintenance, site management and energy management.


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03-2019<br />

16 COVER<br />






24 SPECIAL<br />

K 2019 PREVIEW<br />










+ Best in batch-to-batch<br />

+ Flexible set-up<br />

+ TRI.EASY design<br />

+ Intuitive use<br />


<strong>cpp</strong><br />



WON‘T<br />

QUIT!<br />

PC 3001 VARIO select<br />

Chemistry Vacuum Pump<br />

K 2019 again fully<br />

booked<br />

Only a few days left until K 2019, <strong>the</strong> leading international trade<br />

fair <strong>for</strong> <strong>the</strong> plastics and rubber <strong>industry</strong>, opens its doors at <strong>the</strong><br />

Dusseldorf Exhibition Centre. With over 3000 exhibitors from more<br />

than 60 countries, it will once again be fully booked this year,<br />

occupying a net exhibition space of around 175,000 m² from 16 to<br />

23 October. More than 200,000 trade visitors from all over <strong>the</strong><br />

world are expected to travel to <strong>the</strong> Rhine metropolis.<br />

The 21st K remains <strong>the</strong> per<strong>for</strong>mance barometer <strong>for</strong> <strong>the</strong> <strong>industry</strong> as a<br />

whole and a global marketplace <strong>for</strong> innovation. For eight days, <strong>the</strong><br />

who’s who of <strong>the</strong> entire plastics and rubber world will meet <strong>the</strong>re<br />

to discuss current trends, introduce new products and solutions,<br />

and set <strong>the</strong> course <strong>for</strong> <strong>the</strong> future. K 2019 not only emphasises its<br />

special status due to <strong>the</strong> great popularity of <strong>the</strong> global <strong>industry</strong> but<br />

also addresses current challenges. In particular, <strong>the</strong> event will focus<br />

on “Plastics <strong>for</strong> Sustainable Development & Circular Economy”.<br />

If you are already preparing your visit to K 2019 in October, you<br />

will find a comprehensive trade fair special starting on page 24 of<br />

this issue. The special begins with an interesting article about <strong>the</strong><br />

Contraplex wide-chamber mill from Hosokawa Alpine, which has<br />

been adapted to <strong>the</strong> specific requirements of 3D printing.<br />

As early as April this year, Siemens presented <strong>the</strong> Simatic PCS neo<br />

process control system based entirely on web technologies at <strong>the</strong><br />

Hannover Messe, which on <strong>the</strong> one hand builds on existing knowhow<br />

and protects investments already made but on <strong>the</strong> o<strong>the</strong>r treads<br />

completely new paths. You can discover what <strong>the</strong>se are in our cover<br />

story on page 16.<br />

<br />

<br />

<br />

<br />

<br />

www.<strong>the</strong>bettervacuum.com<br />

Günter Eckhardt, Editor-in-Chief<br />

<strong>cpp</strong> 03-2019 3

<strong>cpp</strong> CONTENTS 03-2019<br />

16 Cover The Simatic<br />

PCS neo process control<br />

system from Siemens is<br />

based entirely on web<br />

technologies but can use<br />

<strong>the</strong> hardware already<br />

installed.<br />

22 The Contraplex CW<br />

250 II wide-chamber<br />

mill features optimised<br />

grinding tools and temperature<br />

control, reducing<br />

liquid nitrogen and<br />

energy consumption.<br />

38 A dashboard enables<br />

users of Wolftechnik's intelligent<br />

filter controller<br />

to manage <strong>the</strong> entire filtration<br />

process via a single<br />

interface, where parameters<br />

can be configured<br />

and monitored and data<br />

backed up and restored.<br />


8 Surge protection system <strong>for</strong> signal circuits<br />

Fuse terminal blocks can be expanded with fuse<br />

carriers<br />

10 Profinet integration in process automation<br />

IP 67 I/O module with Profinet S2 system redundancy<br />

12 Real-time detection of threats<br />

Network monitoring with anomaly detection<br />

14 Access <strong>for</strong> authorised persons only<br />

Safety and security in one operating mode selection and<br />

access permission system<br />

16 COVER Replace <strong>the</strong> software, keep <strong>the</strong> hardware<br />

Web-based process control system uses existing<br />

hardware base<br />

21 Safe control of separation processes<br />

Radiometric system <strong>for</strong> multiphase level measurement<br />


24 Wide-chamber mill <strong>for</strong> 3D printing<br />

Cryogenic size reduction of fine polymer powders<br />

26 Trans<strong>for</strong>ming a dusty process into a clean one<br />

Customised solution <strong>for</strong> clean air in plastics<br />

production<br />

29 PRODUCTS<br />

32 The right vacuum cleaner <strong>for</strong> each material<br />

Cleanliness and health protection in <strong>the</strong> plastics<br />

<strong>industry</strong><br />

34 How to configure your heating and cooling system<br />

Energy-efficient temperature control of stirrer tanks<br />

36 All process steps in one machine<br />

Optimal powder dispersion<br />


38 Networked filter <strong>technology</strong> <strong>for</strong> <strong>the</strong> future<br />

Smart controller paves <strong>the</strong> way <strong>for</strong> Filtration 4.0<br />


40 Tailored to <strong>the</strong> application<br />

Roots pumps <strong>for</strong> vacuum distillation<br />

42 In <strong>the</strong> age of Industry 4.0<br />

Compressed air management: service tool and app <strong>for</strong><br />

compressors<br />

44 Digital transparency on compressed air treatment<br />

Cloud solution captures and visualises compressor and<br />

compressed air system data<br />

47 Drum emptying system with follower plate<br />

Gentle pumping of pastes and non-flowable substances<br />

48 Cloud services <strong>for</strong> digital twins<br />

Keep your process plant up to date at all times<br />

50 Grab sampling systems <strong>for</strong> accurate lab analyses<br />

Collecting representative samples<br />

4 <strong>cpp</strong> 03-2019

40 Oktaline roots<br />

pumping stations have<br />

proven to be an advantageous<br />

solution to realise<br />

<strong>the</strong> exact pressure in<br />

vacuum destillation<br />

plants.<br />

50 Grab sampling systems<br />

provide an effective<br />

way to safely collect<br />

samples from a pipeline,<br />

tank or process vessel to<br />

be transported to a lab<br />

<strong>for</strong> offline analysis.<br />


56 Position indicator <strong>for</strong> supervised <strong>for</strong>mat change<br />

<strong>Process</strong> reliability in track and trace systems<br />

58 Bagging carbon black efficiently<br />

Dust-free thanks to state-of-<strong>the</strong>-art vacuum <strong>technology</strong><br />


3 Editorial<br />

4 Contents<br />

6 News<br />

22 PRODUCTS<br />

53 PRODUCTS<br />

60 Contact <strong>the</strong> Editors<br />

60 Imprint<br />

60 List of Advertisers<br />


More news, facts, products and<br />

solutions <strong>for</strong> <strong>the</strong> process <strong>technology</strong><br />

in <strong>the</strong> <strong>chemical</strong> <strong>industry</strong> can be found<br />

on our internet page!<br />

www.<strong>cpp</strong>-net.com<br />

<strong>cpp</strong> 03-2019 5

<strong>cpp</strong><br />

NEWS<br />

Russian <strong>chemical</strong> complex<br />


Picture: Honeywell<br />

Honeywell was selected as main automation<br />

contractor <strong>for</strong> one of <strong>the</strong> largest PJSC Metafrax<br />

<strong>chemical</strong> complexes in Russia<br />

Casale SA has selected Honeywell <strong>Process</strong><br />

Solutions to be <strong>the</strong> main automation contractor<br />

<strong>for</strong> a more than 950 million euros<br />

ammonia, urea and melamine production<br />

facility being built <strong>for</strong> PJSC Metafrax, one of<br />

Russia’s largest <strong>chemical</strong> companies. The<br />

plant, located in Gubakha, Russia, is scheduled<br />

<strong>for</strong> completion in 2021 and will be<br />

one of <strong>the</strong> largest production facilities of its<br />

type in Russia. The complex is designed <strong>for</strong><br />

a maximum annual production of up to<br />

575 000 t of urea, 308 000 t of ammonia<br />

and 40 000 t of melamine. Honeywell will<br />

work with Casale to deliver a range of<br />

modular process equipment, control, safety<br />

and in<strong>for</strong>mation solutions and competency<br />

management systems including: Experion<br />

<strong>Process</strong> Knowledge System with nine Experion<br />

Orion workstations, Safety Manager,<br />

Uni<strong>for</strong>mance <strong>Process</strong> History Database <strong>for</strong><br />

<strong>the</strong> collection, storage and analysis of process<br />

data, Field Device Manager <strong>for</strong> simplification<br />

of maintenance tasks and complete<br />

device configuration, Unisim Operator<br />

Training Simulator <strong>for</strong> skills training specific<br />

to melamine production, and Honeywell<br />

UOP Pressure Swing Adsorption (PSA)<br />

unit <strong>for</strong> hydrogen recovery and purification.<br />

Picture: Evonik<br />

Construction of a new natural-gas power plant in Marl<br />


Evonik is to install a new advanced high-efficiency<br />

gas and steam turbine power plant<br />

at Marl Chemical Park<br />

Finnish manufacturer of high-per<strong>for</strong>mance butterfly valves<br />


ARI-Armaturen Group has acquired all outstanding<br />

shares of <strong>the</strong> Finnish butterfly<br />

manufacturer Hög<strong>for</strong>s Oy. Hög<strong>for</strong>s develops<br />

and manufactures a wide range of manual<br />

and automated butterfly valves and also provides<br />

ball valves both <strong>for</strong> a vast variety of<br />

applications in <strong>the</strong> power and process <strong>industry</strong>.<br />

Since its establishment in 1927 Hög<strong>for</strong>s<br />

has become a trusted partner with a strong<br />

market position. Hög<strong>for</strong>s will complement<br />

Evonik is to install a new advanced high-efficiency<br />

gas and steam turbine power plant<br />

at Marl Chemical Park. The specialty <strong>chemical</strong>s<br />

group is thus, after more than 80 years,<br />

ending hard-coal based power and steam<br />

generation in Marl, which will reduce its<br />

CO 2 emissions by up to 1 million t/a. Direct<br />

greenhouse gas emissions of its plants<br />

worldwide will <strong>the</strong>n be reduced annually by<br />

almost one fifth. Evonik and its partner<br />

Siemens signed agreements <strong>for</strong> <strong>the</strong> construction<br />

of <strong>the</strong> two-block power plant on<br />

August 30th. Construction is slated to start<br />

be<strong>for</strong>e <strong>the</strong> end of this year. The high-efficiency<br />

and very flexible plant, producing<br />

power and steam in a cogeneration process,<br />

is expected to come on stream in 2022. Its<br />

total system efficiency will exceed 90 %.<br />

The project cost is in <strong>the</strong> three-digit million-euro<br />

range. Siemens Gas and Power is<br />

<strong>the</strong> main contractor and, jointly with its internal<br />

partner Siemens Financial Services, is<br />

responsible <strong>for</strong> <strong>the</strong> planning and construction<br />

of <strong>the</strong> entire power plant, including a<br />

new central control station building. Evonik<br />

will operate <strong>the</strong> plant in conjunction with<br />

<strong>the</strong> existing natural gas power plants.<br />

With <strong>the</strong> new power plant Evonik is securing<br />

cost-efficient and sustainable energy <strong>for</strong><br />

its Marl Chemical Park, Evonik’s largest production<br />

site, over <strong>the</strong> long term. Apart from<br />

power, steam generation is also important<br />

<strong>for</strong> production in <strong>the</strong> Chemical Park. The<br />

plant has a power output of 180 MW and<br />

can produce up to 440 t/h of steam.<br />

ARI’s wide product program of industrial<br />

valves, especially in <strong>the</strong> area of metal-seated<br />

high-per<strong>for</strong>mance butterfly valves. At <strong>the</strong><br />

same time, Hög<strong>for</strong>s will benefit from synergies<br />

in sales, production, sourcing and engineering.<br />

“We are very excited about this<br />

great new opportunity to be able to expand<br />

our value preposition to our customers<br />

worldwide,” notes Mr. Dietmar Roehrmann,<br />

Head of Global Sales and Marketing of ARI.”<br />

Anniversary in <strong>the</strong> Allgäu region<br />


TURNS 50<br />

Pumpenfabrik Wangen GmbH celebrates its<br />

50th anniversary. Founded in September<br />

1969 as a small trade operation, in 2019<br />

Pumpenfabrik Wangen GmbH is now a<br />

globally operating company with its headquarters,<br />

development and production site<br />

in Wangen in <strong>the</strong> Allgäu region of Germany.<br />

Wangen pumps and pump components<br />

enjoy regional, national and international<br />

repute and are used on every continent<br />

across <strong>the</strong> globe. ”We can look back with<br />

satisfaction at our growth over <strong>the</strong> first 50<br />

years. Pumpenfabrik Wangen has continually<br />

grown from being a niche provider in <strong>the</strong><br />

agricultural sector to becoming a global<br />

supplier of progressing cavity pumps and<br />

twin screw pumps <strong>for</strong> a wide range of different<br />

segments. Our engineering services<br />

combined with a desire <strong>for</strong> quality and serious<br />

commitment throughout all departments<br />

and by all employees have enabled<br />

our growth and <strong>for</strong>m <strong>the</strong> basis <strong>for</strong> future<br />

success on <strong>the</strong> global market and in <strong>the</strong><br />

most diverse market segments,” explains <strong>the</strong><br />

company’s management. With a current<br />

work<strong>for</strong>ce of 240, expert and extremely<br />

committed sales partners and a broad-based<br />

range of pumps <strong>for</strong> sectors, including agriculture,<br />

biogas, sewage treatment and environmental<br />

<strong>technology</strong>, food, <strong>chemical</strong>s and<br />

pharmaceuticals, <strong>the</strong> company is looking<br />

optimistically towards <strong>the</strong> future in 2019.<br />

6 <strong>cpp</strong> 03-2019


High quality material <strong>for</strong> demanding<br />

tasks: VitraPOR® glassfilter apparatuses<br />

made from pure borosilicate glass 3.3<br />

fulfill many requirements in <strong>chemical</strong><br />

and pharmaceutical labs as well as <strong>for</strong><br />

industrial, biological and environmental<br />

<strong>technology</strong> applications.<br />

Properties such as heat resistance to<br />

over 500 °C and resistance to most<br />

acids, alkalis and solvents make our<br />

VitraPOR® glassfilters, which con<strong>for</strong>m to<br />

international standards, suitable <strong>for</strong> use<br />

in many <strong>chemical</strong>, pharmaceutical and<br />

technical procedures.<br />

Custom VitraPOR® sintered elements<br />

according to your specifications are<br />

characterized by <strong>the</strong>ir neutral properties<br />

and open-pore structure. They are<br />

suitable <strong>for</strong> even <strong>the</strong> most unusual<br />

applications.<br />

VitraPOR® glassfilter apparatuses can<br />

be supplied in different pore size classes,<br />

from smaller than 1 micron to over 500<br />

micron and as custom-made solutions in<br />

many shapes and sizes.<br />

ROBU Glasfilter-Geräte GmbH<br />

Schützenstrasse 13<br />

57644 Hattert<br />

Germany<br />

Made in Germany<br />

www.robuglas.com<br />

<strong>cpp</strong> 03-2019 7

<strong>cpp</strong><br />


Pictures: Phoenix Contact<br />

The Termitrab complete surge protection system <strong>for</strong> signal circuits is now also available<br />

with a directly attachable fuse carrier<br />

Fuse terminal blocks can be expanded with fuse carriers<br />

Surge protection system<br />

<strong>for</strong> signal circuits<br />

More and more companies demand space-saving components <strong>for</strong> <strong>the</strong> cableconnection<br />

cabinets of <strong>the</strong>ir widely branched measurement and control systems,<br />

which can often be found in process <strong>technology</strong>. With <strong>the</strong> Termitrab complete<br />

product range, Phoenix Contact offers an extremely compact solution <strong>for</strong> <strong>the</strong><br />

connection and distribution level, which now also offers a fine fuse function.<br />

More and more companies demand<br />

space-saving components <strong>for</strong> <strong>the</strong> cable-connection<br />

cabinets of <strong>the</strong>ir widely branched<br />

measurement and control systems, which<br />

can often be found in process <strong>technology</strong>.<br />

With <strong>the</strong> Termitrab complete product range,<br />

Phoenix Contact offers an extremely compact<br />

solution <strong>for</strong> <strong>the</strong> connection and distribution<br />

level, which now also offers a fine<br />

fuse function.<br />

On <strong>the</strong> distribution level of control cabinets<br />

in process <strong>technology</strong>, requirements that<br />

actually are contradictory collide. On <strong>the</strong><br />

one hand, easy access and high maintenance<br />

convenience are required. On <strong>the</strong> o<strong>the</strong>r<br />

hand, costs are to be cut <strong>–</strong> by a compact,<br />

space-saving design. This space-saving<br />

design is also based on <strong>the</strong> large number<br />

of signals in <strong>the</strong> system.<br />

Phoenix Contact designed <strong>the</strong> Termitrab<br />

complete system to, among o<strong>the</strong>r things,<br />

resolve this contradiction in an innovative<br />

manner. The narrow components are origi -<br />

nally surge protection components <strong>for</strong><br />

signals in <strong>the</strong> low-voltage range. They are<br />

designed as multi-level terminal blocks and<br />

offer two connection levels in through<br />

wiring. A third connection level can be used<br />

<strong>for</strong> a joint reference line or cable shielding.<br />

The components of <strong>the</strong> Termitrab complete<br />

8 <strong>cpp</strong> 03-2019

Installation in <strong>the</strong> past (left): fuse terminal block, surge<br />

protective module and knife disconnect terminal block<br />

required a lot of space<br />

Installation today (right): Termitrab complete <strong>–</strong> as a system<br />

combination of fine fuse, surge protection and knife<br />

disconnect terminal block <strong>–</strong> makes <strong>the</strong> installation<br />

significantly more compact<br />

New block of <strong>the</strong> Termitrab complete system: <strong>the</strong> fuse<br />

holder <strong>for</strong> cartridge fuses with 5 x 20 mm<br />

product range also offer two additional,<br />

optional functions: knife disconnection and<br />

modular design. The integrated knife disconnection<br />

<strong>for</strong> <strong>the</strong> two signal wires enables<br />

<strong>the</strong> user to disconnect signals from <strong>the</strong> field<br />

cables during start-up or maintenance work.<br />

This way, measurements or test on <strong>the</strong> field<br />

side can be implemented easily without<br />

having to loosen <strong>the</strong> cables from <strong>the</strong>ir<br />

termination points.<br />

Thanks to <strong>the</strong>ir two-part design, modular,<br />

pluggable protective devices also facilitate<br />

replacing overload voltage-limited components.<br />

This way, recurrent tests according to<br />

IEC 62305-3 can be carried out without affecting<br />

<strong>the</strong> running application. For this, <strong>the</strong><br />

Termitrab complete plug is plugged into <strong>the</strong><br />

Checkmaster 2 test device <strong>–</strong> and <strong>the</strong> function<br />

test is run. The system determines <strong>the</strong><br />

current technical parameters in detail and<br />

compares <strong>the</strong>m to <strong>the</strong> set points taking into<br />

account <strong>the</strong> permissible tolerance. Each<br />

single test is saved. The data of all tests can<br />

<strong>the</strong>n be exported via a USB port to be processed.<br />

This way, test reports are created<br />

with low ef<strong>for</strong>t.<br />

Modular fuse carrier<br />

These functions have been extended <strong>–</strong> by<br />

<strong>the</strong> functions of a modular fuse carrier.<br />

Now, even more space can be saved during<br />

installation because <strong>the</strong> fuse carrier directly<br />

attaches to <strong>the</strong> surge protective terminal<br />

block as a “mounted module”. Installations<br />

<strong>for</strong> which a combination of fine fuse, surge<br />

protection and knife disconnection is desired,<br />

used to consist of fuse terminal<br />

blocks, surge protection modules and knife<br />

disconnect terminal blocks connected in<br />

series, which had to be connected among<br />

one ano<strong>the</strong>r using cables. The new, modular<br />

system now unites all properties in one extendable<br />

terminal block. This combination<br />

not only saves two thirds of <strong>the</strong> space <strong>the</strong><br />

individual terminal blocks would require,<br />

but also a substantial part of <strong>the</strong> wiring.<br />

Selective overcurrent protection<br />

Fine fuses are used, e. g., <strong>for</strong> systems in<br />

which <strong>the</strong> signal circuit is connected to a<br />

24 V(DC) power supply. This can be a connected<br />

actuator circuit in which a control<br />

valve is addressed. Such a design is also used<br />

<strong>for</strong> a power supply to sensors in <strong>the</strong> field.<br />

Usually, a circuit breaker with correspondingly<br />

high current switching capacity is<br />

installed directly downstream of <strong>the</strong> power<br />

supply system. In this main trunk, values of<br />

10 or 20 A are typical. To selectively provide<br />

<strong>the</strong> individual signal circuit branches with<br />

overcurrent protection elements, tuned fine<br />

fuses can be used. The nominal value of<br />

<strong>the</strong>se fuses is correspondingly lower and<br />

depends on <strong>the</strong> operating currents of <strong>the</strong><br />

field devices. In <strong>the</strong> event of a short circuit<br />

in a field cable, or an error in a device, <strong>the</strong><br />

fuse in <strong>the</strong> branch will trip. All o<strong>the</strong>r signal<br />

circuits connected to <strong>the</strong> same main trunk<br />

remain unaffected by this error.<br />

The fine fuse also offers protection <strong>for</strong> <strong>the</strong><br />

surge protective module itself. The rated<br />

current identified <strong>for</strong> <strong>the</strong> component must<br />

not be exceeded. Fine fuses <strong>for</strong> circuits with<br />

less power typically have a nominal current<br />

of some 100 mA. For comparison, <strong>the</strong> rated<br />

current of most 24 V components from <strong>the</strong><br />

Termitrab complete series is 600 mA <strong>–</strong><br />

which means that it is more than sufficient<br />

to cover numerous applications. The High<br />

Current (HC) variants in <strong>the</strong> Termitrab complete<br />

range even permit a current of up to<br />

6 A. This value is also <strong>the</strong> maximum permissible<br />

current <strong>for</strong> <strong>the</strong> fuse holder. There<strong>for</strong>e,<br />

<strong>the</strong>re is also a harmonised and suitable so -<br />

lution <strong>for</strong> actuator circuits with higher<br />

nominal or starting currents.<br />

Termitrab complete offers yet ano<strong>the</strong>r advantage:<br />

<strong>the</strong> clever design of <strong>the</strong> fuse holder<br />

even enables <strong>the</strong> user to add a fuse holder to<br />

all terminal levels at <strong>the</strong> Termitrab complete<br />

housing that feature screw-connection <strong>technology</strong>.<br />

This way, several channels that are<br />

switched via <strong>the</strong> Termitrab complete module<br />

can be secured.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319phoenix<br />

AUTHOR:<br />


Product Manager Business<br />

Unit Trabtech,<br />

Phoenix Contact<br />

<strong>cpp</strong> 03-2019 9

<strong>cpp</strong><br />


IP 67 I/O module with Profinet S2 system redundancy<br />

Profinet integration in<br />

process automation<br />

Profinet is increasingly becoming more attractive to <strong>the</strong> process automation<br />

<strong>industry</strong>. However, <strong>the</strong>re are special requirements that controllers and field<br />

devices have to meet. Turck‘s <strong>for</strong>ward-looking contribution to Profinet<br />

integration is a comprehensive functional extension of fieldbus products to<br />

support S2 system redundancy.<br />

Protecting plants in <strong>the</strong> <strong>chemical</strong> and<br />

pharmaceutical <strong>industry</strong> from downtime<br />

involves considerable ef<strong>for</strong>t. Compared to<br />

factory automation, where <strong>the</strong> focus is on<br />

higher unit quantities and shorter cycle<br />

times, <strong>the</strong> interruption of a continuous<br />

production process can lead to enormous<br />

financial losses. Fur<strong>the</strong>rmore, <strong>the</strong> handling<br />

of hazardous liquid or gaseous substances<br />

involves <strong>the</strong> observance of strict safety precautions<br />

<strong>–</strong> particularly in areas provided<br />

with explosion protection. As a preventative<br />

measure, companies <strong>the</strong>re<strong>for</strong>e firstly invest<br />

in <strong>the</strong> safeguarding of potential ignition<br />

sources and secondly in a high availability<br />

system architecture. Controllers and I/O<br />

modules in <strong>the</strong> field are normally provided<br />

with redundancy in order to ensure safe<br />

plant operation. If one device or connection<br />

fails, <strong>the</strong> o<strong>the</strong>rwise inactive backup solution<br />

is activated. Planners implement <strong>the</strong>se complex<br />

or limited redundant systems in accordance<br />

with <strong>the</strong> relevant requirements <strong>–</strong><br />

both on <strong>the</strong> physical device level as well as<br />

in <strong>the</strong> underlying programming logic.<br />

Picture: buhanovskiy <strong>–</strong> Fotolia.com<br />

Plants in <strong>the</strong> <strong>chemical</strong> and pharmaceutical industries can be more reliably protected<br />

against failures with I/O systems in Profinet S2 system redundancy<br />

S2 system redundancy preferred<br />

In <strong>the</strong> Profinet context, a new standard was<br />

created <strong>for</strong> this with system redundancy. The<br />

terminology used here is based on a gradation<br />

that reflects <strong>the</strong> degree of fail safety<br />

that an automation system is to provide. No<br />

redundancy is implemented (S1) if a controller<br />

and field device only communicate via<br />

a single connection. However, if a Profinet<br />

device supports communication relations to<br />

<strong>the</strong> primary controller as well as its backup<br />

via this single connection, this is classified as<br />

S2. In <strong>the</strong> event that <strong>the</strong> main controller fails,<br />

10 <strong>cpp</strong> 03-2019

a bumpless switching to its physical twin is<br />

per<strong>for</strong>med. For this, <strong>the</strong> I/O system and I/O<br />

module in <strong>the</strong> field must maintain this logical<br />

dual connection to two entirely spatially<br />

separated controllers. These S2 solutions<br />

meet <strong>the</strong> requirements of many applications<br />

and are preferred in practical applications.<br />

The alternative term “simple system redundancy”<br />

should not obscure this fact.<br />

Very high and maximum availability can<br />

only be achieved with R1 or R2 system<br />

redundancy. This involves <strong>the</strong> additional<br />

implementation of a redundant communication<br />

interface on a field device, and is<br />

often used in conjunction with remote I/O.<br />

R2 with its four-way connection represents<br />

<strong>the</strong> highest level of complexity. Here, each<br />

of <strong>the</strong> two communication interfaces of a<br />

device can establish communication relations<br />

<strong>–</strong> to <strong>the</strong> main controller and to its<br />

redundant copy. This crosswise protection<br />

from failures is used extremely rarely.<br />

Redundancy principles: S1 is a simple connection, i.e. no redundancy. If a Profinet device communicates<br />

with <strong>the</strong> primary controller and its back-up via this connection, this is classified as S2. Very high<br />

and maximum availability is only offered by R1 or R2 system redundancy, which also require dual<br />

systems on <strong>the</strong> field side.<br />

Picture: Turck<br />

High availability to <strong>the</strong> field<br />

Siemens initiated <strong>the</strong> Profinet implementation<br />

of <strong>the</strong> redundancy profile and designed<br />

its controller systems to support redundant<br />

infrastructures. Profinet devices<br />

had previously not provided support <strong>for</strong> S2<br />

system redundancy. Turck is now responding<br />

to this demand with an extensive expansion<br />

of functions.<br />

The TBEN-L5<strong>–</strong>8IOL will be <strong>the</strong> first IO-Link<br />

master module that supports S2 system redundancy<br />

and offers protection to IP 67 and<br />

IP 69K, thanks to its fully potted electronic<br />

unit. This combination of Industrial E<strong>the</strong>rnet<br />

and IO-Link offers digitalisation right<br />

through to <strong>the</strong> last meter. Fur<strong>the</strong>rmore,<br />

Turck‘s I/O modules come with an additional<br />

TCP/IP interface <strong>for</strong> read access to device<br />

data, so that all digital treasures can be<br />

ga<strong>the</strong>red. Condition monitoring, asset management<br />

and predictive maintenance can<br />

thus be implemented without any limits.<br />

Turck is also offering SIDI (Simple IO-Link<br />

Device Integration), probably <strong>the</strong> most userfriendly<br />

way of integrating IO-Link into<br />

Profinet projects. IO-Link masters with SIDI<br />

give IO-Link devices <strong>the</strong> identity of a genuine<br />

Profinet module with <strong>the</strong>ir own GSDML<br />

entry. The function considerably simplifies<br />

<strong>the</strong> engineering of IO-Link devices in projects<br />

with Profinet controllers, since it<br />

allows access to all parameters and device<br />

properties from <strong>the</strong> engineering system<br />

without <strong>the</strong> need <strong>for</strong> additional software.<br />

Use in practice<br />

The first TBEN-L5<strong>–</strong>8IOL modules will soon<br />

be deployed in <strong>the</strong> USA in <strong>the</strong> plant of a<br />

The TBEN-L5<strong>–</strong>8IOL IP67 block module is Turck‘s first IO-Link master module to support S2 system<br />

redundancy<br />

biopharmaceutical manufacturer, which will<br />

manage its production with Profinet system<br />

redundancy and IO-Link in <strong>the</strong> future. High<br />

availability is essential <strong>for</strong> <strong>the</strong> handling of<br />

mostly sensitive and cost-intensive products.<br />

An integrator in <strong>the</strong> pigging <strong>technology</strong><br />

sector found <strong>the</strong> additional profile support<br />

<strong>for</strong> IP 67 devices equally important. The<br />

company serves customers in <strong>the</strong> <strong>chemical</strong>,<br />

pharmaceutical and mineral oil sector. The<br />

high protection class of <strong>the</strong> TBEN field devices<br />

now simplifies <strong>the</strong> planning of systems<br />

in <strong>the</strong>se sectors. Decentralized and<br />

modular network architectures can be designed<br />

so that <strong>the</strong> space required in <strong>the</strong> control<br />

cabinet is substantially reduced.<br />

The IO-Link master is at <strong>the</strong> beginning of<br />

<strong>the</strong> major product upgrade to S2 system redundancy.<br />

Over <strong>the</strong> year, Turck will provide<br />

o<strong>the</strong>r multiprotocol devices with <strong>the</strong> additional<br />

function, and block modules of <strong>the</strong><br />

TBEN series will follow, as well as <strong>the</strong> IO<br />

systems <strong>for</strong> <strong>the</strong> control cabinet of <strong>the</strong><br />

FEN20, BL20 and excom series. The changeover<br />

to Profinet with a wide range of signal<br />

types, both <strong>for</strong> <strong>the</strong> Ex and <strong>the</strong> non-Ex area,<br />

can thus be completed without any obstacles.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319turck<br />

AUTHOR:<br />


Director Product Management<br />

Factory Automation Systems,<br />

Turck<br />

Picture: Turck<br />

<strong>cpp</strong> 03-2019 11

<strong>cpp</strong><br />


Picture: Skitterphoto <strong>–</strong> Pixabay<br />

Network monitoring significantly increases security of Industrial Control Systems<br />

Network monitoring with anomaly detection<br />

Real-time detection<br />

of threats<br />

Whe<strong>the</strong>r spillover effects from ransomware or targeted attacks: <strong>the</strong> less pleasing<br />

effects of digitisation on industrial processes can also be felt in <strong>the</strong> <strong>chemical</strong><br />

<strong>industry</strong>. Network monitoring with anomaly detection supports those responsible<br />

in IT and OT in ensuring availability and security of <strong>the</strong> industrial control system<br />

and its connected plants.<br />

It may not always be a targeted attack. Since<br />

<strong>the</strong> pharmaceutical giant Merck became <strong>the</strong><br />

victim of <strong>the</strong> Ransomware Notpetya in<br />

2017, it is clear to <strong>chemical</strong> and pharmaceutical<br />

companies how vulnerable <strong>the</strong> security<br />

and availability of <strong>the</strong>ir industrial<br />

control system (ICS) and automation system<br />

are. Merck had to fight with several weeks<br />

of production downtime and even had to<br />

borrow drugs from U.S. authorities. The<br />

incident cost <strong>the</strong> Group $375 million. Unlike<br />

Bayer or <strong>the</strong> Tasnee oil refinery operating<br />

in Saudi Arabia, Merck was not even actively<br />

attacked. Their losses were purely collateral<br />

damage. The shutdowns in production<br />

were caused by spillover effects. The<br />

malware had leapt from <strong>the</strong> office IT to <strong>the</strong><br />

production line via <strong>the</strong> necessary ICS connections.<br />

The ICS is a blind spot<br />

With this incident, <strong>the</strong> open flanks of digitisation<br />

became apparent: higher system<br />

complexity, opening of <strong>the</strong> ICS to <strong>the</strong> internet<br />

as well as <strong>the</strong> (so far more poorly than<br />

properly functioning) marriage of a security-oriented<br />

office IT and an unsecured,<br />

availability-oriented production IT. In <strong>the</strong><br />

end, Merck was lucky. Nei<strong>the</strong>r were customers<br />

endangered by changes in recipes, nor<br />

were employees injured. Especially in <strong>the</strong><br />

<strong>chemical</strong> <strong>industry</strong>, <strong>the</strong>re is a thin line between<br />

cyber security and occupational<br />

safety. Even <strong>the</strong> <strong>the</strong>ft of sensitive data did<br />

not occur to <strong>the</strong> best of our knowledge. The<br />

vulnerability of <strong>the</strong> process <strong>industry</strong> is due<br />

to various reasons, which can also be applied<br />

to o<strong>the</strong>r branches of <strong>industry</strong> as well<br />

as critical infrastructure. In his book “Industrial<br />

IT Security“ (Vogel, 2019), ICS security<br />

expert Sebastian Rohr describes <strong>the</strong> three<br />

core problems with <strong>the</strong> production IT:<br />

• lack of awareness by employees<br />

• insufficient documentation of assets and<br />

applications<br />

• no monitoring of infrastructure and assets<br />

(components, systems, applications, data)<br />

While <strong>the</strong> first point can be solved through<br />

training, points 2 and 3 deal with organisational<br />

and technical challenges. In terms of<br />

documentation (or asset inventory), Rohr<br />

soberingly states: “In contrast to <strong>the</strong> detailed<br />

documentation of <strong>the</strong> mechanical and<br />

safety-critical components of a plant, which<br />

is constantly improved by quality management,<br />

<strong>the</strong> in<strong>for</strong>mation regarding <strong>the</strong> IT systems,<br />

operating systems, applications, tools<br />

and databases or directories used or in-<br />

12 <strong>cpp</strong> 03-2019

stalled is often inadequate, at best poor, or<br />

sometimes simply not available at all.”<br />

This also complicates <strong>the</strong> management, diagnosis<br />

and troubleshooting of assets. The<br />

minimum requirement would be <strong>the</strong> identification<br />

and visualisation of assets and its<br />

connections to each o<strong>the</strong>r or to communication<br />

partners outside <strong>the</strong> System under<br />

Consideration (SuC). Additionally, <strong>the</strong>re is<br />

in<strong>for</strong>mation on firmware version, configuration,<br />

protocols, IP addresses, ports and<br />

communication patterns. After Rhebo Industry<br />

4.0 Stability and Security Audits at industrial<br />

and critical infrastructure companies,<br />

those responsible usually react with<br />

surprise as to which devices and applications<br />

are hidden in <strong>the</strong> ICS and with<br />

whom <strong>the</strong>y communicate.<br />

The audits use industrial network monitoring<br />

with integrated anomaly detection to<br />

record and subsequently analyse all communication<br />

processes within <strong>the</strong> ICS. This<br />

not only documents <strong>the</strong> communication<br />

that runs through routers and firewalls stationed<br />

at <strong>the</strong> ICS perimeters. The communication<br />

between components within <strong>the</strong> ICS<br />

is also recorded. Thus those responsible <strong>for</strong><br />

<strong>the</strong> ICS gain detailed visibility of all assets,<br />

<strong>the</strong>ir properties and behaviour <strong>for</strong> <strong>the</strong> first<br />

time. Frequently, insecure ports, protocols<br />

and Internet connections are found. Similarly,<br />

almost all evaluated communication<br />

data contains unknown devices as well as<br />

vulnerable firmware versions.<br />

Ostrichism doesn`t solve <strong>the</strong> challenge<br />

Though, monitoring isn‘t completely new<br />

<strong>for</strong> production lines in <strong>the</strong> <strong>chemical</strong> <strong>industry</strong>.<br />

At <strong>the</strong> very least, this applies to <strong>the</strong> per<strong>for</strong>mance,<br />

use and wear parameters of <strong>the</strong><br />

plants. This is essential <strong>for</strong> both process control<br />

and evolving predictive maintenance.<br />

The monitoring of <strong>the</strong> ICS, on <strong>the</strong> o<strong>the</strong>r<br />

hand, is lacking. Sebastian Rohr emphasizes:<br />

“This monitoring and evaluation offers considerable<br />

added value, since <strong>the</strong> analysis of<br />

network traffic or load parameters of <strong>the</strong><br />

ICS components enables conclusions to be<br />

drawn about previously undiscovered attacks<br />

or manipulation attempts.“<br />

The German Federal Office <strong>for</strong> In<strong>for</strong>mation<br />

Security (BSI) recently recommended integrating<br />

network monitoring with anomaly<br />

detection as standard in <strong>the</strong> production IT.<br />

This system continuously monitors every<br />

communication in <strong>the</strong> ICS and reports any<br />

irregularities in <strong>the</strong> expected communication<br />

pattern during normal operation.<br />

Our experience from monitoring projects<br />

has taught us that security is <strong>the</strong> key, but<br />

never <strong>the</strong> whole picture. In addition to new<br />

Picture: Rhebo<br />

Picture: Rhebo<br />

Industrial network monitoring with anomaly detection monitors all connections within an ICS and<br />

provides in<strong>for</strong>mation about <strong>the</strong>ir properties and communication<br />

Deviations from <strong>the</strong> target communication pattern are detected, reported and fully stored <strong>for</strong> <strong>for</strong>ensic<br />

analysis by real-time network monitoring<br />

network nodes, changes in communication<br />

patterns (e.g. changes in protocols and command<br />

structure due to malware, attacks or<br />

manipulation) and unprotected password<br />

transmission, technical error states must<br />

also be taken into account. In production<br />

lines with real-time processes, transmission<br />

errors, extended round trip times and capacity<br />

overloads of individual components<br />

can lead to process interruptions or quality<br />

issues. The evaluation of <strong>the</strong> data from our<br />

network monitoring with anomaly detection<br />

proves that technical error states are<br />

very common. The same applies to insecure<br />

protocols, vulnerable ports and communication<br />

that does not belong to <strong>the</strong> production<br />

process. In order to guarantee cyber security,<br />

product quality and occupational<br />

safety, <strong>the</strong> consistent visibility and continuous<br />

monitoring of <strong>the</strong> ICS should <strong>the</strong>re<strong>for</strong>e<br />

be among <strong>the</strong> core tasks of those responsible<br />

<strong>for</strong> security as well as plant availability.<br />

A network monitoring system with realtime<br />

reporting of threats as well as real-time<br />

visualisation of <strong>the</strong> active assets provides all<br />

functionalities <strong>for</strong> this purpose.<br />

www.prozesstechnik-online.de<br />

Suchwort: <strong>cpp</strong>0319rhebo<br />

AUTHOR:<br />


Sales Manager,<br />

Rhebo<br />

<strong>cpp</strong> 03-2019 13

<strong>cpp</strong><br />


Safety and security in one operating mode selection and access permission system<br />

Access <strong>for</strong> authorised<br />

persons only<br />

Complex plant and machinery in particular requires different access permissions and<br />

operating modes in order to guarantee functionally safe operation. It’s not just a<br />

case of protecting <strong>the</strong> human from <strong>the</strong> machine; <strong>the</strong> machine must also be protected<br />

against manipulation by <strong>the</strong> human. Intelligent operating mode selection and access<br />

permission systems carry out <strong>the</strong>se tasks without being too complex to handle.<br />

Staff who are not trained to use certain<br />

plant and machinery should not even have<br />

access to danger zones around <strong>the</strong>se machines.<br />

Only authorised, trained personnel<br />

should be allowed access <strong>–</strong> and even <strong>the</strong>n<br />

only <strong>for</strong> selected operating modes such as<br />

automatic, manual intervention in restricted<br />

conditions or service mode. Simple machine<br />

operation provides additional support when<br />

it comes to avoiding misuse and accidents.<br />

Permission-based access<br />

Various C standards specify that different<br />

machine operating modes must also incorporate<br />

corresponding safety functions. For<br />

example, EN ISO 16090-1 stipulates at least<br />

two of <strong>the</strong>se operating modes as mandatory<br />

<strong>for</strong> machining centres and special-purpose<br />

machinery, in order to guarantee functional<br />

safety. It must be ensured that only one<br />

operating mode at a time is selected and active<br />

and that <strong>the</strong> selected mode is clearly displayed.<br />

The machine owner decides which<br />

staff are authorised to use which operating<br />

mode. Safety functions can <strong>the</strong>n be modified,<br />

too. For instance, a machine in “setup”<br />

mode can be operated at a safe, reduced<br />

speed even if a safety gate is open. In addition<br />

to functionally safe operating mode<br />

selection, it is also important to control access<br />

permissions in order to protect plant<br />

and machinery from unauthorised access <strong>–</strong><br />

in o<strong>the</strong>r words, to guarantee security at machine<br />

level. The system identifies staff who<br />

are permitted to access <strong>the</strong> plant or machine<br />

because of <strong>the</strong>ir job or qualifications. Depending<br />

on <strong>the</strong> size of <strong>the</strong> company, it may<br />

also be sensible to implement group-based<br />

permission management. In this case, <strong>the</strong><br />

various enables are assigned not to individuals<br />

but to whole groups with identical<br />

access rights. At <strong>the</strong> same time, access rights<br />

<strong>for</strong> a machine type in company-wide use,<br />

<strong>for</strong> example, can be stored and assigned<br />

centrally. This simplifies <strong>the</strong> allocation and<br />

administration of access permissions, particularly<br />

<strong>for</strong> companies with multiple sites.<br />

No possibility of manipulation<br />

When granting access permissions, it is also<br />

necessary to consider <strong>the</strong> issue of manipulation<br />

protection <strong>for</strong> plant and machinery.<br />

An operating mode selection and access permission<br />

system such as <strong>the</strong> modular PITmode<br />

fusion offers this dual functionality.<br />

PITmode fusion consists of <strong>the</strong> PITreader<br />

unit with RFID <strong>technology</strong>, an integrated<br />

web server and a safe evaluation unit (SEU).<br />

Each machine operator has an RFID transponder<br />

key with <strong>the</strong>ir own individual access<br />

permissions. The key is read and taught in<br />

<strong>the</strong> PITreader unit. To increase manipulation<br />

protection, <strong>the</strong> RFID keys can be coded<br />

using PITreaders containing company-specific<br />

programming, i.e. <strong>the</strong> keys are given a<br />

password-protected, private signature which<br />

is encrypted using AES (Advanced Encryption<br />

Standard). Any keys that are not coded<br />

with this signature will be denied access.<br />

Pictures: Pilz<br />

The modular operating mode selection and access permission system<br />

PITmode fusion from Pilz combines safety and security in one system<br />

Sensitive data in good hands<br />

Data is transferred securely between <strong>the</strong><br />

PITreader and <strong>the</strong> RFID key using <strong>the</strong><br />

13.56 MHz RFID <strong>technology</strong> familiar from<br />

14 <strong>cpp</strong> 03-2019

The compact all-in-one device PITmode from Pilz includes <strong>the</strong> pushbuttons<br />

<strong>for</strong> operating mode selection and <strong>the</strong> SEU<br />

contactless payments, amongst o<strong>the</strong>r things.<br />

Each key is uniquely coded and has a 64-bit<br />

security ID. This individual ID lets users assign<br />

<strong>the</strong> RFID key to <strong>the</strong>ir operating mode<br />

selection and access permission system. The<br />

keys can be stored ready <strong>for</strong> use but not<br />

coded until <strong>the</strong>y are actually needed. As soon<br />

as <strong>the</strong> RFID key configuration is complete<br />

and no fur<strong>the</strong>r changes are permitted, <strong>the</strong><br />

key can be locked <strong>for</strong> editing. Group-based<br />

permission management can also be realised<br />

using <strong>the</strong> RFID keys and PITreader. A group<br />

area of 32 groups, each with 0 to 64 permission<br />

levels, is pre-installed on each RFID<br />

transponder key. In future, it will also be<br />

possible to design complex, hierarchical permission<br />

matrices in a free user area. PITmode<br />

fusion can be used to implement a wide<br />

range of functions beyond access permission<br />

and operating mode selection. This could be<br />

a simple enable, which replaces a key switch<br />

on <strong>the</strong> control console, or possibly access<br />

permission <strong>for</strong> machine subfunctions.<br />

Simple handling <strong>–</strong> clear control<br />

The aim should be a user-friendly operating<br />

concept that keeps user handling and operability<br />

simple despite <strong>the</strong> wide range of<br />

functions. This will also help to avoid faults<br />

and manipulation. That’s why an operator<br />

panel should be clear and intuitive and not<br />

contain too many different components. A<br />

modular operating mode selection and access<br />

permission system such as PITmode<br />

fusion can be individually integrated into<br />

<strong>the</strong> design of an existing operator panel due<br />

to its modular structure. Existing pushbuttons<br />

can likewise be retained, improving usability.<br />

A multicoloured LED ring on <strong>the</strong> PITreader<br />

visualises <strong>the</strong> user in<strong>for</strong>mation in<br />

colour, <strong>for</strong> example with a “green light” if<br />

permission is granted. An intelligent operating<br />

mode selection and access permission<br />

system enables several mechanical keys to<br />

be combined within one transponder key,<br />

so that users do not have to manage different<br />

keys or access cards.<br />

Sophisticated operating mode selection and<br />

access permission management guarantees<br />

more efficient production processes in plant<br />

and machinery where it is necessary to<br />

switch between different control sequences<br />

and operating modes. To avoid manipulation<br />

and misuse, it should provide clarity and be<br />

simple to operate. Modular operating mode<br />

selection and access permission systems<br />

such as PITmode fusion unite safety and security<br />

in one system, ensuring more efficient<br />

processes and less downtime.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319pilz<br />

AUTHOR:<br />



Product Manager Operating<br />

and Monitoring and Tools,<br />

Pilz<br />

<strong>cpp</strong> 03-2019 15

<strong>cpp</strong><br />


Pictures: Siemens<br />

Web-based process control system uses existing hardware base<br />



In <strong>the</strong> process <strong>industry</strong>, investment protection and long plant lifecycles<br />

of up to 40 years play an important role in any innovation.<br />

The Siemens engineers’ goal when developing <strong>the</strong> new Simatic<br />

PCS neo process control system, which is based entirely on web<br />

technologies, was to harmonise <strong>the</strong>se three aspects.<br />

16 <strong>cpp</strong> 03-2019

Uncluttered engineering interface: All documents released to <strong>the</strong> project<br />

engineer can be displayed and processed in a single view. Efficient generation<br />

of executable automation programmes using a CFC (Continuous<br />

Function Chart) or ...<br />

... SFC (Sequential Function Chart) <strong>for</strong> sequential controls <strong>–</strong> both based<br />

on IEC 61131.<br />

How do you tackle innovation? Do you choose an incremental approach<br />

or a more disruptive one? Siemens opted <strong>for</strong> <strong>the</strong> golden<br />

mean: on <strong>the</strong> one hand, <strong>the</strong> new Simatic PCS neo control system<br />

has something groundbreaking about it. The system software is<br />

based exclusively on web technologies and has a consistently object-oriented<br />

data model. It is no longer necessary to install software<br />

on specific workstations <strong>for</strong> administration, engineering and<br />

plant operation. Thanks to HTML 5, it is now possible to have secure<br />

access to <strong>the</strong> system and operate it efficiently just using a<br />

browser. The user interface is also completely new: it combines<br />

adaptable, up-to-date technologies with <strong>the</strong> capabilities, tasks and<br />

goals of its users. User Experience (UX) Design has embedded user<br />

experience in <strong>the</strong> design process <strong>for</strong> <strong>the</strong> operator interface.<br />

On <strong>the</strong> o<strong>the</strong>r hand, <strong>the</strong> new system also uses <strong>the</strong> same application<br />

architecture and hardware portfolio as <strong>the</strong> established Simatic PCS 7<br />

process control system, which has proven itself <strong>for</strong> over 20 years.<br />

Simatic PCS neo thus continues <strong>the</strong> Siemens tradition while taking<br />

two important customer requirements into consideration: <strong>the</strong> desire<br />

to protect existing expertise and make a future-proof investment.<br />

Clearly structured from top to bottom<br />

However, <strong>the</strong> Simatic PCS neo process control system also breaks<br />

with tradition. The system is based on HTML 5 and operated entirely<br />

using a current web browser. Classic, single-user PCs with an<br />

installed operator interface or engineering system are a thing of <strong>the</strong><br />

past. Every office computer which meets <strong>the</strong> security specifications<br />

and has <strong>the</strong> relevant certificates can now become an engineering or<br />

operator station. All <strong>the</strong> required applications are installed on a central<br />

server, where all data is managed and saved. The browsers on<br />

<strong>the</strong> terminal devices, which can also be smartphones or tablets, retrieve<br />

data from this central point or send queries back to <strong>the</strong><br />

server, <strong>for</strong> example operator interventions or changes to setpoints.<br />

To create an intuitive working environment, Siemens simplified <strong>the</strong><br />

operating philosophy across all applications and implemented a<br />

‘one workbench’ concept <strong>for</strong> all applications and tasks. In o<strong>the</strong>r<br />

words, authorised users can toggle between an engineering view<br />

and a control and monitoring (operational) view with a single<br />

click. Direct access to operating elements, control sequences, alarms<br />

or interlocks is <strong>the</strong>re<strong>for</strong>e possible at any time from a single point of<br />

entry. Wherever operator interventions are required, clearly structured<br />

tasks and dialogues guide <strong>the</strong> user to <strong>the</strong>ir goal.<br />

Licence and user management integrated<br />

Administration is likewise integrated into this concept, of course.<br />

Licence and user management is controlled here, as is <strong>the</strong> administration<br />

of all software and security-related procedures. Since <strong>the</strong><br />

applications are executed via <strong>the</strong> browser, cumbersome local installations<br />

such as on-site updates are made increasingly redundant:<br />

<strong>the</strong> latest version of <strong>the</strong> application appears every time <strong>the</strong> client<br />

restarts.<br />

Interdisciplinary collaboration redefined<br />

Interdisciplinary collaboration among new project teams assembled<br />

from all parts of <strong>the</strong> world is already a reality in many places today<br />

<strong>–</strong> and <strong>the</strong> trend is steadily increasing. Simatic PCS neo confronts this<br />

challenge with functions which take global collaboration to a new<br />

level. In engineering, <strong>for</strong> instance, consistently object-oriented data<br />

management with centralised data storage ensures that everyone in-<br />

<strong>cpp</strong> 03-2019 17

<strong>cpp</strong><br />


Online view of parameters: <strong>the</strong> current target system values are displayed<br />

after connecting to a controller. This allows <strong>the</strong> parametric values of a<br />

function block in <strong>the</strong> controller, <strong>for</strong> example from a control, to be<br />

checked and optimised.<br />

Increased engineering efficiency: all process objects can be placed on <strong>the</strong><br />

screen intuitively from <strong>the</strong> technological hierarchy using drag and drop.<br />

volved in a project can access up-to-<strong>the</strong>-minute data whenever <strong>the</strong>y<br />

need it. At <strong>the</strong> same time, people contribute knowledge from <strong>the</strong>ir<br />

own working environment to <strong>the</strong> centrally managed project. Owing<br />

to <strong>the</strong> clear session concept with automatic consistency checks, <strong>the</strong><br />

data is always coherent, even during parallel working in multiple<br />

sessions, so that engineering and operational processes can be developed<br />

concurrently. At <strong>the</strong> same time, hardware-independent project<br />

engineering provides an extremely high degree of flexibility.<br />

The following example demonstrates what this means in practice:<br />

imagine how much coordination ef<strong>for</strong>t is saved if an on-site team<br />

in <strong>the</strong> field has access during commissioning to all project data on<br />

mobile devices and makes changes to <strong>the</strong> central project in real<br />

time. Simultaneously with this, employees can toggle between<br />

engineering and monitoring & control views with a single click<br />

during <strong>the</strong> loop check <strong>–</strong> all on <strong>the</strong> same device.<br />

IT security as an integral component<br />

A browser-based control system? This obviously raises <strong>the</strong> question<br />

of cyber security measures. Strict adherence to <strong>the</strong> “security by design”<br />

principle was <strong>the</strong>re<strong>for</strong>e a primary concern with this new development.<br />

Extremely high security standards were applied to <strong>the</strong><br />

hardware and software design from <strong>the</strong> outset, e.g. all known secu -<br />

rity mechanisms are taken into consideration when transferring<br />

data. In addition to functional tests, <strong>the</strong> engineers and software developers<br />

also continuously checked <strong>the</strong> security measures already<br />

implemented. The development process was carried out in accordance<br />

with IEC 62443, <strong>the</strong> international series of standards <strong>for</strong> “Industrial<br />

communication networks <strong>–</strong> Network and system security”.<br />

These defined, secure coding standards provided coders, architects<br />

and designers with guidelines <strong>for</strong> producing secure source codes.<br />

Modern encryption processes<br />

The implemented security functions take effect during subsequent<br />

use. It goes without saying that modern encryption processes are<br />

employed to enable secure communication between <strong>the</strong> web server<br />

and <strong>the</strong> web browser (client). Access to <strong>the</strong> system is only possible<br />

following au<strong>the</strong>ntication and authorisation and all communications<br />

are based on certificates. Users, computers or devices must identify<br />

<strong>the</strong>mselves using a digital certificate be<strong>for</strong>e <strong>the</strong>y are granted access<br />

to an application. The new control system also fits into <strong>the</strong> defencein-depth<br />

concept which Siemens has been applying and driving <strong>for</strong>ward<br />

<strong>for</strong> years now based on <strong>the</strong> recommendations in IEC 62443.<br />

Defence in depth combines plant and network security with system<br />

integrity elements to <strong>for</strong>m a comprehensive protection concept.<br />

This extensive portfolio of secure network components from<br />

Siemens is naturally compatible with <strong>the</strong> new control system.<br />

Summary<br />

The Simatic PCS neo process control system provides several farreaching<br />

innovations. Extensive con<strong>for</strong>mity to international stand -<br />

ards <strong>–</strong> from Industrial E<strong>the</strong>rnet and Control Module Types (CMT) to<br />

Advanced Encryption Standard (AES) <strong>–</strong> simultaneously ensures that<br />

<strong>the</strong> system is future-proofed <strong>for</strong> long-term use. The underlying<br />

hardware structure protects customer investments and know-how.<br />

The modern Simatic ET 200SP HA I/O system and <strong>the</strong> intelligent<br />

Simatic Compact Field Unit (CFU) can be used by ei<strong>the</strong>r Simatic<br />

PCS 7 or Simatic PCS neo. This prudent and sustainable approach<br />

allows individual digitalisation strategies to be implemented very<br />

flexibly step by step.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319siemens<br />

AUTHOR:<br />


Marketing Manager Simatic PCS neo,<br />

Siemens<br />

18 <strong>cpp</strong> 03-2019

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Radiometric system <strong>for</strong> multiphase level measurement<br />

Safe control of separation<br />

processes<br />

<strong>Process</strong>es which take place in aggressive atmospheres, at high pressure or extreme<br />

temperatures require <strong>technology</strong> that can withstand <strong>the</strong>se conditions while delivering<br />

accurate results. Radiometric measuring systems convince with <strong>the</strong>ir non-contact,<br />

reliable and robust operation. The measurement of interfaces under extreme conditions<br />

is <strong>the</strong>re<strong>for</strong>e an ideal application <strong>for</strong> systems such as Berthold’s Emulsionsens.<br />

The measurement of several phases, socalled<br />

multiphase levels, poses some challenges<br />

<strong>for</strong> <strong>the</strong> manufacturers of process<br />

measuring instruments. In addition to <strong>the</strong><br />

often indistinct interfaces, <strong>the</strong>se include <strong>the</strong><br />

(sometimes only slightly) different phase<br />

densities. Multiphase level measurements<br />

are used wherever a live image of <strong>the</strong> highly<br />

complex separation process in a vessel is<br />

required in order to adapt certain process<br />

parameters. Separators, storage tanks, desalters<br />

and hydrocrackers are typical applications.<br />

It is clear from <strong>the</strong>se diverse uses<br />

that multiphase level measurements are frequently<br />

employed in processes operating<br />

under extreme conditions, so that radiometric<br />

measurements are indispensable. The<br />

measuring principle is based on <strong>the</strong> attenuation<br />

of radiation when penetrating materials.<br />

This is virtually independent of o<strong>the</strong>r<br />

process conditions such as vessel size, buildups<br />

or internals.<br />

The Emulsionsens system gives users an<br />

opportunity to get a glimpse inside <strong>the</strong> process<br />

vessel and monitor <strong>the</strong> interfaces<br />

<strong>for</strong>med <strong>the</strong>rein. The multiphase level<br />

measurement system consists of a combination<br />

of high-sensitivity scintillation detectors<br />

and low-activity gamma sources located<br />

along <strong>the</strong> desired measurement range. Based<br />

on <strong>the</strong> radiometry principle and suitable<br />

calibration, each detector delivers an individual<br />

local density value, which can be <strong>for</strong>warded<br />

to <strong>the</strong> customer’s process control<br />

system by means of a Hart signal and used to<br />

create a density profile <strong>for</strong> <strong>the</strong> entire measuring<br />

range. The figure shows <strong>the</strong> measuring<br />

principle of Emulsionsens <strong>for</strong> a desalter and<br />

<strong>the</strong> resulting density profile. By mounting<br />

<strong>the</strong> detectors on <strong>the</strong> outer wall of <strong>the</strong> vessel,<br />

<strong>the</strong>y are easily accessible and adjustable.<br />

Picture: Berthold Technologies<br />

Emulsionsens, shown here <strong>for</strong> a desalter and <strong>the</strong> resulting interface density profile<br />

One-time calibration of <strong>the</strong> system as part of<br />

initial commissioning is sufficient, in o<strong>the</strong>r<br />

words no recalibration is required. Since no<br />

mechanically moving parts are installed and<br />

<strong>the</strong> sensors are not in contact with <strong>the</strong> material<br />

to be measured, radiometric systems<br />

are wear-resistant and maintenance-free. Due<br />

to <strong>the</strong> curved dip tube which is used to position<br />

<strong>the</strong> encapsulated sources, <strong>the</strong> length of<br />

<strong>the</strong> measurement path is almost identical regardless<br />

of <strong>the</strong> position (

<strong>cpp</strong><br />


Ultra-rapid mill with effective air cooling<br />

Picture: Retsch<br />

The ultra centrifugal mill ZM<br />

300 is Retsch’s flagship <strong>for</strong><br />

high-speed size reduction.<br />

Thanks to <strong>the</strong> 1500 W powerdrive<br />

with enhanced per<strong>for</strong>mance<br />

<strong>the</strong> ZM 300 provides a<br />

maximum speed of<br />

23,000 min -1 , resulting in improved<br />

sample throughput<br />

throughout <strong>the</strong> whole speed<br />

range and higher final fineness.<br />

The active air cooling of <strong>the</strong><br />

grinding chamber significantly<br />

reduces heat build-up during<br />

grinding, even at maximum<br />

speed.<br />

The ZM 300 is easily and conveniently<br />

operated via a 4.3"<br />

touch display, e. g. <strong>for</strong> storing<br />

grinding programs. A QR code<br />

in <strong>the</strong> display leads <strong>the</strong> user to<br />

<strong>the</strong> Myretsch web portal which<br />

provides a wealth of productand<br />

application-related in-<br />

<strong>for</strong>mation. The ZM 300 is one of<br />

<strong>the</strong> first mills to be controlled<br />

via <strong>the</strong> optional app which<br />

allows <strong>for</strong> creating own application<br />

routines, accesses <strong>the</strong> application<br />

database and facilitates<br />

direct contact to <strong>the</strong> service<br />

team.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319retsch<br />

Filters instead of fouling<br />

Flow measurement<br />

with added value<br />

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Buntentorsdeich 1 - 28201 Bremen - Germany<br />

Phone: +49 (0) 421 55 909 0 - Fax: +49 (0) 421 55 909 40<br />

info@sab-bremen.de - www.sab-bremen.de<br />

The flow meter type 8098, part<br />

of <strong>the</strong> Flowave product family,<br />

has been fur<strong>the</strong>r developed. In<br />

addition to precise flow<br />

measurement, it now provides<br />

additional in<strong>for</strong>mation: <strong>for</strong><br />

example, <strong>the</strong> integrated detection<br />

of gas bubbles allows rapid<br />

response in <strong>the</strong> event of process<br />

faults. The density factor enables<br />

quick detection of fluid changeovers.<br />

In addition, viscosity<br />

compensation enables precise<br />

measurements even with highly<br />

viscous liquids. Besides Bürkert’s<br />

own BÜS, <strong>the</strong> standard protocols<br />

Canopen and Industrial<br />

E<strong>the</strong>rnet (Profinet, E<strong>the</strong>rnet/IP,<br />

Modbus TCP) are supported <strong>for</strong><br />

digital communication. The<br />

flowmeter operates according to<br />

<strong>the</strong> Surface Acoustic Waves<br />

(SAW) method, which uses surface<br />

waves <strong>for</strong> measurement.<br />

With this process, <strong>the</strong>re are no<br />

installed fittings or constructions.<br />

In addition, <strong>the</strong>re is no<br />

contact between <strong>the</strong> sensor elements<br />

and <strong>the</strong> medium, thus<br />

making <strong>the</strong> process ideal <strong>for</strong> hygienic<br />

applications.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319bürkert<br />

Picture: Bürkert<br />

22 <strong>cpp</strong> 03-2019

Picture: GEA<br />

Ceramic catalyst filter system<br />

GEA has developed high-temperature<br />

filters with ceramic elements<br />

that enable <strong>the</strong> removal<br />

of NO x , dioxins, mercury, and<br />

VOC through an integrated catalyst<br />

matrix. Biscat ceramic catalyst<br />

filters are <strong>chemical</strong>ly inert<br />

and corrosion-resistant. This<br />

means that <strong>for</strong> many applications<br />

only one single system<br />

is required instead of three.<br />

Particle separation takes place<br />

with <strong>the</strong> aid of filter elements<br />

made of mineral fibres, <strong>the</strong> socalled<br />

ceramic candle. These<br />

candles are very flexible to use<br />

even with regard to modifications<br />

of operating parameters,<br />

especially at high gas temperatures.<br />

No cooling of flue gases is<br />

required and no <strong>the</strong>rmal heat<br />

energy is wasted. Filter elements<br />

are cleaned from separated dust<br />

online during operation by<br />

means of separate, compressed<br />

air jet pulses. The single or<br />

multi-sectional housings allow a<br />

maximum filter length of 6 m.<br />

This means that even large gas<br />

volume flows can be cleaned.<br />

The design of <strong>the</strong> system allows<br />

maintenance of <strong>the</strong> individual<br />

elements during operation.<br />

By injecting lime-based<br />

reagents, inorganic pollutants<br />

such as HF, HCl, SOx can also be<br />

absorbed. GEA has fur<strong>the</strong>r developed<br />

<strong>the</strong> ceramic filter elements<br />

and enriched <strong>the</strong>m with<br />

a catalyst. In addition to particles<br />

and acid gases, nitrogen<br />

oxides can thus be efficiently<br />

separated after prior injection of<br />

ammonia. This replaces <strong>the</strong> conventional<br />

selective catalytic reactor<br />

(SCR).<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319gea<br />

Every child<br />

is one of a kind and unique. Each child needs<br />

individual support according to <strong>the</strong>ir needs.<br />

Please help us by donating. Thank you!<br />

Tel.: 0800/50 30 300 (free of charge)<br />

IBAN DE22 4306 0967 2222 2000 00<br />


www.sos-kinderdoerfer.de<br />

2016/1<br />

Electropneumatic positioner<br />

The Samson positioners from<br />

<strong>the</strong> Series 3730 <strong>–</strong> Trovis 3730<strong>–</strong>1<br />

and Trovis 3730 3 <strong>for</strong> 4 to<br />

20 mA applications now combine<br />

<strong>the</strong> latest technological developments<br />

with <strong>the</strong> proven device<br />

base known from <strong>the</strong> Type<br />

3730<strong>–</strong>1 and Type 3730<strong>–</strong>3 predecessor<br />

models. Both positioners<br />

are particularly rugged<br />

thanks to <strong>the</strong>ir no-wear, noncontact<br />

travel sensing system.<br />

Two inductive limit contacts are<br />

available to reliably indicate<br />

both valve end positions.<br />

At <strong>the</strong> same time, <strong>the</strong> positioners’<br />

air consumption has<br />

been reduced considerably by<br />

upgrading <strong>the</strong> pneumatics<br />

block. Operation continues to<br />

rely on <strong>the</strong> rotary pushbutton<br />

taken over from <strong>the</strong> successful<br />

Series 3730. Trovis 3730<strong>–</strong>3<br />

communicates over <strong>the</strong> Hart 7<br />

Picture: Samson<br />

protocol and comes with <strong>the</strong><br />

Expertplus valve diagnostics<br />

with optimised features. To facilitate<br />

operation, <strong>the</strong> positioners<br />

are fitted with a plaintext<br />

display that indicates <strong>the</strong><br />

condensed state according to<br />

Namur, measured values, startup<br />

settings as well as messages<br />

in English or German. Trovis<br />

3730<strong>–</strong>3 is additionally ready <strong>for</strong><br />

interconnection with SAM<br />

Chemicals, <strong>the</strong> cloud-based<br />

business application <strong>for</strong> <strong>the</strong> process<br />

<strong>industry</strong>.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319samson<br />


Resistant from one<br />

extreme to <strong>the</strong> o<strong>the</strong>r.<br />

<br />

<br />

<strong>cpp</strong> 03-2019<br />

www.COG.de/en<br />


<strong>cpp</strong><br />


Cryogenic size reduction of fine polymer powders<br />

Wide-chamber mill<br />

<strong>for</strong> 3D printing<br />

The Contraplex wide-chamber mill from Hosokawa Alpine has been adapted to <strong>the</strong><br />

specific requirements of 3D printing. The CW 250 II features optimised grinding<br />

tools and temperature control, reducing liquid nitrogen and energy consumption.<br />

Tumbler screening machines or air classifiers are used <strong>for</strong> <strong>the</strong> required particle size<br />

distribution.<br />

Pictures: Hosokawa Alpine<br />

Many industrial sectors are focusing increasingly<br />

on additive manufacturing of<br />

components made of metal or polymers. Selective<br />

laser sintering (SLS) constitutes an<br />

important process <strong>for</strong> 3D printing of<br />

polymers. Fine polymer powders are sintered<br />

in a powder bed by means of laser to<br />

<strong>for</strong>m three-dimensional objects. This printing<br />

process, however, calls <strong>for</strong> polymer<br />

powders with a particle size of around<br />

d 90 = 100 μm. Cryogenic comminution is<br />

one method applied <strong>for</strong> <strong>the</strong> production of<br />

such fine powders. In this case, polymer<br />

granules are embrittled by means of liquid<br />

nitrogen (LN 2 ) and <strong>the</strong>n ground in a pin<br />

mill. The specific consumption of liquid nitrogen<br />

is a major cost factor. Hosokawa Alpine<br />

offers solutions to reduce this. Assuming<br />

an efficient classifier and mill exist in<br />

circuit, <strong>the</strong> product specifications can also<br />

be guaranteed and <strong>the</strong> operating costs minimised.<br />

Cryogenic size reduction<br />

The feed material must first of all be embrittled<br />

to enable cryogenic comminution.<br />

To this end, it is cooled in a screw cooler<br />

charged with LN 2 to a temperature of<br />

around -190 °C. The residence time in <strong>the</strong><br />

screw cooler is selected such that <strong>the</strong> granules<br />

adopt this temperature right into <strong>the</strong>ir<br />

core. In order to make as efficient use of <strong>the</strong><br />

liquid nitrogen as possible, LN 2 is constantly<br />

introduced into <strong>the</strong> granule bed along <strong>the</strong><br />

entire conveying line. After being embrittled,<br />

<strong>the</strong> feed material is comminuted in<br />

The Contraplex CW 250 II wide-chamber mill features optimised grinding tools and temperature control,<br />

reducing liquid nitrogen and energy consumption<br />

a pin mill. The Hosokawa Alpine Contraplex<br />

wide-chamber mill CW 250 II is ideal <strong>for</strong><br />

this task. The CW-II product line has been<br />

given a substantial redesign to make it fit<br />

<strong>for</strong> <strong>the</strong> demands posed by cryogenic size reduction<br />

of difficult feed materials. Two<br />

contra-rotating pin discs rotate in <strong>the</strong> mill at<br />

speeds of up to 120 m/s each at <strong>the</strong>ir outer<br />

periphery, allowing relative speeds of up to<br />

240 m/s to be realised. To compensate <strong>for</strong><br />

<strong>the</strong> energy input caused by comminution,<br />

liquid nitrogen can be injected into <strong>the</strong> inlet<br />

area of <strong>the</strong> mill <strong>for</strong> fur<strong>the</strong>r cooling.<br />

Optimised screw geometry<br />

As a result of <strong>the</strong> LN 2 injected, <strong>the</strong> mill outlet<br />

temperature can be regulated to a constant<br />

target temperature. This is important to<br />

ensure that <strong>the</strong> temperature of <strong>the</strong> feed material<br />

in <strong>the</strong> grinding zone is always significantly<br />

less than its glass transition temperature.<br />

Over and above this, it serves to prevent<br />

product deposits. Depending on <strong>the</strong><br />

type of polymer, <strong>the</strong> standard temperature<br />

setting is between -20 and -50 °C. In <strong>the</strong><br />

case of PA-6, it has been established that an<br />

increase in <strong>the</strong> mill outlet temperature from<br />

<strong>the</strong> standard -40 to -10 °C suffices to prevent<br />

<strong>the</strong> particles from starting to melt in<br />

<strong>the</strong> mill. The resultant lower LN 2 consumption<br />

naturally has a positive effect on <strong>the</strong><br />

operating costs.<br />

With regard to <strong>the</strong> specific operating costs,<br />

cryogenic grinding is at its most efficient<br />

when <strong>the</strong> mill is charged with a maximum<br />

feed rate until <strong>the</strong> rated output of <strong>the</strong> mill<br />

drive is reached. Homogenisation of <strong>the</strong><br />

product discharged from <strong>the</strong> screw cooler<br />

helps to avoid per<strong>for</strong>mance and/or current<br />

peaks. The feed material dosing can be<br />

24 <strong>cpp</strong> 03-2019

Influence of <strong>the</strong> number of pins on fines and fines throughput<br />

adapted <strong>for</strong> higher throughputs without<br />

running <strong>the</strong> risk of high feed rate fluctuations,<br />

which would lead to undesirable<br />

current peaks and in <strong>the</strong> worst case bring<br />

production to a halt. Research projects<br />

aimed at optimising <strong>the</strong> product discharge<br />

by means of design measures on <strong>the</strong> screw<br />

cooler were carried out with <strong>the</strong> aid of DEM<br />

simulations and subsequently tested successfully<br />

at <strong>the</strong> testing centre. The greatest<br />

effect with respect to homogenisation was<br />

achieved by modifying <strong>the</strong> screw geometry<br />

at <strong>the</strong> outlet of <strong>the</strong> screw cooler.<br />

Adaptation to <strong>the</strong> pin discs<br />

Fur<strong>the</strong>r optimisation of <strong>the</strong> operating costs<br />

is possible by aligning cryogenic grinding<br />

with <strong>the</strong> screening or classifying step, insofar<br />

as <strong>the</strong> target fineness cannot be achieved<br />

without downstream classifying. During<br />

grinding, <strong>the</strong> highest possible throughput<br />

of finely ground product <strong>–</strong> <strong>for</strong> example, less<br />

than 100 μm <strong>–</strong> should be generated and<br />

presented to <strong>the</strong> classifier. In principle, this<br />

enables a higher yield of end product. To<br />

this end, <strong>the</strong> design of <strong>the</strong> pin discs can be<br />

adapted accordingly and <strong>the</strong> mill operated<br />

at full load. Amongst o<strong>the</strong>r things, <strong>the</strong>se<br />

modifications can include changes to <strong>the</strong><br />

number and dimensions of <strong>the</strong> impact pins.<br />

By reducing <strong>the</strong> number of pins, <strong>the</strong> noload<br />

power decreases and <strong>the</strong> feed material<br />

can be charged to <strong>the</strong> mill at a higher rate.<br />

The lower stressing frequency leads to a<br />

somewhat coarser particle size in comparison.<br />

In spite of this, a higher throughput of<br />

fines smaller than 100 μm is never<strong>the</strong>less<br />

possible. Compared to just cryogenic grinding<br />

with <strong>the</strong> CW 250 II, <strong>the</strong> specific operating<br />

costs are moreover lower if <strong>the</strong> feed<br />

rates are higher.<br />

Intelligent system concept<br />

It is often only possible to produce polymer<br />

DEM simulation of <strong>the</strong> product outlet of <strong>the</strong> vortex screw cooler<br />

powders with <strong>the</strong> target specification d 90 =<br />

100 μm by means of a downstream classifying<br />

step using a screen or air classifier <strong>–</strong> or<br />

both processes in circuit with automatic return<br />

of <strong>the</strong> coarse material. Assuming an intelligent<br />

system concept <strong>for</strong> a circuit process,<br />

<strong>the</strong> liquid nitrogen that evaporates<br />

during cryogenic size reduction is perfect<br />

<strong>for</strong> direct use as circuit gas <strong>for</strong> <strong>the</strong> classifying<br />

step. This does away with <strong>the</strong> need <strong>for</strong><br />

gaseous nitrogen, which would o<strong>the</strong>rwise<br />

be required <strong>for</strong> <strong>the</strong> inert mode of operation.<br />

Routed in circuit, <strong>the</strong> nitrogen gas is free<br />

from moisture which could condense on<br />

<strong>the</strong> particle surface. This ensures that no additional<br />

conditioning of <strong>the</strong> gas is necessary<br />

<strong>for</strong> classifying. Agglomeration is prevented<br />

in this way.<br />

At a constant sharpness of cut of <strong>the</strong> classifier,<br />

<strong>the</strong> throughput of <strong>the</strong> end product is<br />

higher <strong>the</strong> finer <strong>the</strong> material. As a result of<br />

<strong>the</strong> improved fines yield, a correspondingly<br />

small amount of coarse material needs to be<br />

returned to <strong>the</strong> grinding process. The lesser<br />

amount of circuit material <strong>the</strong>re<strong>for</strong>e has a<br />

positive effect on <strong>the</strong> total operating costs of<br />

<strong>the</strong> grinding and classifying circuit. Tests<br />

have shown that <strong>the</strong>re is an optimum fineness<br />

at which <strong>the</strong> specific operating costs<br />

<strong>for</strong> <strong>the</strong> manufacture of polymer powders<br />

with a d 90 of 100 μm are at a minimum. For<br />

<strong>the</strong> tested PA-6, this results in an optimum<br />

operating point <strong>for</strong> <strong>the</strong> CW 250 II at which<br />

<strong>the</strong> generated fines portion

<strong>cpp</strong><br />


Pictures: Keller Lufttechnik<br />

Aurora Kunststoffe currently operates five extruders that produce over 50 tons of recompounds daily. They expect demand to rise in<br />

<strong>the</strong> future, especially if <strong>the</strong>re is a legally mandated recycling quota.<br />

Customised solution <strong>for</strong> clean air in plastics production<br />

Trans<strong>for</strong>ming a dusty<br />

process into a clean one<br />

Aurora, a manufacturer of plastic composites, trans<strong>for</strong>ms a dusty process into a<br />

clean one: production manager Alexander Schweinle selected Cleacom from Keller<br />

Lufttechnik <strong>–</strong> a customised solution <strong>for</strong> clean air in plastics production.<br />

Plastic is truly ubiquitous: depending on<br />

its <strong>for</strong>mulation, <strong>the</strong> indestructible material<br />

takes on numerous properties and is utilised,<br />

<strong>for</strong> example, <strong>for</strong> office chairs, car door<br />

panels, cable ducts or foil tunnels. It has become<br />

indispensable in our daily lives. Today,<br />

however, <strong>the</strong> use of this neutral material has<br />

acquired a bad reputation. It has become<br />

synonymous with environmental disgrace.<br />

The <strong>industry</strong> requires new sustainability<br />

concepts. Aurora Kunststoffe GmbH from<br />

Neuenstein in north-eastern Baden-Württemberg<br />

has found a solution: The company<br />

repurposes recycled plastic granulate into<br />

quality new products. “The production of<br />

plastic parts results in about five per cent rejects.<br />

We purchase this industrial waste and<br />

trans<strong>for</strong>m it into a new, high-quality raw<br />

material,“ says Alexander Schweinle, production<br />

manager at Aurora Kunststoffe.<br />

Specialised knowledge required<br />

The Aurora experts first examine <strong>the</strong>ir raw<br />

material using spectral analysis in <strong>the</strong> laboratory,<br />

in order to precisely ascertain its<br />

composition. Then <strong>the</strong>y grind <strong>the</strong> plastic<br />

parts into small pieces. Some of <strong>the</strong> ground<br />

material is re-sold directly, but <strong>the</strong> bulk is<br />

processed into first-class composite following<br />

<strong>the</strong> addition of molten additives in a<br />

new extrusion process, from which new<br />

materials can be produced. “We have <strong>the</strong><br />

expertise and experience to master this process,“<br />

reports Alexander Schweinle. “In our<br />

laboratory, new recycled plastic <strong>for</strong>mulations<br />

are constantly being developed <strong>for</strong> a<br />

wide variety of applications. We test <strong>the</strong>m<br />

directly with our own injection moulding<br />

machine.“<br />

Increased production<br />

Alexander Schweinle is proud of his highly<br />

modernised compounding plant. “Our old<br />

building burned down in 2017, so we built<br />

a modernised, larger plant,“ says <strong>the</strong> production<br />

manager. “In February 2019, five<br />

extruders were put into operation instead of<br />

three. Completely expanded, <strong>the</strong> plant ac-<br />

26 <strong>cpp</strong> 03-2019

The powdered raw material is processed with <strong>the</strong> addition of additives in a new extrusion<br />

process into a quality recompound from which new products can be manufactured<br />

commodates seven lines. We currently produce<br />

over 50 tons of compounds per day.“<br />

Aurora expects demand to rise in <strong>the</strong> future.<br />

“I am certain that eventually <strong>the</strong>re will be a<br />

legally mandated recycling quota,“ says<br />

Schweinle.<br />

Investment in clean air<br />

With <strong>the</strong> new factory, Aurora also invested<br />

in high-tech machinery. “Anyone familiar<br />

with <strong>the</strong> recycling of <strong>the</strong>rmoplastics knows<br />

that it is a challenging and dusty business,“<br />

says Schweinle. Visitors would be all <strong>the</strong><br />

more surprised when <strong>the</strong>y viewed <strong>the</strong> production<br />

at Aurora, where Keller Lufttechnik<br />

extraction systems ensure clean air. The<br />

plant looks splendid. “Anyone who demands<br />

a clean operation in our <strong>industry</strong><br />

should consider Cleacom from Keller Lufttechnik,“<br />

concludes Alexander Schweinle,<br />

who conducted extensive market research<br />

prior to his investment. Cleacom stands <strong>for</strong><br />

Clean Compounding. Keller Lufttechnik developed<br />

this separation concept specifically<br />

<strong>for</strong> plastics manufacturers. It combines dry<br />

separation, which is used <strong>for</strong> weighing and<br />

mixing raw materials, with a wet separation<br />

system <strong>for</strong> <strong>the</strong> extrusion process.<br />

Dry separator <strong>for</strong> dosing scales<br />

In association with <strong>the</strong> production manager<br />

at Aurora, Thomas Nägele, project manager<br />

at Keller Lufttechnik, adapted <strong>the</strong> Cleacom<br />

<strong>technology</strong> to <strong>the</strong> specific requirements at<br />

Aurora. He says: “Where aggregates are<br />

weighed and added at <strong>the</strong> dosing scales,<br />

dust particles are created, some of which<br />

are highly reactive and explosive. We have<br />

equipped our Vario dry separator, to which<br />

all five lines are connected, with <strong>the</strong> constructive<br />

explosion protection ‚ProVent‘, a<br />

system <strong>for</strong> flameless pressure relief inside<br />

buildings.” The extraction system is already<br />

designed <strong>for</strong> any future expansion. Following<br />

demand, an integrated frequency inverter<br />

will automatically adjust <strong>the</strong> per<strong>for</strong>mance<br />

of <strong>the</strong> dust extractor, <strong>the</strong>reby reducing<br />

power consumption. If fur<strong>the</strong>r dosing<br />

stations are added, <strong>the</strong> experts will merely<br />

supplement some collection units.<br />

Once <strong>the</strong> filter elements in <strong>the</strong> central system<br />

are contaminated with dust and a certain<br />

differential pressure is reached, a compressed<br />

air pulse ensures automatic cleaning.<br />

A filter change is only due after 15,000<br />

to 20,000 operating hours. “If necessary, we<br />

merely change <strong>the</strong> big bags which collect<br />

<strong>the</strong> dust,“ says Alexander Schweinle. Keller<br />

technicians inspect <strong>the</strong> system once a year.<br />

Wet separator <strong>for</strong> clean air<br />

The more challenging task is assumed by<br />

<strong>the</strong> VDN-TA wet separator, which ensures<br />

breathable air at <strong>the</strong> extruders. The ex-<br />

<strong>cpp</strong> 03-2019 27

<strong>cpp</strong><br />


Alexander Schweinle, production manager at Aurora Kunststoffe: “Visitors<br />

may be pleasantly surprised if <strong>the</strong>y view <strong>the</strong> production at Aurora, where<br />

Keller Lufttechnik extraction systems ensure clean air.“<br />

At <strong>the</strong> extruders, adhesive gases escape as well as dust. This challenging<br />

air cleaning task is solved with <strong>the</strong> VDN-TA wet separator, which improves<br />

air quality at <strong>the</strong> extruders and inside <strong>the</strong> plant.<br />

truders produce a homogeneous, molten<br />

plastic mass from <strong>the</strong> previously prepared<br />

<strong>for</strong>mulation at high temperatures, which<br />

<strong>the</strong>y press through fine openings. Long<br />

continuous plastic strands are <strong>for</strong>med,<br />

which are cooled with water and <strong>the</strong>n<br />

broken into pellets. The material is dispersed<br />

using rotating screws be<strong>for</strong>e <strong>the</strong><br />

finished granulate falls into a collection<br />

hopper. At <strong>the</strong> extruders, adhesive fumes as<br />

well as dust can escape. These emissions<br />

cannot be addressed by solely using dry<br />

separation. Alexander Schweinle confirms<br />

this: “The result of <strong>the</strong> dry separation in<br />

<strong>the</strong> old production facility was disastrous.<br />

The adhesive dusts coated each column of<br />

<strong>the</strong> separator, as well as in <strong>the</strong> extruder and<br />

inside <strong>the</strong> plant. Dust re<strong>for</strong>med soon after<br />

cleaning,“ he remembers. As a result of <strong>the</strong><br />

wet separation process, <strong>the</strong> laborious<br />

cleaning task no longer plays a role today,<br />

and Aurora employees can devote more<br />

time to <strong>the</strong>ir core business and to quality<br />

control.<br />

Water mist absorbs adhesive dust<br />

“In order to keep <strong>the</strong> ductwork clean, we<br />

saturate <strong>the</strong> adhesive particles with water<br />

as soon as <strong>the</strong>y enter <strong>the</strong> ductwork system.<br />

We use <strong>the</strong> Venturi principle to create a<br />

fairly even mist,“ says Thomas Nägele.<br />

When <strong>the</strong> contaminated air finally enters<br />

<strong>the</strong> separator, it is doused <strong>the</strong>re by ano<strong>the</strong>r<br />

Venturi nozzle. Using centrifugal <strong>for</strong>ce, <strong>the</strong><br />

system <strong>the</strong>n separates <strong>the</strong> fine water mist<br />

loaded with <strong>for</strong>eign substances from <strong>the</strong><br />

air stream. In large plants such as Aurora’s,<br />

<strong>the</strong> water <strong>the</strong>n flows into a huge holding<br />

tank where <strong>the</strong> impurities will settle. A<br />

sludge scraper clarifies <strong>the</strong> water, which<br />

can <strong>the</strong>n be reused.<br />

“Keller Lufttechnik referred us to its<br />

partner Hebro Chemie <strong>for</strong> <strong>the</strong> correct<br />

handling of <strong>the</strong> waste water. The company<br />

advised us on measures to prevent <strong>the</strong><br />

growth of microorganisms and reliably<br />

bind <strong>the</strong> impurities. This makes <strong>the</strong> water<br />

that we recycle very clean,“ says Alexander<br />

Schweinle. “What remains is about one<br />

bulk container of sludge per month, which<br />

we hand over to a specialised waste disposal<br />

company.<br />

Customised solutions<br />

The reason that <strong>the</strong> new Aurora production<br />

plant is so clean is due to <strong>the</strong> beneficial cooperation<br />

between Aurora and Keller Lufttechnik.<br />

“We co-designed <strong>the</strong> system and<br />

determined customised solutions <strong>for</strong> some<br />

special challenges,“ confirms Alexander<br />

Schweinle. For example, <strong>the</strong>re was a seal on<br />

<strong>the</strong> extruder, located on <strong>the</strong> coupling between<br />

<strong>the</strong> blower and <strong>the</strong> material feed<br />

screw. “Although we tightened <strong>the</strong> seal<br />

regularly, fine powder always escaped. Previously,<br />

our employees would address <strong>the</strong><br />

problem directly. Additionally, <strong>the</strong> powdery<br />

residue caked onto <strong>the</strong> warm surface of <strong>the</strong><br />

extruder,“ explains <strong>the</strong> plastics expert.<br />

“Now we’ve installed a collection system at<br />

this point that immediately removes <strong>the</strong><br />

dust and works perfectly.”<br />

Everything is operating smoothly<br />

Aurora operates six days a week, in three<br />

shifts intervals. To ensure that production<br />

does not experience a shutdown, <strong>the</strong> company<br />

relies on a functioning extraction system.<br />

“We conscientiously maintain <strong>the</strong> separators,“<br />

says Alexander Schweinle. Saturday<br />

is designated <strong>for</strong> cleaning so that <strong>the</strong> process<br />

resumes smoothly again on Monday.<br />

The fan of <strong>the</strong> wet separator is equipped<br />

with a vibration sensor. This signals when<br />

<strong>the</strong> blower is not operating smoothly and if<br />

<strong>the</strong> fan impeller may ei<strong>the</strong>r have to be<br />

cleaned or replaced soon. “Aurora <strong>the</strong>reby<br />

has adequate lead time to plan a shutdown<br />

<strong>for</strong> <strong>the</strong> exchange of spare parts that is compatible<br />

with <strong>the</strong> production schedule,“ explains<br />

Thomas Nägele.<br />

Alexander Schweinle is very satisfied with<br />

his decision to install Cleacom. “We primarily<br />

did this <strong>for</strong> our employees,“ he says.<br />

„However, I now see how <strong>the</strong> clean production<br />

at Aurora Kunststoffe also benefits our<br />

reputation with customers, suppliers and<br />

<strong>the</strong> general public.“<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319keller<br />

Hall 11, Booth B31<br />

AUTHOR:<br />


Marketing department<br />

Keller Lufttechnik<br />

28 <strong>cpp</strong> 03-2019

Organic TPE based on sugar cane<br />

With Septon Bio, Kuraray is expanding its product range<br />

of TPE materials with a variant based on natural, renewable<br />

raw materials. The hydrogenated styrene farnesene<br />

block copolymer (HSFC) is particularly easy to process<br />

thanks to its very good flow ability and adhesion. It does<br />

not require any additional plasticisers and has a broader<br />

damping range than conventional hydrogenated styrene<br />

block copolymers (HSBC). Septon BIO series materials<br />

are based on beta-farnesene, a renewable monomer derived<br />

from sugar cane. In fermentation processes, proprietary<br />

yeast strains convert <strong>the</strong> sugar into beta-farnesene.<br />

The TPE raw materials are ideal <strong>for</strong> applications in adhesives,<br />

sealants, gels, films, and soft compounds and are<br />

used with <strong>the</strong>ir unique grip per<strong>for</strong>mance in <strong>the</strong> manufacture<br />

of handles, <strong>for</strong> example <strong>for</strong> sports equipment.<br />

www.prozesstechnik-online.de<br />

Online search: <strong>cpp</strong>0319kuraray<br />

Hall 7a, Booth D6<br />

Picture: Kuraray<br />

High-per<strong>for</strong>mance additive <strong>for</strong> TPUs<br />

Picture: Wacker Chemie AG<br />

Wacker Chemie's new silicone<br />

additive <strong>for</strong> <strong>the</strong>rmoplastic polyurethanes<br />

(TPU), named Genioplast<br />

Pellet 345, lowers <strong>the</strong><br />

hardness of TPUs, while boosting<br />

<strong>the</strong>ir elasticity and enhancing<br />

<strong>the</strong>ir properties. The surfaces<br />

of molded parts modified with<br />

<strong>the</strong> additive are pleasantly soft<br />

to <strong>the</strong> touch and more resistant<br />

to scratches, abrasion and contamination.<br />

The new additive is<br />

readily incorporated into<br />

<strong>the</strong>rmoplastic polyurethanes and<br />

has fewer undesirable secondary<br />

effects than conventional silicone<br />

products.<br />

Genioplast Pellet 345 can also<br />

be used <strong>for</strong> modifying o<strong>the</strong>r<br />

<strong>the</strong>rmoplastic elastomers as<br />

well, <strong>for</strong> example <strong>the</strong> product,<br />

can markedly boost <strong>the</strong> properties<br />

of <strong>the</strong>rmoplastic polyamide<br />

and copolyester elastomers.<br />

Genioplast Pellet 345 is a silicone<br />

copolymer and is processed<br />

like a <strong>the</strong>rmoplastic. Organic<br />

polymer segments contained<br />

within Genioplast Pellet<br />

345 make it so compatible with<br />

<strong>the</strong>rmoplastic polyurethanes<br />

that it disperses very finely and<br />

homogeneously throughout <strong>the</strong><br />

polyurethane matrix. The copolymer<br />

becomes physically<br />

bound to <strong>the</strong> matrix and is<br />

<strong>the</strong>re<strong>for</strong>e unable to migrate. In<br />

Europe, Genioplast Pellet 345 is<br />

authorised <strong>for</strong> food-contact applications.<br />

www.prozesstechnik-online.de<br />

Online search: <strong>cpp</strong>0319wacker<br />

Hall 16, Booth F71<br />

See us in Dusseldorf:<br />

MESSE K<br />

Hall 10, Stand H 08<br />

October 16 <strong>–</strong> 23, 2019<br />







We constantly encounter bulk<br />

products and powdery materials in<br />

everyday life. They come in various<br />

particle sizes <strong>–</strong> from lumpy to powdery.<br />

Bulk products are processed in many<br />

industries, <strong>for</strong> example in <strong>the</strong> <strong>chemical</strong><br />

and pharmaceutical <strong>industry</strong>.<br />

AMANDUS KAHL GmbH & Co. KG<br />

Dieselstrasse 5<strong>–</strong>9 · 21465 Reinbek<br />

Hamburg, Germany<br />

+49 (0) 40 72 77 10<br />

info@akahl.de · akahl.de<br />

<strong>cpp</strong> 03-2019 29

<strong>cpp</strong><br />


Perfomance-enhancing additives <strong>for</strong> PA<br />

At K 2019, Brüggemann presents<br />

its latest developments in<br />

per<strong>for</strong>mance-enhancing additives<br />

<strong>for</strong> both virgin polyamides<br />

and polyamide recyclates. The<br />

product variants range from efficiency-increasing<br />

flow enhancers<br />

<strong>for</strong> shorter cycle times<br />

and thinner wall thicknesses,<br />

through heat stabilisers <strong>for</strong><br />

medium to very high temperatures,<br />

to reactive additives <strong>for</strong><br />

<strong>the</strong> production of recyclates<br />

which match <strong>the</strong> quality of virgin<br />

materials.<br />

Bruggolen TP-P1810 <strong>for</strong><br />

example allows a significant improvement<br />

in flow properties of<br />

polyphthalamides (PPA, such as<br />

PA6T, PA6T/6I, PA6T/6.6 etc.)<br />

while retaining overall mechanical<br />

property characteristics.<br />

Compounders and injection<br />

molders can thus significantly<br />

widen <strong>the</strong> processing window<br />

and combine high cost efficiency<br />

with application-specific optimisation.<br />

For example, it is<br />

possible with Bruggolen<br />

TP-P1810 to reliably produce<br />

and easily process compounds<br />

with very high fiber contents<br />

(e.g. 60 %). Producers and processors<br />

of <strong>the</strong> corresponding<br />

compounds will benefit from<br />

much shorter cycle times. Fur<strong>the</strong>rmore,<br />

both flow enhancers<br />

allow <strong>the</strong> production of large or<br />

complex parts with long flow<br />

paths and/or low wall thicknesses.<br />

With <strong>the</strong> heat stabiliser Bruggolen<br />

TP-H1805, Brüggemann<br />

offers <strong>the</strong> opportunity to stabilise<br />

fiber-rein<strong>for</strong>ced aliphatic<br />

polyamides <strong>for</strong> long-term use at<br />

temperatures up to 200 °C <strong>for</strong><br />

PA 6 or up to 230 °C <strong>for</strong> PA 6.6.<br />

This enables compounders to<br />

tailor-make products <strong>for</strong> applications<br />

in borderline areas that<br />

were until now <strong>the</strong> preserve of<br />

polyphthalamides or o<strong>the</strong>r<br />

high-per<strong>for</strong>mance polymers<br />

such as PPS. Injection-molded<br />

parts produced with this additive<br />

<strong>–</strong> <strong>for</strong> example air ducts and<br />

Picture: Brüggemann<br />

pipes in <strong>the</strong> engine compartment<br />

<strong>–</strong> offer excellent heat resistance<br />

over <strong>the</strong> entire required<br />

temperature range. Separate activation<br />

is not needed.<br />

www.prozesstechnik-online.de<br />

Online search:<br />

<strong>cpp</strong>0319brueggemann<br />

Hall 8a, Booth D08<br />

Mixer <strong>for</strong> natural fibre compounds<br />

Vibratory feeders with automatic refill<br />

Picture: MTI Mischtechnik<br />

MTI Mischtechnik will be showing<br />

a heating/cooling mixer<br />

combination designed <strong>for</strong> processing<br />

natural fibre compounds<br />

(NFC). The mixing plant has<br />

been optimised <strong>for</strong> <strong>the</strong> production<br />

of Resysta material and <strong>the</strong><br />

MTI Flex-line M 1000 / K 3300<br />

has a heating mixer volume of<br />

1101 l and a cooling mixer volume<br />

of 3308 l. A Vent tec 2.0 aspiration<br />

system ensures <strong>the</strong> dehumidification<br />

of <strong>the</strong> mixture.<br />

The Resysta material consists of<br />

about 60 % rice husks, rock salts<br />

and mineral oil. It can be processed<br />

like wood and thus opens<br />

up a wide range of applications.<br />

www.prozesstechnik-online.de<br />

Online search: <strong>cpp</strong>0319mti<br />

Hall 9, Booth B22<br />

Coperion K-Tron will display <strong>the</strong><br />

redesigned K3 vibratory feeder<br />

in action as part of a recirculating<br />

system <strong>–</strong> with automatic refill<br />

provided by a P-Series vacuum<br />

receiver and a compact vacuum<br />

pump. K3 vibratory feeders<br />

are suitable <strong>for</strong> feeding recycled<br />

material or flakes as well as <strong>for</strong><br />

<strong>the</strong> addition of glass fiber in<br />

compounding processes. They<br />

are practically maintenance-free,<br />

since <strong>the</strong>re is no wear on <strong>the</strong><br />

mechanical parts. P-Series vacuum<br />

receivers can be used to<br />

convey a wide range of bulk ma-<br />

terials. They are constructed of<br />

stainless steel and features include<br />

steep cone angles to ensure<br />

excellent discharge and band<br />

clamps <strong>for</strong> quick disassembly.<br />

www.prozesstechnik-online.de<br />

Online search: <strong>cpp</strong>0319coperion<br />

Hall 14, Booth B19<br />

Picture: Coperion<br />

New at <strong>the</strong> K 2019 fair,<br />

WITTE gear pumps in AT design.<br />

<br />

<br />

<br />

Hall 10, Booth E40<br />

Our competence <strong>for</strong> your success.<br />

Advanced Technology! The next evolutionary step <strong>for</strong> polymer pumps.<br />

<br />

<br />

<br />

<br />

<br />

<br />

<br />

<br />

<br />

30 <strong>cpp</strong> 03-2019<br />

Brian<br />

Industrial mechanic in <strong>the</strong><br />

WITTE assembly workshop since 2006<br />


Lise-Meitner-Allee 20<br />

25436 Tornesch<br />

Tel. 04120 70 65 9 -0<br />

www.witte-pumps.com<br />


Directly on <strong>the</strong> motor mounted servo pump<br />

Picture: Baumüller<br />

Baumüller's servo pump combines<br />

<strong>the</strong> advantages of hydraulic<br />

power transmission with<br />

<strong>the</strong> benefits of electric servo<br />

drive <strong>technology</strong>. The intelligent<br />

control of <strong>the</strong> drive and <strong>the</strong> low<br />

energy consumption of <strong>the</strong> components,<br />

especially in <strong>the</strong> partial<br />

load range, results in a highly<br />

energy-efficient and yet economical<br />

solution. And <strong>the</strong> latest<br />

enhancement of <strong>the</strong> servo pump<br />

solution offers fur<strong>the</strong>r advantages.<br />

For example, <strong>the</strong> servo<br />

pump is mounted directly on<br />

<strong>the</strong> motor with an internal toothing,<br />

which has a shorter installation<br />

length and <strong>the</strong>re<strong>for</strong>e a<br />

smaller machine installation<br />

area. Fur<strong>the</strong>rmore, direct mounting<br />

means that several mechanical<br />

parts are no longer required.<br />

Ano<strong>the</strong>r advantage is <strong>the</strong> intelligent<br />

use of hydraulic oil as a<br />

lubricant <strong>for</strong> <strong>the</strong> gear tooth<br />

system. In both <strong>the</strong> motor and<br />

<strong>the</strong> constant pump, existing<br />

connections allow <strong>the</strong> hydraulic<br />

oil to be returned to <strong>the</strong> circulation<br />

system, thus allowing <strong>the</strong><br />

leakage flow of <strong>the</strong> pump to be<br />

used <strong>for</strong> <strong>the</strong> permanent lubrication<br />

of <strong>the</strong> gear tooth system.<br />

There is no need <strong>for</strong> a grease<br />

lubrication of <strong>the</strong> internal<br />

toothing, which is required<br />

every 3000 operating hours on<br />

average. The machine can operate<br />

without interruption, thus<br />

increasing productivity.<br />

The motor can be installed horizontally<br />

or vertically, depending<br />

on <strong>the</strong> application.<br />

www.prozesstechnik-online.de<br />

Online search:<br />

<strong>cpp</strong>0319baumueller<br />

Hall 11, Booth A41<br />

Infrared drum dryer <strong>for</strong> PET recycling<br />

Kreyenborg’s infrared rotary<br />

drum IR-Clean has been developed<br />

<strong>for</strong> <strong>the</strong> treatment of PET<br />

recycling material. Its tailormade<br />

geometry, <strong>the</strong> targeted<br />

process control and a special<br />

control unit make <strong>the</strong> IR-Clean<br />

especially suitable <strong>for</strong> drying<br />

and decontaminating PET recycling<br />

material. This has been confirmed<br />

by <strong>the</strong> American FDA<br />

Authority and by several challenge<br />

tests, which have proven<br />

con<strong>for</strong>mity with <strong>the</strong> criteria of<br />

<strong>the</strong> European EFSA. After <strong>the</strong><br />

drying and decontamination<br />

process <strong>the</strong> PET recycling ma-<br />

terial can be used <strong>for</strong> packaging<br />

that comes directly in contact<br />

with <strong>the</strong> foodstuff. Consequently,<br />

<strong>the</strong> IR-Clean itself,<br />

which works without any specific<br />

additional equipment and<br />

in a very energy-efficient<br />

manner, but also <strong>the</strong> material<br />

cycle it closes and which preserves<br />

resources without any loss<br />

in quality, both represent a<br />

sustainable solution.<br />

www.prozesstechnik-online.de<br />

Online search:<br />

<strong>cpp</strong>0319kreyenborg<br />

Hall 9, Booth A55<br />

Picture: Kreyenborg<br />

<strong>cpp</strong> 03-2019 31

<strong>cpp</strong><br />


Cleanliness and health protection in <strong>the</strong> plastics <strong>industry</strong><br />

The right vacuum cleaner<br />

<strong>for</strong> each material<br />

The global plastics <strong>industry</strong> is one of <strong>the</strong> main customers <strong>for</strong> Ruwac vacuum cleaners<br />

and extraction systems. There, where powders and granulates are processed on a<br />

large scale, powerful industrial vacuum cleaners are particularly important, as <strong>the</strong><br />

examples described here show.<br />

The plastics <strong>industry</strong> has many applications<br />

<strong>for</strong> mobile industrial vacuum cleaners<br />

and stationary dedusting systems <strong>–</strong> from<br />

<strong>the</strong> dust created during production through<br />

granules of raw material to <strong>the</strong> powdery additives<br />

used <strong>for</strong> processing. The market is<br />

large enough to be worthwhile <strong>for</strong> manufacturers<br />

like Ruwac to specifically target it<br />

when developing new product series.<br />

The DA 5112 and DA 5152 mobile vacuum<br />

cleaners, which will be presented at K 2019,<br />

are two good examples here. They are<br />

specially designed <strong>for</strong> vacuuming large<br />

quantities of solid material, <strong>for</strong> instance<br />

when loading and storing plastic granules.<br />

This type of application requires a powerful<br />

drive. To meet this requirement, <strong>the</strong> vacuum<br />

cleaners are equipped with a side-channel<br />

compressor, which simultaneously contributes<br />

to <strong>the</strong>ir compactness. The motor has<br />

an output of 11 or 15 kW.<br />

Easy emptying, improved control<br />

Since <strong>the</strong> bin must be emptied quite frequently<br />

when vacuuming large quantities of<br />

material, <strong>the</strong> Ruwac designers made it very<br />

simple to remove. All <strong>the</strong> operator needs to<br />

do is press a lever. The bin, which is<br />

equipped with a tilting device, is <strong>the</strong>n low -<br />

ered to floor level. It can be moved on its<br />

own casters and transported quickly and<br />

easily with <strong>the</strong> aid of <strong>for</strong>klift pockets.<br />

Not only <strong>the</strong> 150 litre bin and <strong>the</strong> drive but<br />

also <strong>the</strong> filter unit (a dust class M filter bag)<br />

has a large capacity to suit <strong>the</strong> target application<br />

<strong>for</strong> <strong>the</strong> vacuum cleaners. Cleaning<br />

can be carried out ei<strong>the</strong>r manually or by<br />

Airshock. Due to its modular design, <strong>the</strong> industrial<br />

vacuum cleaner can easily accommodate<br />

an added residual dust filter <strong>for</strong> dust<br />

class H. Ano<strong>the</strong>r feature of <strong>the</strong> two new<br />

models is <strong>the</strong> improved control system,<br />

Pictures: Ruwac<br />

In <strong>the</strong> plastics <strong>industry</strong>, <strong>the</strong>re are many possible applications <strong>for</strong> industrial<br />

vacuum cleaners <strong>–</strong> here, a hazardous dust extractor <strong>for</strong> cleaning a system<br />

<strong>for</strong> <strong>the</strong> production of additives<br />

During filling, <strong>the</strong> granulate is collected and vacuumed off be<strong>for</strong>e it<br />

reaches <strong>the</strong> floor. It can <strong>the</strong>n be reinserted in <strong>the</strong> transport chain<br />

32 <strong>cpp</strong> 03-2019

machines and systems are rinsed with water<br />

to ensure no contamination occurs between<br />

individual pellets be<strong>for</strong>e packing. The plastic<br />

pellets thus collect in <strong>the</strong> pre-separator and<br />

<strong>the</strong> water in <strong>the</strong> vacuum cleaner itself. The<br />

pellets are <strong>the</strong>n recycled and <strong>the</strong> water is<br />

disposed of in <strong>the</strong> company’s own wastewater<br />

treatment plant.<br />


The DA 5112 and 5152 type vacuum<br />

cleaners have been developed <strong>for</strong><br />

vacuuming large quantities of material<br />

which monitors both <strong>the</strong> motor’s direction<br />

of rotation and its temperature and enables<br />

<strong>the</strong> vacuum cleaner to be switched on remotely<br />

(<strong>for</strong> example, when a production<br />

system is switched on).<br />

PC granules in a clean environment<br />

Depending on <strong>the</strong> conditions surrounding<br />

<strong>the</strong> application, <strong>the</strong>re are o<strong>the</strong>r vacuum<br />

cleaner models which can also be used to<br />

vacuum granules. In <strong>the</strong> case of filling and<br />

silo logistics, when <strong>the</strong> systems are rinsed<br />

with water, an extractor <strong>for</strong> metal chips<br />

(used here <strong>for</strong> ano<strong>the</strong>r purpose) can be <strong>the</strong><br />

optimum solution. One example of this is<br />

<strong>the</strong> application at Chemion, a logistics service<br />

provider handling Makrolon polycarbonate<br />

manufactured by Covestro at Uer -<br />

dingen Chemical Park.<br />

Chemion operates a logistics centre with<br />

nearly 80 shipping and mixing silos <strong>for</strong> storing,<br />

filling and packing around 250,000 t of<br />

Makrolon per year. When handling <strong>the</strong>se<br />

quantities, some pellets inevitably fall onto<br />

<strong>the</strong> floor. Since <strong>the</strong> pellets are small, hard and<br />

round, employees can slip on <strong>the</strong>m, which is<br />

why <strong>the</strong>y must be removed immediately.<br />

Ruwac SPS 35 and SPS 250 chip extractors <strong>–</strong><br />

which were originally developed <strong>for</strong> a completely<br />

different purpose, namely vacuuming<br />

and extracting chips in <strong>the</strong> metalworking<br />

<strong>industry</strong> <strong>–</strong> are used here.<br />

Separation of liquids and solids<br />

A typical feature of this type of vacuum<br />

cleaner is <strong>the</strong> two-stage operation: <strong>the</strong> chips<br />

are extracted from <strong>the</strong> liquid part (normally<br />

cooling lubricants) and retained in a preseparator.<br />

This is also an advantage when<br />

vacuuming Makrolon pellets, because <strong>the</strong><br />

Back into <strong>the</strong> transport chain<br />

A Ruwac DS 2520 L-B1 vacuum cleaner<br />

with pre-separator is used in ano<strong>the</strong>r Chemion<br />

shop at Uerdingen Chemical Park. It is<br />

installed on a line <strong>for</strong> filling 900 kg sacks. If<br />

pellets fall onto <strong>the</strong> floor next to <strong>the</strong> container,<br />

<strong>the</strong>y are collected in a tray underneath<br />

<strong>the</strong> machine and vacuumed away. The<br />

pellets are first of all fed into a customised<br />

pre-separator designed by Ruwac. They can<br />

<strong>the</strong>n be filled into a big bag via a rotary<br />

valve. Clean Makrolon pellets that have not<br />

yet touched <strong>the</strong> ground are now returned<br />

directly to <strong>the</strong> transport chain, leading to an<br />

increased material yield. The vacuum cleaner<br />

hence contributes to <strong>the</strong> efficiency of <strong>the</strong><br />

plastics logistics while <strong>the</strong> SPS chip extractors<br />

improve work safety and cleanliness.<br />

Use case: Additive manufacturing<br />

As many ingredients of plastics, compounds<br />

and masterbatches are obtained from organic,<br />

powdery materials, hazardous dust<br />

extraction systems are a common feature in<br />

<strong>the</strong> plastics <strong>industry</strong>. O<strong>the</strong>r vacuum and<br />

extraction systems are required to manufacture<br />

and process CFRP or GFRP components<br />

such as rotor blades <strong>for</strong> wind turbines. The<br />

focus is on extracting dust and fibres which<br />

are hazardous to health <strong>–</strong> a field in which<br />

Ruwac has extensive experience and many<br />

reference installations. The same applies to<br />

additive manufacturing, a relatively new<br />

branch of plastics processing. Dedusting<br />

plays an important role here <strong>–</strong> also <strong>for</strong> occupational<br />

safety reasons <strong>–</strong> and Ruwac will<br />

be presenting suitable industrial vacuum<br />

cleaners and dedusting systems at K 2019.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319ruwac<br />

Hall 11, Booth G3<br />

AUTHOR:<br />


Technology journalist<br />





RPG<br />



GF/RA<br />



Visit us:<br />

BASEL | 24. - 27.09.2019<br />

Plat<strong>for</strong>m <strong>for</strong> Chemistry,<br />

Pharmacy and Bio<strong>technology</strong><br />

STAND D122<br />

HALL 1.1<br />


78224 Singen, Germany<br />

Tel. +49 (0) 77 31 792-0<br />

tools@orbitalum.com <strong>cpp</strong> 03-2019 33<br />


<strong>cpp</strong><br />


Energy-efficient temperature control of stirrer tanks<br />

How to configure your<br />

heating and cooling system<br />

In <strong>the</strong> pharmaceutical and <strong>chemical</strong> <strong>industry</strong>, <strong>the</strong> use of stirrer tanks is routine. The<br />

reliable temperature control of <strong>the</strong> tank, however, poses several challenges <strong>for</strong><br />

operators. This article explains what you need to know about configuring a<br />

temperature control system and how to make it energy-efficient.<br />

When it comes to <strong>the</strong> temperature control<br />

of stirrer tanks, indirect heating and<br />

cooling has become prevalent in <strong>the</strong> <strong>industry</strong>:<br />

this means a liquid heat carrier circulates<br />

between <strong>the</strong> product and consumer.<br />

The typical temperature control system consists<br />

of a circulation pump, heater, cooler,<br />

freezer, expansion vessel, temperature controller<br />

and consumer. Such a temperature<br />

control system, however, has complex<br />

requirements. To ensure <strong>the</strong> consistent<br />

quality of <strong>the</strong> products, local overheating or<br />

undercooling must be prevented. Thermally<br />

induced tensions can also have negative effects<br />

on <strong>the</strong> stirrer tank, which can be prevented<br />

by configuring temperature differences<br />

via <strong>the</strong> temperature control system.<br />

In terms of reproducibility, one of <strong>the</strong> most<br />

important requirements is <strong>the</strong> precise adjustability<br />

of <strong>the</strong> temperatures. This often<br />

requires an accuracy of 0.5 K or better. This<br />

temperature control is only possible with an<br />

integrated heat carrier <strong>for</strong> heating, cooling<br />

and freezing (monofluid system).<br />

Energy-efficient configuration<br />

Available primary energies like steam, cooling<br />

water or brine need to be harnessed and<br />

effectively integrated in such a system. The<br />

compound connection of <strong>the</strong> heat flow<br />

yields energy savings. Fast switching from<br />

heating to cooling is ano<strong>the</strong>r basic prerequisite<br />

<strong>for</strong> temperature control systems in<br />

<strong>chemical</strong> reaction <strong>technology</strong>. When doing<br />

so, it is particularly important that <strong>the</strong> system<br />

is able to pass seamlessly through <strong>the</strong><br />

entire necessary temperature range. A closed<br />

temperature control system also prevents<br />

corrosion and expensive downtime <strong>for</strong><br />

maintenance or repair. The heat carrier<br />

liquid serves as an effective separating agent<br />

between <strong>the</strong> product and <strong>the</strong> environment,<br />

as <strong>the</strong> product cannot get into <strong>the</strong> primary<br />

systems, such as steam and cooling water, in<br />

<strong>the</strong> event of a rupture. Often, <strong>the</strong>rmal oils<br />

are used as a heat carrier. The benefit: They<br />

can be operated within a broad temperature<br />

range almost unpressurized. All <strong>the</strong>se<br />

requirements are fulfilled by a fluid circuit<br />

connected to primary energy sources,<br />

which is easily regulated as a closed temperature<br />

control system. In addition, <strong>the</strong> installed<br />

measuring <strong>technology</strong> allows precise<br />

balancing of <strong>the</strong> stirrer tank and primary<br />

energies. This enables extremely energy-efficient<br />

operation.<br />

For an energy-efficient configuration, it is<br />

important that <strong>the</strong> temperature control system<br />

and <strong>the</strong> stirrer tank are optimally compatible.<br />

This can be ensured by determining<br />

<strong>the</strong> heating and cooling curves of <strong>the</strong> stirrer<br />

tank.<br />

Pictures: Lauda<br />

Temperature control systems, like this one from Lauda, are suitable <strong>for</strong> use in pharmaceutical<br />

and <strong>chemical</strong> batch processes. Equipped with three heat exchangers, it is able to<br />

heat, cool or freeze a 16,000 l reactor.<br />

Selecting <strong>the</strong> heat carrier<br />

Selecting <strong>the</strong> optimum heat carrier is ano<strong>the</strong>r<br />

important part of <strong>the</strong> configuration<br />

process. Often, it makes sense to compare<br />

different heat carriers within <strong>the</strong> complete<br />

temperature range. As shown by <strong>the</strong> two<br />

cooling curves, <strong>the</strong>re can be considerable<br />

differences: Both <strong>the</strong>rmal oils are approved<br />

<strong>for</strong> -20 °C. In <strong>the</strong> first case, a product temperature<br />

of 20 °C is reached after only three<br />

hours, while in <strong>the</strong> second case, it takes six<br />

hours. It is <strong>the</strong>re<strong>for</strong>e extremely important to<br />

34 <strong>cpp</strong> 03-2019



Lauda secondary circuit units reliably<br />

control temperatures up to 400 °C and<br />

can be connected to in-house primary<br />

energies<br />

Cooling curves of an enameled 6,300 l<br />

double-jacket stirrer tank with two different<br />

<strong>the</strong>rmal oils as a cooling medium. The<br />

graphic shows how important it is to<br />

choose <strong>the</strong> right heat carrier.<br />

Both <strong>the</strong>rmal oils are approved <strong>for</strong> -20 °C.<br />

Never<strong>the</strong>less, <strong>the</strong> second medium takes<br />

twice as long to reach <strong>the</strong> required temperature.<br />

Systems that use primary energy<br />

are best suited to <strong>the</strong> temperature<br />

control of stirrer tanks.<br />

Heating and cooling systems<br />

from <strong>the</strong> TR series in <strong>the</strong> secondary<br />

circuit unit range consist<br />

of ei<strong>the</strong>r one or multiple heat<br />

exchanger modules. They feature<br />

a direct media coupling or<br />

electric heater module. The additional<br />

letters, such as HKT, indicate<br />

<strong>the</strong> number of heating or<br />

cooling modules, as well as<br />

temperature control functions.<br />

These systems produce a temperature-controlled<br />

liquid flow<br />

and are designed as a compact,<br />

fully insulated, ready-to-connect<br />

system with control cabinet,<br />

completely pre-tested at <strong>the</strong> factory.<br />

The Lauda systems control<br />

temperatures from -150 to<br />

+400 °C and use water/glycol,<br />

<strong>the</strong>rmal oil or special fluids as a<br />

heat carrier. Suitable primary<br />

energies are electrical energy,<br />

steam, hot oil, hot water, air,<br />

cooling water, cold oil or nitrogen,<br />

and energy is transferred<br />

indirectly via heat exchangers or<br />

electric heaters or a direct coupling.<br />

Every system is designed<br />

and constructed precisely to<br />

user requirements: processoriented,<br />

tailor-made and highprecision,<br />

while fulfilling <strong>the</strong><br />

strictest safety standards.<br />

optimise <strong>the</strong> heat transfer. On <strong>the</strong> jacket<br />

side, <strong>the</strong>re are several ways of going about<br />

this. For example, a heat carrier should be<br />

selected with optimal material properties<br />

<strong>for</strong> <strong>the</strong> process. The use of flow nozzles supports<br />

<strong>the</strong> heat transfer, as do welded halfpipes<br />

or <strong>the</strong> installation of spiral baffle<br />

plates on <strong>the</strong> double-jacket. The heating and<br />

cooling capacities determined from <strong>the</strong><br />

heating and cooling curves serve as <strong>the</strong><br />

basis <strong>for</strong> <strong>the</strong> configuration of <strong>the</strong> temperature<br />

control system. Three-way control<br />

valves provide high accuracy of control,<br />

easily getting to grips with even <strong>the</strong> tricky<br />

partial load range. The circulation pump is<br />

configured with <strong>the</strong> maximum heating and<br />

cooling capacities. Here <strong>the</strong> circulation<br />

quantity must be increased to ensure <strong>the</strong><br />

high accuracy of <strong>the</strong> product temperature<br />

control, in order to reduce <strong>the</strong> Delta-T between<br />

<strong>the</strong> jacket inlet and <strong>the</strong> jacket outlet<br />

of <strong>the</strong> reactor.<br />

Detailed planning with experts<br />

Temperature control systems <strong>for</strong> stirrer<br />

tanks have multiple functions. As well as <strong>the</strong><br />

ability to control <strong>the</strong> outflow temperature<br />

and product temperature, <strong>the</strong> setting of <strong>the</strong><br />

maximum difference between <strong>the</strong> outflow<br />

temperature and product temperature <strong>–</strong> <strong>the</strong><br />

Delta T control <strong>–</strong> also comes into effect. A<br />

protective enamel function ensures that <strong>the</strong><br />

permissible temperature differences of <strong>the</strong><br />

product and heat carrier are not exceeded.<br />

Ano<strong>the</strong>r function of temperature control<br />

systems is to balance <strong>the</strong> heating and cooling<br />

capacity in order to collect important<br />

process data directly and optimise <strong>the</strong> process<br />

control. If large temperature fluctuations<br />

are to be avoided when switching<br />

from heating to cooling, it is recommended<br />

to use <strong>the</strong> temperature controller of <strong>the</strong><br />

temperature control system in program and<br />

ramp mode. When it comes to detailed<br />

planning, <strong>the</strong>re are fur<strong>the</strong>r points to consider.<br />

For example, <strong>the</strong> installation site (indoors<br />

or outdoors) comes into play, as does<br />

<strong>the</strong> distance to <strong>the</strong> stirrer tank. In addition,<br />

<strong>the</strong> working temperature range of <strong>the</strong> heat<br />

carrier and product must be defined, <strong>the</strong><br />

optimum heat carrier selected and <strong>the</strong> desired<br />

heating and cooling times specified.<br />

Experienced manufacturers of temperature<br />

control systems, like Lauda, will provide<br />

support with any questions. In our experience,<br />

no two projects are alike.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319lauda<br />

Hall 10, BoothG39<br />

AUTHOR:<br />


Project manager <strong>for</strong> heating<br />

and cooling systems,<br />

Lauda<br />

<strong>cpp</strong> 03-2019 35

<strong>cpp</strong><br />


Optimal powder dispersion<br />

All process steps<br />

in one machine<br />

Powders are used in <strong>the</strong> production of many different products. Whe<strong>the</strong>r in lacquers or<br />

paints, sealing compounds, adhesives or construction <strong>chemical</strong>s, food and cosmetics <strong>–</strong><br />

<strong>the</strong> production of all <strong>the</strong>se products requires <strong>the</strong> addition of powders into liquids. To<br />

achieve best results, <strong>the</strong> powder has to be dispersed perfectly. Using conventional<br />

agitators, mixers or dissolvers this is impossible or at least very difficult. However,<br />

<strong>the</strong>re is a solution: The Conti-TDS from ystral inducts and disperses powders optimally.<br />

Main target in <strong>the</strong> processing of powder<br />

is its complete wetting, desagglomeration<br />

and homogeneous distribution in <strong>the</strong><br />

liquid. The process starts with <strong>the</strong> transfer of<br />

<strong>the</strong> powder into <strong>the</strong> process tank, incorpo -<br />

ration, wetting and dispersion and finally<br />

ends with <strong>the</strong> homogenous distribution in<br />

<strong>the</strong> liquid. Ystral TDS machines are designed<br />

to handle all five steps in one single machine.<br />

The meaning of TDS is Transport and<br />

Dispersion System. This combination not<br />

Pictures: Ystral<br />

Conti-TDS between three<br />

process vessels<br />

only streamlines <strong>the</strong> overall process, but also<br />

reduces production costs and time.<br />

Dust-free handling<br />

Conventional powder addition from top<br />

into a process tank always creates dust. But<br />

TDS machines add <strong>the</strong> powder in a different<br />

way, <strong>the</strong>y induct it with vacuum. The vacuum<br />

is created by <strong>the</strong> machine directly inside<br />

<strong>the</strong> liquid. This way <strong>the</strong> powder is incorporated<br />

dust free directly from bag,<br />

hopper or container. The dust-free induction<br />

is one of <strong>the</strong> key arguments to use that system.<br />

No powder is poured onto <strong>the</strong> surface<br />

of <strong>the</strong> liquid. No bag has to be lifted on top<br />

of <strong>the</strong> vessel. No dust sticks to <strong>the</strong> inner<br />

wall of <strong>the</strong> tank, and no powder is emptied<br />

onto <strong>the</strong> surface of <strong>the</strong> liquid in <strong>the</strong> presence<br />

of solvent vapour.<br />

TDS machines are available in two basic versions.<br />

The TDS-Induction mixer is installed<br />

inside <strong>the</strong> tank. It mixes homogenously and<br />

inducts <strong>the</strong> powder sub surface. The o<strong>the</strong>r<br />

version, <strong>the</strong> Conti-TDS, is installed in a loop<br />

outside <strong>the</strong> tank. Powder is inducted in line.<br />

Powder and liquid enter <strong>the</strong> machine via<br />

separate inlets and get in contact with each<br />

o<strong>the</strong>r not be<strong>for</strong>e reaching <strong>the</strong> high shear<br />

dispersing zone. Dispersion is carried out<br />

under maximum vacuum and high shear. If<br />

<strong>the</strong> powder concentration is low, it may be<br />

inducted completely in just one single pass.<br />

This method is used <strong>for</strong> example during<br />

filling a tank or transferring a product into<br />

ano<strong>the</strong>r vessel.<br />

Since powder is inducted directly into <strong>the</strong><br />

liquid, it can be inducted easily into flammable<br />

liquids as well. When using <strong>the</strong> term<br />

“flammable liquid” this is not quite correct:<br />

it’s a matter of fact, that <strong>the</strong> liquid itself is<br />

not inflammable, only <strong>the</strong> vapours above it.<br />

Using Conti-TDS <strong>the</strong> powder is inducted<br />

into <strong>the</strong> streaming liquid under vacuum. It<br />

does not get in contact with any inflammable<br />

vapour above <strong>the</strong> liquid.<br />

Wetting and dispersing<br />

Powder has a large specific surface. The<br />

powder in a normal 25 kg bag may have a<br />

36 <strong>cpp</strong> 03-2019

Powders and liquids collide dust-free only<br />

in <strong>the</strong> dispersing zone of <strong>the</strong> Conti-TDS<br />

Conti-TDS module with process vessel on load cells and<br />

powder addition from a big bag station<br />

surface in <strong>the</strong> range from less than<br />

100 000 m² to more than a square kilometre,<br />

depending on particle size and structure.<br />

This huge surface has to be wetted<br />

with liquid completely. When powder is<br />

poured into <strong>the</strong> tank from above, it is added<br />

to a liquid surface of not more than a few<br />

square meters. Of course <strong>the</strong> powder is<br />

somehow getting below <strong>the</strong> liquid surface<br />

with <strong>the</strong> movement of <strong>the</strong> agitator, but <strong>the</strong><br />

extreme mismatch of powder and available<br />

liquid surface causes <strong>the</strong> <strong>for</strong>mation of agglomerates.<br />

These agglomerates have to be<br />

destroyed again. This takes time, requires<br />

energy and often destroys shear sensitive ingredients<br />

in <strong>the</strong> <strong>for</strong>mulation.<br />

The Conti-TDS works differently: The vacuum<br />

expands <strong>the</strong> air between <strong>the</strong> powder<br />

particles and separates <strong>the</strong>m on <strong>the</strong>ir way<br />

into <strong>the</strong> dispersing zone. The turbulence in<br />

<strong>the</strong> high shear zone increases <strong>the</strong> liquid surface<br />

a million times. This way every single<br />

particle is wetted completely without <strong>the</strong><br />

<strong>for</strong>mation of agglomerates. Normally <strong>the</strong><br />

machine can be stopped after induction and<br />

<strong>the</strong> dispersion process is finished already.<br />

Not only <strong>for</strong> powders<br />

The TDS process is not restricted to powder<br />

induction alone; <strong>the</strong> same machines can be<br />

used <strong>for</strong> <strong>the</strong> dispersion of liquids into<br />

liquids as well. This is especially interesting<br />

<strong>for</strong> oil/water emulsions, but also, when<br />

liquids with totally different viscosities have<br />

to be mixed. In <strong>the</strong> production of adhesives,<br />

coatings and anti-perspirants <strong>for</strong> example<br />

high-viscous thickener concentrates have to<br />

be mixed into a low viscous basic liquid. In<br />

a normal agitated tank, <strong>the</strong> gel swims on <strong>the</strong><br />

top or sticks to <strong>the</strong> wall. Real homogenous<br />

distribution is very difficult to get and takes<br />

long. Using <strong>the</strong> Conti-TDS <strong>the</strong> high viscous<br />

gel is dispersed into <strong>the</strong> liquid inline, meaning<br />

when it reaches <strong>the</strong> process tank it is already<br />

homogeneously dispersed.<br />

The opposite problem is mixing low viscous<br />

additives into very high viscous dispersions<br />

or pastes. The low viscous components remain<br />

on <strong>the</strong> surface of <strong>the</strong> high viscous material.<br />

With <strong>the</strong> agitator or dissolver you<br />

simply don’t get it in. You can see <strong>the</strong> low<br />

viscous material standing on <strong>the</strong> high viscous<br />

mix. Here, as well, <strong>the</strong> Conti-TDS provides<br />

immediately a homogeneous dispersion<br />

in <strong>the</strong> external recirculation loop.<br />

Rheological additives<br />

One of <strong>the</strong> most difficult and tricky field is<br />

<strong>the</strong> addition and dispersion of rheological<br />

additive powders. Rheological additives like<br />

thickeners or stabilisers are used to create a<br />

specific flow behaviour and texture in <strong>the</strong><br />

final product. They prevent <strong>the</strong> product<br />

from separating and <strong>the</strong> dispersed ingredients<br />

from sedimenting or floating. They<br />

come as a powder, ei<strong>the</strong>r inorganic or organic,<br />

and have to be dispersed into a liquid<br />

to create <strong>the</strong> required rheology. To achieve<br />

<strong>the</strong>ir maximum effect, <strong>the</strong>y require a colloidal<br />

dispersion in <strong>the</strong> liquid phase.<br />

Because of <strong>the</strong>ir strong thickening effect,<br />

<strong>the</strong>y are used in low concentrations only.<br />

They tend to <strong>for</strong>m lumps and agglomerates<br />

which have to be broken down again. In a<br />

conventional powder addition, <strong>the</strong> product<br />

has to be fur<strong>the</strong>r dispersed until all lumps<br />

are destroyed. Swelling and hydration of<br />

<strong>the</strong>se powders starts immediately upon <strong>the</strong>ir<br />

first contact with water. They develop shearsensitive<br />

polymer structures and <strong>for</strong>m gels.<br />

But from this point on, any fur<strong>the</strong>r shear<br />

destroys <strong>the</strong> gel structure and reduces <strong>the</strong><br />

thickening effect. Already hydrated gel is<br />

damaged. Finally, more powder has to be<br />

added since a part of <strong>the</strong> thickener is destroyed<br />

again by agglomerate dispersion.<br />

But Conti-TDS machines work in a different<br />

way. In <strong>the</strong> dispersing zone, <strong>the</strong> powder particles<br />

get in contact with <strong>the</strong> liquid under<br />

maximum turbulence and <strong>the</strong>y are completely<br />

wetted on an individual basis and<br />

colloidally dispersed. At this moment <strong>the</strong><br />

powder is not yet hydrated and <strong>the</strong>re<strong>for</strong>e it<br />

is not yet sensitive to shear. The Conti-TDS<br />

wets and disperses every single particle. Agglomerates<br />

do not occur. Fur<strong>the</strong>r subsequent<br />

dispersion when <strong>the</strong> gel gets shear<br />

sensitive is not required.<br />

Conti-TDS machines are available in different<br />

sizes, with a power spectrum ranging<br />

from 3 to almost 300 kW. Depending on <strong>the</strong><br />

application, <strong>the</strong>y can be equipped with a<br />

variety of powder inlets and tools. Optimum<br />

equipment <strong>for</strong> powder handling and<br />

dosing comes with <strong>the</strong> system.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319ystral<br />

Hall 9, Booth E36<br />

AUTHOR:<br />

DR. ING. HANS-<br />


<strong>Process</strong> and Application<br />

Engineering,<br />

Ystral<br />

<strong>cpp</strong> 03-2019 37

<strong>cpp</strong><br />


Smart controller paves <strong>the</strong> way <strong>for</strong> Filtration 4.0<br />

Networked filter<br />

<strong>technology</strong> <strong>for</strong> <strong>the</strong> future<br />

Wolftechnik has developed an intelligent filter system with <strong>the</strong> support of Mittelstand<br />

4.0-Kompetenzzentrum Stuttgart, a centre dedicated to supporting SMEs.<br />

This smart filter monitors its operating parameters and is <strong>the</strong>re<strong>for</strong>e able to detect<br />

problems in <strong>the</strong> process at an early stage, so that servicing can be scheduled as <strong>the</strong><br />

need arises. This reduces <strong>the</strong> number of unscheduled disruptions and helps minimise<br />

<strong>the</strong> costs <strong>for</strong> stocking filter cartridges.<br />

For manufacturers, Industry 4.0 means<br />

higher output, as all in<strong>for</strong>mation is available<br />

in near real-time, allowing completely new<br />

approaches to <strong>the</strong> control of production<br />

systems. For this to work, <strong>the</strong> production<br />

systems must be able to generate reliable<br />

and contextual in<strong>for</strong>mation from a wealth<br />

of data and make it available to people, machines<br />

and IT services. Wolftechnik Filtersysteme<br />

GmbH & Co. KG is heavily involved<br />

in <strong>the</strong> development of networked <strong>technology</strong><br />

and future-proof solutions <strong>for</strong> industrial<br />

manufacturing. With <strong>the</strong> support of<br />

Mittelstand 4.0-Kompetenzzentrum Stuttgart,<br />

<strong>the</strong> filter system specialist has now designed<br />

a smart filter. At its core is a smart<br />

controller that collects and processes all relevant<br />

parameter data <strong>for</strong> <strong>the</strong> filter system’s<br />

pressure vessels. In November 2018, a<br />

prototype of <strong>the</strong> controller passed all tests<br />

with flying colours and was subsequently<br />

integrated into a Wolftechnik filter system.<br />

Advantages of <strong>the</strong> smart filter<br />

Smart filter controllers monitor a number of<br />

operating parameters such as pressure, temperature<br />

and flow rate or volumetric flow. A<br />

log file is kept of all data recorded and<br />

transmitted. Filter-specific in<strong>for</strong>mation regarding<br />

spare parts and replacement filters<br />

is stored in <strong>the</strong> operator’s IT system, where<br />

digital maintenance and inspection schedules<br />

are generated. In addition, operators<br />

have <strong>the</strong> option of storing user instructions<br />

<strong>for</strong> maintenance, servicing and filter<br />

changes, so that personnel can call up texts<br />

and images to guide <strong>the</strong>m through <strong>the</strong> procedures.<br />

This set-up not only facilitates correct<br />

installation; it also makes sure that<br />

A dashboard enables users to<br />

manage <strong>the</strong> entire filtration<br />

process via a single interface,<br />

where parameters can be<br />

configured and monitored<br />

and data backed up and restored.<br />

The dashboard also<br />

provides access to user manuals<br />

and o<strong>the</strong>r documents.<br />

Picture: Wolftechnik<br />

38 <strong>cpp</strong> 03-2019

Picture: Wolftechnik/Fraunhofer IPA<br />

Picture: Martin Wolf Wagner<br />

The IT concept: smart filters read <strong>the</strong> sensor values and send <strong>the</strong>m to <strong>the</strong> gateway. They also control <strong>the</strong><br />

sensors by means of commands (local decisions are possible as well). Both <strong>the</strong> end user’s smart filters<br />

and <strong>the</strong> service provider’s systems can be integrated into a public or private cloud.<br />

Designing a plat<strong>for</strong>m that can be configured<br />

with control variables to cater <strong>for</strong> any filter<br />

system and process was one of <strong>the</strong> key objectives<br />

of <strong>the</strong> development project. The QP-<br />

Quick-Pack filter system, too, can be operated<br />

as a smart filter.<br />

maintenance and servicing tasks, including<br />

filter changes, can be per<strong>for</strong>med quickly<br />

and safely.<br />

Thanks to <strong>the</strong> near real-time availability of<br />

in<strong>for</strong>mation, <strong>the</strong> solution allows a completely<br />

new approach with regard to filter<br />

system organisation and control. With smart<br />

filters, it is possible to exchange operating<br />

data with external service technicians, e.g.<br />

specialists from Wolftechnik. Based on <strong>the</strong><br />

data collected, <strong>the</strong>y can analyse and diagnose<br />

faults quickly and rectify problems<br />

without delay. Apart from innovative services<br />

such as automated spare parts ordering<br />

and notifications, <strong>the</strong> system also enables<br />

preventive maintenance and optimised production.<br />

Supporting <strong>the</strong> production process<br />

An example from <strong>the</strong> paint <strong>industry</strong> illustrates<br />

<strong>the</strong> advantages of intelligent, networked<br />

filter systems. Be<strong>for</strong>e varnishes are<br />

filled into containers <strong>for</strong> end consumers,<br />

<strong>the</strong>y are passed through a filter to ensure<br />

that <strong>the</strong> containers are not contaminated<br />

with substances originating from <strong>the</strong> production<br />

process. For this purpose, a<br />

WTGDS-type cartridge filter housing or a<br />

filter housing <strong>for</strong> <strong>the</strong> QP-Quick-Pack filter<br />

system is installed. These housings have <strong>the</strong><br />

added benefit that particles collected by <strong>the</strong><br />

filter remain in a protective bag, doing away<br />

with time-consuming cleaning. Under certain<br />

circumstances, both cartridge filters<br />

and QP-Quick-Pack filters could become<br />

clogged be<strong>for</strong>e <strong>the</strong> varnish to be filled into<br />

a container has passed through <strong>the</strong>m. Less<br />

and less product leaves <strong>the</strong> filter until eventually<br />

<strong>the</strong> filling process comes to a halt. At<br />

this point, a frantic search normally starts<br />

<strong>for</strong> spare cartridges. Provided that <strong>the</strong>se are<br />

actually available on site in <strong>the</strong> required<br />

quantity, <strong>the</strong> next step is a hurried filter<br />

change, so that <strong>the</strong> filling process can resume<br />

as soon as possible.<br />

Wolftechnik’s smart filter featuring a smart<br />

controller unit continuously monitors <strong>the</strong><br />

pressures at <strong>the</strong> input and output of <strong>the</strong><br />

filter system (differential pressure). This intelligent<br />

<strong>technology</strong> helps reduce downtime<br />

in <strong>the</strong> production process. As <strong>the</strong> filter load<br />

is constantly monitored and preliminary<br />

warnings are generated <strong>the</strong> moment <strong>the</strong>re is<br />

a change in pressure, <strong>the</strong> operator can prepare<br />

<strong>for</strong> a filter change as appropriate without<br />

interrupting <strong>the</strong> flow of varnish. The<br />

smart filter also permits optimised stock<br />

management because orders <strong>for</strong> spare parts<br />

and consumables are generated directly by<br />

<strong>the</strong> system based on actual needs.<br />

Development of <strong>the</strong> smart filter<br />

Wolftechnik cooperated on <strong>the</strong> development<br />

of <strong>the</strong> smart filter with Mittelstand<br />

4.0-Kompetenzzentrum Stuttgart. This<br />

centre is an initiative of various institutions<br />

in <strong>the</strong> region that have bundled <strong>the</strong>ir competences<br />

in a number of fields. One of <strong>the</strong><br />

partners is <strong>the</strong> Fraunhofer Institute <strong>for</strong><br />

Manufacturing Engineering and Automation<br />

IPA, whose experts designed <strong>the</strong> IT concept<br />

and <strong>the</strong> smart controller <strong>for</strong> recording and<br />

transmitting sensor data while Wolftechnik<br />

provided <strong>the</strong> filter <strong>technology</strong> know-how.<br />

Designing a plat<strong>for</strong>m that can be configured<br />

with control variables to cater <strong>for</strong> any filter<br />

system and process was one of <strong>the</strong> key objectives<br />

of <strong>the</strong> development project. Additional<br />

sensors combined with micro controllers<br />

and a suitable cloud infrastructure<br />

had to be put in place in order to realise it.<br />

At <strong>the</strong> heart of <strong>the</strong> intelligent filter system is<br />

<strong>the</strong> smart filter controller. This micro controller<br />

unit (MCU) controls communication<br />

with <strong>the</strong> sensors and <strong>the</strong> gateway of <strong>the</strong> end<br />

user environment. The gateway consists of a<br />

PC that is part of <strong>the</strong> local IT network. The<br />

filter controller transmits sensor values such<br />

as pressure and temperature to <strong>the</strong> gateway<br />

and also processes commands, <strong>for</strong> instance<br />

to adjust <strong>the</strong> sensor sampling rate. Through<br />

<strong>the</strong> gateway, <strong>the</strong> system is connected to <strong>the</strong><br />

Internet, so that <strong>the</strong> aggregated sensor readings<br />

can be sent to a database in <strong>the</strong> cloud.<br />

Users can monitor <strong>the</strong> state of <strong>the</strong> filter and<br />

its operation on a visualisation screen or<br />

dashboard. A specially designed application<br />

known as Filter Assessment Service monitors<br />

<strong>the</strong> filter parameters and makes smart decisions<br />

based on <strong>the</strong> sensor data.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319wolftechnik<br />

AUTHOR:<br />


Managing Director,<br />

Wolftechnik Filtersysteme<br />

<strong>cpp</strong> 03-2019 39

<strong>cpp</strong><br />


Picture: VTA<br />

VTA vacuum distillation plant<br />

Roots pumps <strong>for</strong> vacuum distillation<br />

Tailored to <strong>the</strong> application<br />

Vacuum distillation is used to separate temperature-sensitive substances gently, <strong>for</strong><br />

example in thin-film vaporisers and short-path evaporators. Maintaining <strong>the</strong> exact<br />

vacuum pressure required in <strong>the</strong> vaporiser is vitally important <strong>for</strong> <strong>the</strong> quality of <strong>the</strong><br />

separation process and imposes considerable demands on <strong>the</strong> vacuum control<br />

system and <strong>the</strong> vacuum pumps used. In practice, <strong>the</strong> Roots pumping stations in<br />

Pfeiffer Vacuum’s Oktaline series have proven to be <strong>the</strong> ideal solution.<br />

Many organic substances have a boiling<br />

point higher than 200 °C or are temperature-sensitive,<br />

and in this case vacuum distillation<br />

is <strong>the</strong> preferred separation method.<br />

Especially with temperature-sensitive products,<br />

<strong>the</strong> dwell time in <strong>the</strong> vaporisation device<br />

is an important aspect.<br />

In many cases, batch distillation in a reactor<br />

is unsuitable due to <strong>the</strong> dwell time, which<br />

can extend to hours, and because not<br />

enough vacuum results from <strong>the</strong> fluid column<br />

in <strong>the</strong> vessel. A fill level of 10 cm, <strong>for</strong><br />

instance, means a density-dependent pressure<br />

of about 10 hPa. For this reason, thinfilm<br />

vaporisers and short-path evaporators<br />

are used in industrial applications. In <strong>the</strong>se<br />

cylindrical systems, a very thin film (thickness<br />

1 to 3 mm) of <strong>the</strong> liquid to be vaporised<br />

is applied to <strong>the</strong> inside surface of <strong>the</strong><br />

heated cylinder using rollers or wiper<br />

blades. Depending on <strong>the</strong> size of <strong>the</strong> system,<br />

<strong>the</strong> dwell time may be only a few seconds.<br />

Thin-film vaporisation works best within a<br />

pressure range from 1 to 100 hPa. Lower<br />

pressures are difficult to achieve due to<br />

pressure losses in <strong>the</strong> vaporous substances<br />

flowing from <strong>the</strong> device to <strong>the</strong> condenser.<br />

However, pressures in <strong>the</strong> region of<br />

0.01 hPa are required <strong>for</strong> <strong>the</strong> separation of<br />

mono-, di- and triglycerides, <strong>for</strong> example.<br />

In this case, <strong>the</strong> so-called short-path distillation<br />

method is chosen. The condenser is<br />

located at <strong>the</strong> centre of <strong>the</strong> cylindrical<br />

vaporiser and <strong>the</strong> distances between <strong>the</strong> hot<br />

wall and <strong>the</strong> water-cooled pipe coil are in<br />

<strong>the</strong> order of a few centimetres, depending<br />

on <strong>the</strong> size of <strong>the</strong> device. Pressure losses are<br />

minimised because <strong>the</strong> material to be evaporated<br />

condenses directly on <strong>the</strong> cold surface.<br />

Since <strong>the</strong> mean free path of a molecule<br />

in a medium vacuum is similar to, or significantly<br />

greater than, <strong>the</strong> distance between<br />

<strong>the</strong> cylinder and <strong>the</strong> internal condenser, this<br />

method is also referred to as molecular distillation.<br />

If <strong>the</strong> vapour pressures of <strong>the</strong> substances to<br />

be separated are very close toge<strong>the</strong>r, vacuum<br />

rectification columns are used. In <strong>the</strong>se<br />

counter-current distillation systems, <strong>the</strong> vapour<br />

flows through a vertically aligned column<br />

to <strong>the</strong> condensed liquid. Installations<br />

such as structured packings ensure good<br />

mixing of <strong>the</strong> two phases, so that a phase<br />

equilibrium can be achieved. The dwell<br />

times and pressure levels are higher than<br />

with thin-film vaporisers, however. The two<br />

processes are often combined.<br />

40 <strong>cpp</strong> 03-2019

Picture: Pfeiffer Vacuum<br />

Picture: Pfeiffer Vacuum<br />

Three-stage pumping station <strong>for</strong> distillation<br />

processes<br />

Okta 500 Atex: Roots pumps with a pumping speed of 280 to 670 m 3 /h<br />

Roots pumping stations<br />

Maintaining <strong>the</strong> exact vacuum pressure<br />

required in <strong>the</strong> vaporiser is vitally important<br />

<strong>for</strong> <strong>the</strong> quality of <strong>the</strong> separation process and<br />

imposes considerable demands on <strong>the</strong> vacuum<br />

control system and <strong>the</strong> vacuum pumps<br />

used.<br />

Pfeiffer Vacuum <strong>the</strong>re<strong>for</strong>e offers a large selection<br />

of suitable vacuum equipment <strong>for</strong><br />

thin-film and short-path distillation. In<br />

practice, Roots pumping stations with<br />

liquid ring pumps have proven to be <strong>the</strong><br />

ideal solution. Depending on <strong>the</strong> number of<br />

Roots piston stages, a pressure of 10 <strong>–</strong>3 hPa<br />

can be achieved without much ef<strong>for</strong>t. It is<br />

also possible to operate <strong>the</strong> liquid ring<br />

pump with <strong>the</strong> substance that needs to be<br />

distilled. One example involves processing<br />

rolling oil. The oil contaminated by <strong>the</strong> rolling<br />

operation is reprocessed by distillation.<br />

For this, three-stage Roots pumping stations<br />

consisting of two Roots pumps and a liquid<br />

ring pump are used. The rolling oil to be<br />

distilled serves as <strong>the</strong> operating liquid <strong>for</strong><br />

<strong>the</strong> liquid ring pump. At a pressure of approximately<br />

5 hPa, <strong>the</strong> rolling oil evaporates<br />

and is condensed in <strong>the</strong> downstream condenser.<br />

The possibility of leakage air saturated<br />

with oil vapours being sucked into <strong>the</strong><br />

vacuum pump system, where <strong>the</strong>se vapours<br />

are <strong>the</strong>n condensed again in <strong>the</strong> liquid ring<br />

pump, cannot be completely ruled out,<br />

however. Yet if <strong>the</strong> rolling oil is used as <strong>the</strong><br />

operating liquid, this will have no negative<br />

effects on <strong>the</strong> pump’s throughput. The level<br />

of <strong>the</strong> liquid in <strong>the</strong> circulatory container of<br />

<strong>the</strong> liquid ring pump rises slowly. When <strong>the</strong><br />

maximum permitted level is reached, <strong>the</strong><br />

operating liquid is automatically discharged<br />

and fed to a suitable treatment process. Depending<br />

on <strong>the</strong> application, dry backing<br />

pumps can also be employed instead of <strong>the</strong><br />

liquid ring pump.<br />

Complete range<br />

Based on its comprehensive range of products,<br />

Pfeiffer Vacuum offers customised solutions<br />

to create <strong>the</strong> vacuum conditions<br />

required <strong>for</strong> a variety of applications. Especially<br />

where applications in <strong>the</strong> <strong>chemical</strong><br />

<strong>industry</strong> are concerned that require a pressure<br />

of less than 33 hPa, <strong>the</strong> Roots pumping<br />

stations in Pfeiffer Vacuum’s Oktaline series<br />

have established <strong>the</strong>mselves as ideal solutions.<br />

Depending on <strong>the</strong> required pumping<br />

speed and ultimate pressure, different<br />

pumping stages can be built in. Roots<br />

pumps with a pumping capacity of<br />

145 m 3 /h to 8000 m 3 /h are available as<br />

standard. In special cases, Roots pumps with<br />

a pumping speed of up to 25,000 m 3 /h can<br />

be manufactured.<br />

The gas circulation-cooled version of <strong>the</strong><br />

Oktaline allows compression to ambient<br />

pressure and is used predominantly in critical<br />

processes in <strong>the</strong> <strong>chemical</strong> <strong>industry</strong>. The<br />

standard pumps are made of spheroidal<br />

graphite cast iron (GGG40), which ensures<br />

<strong>the</strong> high pressure shock resistance (16 bar)<br />

of <strong>the</strong> pump housing. This is particularly<br />

important <strong>for</strong> Atex applications. For highly<br />

corrosive applications, <strong>the</strong> Oktaline can be<br />

made of stainless steel. It is also possible to<br />

apply a plasma-polymer coating to <strong>the</strong> parts<br />

of <strong>the</strong> suction chamber that come into contact<br />

with <strong>the</strong> product. More demanding<br />

pump tightness requirements are met with<br />

<strong>the</strong> aid of magnetically coupled drives with<br />

leakage rates of less than 1 · 10 <strong>–</strong>6 Pa m 3 /s.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319pfeiffervacuum<br />

AUTHORS:<br />


Application- & Project Manager Industry market<br />

segment,<br />

Pfeiffer Vacuum<br />


Industry market segment,<br />

Pfeiffer Vacuum<br />


Industry market segment,<br />

Pfeiffer Vacuum<br />

<strong>cpp</strong> 03-2019 41

<strong>cpp</strong><br />


Compressed air management: service tool and app <strong>for</strong> compressors<br />

In <strong>the</strong> age of Industry 4.0<br />

The Boge connect service tool is tailored to <strong>the</strong> entire life cycle of a compressor,<br />

from partially digitalised commissioning and comprehensive monitoring to extended<br />

service functions and automatically generated optimisation proposals. All important<br />

operating parameters are recorded, monitored and visualised without paper. Boge<br />

connect replaces <strong>the</strong> airstatus option and will in future be available as standard <strong>for</strong><br />

all 45 kW compressors and higher.<br />

Intelligent analysis and optimisation options<br />

are of fundamental importance <strong>for</strong> <strong>the</strong><br />

efficient and future-oriented operation of<br />

compressed air systems. The compressed air<br />

expert Boge offers extensive services <strong>for</strong> this<br />

challenge. The currently available Boge airstatus<br />

option, <strong>for</strong> example, allows up to 32<br />

components of a compressed air system to<br />

be analysed, controlled and evaluated. The<br />

data is available almost in real time. With<br />

<strong>the</strong> development of <strong>the</strong> Boge connect service<br />

function, <strong>the</strong> family-owned company<br />

from Bielefeld goes one step fur<strong>the</strong>r. With<br />

<strong>the</strong> associated app, <strong>the</strong> tool provides an<br />

ideal basis <strong>for</strong> networking intelligent systems<br />

and is <strong>the</strong>re<strong>for</strong>e an important building<br />

block <strong>for</strong> Industry 4.0 processes. Boge connect<br />

offers clear visualisation of all data and<br />

reduces <strong>the</strong> administrative ef<strong>for</strong>t <strong>for</strong> dealers<br />

enormously. The service function accompanies<br />

<strong>the</strong> machine throughout its entire<br />

life cycle. In conventional commissioning,<br />

<strong>for</strong> example, <strong>the</strong> dealer collects data from<br />

<strong>the</strong> nameplate and o<strong>the</strong>r system parameters<br />

and, in many cases, records <strong>the</strong> details manually<br />

in documents. With Boge connect,<br />

commissioning is faster, easier and paperless.<br />

The manufacturer stores machine data<br />

in a QR code and attaches it to <strong>the</strong> machine.<br />

The Boge connect app scans <strong>the</strong> QR code<br />

and makes all relevant data available immediately<br />

in digital <strong>for</strong>m. In addition, <strong>the</strong><br />

tool supports <strong>the</strong> maintenance of compressors.<br />

In good time and be<strong>for</strong>e any mainte -<br />

nance is due, <strong>the</strong> responsible service employee<br />

receives a notification by SMS or<br />

e-mail. This leaves enough time to order<br />

machine parts, prepare maintenance quotes<br />

and schedule an appointment with <strong>the</strong> customer.<br />

Maintenance intervals, commissioning<br />

data and o<strong>the</strong>r in<strong>for</strong>mation are stored in<br />

a digital machine file, which can be accessed<br />

from anywhere via password-protected<br />

log-in. In addition, <strong>the</strong> employee can<br />

use a machine-specific checklist to carry out<br />

maintenance work.<br />

Pictures: Boge<br />

Boge connect captures, monitors and visualises all important operating parameters<br />

paperlessly and available from anywhere<br />

Warranty and remote access<br />

All important operating parameters are re -<br />

corded, monitored and visualised via Boge<br />

connect. The service can be used <strong>for</strong> one<br />

compressor as well as <strong>for</strong> a system consisting<br />

of several compressors. If <strong>the</strong> service<br />

agreement covers several compressors, <strong>the</strong>se<br />

are marked in colour on a digital map. This<br />

way you can see immediately which compressors<br />

are operating smoothly, which ones<br />

42 <strong>cpp</strong> 03-2019

equire maintenance, and which ones have<br />

malfunctioned. All machines equipped with<br />

<strong>the</strong> service tool have a warranty of five<br />

years. The warranty includes professional<br />

service by certified service technicians as<br />

well as <strong>the</strong> use of original wear parts and<br />

operating materials. If <strong>the</strong> customer reports<br />

a problem with a machine, <strong>the</strong> service technician<br />

can immediately retrieve all machine<br />

data via <strong>the</strong> tool. This new service program<br />

<strong>the</strong>re<strong>for</strong>e leads to more efficient technical<br />

support. If <strong>the</strong> customer agrees, <strong>the</strong> system<br />

can be accessed directly from a distance<br />

using <strong>the</strong> remote access function, <strong>for</strong><br />

example to change parameters or carry out<br />

a software update.<br />

Smart solution<br />

Beyond <strong>the</strong> simple analysis of data, additional<br />

functions are required in <strong>the</strong> age of<br />

increasing digitalisation and networking.<br />

This includes, <strong>for</strong> example, precise predictions<br />

of <strong>the</strong> time of occurrence of a potential<br />

malfunction. The Boge connect portal<br />

enables both service technicians and dealers<br />

to obtain in<strong>for</strong>mation on <strong>the</strong> condition of<br />

<strong>the</strong> systems at any time: The per<strong>for</strong>mance<br />

data is continuously analysed in order to<br />

identify leaks and potential savings. By<br />

evaluating large and heterogeneous amounts<br />

of data, such as a specific correlation of<br />

pressure, temperature, vibration and o<strong>the</strong>r<br />

key figures, errors and operating anomalies<br />

can be detected at an early stage. Machine<br />

maintenance can be proactive, reducing <strong>the</strong><br />

risk of failure and minimising downtime.<br />

The machine control focus control 2.0 calculates<br />

<strong>the</strong> efficiency of <strong>the</strong> system and<br />

shows <strong>the</strong> ratio of load to idling speed. This<br />

can be used to establish whe<strong>the</strong>r <strong>the</strong> machine<br />

may have been incorrectly dimensioned<br />

or set up. The analysis takes place<br />

automatically, without <strong>the</strong> service technician<br />

having to actively display and evaluate<br />

<strong>the</strong> data. This increases <strong>the</strong> service life of <strong>the</strong><br />

system and avoids damage. The intelligent<br />

data analysis ensures that <strong>the</strong> system is always<br />

operated according to <strong>the</strong> state of <strong>the</strong><br />

art.<br />

Picture: Boge<br />

The digital map shows which compressors are running smoothly and which require maintenance<br />

The machine control focus control 2.0<br />

automatically calculates <strong>the</strong> efficiency of<br />

<strong>the</strong> system<br />

Wide range of use<br />

All screw compressors with an output of<br />

over 45 kW will in future be equipped as<br />

standard with <strong>the</strong> necessary hardware. Older<br />

or smaller models can be easily retrofitted.<br />

The basic functions of Boge connect - visualisation,<br />

service notification and use of<br />

<strong>the</strong> app - can be used free of charge. Additional<br />

functions, such as predictive maintenance,<br />

live view of consumption and payper-use<br />

can be booked optionally. The prerequisite<br />

<strong>for</strong> using Boge connect is good<br />

mobile phone reception. Boge connects <strong>the</strong><br />

service program directly with <strong>the</strong> focuscontrol<br />

2.0 machine control of <strong>the</strong> compressors.<br />

Data transmission is carried out via<br />

<strong>the</strong> Modbus TCP or Modbus RTU protocols.<br />

The portal also allows third-party products<br />

to be integrated into <strong>the</strong> system; however,<br />

some functions may <strong>the</strong>n be limited.<br />

Oil filter change on <strong>the</strong> compressor:<br />

continuous monitoring with Boge connect<br />

increases planning reliability<br />

Classic win-win situation<br />

Boge connect visualises and networks not<br />

only machine data. The service tool offers<br />

both dealers and manufacturers added value.<br />

Continuous monitoring along with early<br />

fault reports and proactive maintenance lead<br />

to increased planning reliability <strong>for</strong> <strong>the</strong><br />

service technician. Regular maintenance ensures<br />

that <strong>the</strong> warranty conditions are met.<br />

In addition, dealers benefits from <strong>the</strong> automatic<br />

display of potential savings, allowing<br />

<strong>the</strong>m to operate <strong>the</strong> customer‘s system<br />

highly efficiently. Thanks to <strong>the</strong> detailed<br />

analyses, <strong>the</strong> compressed air expert is provided<br />

with important in<strong>for</strong>mation regarding<br />

<strong>the</strong> fur<strong>the</strong>r development of its compressors.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319boge<br />

AUTHOR:<br />


Team Leader Aftermarket,<br />

Boge<br />

<strong>cpp</strong> 03-2019 43

<strong>cpp</strong><br />


Picture: BillionPhotos.com <strong>–</strong> Fotolia.com<br />

Compressed air is an important medium in <strong>the</strong> <strong>chemical</strong> and pharmaceutical industries and is used, <strong>for</strong> example, in <strong>the</strong> manufacture<br />

of pharmaceuticals<br />

Cloud solution captures and visualises compressor and compressed air system data<br />

Digital transparency on<br />

compressed air treatment<br />

There is considerable demand in <strong>the</strong> market <strong>for</strong> <strong>for</strong>ward-looking digitalisation of<br />

processes related to compressed air treatment. This calls <strong>for</strong> innovative and useroriented<br />

solutions that support increasingly networked machines as well as Internet<br />

of Things technologies. There is no alternative <strong>for</strong> users seeking maximum possible<br />

transparency on <strong>the</strong>ir compressed air treatment processes or on <strong>the</strong>ir compressed<br />

air quality in everyday operations.<br />

Industrial companies that use compressed<br />

air in <strong>the</strong>ir production processes need maximum<br />

possible transparency when it comes to<br />

compressed air treatment. The <strong>chemical</strong> and<br />

pharmaceutical industries in particular demand<br />

to be in<strong>for</strong>med about compressed air<br />

quality at all times to be able to react quickly<br />

to deviations. This is because compressed air<br />

is employed in many sensitive applications<br />

and often comes into contact with <strong>the</strong> product<br />

directly <strong>–</strong> from tabletting or cleaning systems<br />

and containers through component<br />

transport and packaging systems to air curtains<br />

<strong>for</strong> defining safe and clean areas. In<br />

order to ensure safe and stable processes and<br />

products, companies in this sector are reliant<br />

on a constant supply of absolutely oil-free<br />

and sterile compressed air. The compressed<br />

air quality must be comprehensively monitored<br />

<strong>for</strong> this purpose.<br />

Seamless quality control<br />

If <strong>the</strong> compressed air is contaminated by oil<br />

particles, germs or moisture, <strong>for</strong> example,<br />

this can have a decisive influence on <strong>the</strong><br />

manufacturing process and cause considerable<br />

damage. Contaminated compressed air<br />

in tablet production can lead to breakage or<br />

colour variations and pose health risks <strong>for</strong><br />

end users. To guarantee safe applications, it<br />

is important to treat <strong>the</strong> compressed air<br />

using filtration, drying and catalysis <strong>technology</strong><br />

and monitor it continuously.<br />

Pfizer Manufacturing Deutschland GmbH is<br />

a pharmaceutical company which relies on<br />

continuous quality controls of compressed<br />

air. The medium is in direct contact with <strong>the</strong><br />

drug during coating, i. e. when <strong>the</strong> protective<br />

layer is sprayed onto film tablets, as<br />

44 <strong>cpp</strong> 03-2019

well as during blow-out processes on<br />

production machines. Pfizer monitors <strong>the</strong><br />

residual oil content using measurement<br />

<strong>technology</strong> with an integrated alarm<br />

system, enabling countermeasures to be<br />

initiated be<strong>for</strong>e <strong>the</strong> defined limit values are<br />

exceeded and resulting in higher overall<br />

process reliability.<br />

Monitoring <strong>the</strong> compressed air system<br />

Intelligent measurement <strong>technology</strong><br />

provides companies using compressed air<br />

in <strong>the</strong>ir production processes with <strong>the</strong><br />

transparency <strong>the</strong>y need to manufacture<br />

safely and reliably. Measuring systems from<br />

Beko Technologies GmbH, <strong>for</strong> example, let<br />

users continuously record key compressed<br />

air parameters such as residual oil vapour<br />

content, pressure and relative humidity and<br />

keep an eye on <strong>the</strong> compressed air quality at<br />

all times. They can <strong>the</strong>n react quickly to any<br />

quality deviations and design more energyefficient<br />

compressed air systems overall.<br />

They are supported by individually adjustable<br />

alarm functions, which <strong>for</strong>ward important<br />

in<strong>for</strong>mation via various channels<br />

such as text messaging or e-mail.<br />

When monitoring compressed air quality<br />

The quality of compressed air can be continuously monitored using intelligent measurement <strong>technology</strong><br />

systems <strong>–</strong> <strong>for</strong> safe and stable production processes<br />

and setting up an efficient treatment<br />

process, it is vital to take a holistic view of<br />

<strong>the</strong> compressed air system <strong>–</strong> including <strong>the</strong><br />

compressor required <strong>for</strong> compressed air<br />

generation. This is because oil-lubricated<br />

and even oil-free compressors can be a<br />

source of residual oil vapours in <strong>the</strong> compressed<br />

air network. Although a compressor<br />

which compresses without oil does not<br />

allow any additional oil to enter <strong>the</strong> compressed<br />

air network, it also does not af<strong>for</strong>d<br />

absolute safety since impurities such as oil<br />

aerosols or microorganisms are already<br />

contained in <strong>the</strong> intake air or can get into<br />

<strong>the</strong> compressed air network through o<strong>the</strong>r<br />

components. “Against this background, as a<br />

specialist <strong>for</strong> compressed air treatment and<br />

monitoring, we have once again addressed<br />

Picture: Beko<br />

Rethink your<br />

production process<br />

The production of plastics involves <strong>the</strong> use of numerous<br />

powders and granulates. These substances<br />

have a wide variety of functions. Only if <strong>the</strong> powders<br />

and granulates are dissolved, completely wetted<br />

and dispersed are high-quality products created.<br />

ystral develops and manufactures customized process<br />

systems that generate significant and proven<br />

savings in process time, floor space, ressources<br />

and energy consumption compared to conventional<br />

dissolvers.<br />




16. - 23.10.19 HALL 9/E36<br />


With <strong>the</strong> right mix<br />

ystral gmbh maschinenbau + processtechnik<br />

Wettelbrunner Strasse 7 I 79282 Ballrechten-Dottingen I Germany<br />

Tel. +49 7634 5603 0 I ystral@ystral.de I ystral.com<br />

<strong>cpp</strong> 03-2019 45

<strong>cpp</strong><br />


Picture: Beko<br />

Metpoint MEQ <strong>–</strong> <strong>the</strong> data assistant <strong>for</strong> total visualisation of compressed air systems<br />

current clamps, making it possible to record<br />

compressor energy consumption in real<br />

time and demonstrate efficiency increases<br />

transparently in <strong>the</strong> entire compressed air<br />

system.<br />

Toge<strong>the</strong>r with <strong>the</strong> in<strong>for</strong>mation from <strong>the</strong><br />

compressed air quality sensors, all data is<br />

visualised in a cloud GUI. Users can hence<br />

check <strong>the</strong> condition of <strong>the</strong>ir compressed air<br />

system anywhere at any time and retain full<br />

control over <strong>the</strong> system and compressor<br />

data. If required, an automated energy or<br />

quality report can be called up at <strong>the</strong> touch<br />

of a button in order to analyse <strong>the</strong> efficiency<br />

potential. Compressor operating hours can<br />

also be viewed centrally. Servicing and<br />

maintenance cycles can be planned more<br />

efficiently as a result with <strong>the</strong> help of automated<br />

reports and notification functions.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319beko<br />

<strong>the</strong> central issue of optimum transparency<br />

in <strong>the</strong> compressed air treatment process”,<br />

says Yannick Koch, Head of Global Corporate<br />

Development at Beko Technologies.<br />

Data assistant enables full control<br />

The company, based in Neuss (Germany),<br />

has consequently expanded its measurement<br />

<strong>technology</strong> solutions with Metpoint MEQ,<br />

thus taking a fur<strong>the</strong>r step towards energy<br />

efficiency and digital transparency. The data<br />

assistant not only records <strong>the</strong> data of <strong>the</strong><br />

treatment plant but also <strong>the</strong> energy and per<strong>for</strong>mance<br />

data of <strong>the</strong> upstream compressors.<br />

The system measures <strong>the</strong> real current consumption<br />

at <strong>the</strong>se compressors by means of<br />

AUTHOR:<br />


Freelance specialised<br />

journalist<br />



Picture: Beko<br />

Yannick Koch, Head of Global Corporate<br />

Development at Beko Technologies<br />

Mr. Koch, Beko Technologies<br />

has added <strong>the</strong> Metpoint MEQ<br />

data assistant to its measurement<br />

<strong>technology</strong> family. How<br />

did this idea come about?<br />

Koch: The idea <strong>for</strong> <strong>the</strong> product<br />

originated in an interdiscipli -<br />

nary working group called<br />

Products & Services 2020 and<br />

led us to consider how best to<br />

provide compressed air users<br />

with maximum possible transparency<br />

on <strong>the</strong>ir compressed air<br />

preparation process while leveraging<br />

<strong>the</strong> opportunities arising<br />

from digitisation. This thought<br />

process resulted in a cloud solution<br />

that was unveiled at this<br />

year’s Comvac in Hannover.<br />

What does <strong>the</strong> “Q” in <strong>the</strong> product<br />

name stand <strong>for</strong>?<br />

Koch: The aim of comprehensive<br />

compressed air treatment,<br />

which we enable with our<br />

solutions, is always to ensure<br />

<strong>the</strong> compressed air quality<br />

required <strong>for</strong> a particular application<br />

<strong>–</strong> hence <strong>the</strong> “Q” in <strong>the</strong><br />

product name. The quality of<br />

compressed air and continuous<br />

monitoring play an important<br />

role <strong>for</strong> our customers because<br />

<strong>the</strong>y have an enormous influence<br />

on <strong>the</strong>ir manufacturing<br />

processes and <strong>the</strong> quality of<br />

<strong>the</strong>ir end products.<br />

The new measuring <strong>technology</strong><br />

system is characterised in particular<br />

by a holistic view of<br />

compressor and compressed air<br />

treatment system and a digital<br />

alignment. How did you consider<br />

<strong>the</strong>se aspects in <strong>the</strong> deve -<br />

lopment of <strong>the</strong> solution?<br />

Koch: We cooperated with experts<br />

from <strong>the</strong> energy and com-<br />

pressor sectors during <strong>the</strong> deve -<br />

lopment process and bundled<br />

<strong>the</strong>ir expertise with our knowhow.<br />

About two and a half years<br />

passed from <strong>the</strong> idea to <strong>the</strong> market-ready<br />

product in line with<br />

our quality standards. Apart<br />

from developing an intelligent<br />

measurement system, we also<br />

wanted to offer our customers<br />

even better service. We <strong>the</strong>re<strong>for</strong>e<br />

addressed aspects such as mobile<br />

connectivity, software as a<br />

service and online support in<br />

<strong>the</strong> course of <strong>the</strong> development<br />

project. The digitally oriented<br />

business model which was <strong>the</strong><br />

outcome of all this meets<br />

customers’ need <strong>for</strong> self-in<strong>for</strong>mation<br />

independent of place<br />

and time as well as support on<br />

demand.<br />

46 <strong>cpp</strong> 03-2019

<strong>cpp</strong><br />


Gentle pumping of pastes and non-flowable substances<br />

Drum emptying system<br />

with follower plate<br />

Even high viscosity pumps come to <strong>the</strong>ir application limits very fast, when trying to<br />

pump high-viscous, non-flowable substances. The newly developed drum emptying<br />

system with follower plate from Lutz exceeds <strong>the</strong>se limits and <strong>the</strong> infinitely variable<br />

operation enables particularly gentle pumping of pastes and non-flowable<br />

substances in <strong>the</strong> food, pharmaceutical and industrial sectors.<br />

The drum emptying system is supplied on<br />

a mobile trolley, which ensures maximum<br />

mobility and flexibility. The ergonomic design<br />

simplifies <strong>the</strong> operation <strong>for</strong> <strong>the</strong> user. A<br />

simple and convenient control system enables<br />

<strong>the</strong> commissioning. The manual, infinitely<br />

variable control of <strong>the</strong> FDA-compliant<br />

hydraulics gently deposits <strong>the</strong> follower plate<br />

on <strong>the</strong> medium. The conveying speed is infinitely<br />

variable and <strong>the</strong> containers are emptied<br />

almost pulsation-free.<br />

Sealing lips made of EPDM (also available in<br />

FKM or PTFE) adapt perfectly to <strong>the</strong> container.<br />

Due to <strong>the</strong> pressureless guidance, <strong>the</strong><br />

pumped medium is not pressed out at <strong>the</strong><br />

wall. Only a small amount remains in <strong>the</strong><br />

container after emptying which is both<br />

cost-effective and environmentally friendly.<br />

An integrated sensor ensures that <strong>the</strong> pump<br />

is protected against dry running. Cylindrical<br />

drums, but also slightly conical containers,<br />

with or without drum inliner, can be emptied.<br />

Adjustable drum retaining clamps secure<br />

<strong>the</strong> containers from <strong>the</strong> outside when<br />

<strong>the</strong> follower plate is removed. This is additionally<br />

supported by <strong>the</strong> application of<br />

compressed air.<br />

Fast cleaning no problem<br />

To ensure fast and cost-effective cleaning,<br />

<strong>the</strong> plate and pump tube can be dis -<br />

assembled quickly by using Tri-Clamp<br />

connections. Generally, <strong>the</strong> follower plate is<br />

operated with a 3A-approved free of bacteria<br />

traps and thread-free pump. The mobile<br />

trolley, <strong>the</strong> hydraulic unit and <strong>the</strong> follower<br />

plate are also made of polished stainless<br />

steel.<br />

Depending on <strong>the</strong> pump size and <strong>the</strong> drive<br />

motors that can be combined with it, flow<br />

rates of up to 120 l/min can be achieved.<br />

The range of drive options extends from<br />

standard three-phase motors with frequency<br />

converter to compressed air motors and<br />

gear motors.<br />

When retracted, <strong>the</strong> total height of <strong>the</strong> system<br />

is only 2.12 m and is <strong>the</strong>re<strong>for</strong>e ideally<br />

suited <strong>for</strong> low ceiling heights and transport<br />

in elevators. The weight of <strong>the</strong> mobile unit,<br />

without pump, is approx. 140 kg.<br />

In order to cover <strong>the</strong> largest possible range<br />

Pictures: Lutz Pumpen<br />

A simple and convenient control system<br />

enables <strong>the</strong> commissioning<br />

of tasks, <strong>the</strong> system can also be used without<br />

<strong>the</strong> follower plate as a pure, mobile lifting<br />

stand toge<strong>the</strong>r with <strong>the</strong> pump.<br />

The follower plate system can be used to<br />

pump highly viscous, pasty and viscous<br />

substances which are not capable of flow -<br />

ing. Examples from <strong>the</strong> various application<br />

fields are lipsticks, mascara, ice cream, to -<br />

mato paste, infant food, ointments, fats and<br />

colours.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319lutz<br />

The ergonomic design of<br />

<strong>the</strong> drum emptying system<br />

simplifies <strong>the</strong> operation<br />

<strong>for</strong> <strong>the</strong> user<br />

<strong>cpp</strong> 03-2019 47

<strong>cpp</strong><br />


Keep your process plant up to date at all times<br />

Cloud services <strong>for</strong> digital<br />

twins<br />

Plantsight, a suite of cloud services developed by Siemens and Bentley, enables <strong>the</strong><br />

delivery of constantly updated, true-to-life digital twins. Real process equipment<br />

and engineering data are synchronised. Multiple data sources, including dark data,<br />

are integrated to create an immersive environment with visible analysis <strong>for</strong> more<br />

efficient operations and better in<strong>for</strong>med decisions.<br />

Plantsight is a set of digital twin cloud<br />

services that provides an evergreen digital<br />

twin environment <strong>for</strong> process plants in<br />

which to consolidate and aggregate plant<br />

models and data, validate, visualise and analyse<br />

<strong>the</strong>m to facilitate in<strong>for</strong>med decisions. It<br />

trans<strong>for</strong>ms raw data into one complete,<br />

living digital twin that is continuously updated.<br />

The digital twin can include process<br />

and plant engineering, physical layout<br />

modelling, project and construction planning,<br />

maintenance, reliability and asset per<strong>for</strong>mance<br />

modelling.<br />

One decisive factor is <strong>the</strong> federation of data.<br />

Thanks to intelligent scanning and data interpretation,<br />

imaging <strong>technology</strong> allows access<br />

to previously inaccessible in<strong>for</strong>mation.<br />

This allows data to be validated and linked<br />

with o<strong>the</strong>r in<strong>for</strong>mation; changes can be<br />

tracked in order to improve not only <strong>the</strong> accuracy,<br />

completeness and trustworthiness of<br />

asset data and documentation but also compliance<br />

and decision making. The solution is<br />

scalable, secure and extensible and will reduce<br />

<strong>the</strong> IT footprint and costs.<br />

Introducing Plantsight<br />

Plantsight is a cloud-based plant engineering<br />

and operations solution that scales from<br />

<strong>the</strong> simplest plant modification to <strong>the</strong> workflows<br />

required <strong>for</strong> complex capital projects.<br />

The solution shares a common data model<br />

across an open and connected data environment<br />

(CDE), which integrates services from<br />

both Siemens and Bentley.<br />

These services include data acquisition <strong>–</strong><br />

which apart from Comos and Openplant<br />

can also load plant design in<strong>for</strong>mation from<br />

Aveva and Hexagon <strong>–</strong>, data aggregation<br />

services to consolidate and aggregate data<br />

into <strong>the</strong> CDE and ensure that all data is correctly<br />

synchronised and a tag registry service<br />

that manages tags across all <strong>the</strong>se<br />

multiple systems. Tags are used to identify<br />

assets and are typically <strong>the</strong> common de-<br />

Pictures: Bentley Systems<br />

Plantsight side-by-side comparison model<br />

48 <strong>cpp</strong> 03-2019

Operation and maintenance engineers keep<br />

an eye on plant health from Plantsight dashboards<br />

nominator between different engineering<br />

and operations systems. They are also one of<br />

<strong>the</strong> hardest things to consolidate and keep<br />

updated across such systems.<br />

Thanks to Siemens’ know-how in functional<br />

in<strong>for</strong>mation and Bentley’s expertise in 3-D<br />

spatial in<strong>for</strong>mation, Plantsight solves this<br />

problem. In addition to aggregating data<br />

from plant design systems, it can also aggregate<br />

in<strong>for</strong>mation from Excel, ISO 15926<br />

and o<strong>the</strong>r sources, giving <strong>the</strong> operator instant<br />

access to accurate tag in<strong>for</strong>mation. The<br />

Plantsight tag registry is likewise integrated<br />

directly with Comos and Openplant, so that<br />

<strong>the</strong>y share this capability with design workflows.<br />

O<strong>the</strong>r Plantsight services can similarly<br />

be shared as user requirements demand.<br />

Yet what if <strong>the</strong>re is no 3-D model of <strong>the</strong><br />

existing plant? Plantsight can also combine<br />

a reality mesh of this plant with any 3-D<br />

models that may be available and link tag<br />

in<strong>for</strong>mation to <strong>the</strong> geospatial coordinates of<br />

<strong>the</strong> tagged component.<br />

No more dark data<br />

A digital twin combines data from many<br />

online and offline sources with open IT integration.<br />

It helps incorporate data from digitally<br />

inaccessible sources, sometimes referred<br />

to as “dark data”, and mobile sources<br />

used in <strong>the</strong> field.<br />

An accurate, up-to-date, accessible digital<br />

twin reduces <strong>the</strong> time to operational readiness<br />

and can also influence <strong>the</strong> time to market.<br />

The ease with which this digital twin<br />

can be updated during operation or modified<br />

during projects meets <strong>the</strong> need <strong>for</strong> increased<br />

flexibility and adaptability. The<br />

seamless and ongoing integration of process<br />

engineering, maintenance, 3-D representation<br />

and operational per<strong>for</strong>mance in<strong>for</strong>mation<br />

speeds up and supports continuous<br />

improvements and hence efficiency,<br />

sustainability and <strong>the</strong> return on assets. The<br />

digital twin makes it more straight<strong>for</strong>ward<br />

to engineer <strong>for</strong> safety and compliance and<br />

verify <strong>the</strong> as-built and as-maintained facility.<br />

In addition to in<strong>for</strong>mation which is accessible<br />

online, <strong>the</strong>re is a category of inaccessible<br />

sources such as PDF documents, drawings<br />

or paper documentation as well as electronic<br />

data in legacy systems that can benefit<br />

a broader set of users if made available.<br />

Plantsight includes intelligent services to<br />

help incorporate, analyse and connect data<br />

from <strong>the</strong>se dark sources. As data quality may<br />

be inconsistent, validation steps allow useful<br />

data to be differentiated from poor data.<br />

Change synchronisation<br />

For operation and maintenance, one of <strong>the</strong><br />

biggest challenges is knowing what has<br />

changed and when, so that accurate decisions<br />

can be made. Not just <strong>the</strong> most recent<br />

change is relevant but every change historically<br />

on record. P&IDs are probably among<br />

<strong>the</strong> most important operational documents,<br />

so it makes sense to view those same<br />

changes you saw in 3-D visualised on <strong>the</strong><br />

P&ID. Visualising changes using <strong>the</strong> context<br />

of a familiar document adds real value <strong>for</strong><br />

operators.<br />

Today, it is possible to hand over <strong>the</strong> complete<br />

digital twin and keep it evergreen.<br />

When <strong>the</strong> twin starts deviating over time<br />

because <strong>the</strong> equipment is modified or <strong>the</strong>re<br />

are add-ons, it is possible to create a new<br />

project digital twin (based on <strong>the</strong> most current<br />

per<strong>for</strong>mance digital twin) and engineer<br />

<strong>the</strong> modifications in parallel with operation<br />

of <strong>the</strong> plant until shutdown. Any changes<br />

compared to <strong>the</strong> design are captured in <strong>the</strong><br />

project twin, <strong>the</strong>n a simple reconciliation<br />

step combines <strong>the</strong> latest changes in <strong>the</strong> per<strong>for</strong>mance<br />

digital twin with <strong>the</strong> in<strong>for</strong>mation<br />

from <strong>the</strong> project twin. This is easy to do in a<br />

side-by-side view of differences and a stepby-step<br />

process <strong>for</strong> approving or rejecting<br />

changes.<br />

With its ability to leverage new technologies<br />

such as reality modelling, 3-D webbased<br />

visualisation, cloud services and IoT,<br />

Plantsight is <strong>the</strong> next-generation asset per<strong>for</strong>mance<br />

management system <strong>for</strong> consolidating<br />

and aggregating in<strong>for</strong>mation and<br />

supporting constant and continuous change<br />

management, leading to better <strong>–</strong> and better<br />

in<strong>for</strong>med <strong>–</strong> decisions on asset per<strong>for</strong>mance<br />

and reliability.<br />

Plant operation and maintenance can now<br />

manage as-operated digital twins of <strong>the</strong>ir<br />

assets.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319bentley<br />

AUTHOR:<br />


Director of Marketing,<br />

Digital Twin Solutions,<br />

Bentley Systems<br />

<strong>cpp</strong> 03-2019 49

<strong>cpp</strong><br />


Collecting representative samples<br />

Grab sampling systems <strong>for</strong><br />

accurate lab analyses<br />

Grab sampling systems provide an effective way to safely collect samples from a<br />

pipeline, tank or process vessel to be transported to a lab <strong>for</strong> offline analysis. The<br />

key to accurate analysis is ensuring <strong>the</strong> captured sample is representative of process<br />

conditions when collected and analysed. This article provides tips to help realise<br />

more efficient and accurate grab sampling analyses.<br />

Grab sampling systems are ubiquitous<br />

throughout processing plants, refineries and<br />

o<strong>the</strong>r industrial facilities. They play a key<br />

role in quality and process controls, compliance<br />

with regulations and verifying <strong>the</strong><br />

per<strong>for</strong>mance of process analysers. To per<strong>for</strong>m<br />

grab sampling, operators must capture<br />

a sample in a container, typically ei<strong>the</strong>r a<br />

cylinder or a bottle, at a collection point<br />

and <strong>the</strong>n promptly transport it to a remote<br />

laboratory <strong>for</strong> offline analysis. The sample<br />

must be representative of <strong>the</strong> process conditions<br />

at <strong>the</strong> time it is collected, and it must<br />

remain as close to those conditions as possible<br />

when it is analysed.<br />

Pictures: Swagelok<br />

The GSM-G-2(-N) grab sampling system is <strong>for</strong> sampling gas without using a separate purge line. With<br />

<strong>the</strong> sampling system valves and <strong>the</strong> cylinder valves open, process fluid flows through <strong>the</strong> cylinder and<br />

out via <strong>the</strong> hose to <strong>the</strong> outlet port, where it returns to <strong>the</strong> process. When retrieving a sample, <strong>the</strong> operator<br />

will close <strong>the</strong> cylinder valves and turn <strong>the</strong> system to vent, in order to isolate <strong>the</strong> supply and return<br />

lines and allow <strong>the</strong> fill lines to vent. Next, <strong>the</strong> operator will turn <strong>the</strong> system off be<strong>for</strong>e disconnecting<br />

<strong>the</strong> cylinder and transporting <strong>the</strong> sample <strong>for</strong> offline analysis.<br />

Specifying a grab sampling system<br />

When configuring a grab sampling system,<br />

designers must first decide which sample<br />

transport vessel to use <strong>–</strong> ei<strong>the</strong>r a sealed<br />

metal cylinder or a glass or polyethylene<br />

bottle. Both <strong>the</strong> system pressure requirements<br />

and <strong>the</strong> sample phase influence this<br />

decision. Cylinders may contain pressure<br />

and can be used <strong>for</strong> gas or liquid samples,<br />

while bottles cannot contain pressure and<br />

are used <strong>for</strong> liquid samples only, as <strong>the</strong>y are<br />

not airtight. O<strong>the</strong>r key criteria driving system<br />

design considerations include:<br />

• Pressure: To ensure safe operation, <strong>the</strong><br />

maximum rated pressure of a grab sampling<br />

system must not be exceeded. Additionally,<br />

a rupture disc or relief valve<br />

should be fitted to enhance safety when<br />

using <strong>chemical</strong>s that can rapidly expand<br />

and pressurise due to temperature changes.<br />

• Temperature: The sampling system’s<br />

maximum fluid operating temperature<br />

must not be exceeded, to protect <strong>the</strong> integrity<br />

of its seats and seals. Conversely,<br />

<strong>the</strong> system must operate above its minimum<br />

operating temperature, so that <strong>the</strong><br />

process fluid flows at a sufficient rate <strong>for</strong><br />

timely analysis. If <strong>the</strong> supply temperature<br />

exceeds 60°C, <strong>the</strong> option of cooling <strong>the</strong><br />

sample should be considered in order to<br />

reduce <strong>the</strong> risk to operators retrieving<br />

samples, while keeping in mind that this<br />

50 <strong>cpp</strong> 03-2019

lower temperature could affect <strong>the</strong><br />

sample’s representativeness.<br />

• Material compatibility: The materials<br />

used in a grab sampling system must be<br />

compatible with <strong>the</strong> process fluid as well<br />

as with <strong>the</strong> operating environment. The<br />

standard construction material is 316<br />

stainless steel, but system requirements<br />

may dictate <strong>the</strong> use of alternative materials<br />

such as alloys 400 and C-276.<br />

• Purging needs: Some <strong>chemical</strong>s may<br />

contaminate or corrode grab sampling<br />

lines, or possibly pose a hazard to <strong>the</strong><br />

operator if not flushed from <strong>the</strong> system. In<br />

such cases, designers should add a purge<br />

setup to remove residual process fluid<br />

from <strong>the</strong> lines.<br />

Capturing samples in cylinders<br />

There are a variety of options <strong>for</strong> confi -<br />

guring grab sampling systems that capture<br />

gases or liquids in a sealed cylinder. Perhaps<br />

<strong>the</strong> most efficient design is a closed-loop<br />

system with <strong>the</strong> sample continuously circulating<br />

through <strong>the</strong> cylinder while <strong>the</strong> operator<br />

takes a sample. A closed-loop system<br />

pulls samples from a positive-pressure process<br />

and returns <strong>the</strong>m back to <strong>the</strong> process at<br />

a lower-pressure location <strong>–</strong> <strong>for</strong> example, upstream<br />

of a pump <strong>–</strong> using <strong>the</strong> differential<br />

pressure to drive <strong>the</strong> fluid through <strong>the</strong><br />

sample system. Such a design can reduce or<br />

eliminate system purging needs, as <strong>the</strong> sampling<br />

system becomes an extension of <strong>the</strong><br />

process system. Upon opening <strong>the</strong> inlet<br />

valve of <strong>the</strong> Swagelok GSM-G-2(-N) grab<br />

sampling system with continuous flow and<br />

without purging, <strong>for</strong> example, process fluid<br />

will flow through <strong>the</strong> system tubing and <strong>the</strong><br />

sample cylinder be<strong>for</strong>e flowing out via a<br />

hose to <strong>the</strong> outlet port. Any older process<br />

fluid remaining in <strong>the</strong> short inlet line will<br />

quickly move through <strong>the</strong> closed loop path<br />

and return to process as <strong>the</strong> cylinder fills.<br />

When <strong>the</strong> sample vessel is ready <strong>for</strong> removal,<br />

<strong>the</strong> operator can simply close <strong>the</strong><br />

cylinder’s inlet and outlet valves and turn<br />

<strong>the</strong> system to vent, isolating <strong>the</strong> supply and<br />

return lines and allowing fill lines to vent.<br />

Finally, <strong>the</strong> operator will close <strong>the</strong> system’s<br />

inlet valve to halt all flow and remove <strong>the</strong><br />

cylinder <strong>for</strong> lab analysis. The fluid in <strong>the</strong><br />

cylinder remains under <strong>the</strong> same process<br />

conditions that existed at <strong>the</strong> time of <strong>the</strong><br />

sample, except <strong>for</strong> temperature, and is<br />

<strong>the</strong>re<strong>for</strong>e always representative of <strong>the</strong><br />

process.<br />

For gas and liquid samples<br />

While grab sampling systems with cylinders<br />

can be used <strong>for</strong> gas or liquid samples, design<br />

considerations differ between <strong>the</strong> two<br />

types. Most notably, <strong>the</strong> flow path should be<br />

different <strong>for</strong> liquids and gases to purge outof-phase<br />

fluid from <strong>the</strong> cylinder. Gases<br />

should flow from <strong>the</strong> top of <strong>the</strong> cylinder<br />

down, pushing out any liquid or condensate<br />

from <strong>the</strong> sample cylinder as it fills, to ensure<br />

liquid doesn’t collect in <strong>the</strong> cylinder<br />

and skew lab analyser readings. Liquids<br />

should fill from <strong>the</strong> bottom up to displace<br />

<strong>the</strong> vapour space and ensure <strong>the</strong> cylinder is<br />

full. Designers may also add an outage tube<br />

to cylinders capturing liquid samples to<br />

keep expansion space in <strong>the</strong> cylinder, as <strong>the</strong><br />

trapped vapour may compress under pressure.<br />

Swagelok offers a variety of sampling<br />

cylinder (GSC) configurations, including<br />

options <strong>for</strong> purging bypass tubes, quick<br />

couplings with plug or body caps, outage<br />

tubes and specific certifications.<br />


Precise DO Measurements<br />

with Less Frequent Calibration<br />

See <strong>the</strong> Sensor<br />

That Reduces<br />

<strong>the</strong> Negative<br />

Impact of SIP and<br />

Photobleaching<br />

Hamilton Bonaduz AG | CH-7402 Bonaduz, Switzerland<br />

contact.pa.ch@hamilton.ch | www.hamiltoncompany.com<br />

Hamilton<br />

30YEARS<br />

<strong>Process</strong> Analytics<br />

<strong>cpp</strong> 03-2019 51

<strong>cpp</strong><br />


The Swagelok GSL3 bottled grab sampling system design is used when continuous flow<br />

is required from <strong>the</strong> inlet to <strong>the</strong> outlet. The inlet port supplies <strong>the</strong> sample panel and <strong>the</strong><br />

outlet port allows bypass flow.<br />

Outage tubes help to prevent cylinder overfilling<br />

when capturing liquid samples<br />

Capturing liquid samples in bottles<br />

Liquid-only grab sampling systems draw<br />

fluid into a non-pressure-containing bottle.<br />

Operators draw <strong>the</strong> fluid directly from <strong>the</strong><br />

process <strong>–</strong> perhaps after some conditioning <strong>–</strong><br />

and <strong>the</strong>n transport <strong>the</strong> vessel without risk of<br />

spillage or evaporation. Such systems can be<br />

used in a number of liquid applications,<br />

where <strong>the</strong> process fluid is not at risk of fractionating<br />

or evaporating when stored at atmospheric<br />

pressure to ensure <strong>the</strong> sample remains<br />

representative. This precaution allows<br />

designers to use less expensive glass laboratory<br />

bottles <strong>for</strong> samples, with <strong>the</strong> added<br />

benefit of gaining immediate feedback on<br />

<strong>the</strong> visual quality of <strong>the</strong> sample stream.With<br />

bottle sampling, <strong>the</strong> sample is taken at atmospheric<br />

pressure. Any increase in internal<br />

pressure may cause loss of sample through<br />

<strong>the</strong> lid or septum cap seal. There<strong>for</strong>e, liquid<br />

grab sampling systems with bottles are typically<br />

used with water or o<strong>the</strong>r low vapourpressure<br />

liquids. If bottle sampling is suitable,<br />

designers must determine whe<strong>the</strong>r<br />

continuous flow and purging are required<br />

or whe<strong>the</strong>r a fixed-volume option would be<br />

more appropriate.<br />

Continuous flow during sampling<br />

Continuous flow is useful during sampling<br />

when <strong>the</strong> sample requires constant motion<br />

<strong>–</strong> to keep it from freezing, <strong>for</strong> instance <strong>–</strong> or<br />

if a long tubing run leads up to <strong>the</strong> sample<br />

point. The sample flow runs continuously<br />

through a bypass loop in <strong>the</strong> grab sampling<br />

system, as shown in <strong>the</strong> Swagelok GSL3<br />

“Continuous Flow Sampling System Design”.<br />

This ensures that <strong>the</strong> sampled fluid<br />

remains representative of <strong>the</strong> process, as it<br />

will not be sitting in <strong>the</strong> tubes <strong>for</strong> an extended<br />

period of time. An operator can <strong>the</strong>n<br />

fill <strong>the</strong> sample bottle, using a spring-loaded<br />

sampling valve to retrieve <strong>the</strong> sample. If <strong>the</strong><br />

sampled fluid has <strong>the</strong> potential to solidify in<br />

place, a purge assembly is advised to aid in<br />

cleaning <strong>the</strong> dispensing needle and internal<br />

tubing. If <strong>the</strong> sampled fluid is under high<br />

pressure or hazardous, designers should<br />

consider a fixed-volume system, which effectively<br />

isolates <strong>the</strong> process pressure from<br />

<strong>the</strong> user while limiting <strong>the</strong> volume of dispensed<br />

fluid. In a fixed-volume system, <strong>the</strong><br />

sample first fills a metal cylinder and is <strong>the</strong>n<br />

gently pushed into <strong>the</strong> sampling bottle by a<br />

low-pressure purge gas. This precaution<br />

helps prevent accidental overfilling.<br />

Outage tubes as a safety mechanism<br />

System designers should consider using an<br />

outage tube as a safety mechanism <strong>for</strong> any<br />

grab sampling system that captures a liquid<br />

sample in a cylinder. The outage tube enables<br />

a defined volume of vapour space to<br />

remain inside <strong>the</strong> cylinder when capturing<br />

a sample. This vapour space will allow <strong>the</strong><br />

liquid in <strong>the</strong> cylinder to expand if <strong>the</strong> temperature<br />

increases. Without enough space,<br />

even a small temperature increase can cause<br />

<strong>the</strong> liquid to expand and <strong>the</strong> pressure to increase<br />

dramatically. During sampling, <strong>the</strong><br />

cylinder is held vertically with <strong>the</strong> outage<br />

tube at <strong>the</strong> top, as shown. The length of <strong>the</strong><br />

outage tube determines <strong>the</strong> amount of vapour<br />

space, which is expressed as a percentage<br />

of <strong>the</strong> cylinder’s total volume.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319swagelok<br />

AUTHOR:<br />


Senior Principal Design<br />

Engineer,<br />

Swagelok<br />

52 <strong>cpp</strong> 03-2019

<strong>cpp</strong><br />


Hygienic safety valve with ASME approval<br />

Picture: Goetze<br />



The valve specialist Goetze’s<br />

Series 4000 safety valve is now<br />

available with <strong>the</strong> ASME certification.<br />

The extended certification<br />

makes <strong>the</strong> valve even<br />

more versatile in applications<br />

where particularly high requirements<br />

must be met with regard<br />

to <strong>the</strong> cleanability of surfaces in<br />

contact with <strong>the</strong> medium.<br />

Particularly <strong>for</strong> applications in<br />

<strong>the</strong> medical or pharmaceutical<br />

sector, <strong>the</strong> requirements <strong>for</strong> <strong>the</strong><br />

manufacture and cleanability of<br />

<strong>the</strong> valves are very high. As with<br />

<strong>the</strong> safety valve 4000, contamination<br />

can be avoided by not<br />

allowing nests and dead spaces.<br />

For this purpose, <strong>the</strong> area of <strong>the</strong><br />

spring chamber is separated<br />

from <strong>the</strong> media chamber by an<br />

elastomer diaphragm. The media<br />

chamber itself can be opened<br />

with <strong>the</strong> aid of <strong>the</strong> clamp connections.<br />

This ensures simple<br />

and professional cleaning.<br />

The valve is secured against unauthorised<br />

adjustment by a visible<br />

sealing disc pressed into <strong>the</strong><br />

cap. This means that <strong>the</strong> usual<br />

sealing wire, which is not easy<br />

to clean, can be dispensed with.<br />

This allows simple assembly or<br />

disassembly with standard tools<br />

without any changes or effects<br />

on <strong>the</strong> set pressure of <strong>the</strong> valve.<br />

The set pressure can vary between<br />

0.4 and 16 bar.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319goetze<br />

Rapid delivery<br />

Made in Germany<br />

ISO 9001<br />

Protection module monitors pumps<br />

The Amacontrol III device<br />

monitors <strong>the</strong> phase sequence<br />

and detects any phase failures,<br />

overvoltage/undervoltage or<br />

voltage asymmetry that may<br />

occur. It can also monitor temperature<br />

sensors, two conductance<br />

sensors <strong>for</strong> leakage monitoring<br />

and a 4...20 mA vibration<br />

signal. Additional functions<br />

include logging <strong>the</strong> frequency<br />

of starts, recording <strong>the</strong><br />

number of operating hours and<br />

detecting any failures of connected<br />

sensors.<br />

A fault relay and warning relay<br />

ensure <strong>the</strong> units are reliably<br />

stopped or, respectively, a warning<br />

is emitted. This makes it<br />

possible to control <strong>the</strong> monitored<br />

units via an app on a<br />

smartphone or tablet computer.<br />

The device is mounted in <strong>the</strong><br />

control cabinet on a 35 mm<br />

Bild: KSB<br />

standard rail and wired with removable<br />

spring-loaded terminals.<br />

The module requires<br />

ei<strong>the</strong>r a supply voltage of<br />

24 V(DC) or single-phase AC<br />

from 115 to 230 V and a frequency<br />

of 50 to 60 Hz. The<br />

modules supplied by KSB are<br />

preset with all <strong>the</strong> values<br />

required <strong>for</strong> operation.<br />

www.prozesstechnik-online.de<br />

Suchwort: <strong>cpp</strong>0319ksb<br />

Multi-coupling<br />

li<br />

The perfect interface. A customizable multi-coupling system<br />

that combines multiple process media connections in<br />

a single interface. Robust, extremely reliable and easy to use.<br />

• Fast, simultaneous connection and disconnection<br />

of up to 20 couplings<br />

• Arrangement can include different coupling types and sizes<br />

• Customer-specific configurations possible<br />

www.ga<strong>the</strong>r-industrie.de · kupplung@ga<strong>the</strong>r-industrie.de · +49 2058 89381-23<br />

<strong>cpp</strong> 03-2019 53<br />

Pump Technology · Metering Technology · Coupling Technology

<strong>cpp</strong><br />


Intelligent infrastructure plug-in connector<br />

The development of plug-in<br />

connectors is influenced by<br />

three trends: digitalisation, decentralisation<br />

and miniaturisation.<br />

In decentralisation, increasing<br />

numbers of functions<br />

in <strong>the</strong> industrial environment<br />

are shifting to <strong>the</strong> device and<br />

field level, meaning that <strong>the</strong>re<br />

will be an increasing demand<br />

<strong>for</strong> a comprehensive connection<br />

between devices along <strong>the</strong> horizontal<br />

and vertical axes of <strong>the</strong><br />

automation pyramid. This also<br />

includes supplementation with<br />

intelligent functions. Integrating<br />

sensor and diagnostic functions<br />

directly into <strong>the</strong> connectors<br />

opens up completely new application<br />

fields and renders additional<br />

sensors superfluous.<br />

Measured variables like current,<br />

voltage, power and temperature<br />

can be measured, as well as<br />

saved and evaluated with an<br />

app, an ERP/SCADA system or a<br />

cloud. Weidmüller developed<br />

such an intelligent plug-in connector.<br />

The smart connector was<br />

created as part of <strong>the</strong> German<br />

Federal Ministry of Education<br />

and Research (BMBF) funded<br />

Picture: Weidmüller<br />

project: “Intelligent electric<br />

plug-in connector and connection<br />

<strong>technology</strong> with electronic<br />

signal processing (ISA)”.<br />

www.<strong>cpp</strong>-net.com<br />

Online search:<br />

<strong>cpp</strong>0319weidmüller<br />

Compact chamber dryer<br />

Safety laser scanner <strong>for</strong> outdoor use<br />

The chamber dryer H01compact<br />

from Harter is perfectly suited<br />

<strong>for</strong> laboratory testing very small<br />

quantities or <strong>for</strong> developing<br />

new products. The H01compact<br />

has a drying chamber designed<br />

<strong>for</strong> inserting plates or trays<br />

straightaway. As in <strong>the</strong> H01,<br />

products placed separately or at<br />

filling heights of 200 mm maximum<br />

may be dried. Batch sizes<br />

range between 30 and 70 kg depending<br />

on <strong>the</strong> specific application<br />

and <strong>the</strong> product to be<br />

dried. Essentials of heat pump<br />

based condensation comprise<br />

<strong>the</strong> use of extremely dry air and<br />

adequate routing of this air<br />

which ensures very high process<br />

reliability. Drying is effected at<br />

temperatures which may be varied<br />

and controlled at 15 to<br />

75 °C as required <strong>for</strong> <strong>the</strong> specific<br />

application. This drying<br />

process ensures gentle drying of<br />

products to <strong>the</strong> desired residual<br />

humidity level. As <strong>the</strong> system is<br />

closed air-wise, drying is independent<br />

of <strong>the</strong> climate. The processes<br />

may be validated <strong>for</strong><br />

pharmaceutical applications and<br />

are thus eligible <strong>for</strong> GMP<br />

qualification.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319harter<br />

Picture: Harter<br />

The safety laser scanner Outdoorscan3 from Sick is certified<br />

to IEC 62998 <strong>for</strong> use in outdoor applications. Thanks<br />

to its outdoor-safe HDDM scanning <strong>technology</strong>, Outdoorscan3<br />

works safely and reliably in all wea<strong>the</strong>r <strong>–</strong> thus<br />

closing a major gap in <strong>the</strong> automation of industrial processes.<br />

This <strong>technology</strong> means <strong>the</strong> laser scanner can work<br />

without errors when exposed to sunlight with an illumination<br />

intensity of up to 40,000 lux. In addition, <strong>the</strong> intelligent<br />

software algorithm of <strong>the</strong> laser scanner detects<br />

rain and snow, easily filtering out <strong>the</strong>se environmental<br />

influences <strong>–</strong> rain, <strong>for</strong> example, up to a precipitation intensity<br />

of 10 mm/h. Even in fog with a meteorological<br />

visual range of up to 50 m, it detects all obstacles with<br />

total reliability, due to its special fog function.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319sick<br />

Picture: Sick<br />

T +49 2961 7405-0 | info@rembe.de<br />

Gallbergweg 21 | 59929 Brilon, Germany<br />

F +49 2961 50714 | www.rembe.de<br />

Your Specialist <strong>for</strong><br />



Consulting. Engineering. Products. Service.<br />

© REMBE® | All rights reserved<br />

54 <strong>cpp</strong> 03-2019

Profinet Gateway <strong>for</strong> remote I/O<br />

With <strong>the</strong> LB Profinet gateway,<br />

Pepperl+Fuchs is connecting LB<br />

remote I/O systems to <strong>the</strong><br />

Profinet world. End-to-end<br />

communication also ensures optimal<br />

use of existing intelligence<br />

in <strong>the</strong> field, representing a crucial<br />

step toward making plants<br />

suitable <strong>for</strong> future requirements<br />

and Industry 4.0. The LB Profinet<br />

gateway delivers not only<br />

conventional Profinet functionality,<br />

but also full access to<br />

all connected Hart devices. In<br />

practical terms, this will give<br />

users access to Hart auxiliary<br />

variables as a second measuring<br />

value in addition to process<br />

variables. Fur<strong>the</strong>rmore, <strong>the</strong><br />

diagnostic data from <strong>the</strong> field<br />

devices can be read out via Hart<br />

IP, thus significantly increasing<br />

transparency and plant availability.<br />

The gateway also offers<br />

maximum flexibility since different<br />

protocols can run via <strong>the</strong><br />

same cordset (e.g., Profinet and<br />

Hart IP), and, of course, it represents<br />

a high-per<strong>for</strong>mance solution:<br />

up to 80 field devices can<br />

be connected to a fully occupied<br />

remote I/O system. These devices<br />

communicate without a<br />

time delay.<br />

Picture: Pepperl + Fuchs<br />

Ano<strong>the</strong>r highlight of <strong>the</strong> gateway<br />

is <strong>the</strong> intelligent redundancy<br />

concept. An integrated switch<br />

ensures <strong>the</strong> functionality of <strong>the</strong><br />

network at all times based on<br />

<strong>the</strong> medium redundancy protocol<br />

(MRP). If a line fails, <strong>the</strong><br />

ring network is reconfigured to<br />

send <strong>the</strong> data packets via <strong>the</strong> alternative<br />

route. Since <strong>the</strong> potential<br />

<strong>for</strong> hazards increases as a result<br />

of big data being used<br />

alongside increased networking<br />

of industrial plants, <strong>the</strong> gateway<br />

also fulfills <strong>the</strong> appropriate<br />

safety requirements.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319pepperl<br />

30 th international exhibition<br />

<strong>for</strong> industrial automation<br />

Nuremberg, Germany<br />

26 <strong>–</strong> 28 November 2019<br />

sps-exhibition.com<br />

Bringing Automation to Life<br />

Magnetic pump range expanded<br />

Picture: Munsch<br />

The CM series magnetic pumps<br />

have experienced a significant<br />

increase in per<strong>for</strong>mance in <strong>the</strong>ir<br />

conveying distance to up to<br />

85 m. They are intended to convey<br />

critical or environmentally<br />

harmful liquids, or liquids that<br />

are hazardous to health such as<br />

acids, alkalis, solvents and<br />

<strong>chemical</strong>ly contaminated materials<br />

containing few solids. The<br />

CM-FA series magnetic pump,<br />

however, is also suitable <strong>for</strong><br />

conveying material containing<br />

solids. The spacer can of <strong>the</strong> CM<br />

series is designed as a vacuumtight,<br />

metal-free double-wall<br />

composite unit with no edgy<br />

currents, meaning no heat<br />

transfer to <strong>the</strong> material being<br />

pumped, no loss to magnetic<br />

per<strong>for</strong>mance, meaning no losses<br />

to efficiency, and <strong>the</strong> spacer can<br />

is protected against mechanical<br />

contact with <strong>the</strong> drive rotor. An<br />

electronic monitor is also possible<br />

as an option.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319munsch<br />

Hands-on. Visionary. Personal.<br />

Find answers to your current needs on-site, as well as<br />

possible solutions <strong>for</strong> <strong>the</strong> challenges of tomorrow.<br />

Register now and get<br />

30% off with <strong>the</strong> discount code: SPS19BESV12<br />

sps-exhibition.com/tickets<br />

<strong>cpp</strong> 03-2019 55

<strong>cpp</strong><br />


Picture: Wipotec-OCS<br />

The TQS serialisation system accomplishes modular labelling of medication according to all country-specific particularities<br />

<strong>Process</strong> reliability in track and trace systems<br />

Position indicator <strong>for</strong><br />

supervised <strong>for</strong>mat change<br />

The European Falsified Medicines Directive (2011/62/EU), which entered into <strong>for</strong>ce<br />

on 9 February 2019, requires all prescription medicines to be clearly labelled in a<br />

way that allows <strong>the</strong> entire production and transport process to be traced. What is<br />

needed in this context are track and trace systems such as TQS. If <strong>the</strong> machines are<br />

equipped with electronic position indicators, process reliability and easy batch<br />

changes between various packaging sizes are ensured.<br />

The introduction and starting date of <strong>the</strong><br />

new anti-falsification directive have been<br />

known since 2016, yet increased demand<br />

<strong>for</strong> suitable track and trace systems was only<br />

evident in <strong>the</strong> months preceding its entry<br />

into <strong>for</strong>ce. Wipotec-OCS, which specialises<br />

in weighing and inspection solutions, including<br />

mechanical engineering <strong>for</strong> processes<br />

such as printing, reading and labelling,<br />

confirms this trend: “This is a massive<br />

drag on <strong>the</strong> market now. As of February,<br />

every company that produces prescription<br />

medication and wants to bring it onto <strong>the</strong><br />

market needs to ensure that serial numbers<br />

are assigned to each drug and that a track &<br />

trace solution is integrated into <strong>the</strong> production<br />

line”, explains Daniel Anders, product<br />

manager <strong>for</strong> track and trace at Wipotec-<br />

OCS. “It is useful to have systems that can<br />

be incorporated into <strong>the</strong> production line<br />

quickly without major expense and that do<br />

not slow down <strong>the</strong> production process unnecessarily,<br />

with severe negative impacts on<br />

manufacturing efficiency”.<br />

Modular labelling<br />

With its TQS solution, Wipotec-OCS has established<br />

a system <strong>for</strong> <strong>the</strong> pharmaceutical<br />

sector that accomplishes highly modular labelling<br />

of medication according to all<br />

country-specific particularities. Serial numbering<br />

involves several potential process<br />

steps <strong>–</strong> printing, reading, labelling and<br />

weighing <strong>–</strong> which <strong>the</strong> TQS-HC-A machine<br />

combines into one unit. It is designed <strong>for</strong><br />

folding boxes, which make up at least 90 %<br />

of all medication packaging in <strong>the</strong> European<br />

market. The boxes are labelled on <strong>the</strong> front<br />

and/or back, as well as optionally on <strong>the</strong><br />

top, and <strong>the</strong>n weighed with a high-precision<br />

load cell from Wipotec to determine<br />

whe<strong>the</strong>r <strong>the</strong>y are fully packed. Faulty products<br />

are automatically removed in this process.<br />

Where needed, tamper-evident labels<br />

can be applied to secure <strong>the</strong> packaging<br />

against manipulation.<br />

For pharmaceutical clients, who often have<br />

long production lines, it is important to<br />

56 <strong>cpp</strong> 03-2019

have a track and trace solution that is as<br />

compact as possible. In fact, <strong>the</strong> new European<br />

directive requires high initial investments<br />

and commitment of resources on <strong>the</strong><br />

part of pharmaceutical manufacturers. Acceptance<br />

is <strong>the</strong>re<strong>for</strong>e much higher if <strong>the</strong><br />

track and trace machines fit smoothly into<br />

<strong>the</strong> overall concept <strong>–</strong> and additional benefits<br />

are created as a result.<br />

Supervised <strong>for</strong>mat change<br />

A small but highly significant component<br />

on <strong>the</strong> machine offers fur<strong>the</strong>r advantages.<br />

Siko’s AP05 position indicator provides an<br />

option <strong>for</strong> supervised <strong>for</strong>mat changes. Optimised<br />

<strong>for</strong>mat changes facilitate batch<br />

changes between various packaging sizes.<br />

The present trend is towards smaller<br />

batches, which also means more frequent<br />

changes. All units generally need to be<br />

shifted on two axes. Up to 13 Siko indicators<br />

may be installed in a TQS-HC-A.<br />

These shifts are best carried out quickly in a<br />

controlled and reliable manner. Electronic<br />

AP05 indicators are bus-compatible and can<br />

be integrated into <strong>the</strong> machine controls,<br />

where new target values <strong>for</strong> <strong>the</strong> next folding<br />

box size (stored in <strong>the</strong> machine controls in<br />

a recipe list <strong>for</strong> each product) can be transmitted<br />

to <strong>the</strong> position indicator and shown<br />

on its display under <strong>the</strong> current actual value.<br />

If <strong>the</strong> actual and target values match, <strong>the</strong><br />

LEDs on <strong>the</strong> position indicator change to<br />

green. If not, <strong>the</strong> LEDs are red (position not<br />

yet reached). The machine is ready <strong>for</strong> operation<br />

again only when all LEDs are green;<br />

only <strong>the</strong>n can production be started safely.<br />

Incorrect settings no longer occur. The operator<br />

can see from <strong>the</strong> LEDs which shift<br />

points still need to be adjusted. This prevents<br />

defective products and improves process<br />

reliability. Ano<strong>the</strong>r advantage is that<br />

with supervised <strong>for</strong>mat changes <strong>the</strong> changeover<br />

times are significantly shorter and<br />

hence more efficient.<br />

In <strong>the</strong> past, Wipotec-OCS’s TQS machines<br />

were equipped as standard with mechanical<br />

position indicators from Siko to indicate <strong>the</strong><br />

current position of <strong>the</strong> axes. The AP05, <strong>the</strong><br />

supervised electronic variant, is mechanically<br />

compatible and can be retrofitted at<br />

any time.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319siko<br />

Picture: Christian Fischer <strong>–</strong> Siko<br />

The bus-compatible AP05 electronic position<br />

indicator ensures a secure and efficient<br />

changeover to different folding box sizes<br />

AUTHOR:<br />



Freelance journalist<br />

Versioned catalog production<br />

intelligent<br />

Medien<br />

produzieren<br />

Perfect project management <strong>for</strong> highly complex jobs<br />

Tools <strong>for</strong> an efficient workflow<br />

www.konradinheckel.de<br />

<strong>cpp</strong> 03-2019 57

<strong>cpp</strong><br />


Dust-free thanks to state-of-<strong>the</strong>-art vacuum <strong>technology</strong><br />

Bagging carbon black<br />

efficiently<br />

Products with such low bulk densities as carbon black place very high demands on<br />

bagging <strong>technology</strong> in <strong>the</strong> packaging process. Using Greif-Velox’s Velovac system,<br />

speciality graphite supplier Imerys Graphite & Carbon was able to increase its bagging<br />

capacity to 90 bags per hour and reduce <strong>the</strong> costs <strong>for</strong> storage and logistics by<br />

75 %. At <strong>the</strong> same time, dust pollution during bagging and transport was completely<br />

eliminated.<br />

Carbon black is an extremely valuable industrial<br />

raw material consisting of tiny,<br />

mainly spherical, so-called primary particles.<br />

In most cases, <strong>the</strong>se particles have a<br />

size of 10 to 300 nm, which is why <strong>the</strong>y are<br />

also referred to as nanoparticles. Their specific<br />

surface area can be anything between<br />

10 and 1000 m 2 /g. On <strong>the</strong> one hand, carbon<br />

black manufacturers can take advantage<br />

of <strong>the</strong>se properties and influence <strong>the</strong>m by<br />

means of <strong>the</strong> production process or by varying<br />

<strong>the</strong> process parameters. On <strong>the</strong> o<strong>the</strong>r<br />

hand, <strong>the</strong>y also face challenges, especially<br />

with regard to <strong>the</strong> packaging process.<br />

Cost-intensive with high health risk<br />

Products with such low bulk densities as<br />

carbon black place very high demands on<br />

bagging <strong>technology</strong> in <strong>the</strong> packaging process.<br />

Many packaging solutions involve a<br />

large amount of air in <strong>the</strong> filled bags. These<br />

voluminous and unstable bags result in an<br />

untidy pallet appearance in two respects:<br />

since extreme dust is produced during filling,<br />

<strong>the</strong> bags are often contaminated with<br />

residues. In addition, <strong>the</strong> air-pumped bags<br />

can no longer be stacked precisely. Apart<br />

from losing valuable product, this also<br />

means paying <strong>for</strong> logistics and transport of<br />

bulky bags filled with up to 70 % air. However,<br />

high dust loads contaminate not only<br />

<strong>the</strong> bags <strong>the</strong>mselves but also <strong>the</strong> production<br />

environment. Cleaning is exceedingly timeconsuming<br />

and flying particles pose an immense<br />

health risk to employees. Technical<br />

rules <strong>for</strong> hazardous substances, in particular<br />

TRGS 900, describe <strong>the</strong> limit values <strong>for</strong> a<br />

large number of dust types.<br />

Dust-free bagging<br />

Imerys Graphite & Carbon turned to Lübeck-based<br />

packaging machine specialist<br />

Greif-Velox Maschinenfabrik GmbH <strong>for</strong> support<br />

optimising <strong>the</strong> packaging process <strong>for</strong><br />

carbon black in general while meeting <strong>the</strong><br />

above-mentioned protection requirements.<br />

The solution: <strong>the</strong> highly efficient Velovac<br />

system. Ultra-lightweight materials with<br />

particle sizes of less than 200 mm and bulk<br />

densities from 10 to 450 g/l are bagged in a<br />

completely closed vacuum chamber. The<br />

product is sucked into <strong>the</strong> vacuum bags by<br />

creating an atmospheric vacuum. Any dust<br />

which escapes is sucked off and returned to<br />

<strong>the</strong> bagging process directly, saving product<br />

and air. Even without upstream compaction<br />

equipment, little or no air gets into <strong>the</strong> vacuum<br />

bags. Depending on <strong>the</strong> material to be<br />

packed, up to 400 % product compaction is<br />

possible.<br />

Pictures: Greif-Velox<br />

Velovac vacuum packer <strong>for</strong> dust-free filling<br />

Excellent sealing <strong>technology</strong><br />

After filling, <strong>the</strong> bags are hermetically sealed<br />

using patented methods <strong>for</strong> external valve<br />

cutting and ultrasonic sealing. The valve cutting<br />

technique has been optimised by Greif-<br />

Velox in a way that leads to more process<br />

58 <strong>cpp</strong> 03-2019

Thanks to <strong>the</strong> Velovac vacuum packer, valve bags are up to 50 % narrower as well as considerably more<br />

compact and stable (left stack)<br />

reliability, better knife per<strong>for</strong>mance and increased<br />

productivity. The improved knife<br />

system is particularly durable; modern sensor<br />

<strong>technology</strong> provides users with dynamic<br />

predictions <strong>for</strong> upcoming maintenance<br />

cycles and warns of imminent failure or a<br />

deterioration in per<strong>for</strong>mance. In addition,<br />

an integrated self-regulating process is controlled<br />

by an intelligent algorithm, preventing<br />

operators from selecting <strong>the</strong> wrong parameters.<br />

The cutting time is automatically<br />

adjusted to between 50 and 500 ms and <strong>the</strong><br />

cutting pressure to between 2.6 and 5 bar.<br />

No unnecessary time is wasted after cutting,<br />

as no cooling is required and <strong>the</strong> bags can<br />

be processed immediately. The patented<br />

wafer closure prevents incorrect sealing. The<br />

cutting edge is additionally welded in line<br />

with <strong>the</strong> motto “better to be on <strong>the</strong> safe<br />

side”.<br />

More stable, cleaner, safer, faster<br />

Instead of seven precariously balanced<br />

layers, Imerys Graphite & Carbon now has<br />

secure pallets with 22 stable and steady<br />

layers each. The bagging capacity has been<br />

increased to 90 bags per hour and <strong>the</strong> costs<br />

<strong>for</strong> storage and logistics reduced by 75%. At<br />

<strong>the</strong> same time, dust pollution during bagging<br />

and transport has been completely<br />

eliminated. The entire process remains absolutely<br />

dust-free. The Greif-Velox Velovac system<br />

thus benefits Imerys and its customers<br />

right down <strong>the</strong> line.<br />

www.<strong>cpp</strong>-net.com<br />

Online search: <strong>cpp</strong>0319greif<br />

AUTHOR:<br />



Head of Research &<br />

Development,<br />

Greif-Velox<br />

Industrie<br />

The<br />

network of<br />

expertise<br />

<strong>for</strong> <strong>industry</strong><br />

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Practical knowledge spanning all media<br />

channels: Trade journals, websites, events,<br />

newsletters, whitepapers, webinars<br />

Discover <strong>the</strong> appropriate media <strong>for</strong><br />

you and your specific <strong>industry</strong> sector:<br />

konradin.de/industrie<br />

media.industrie.de<br />

<strong>cpp</strong> 03-2019 59

<strong>cpp</strong><br />



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<strong>cpp</strong><br />


AZO GmbH & Co. KG, Osterburken 5<br />

Bausch + Ströbel Maschinenfabrik<br />

Ilshofen GmbH + Co. KG, Ilshofen 19<strong>–</strong>20<br />

Brabender Technologie GmbH & Co.KG,<br />

Duisburg 27<br />

C. Otto Gehrckens GmbH & Co. KG, Pinneberg 23<br />

Ecolab Engineering GmbH, Siegsdorf 15<br />

Fette Engineering GmbH, Schwarzenbek 2<br />

GATHER INDUSTRIE GmbH, Wülfrath 53<br />

Hamilton Bonaduz AG, CH-Bonaduz 51<br />

Dr. Jeßberger GmbH, Ottobrunn 61<br />

Amandus Kahl GmbH & Co., Reinbek 29<br />

KELLER AG für Druckmesstechnik,<br />


Mesago Messe Frankfurt GmbH, Stuttgart 55<br />

Orbitalum Tools GmbH, Singen 33<br />

Rembe GmbH Safety + Control, Brilon 54<br />

Robu Glasfilter-Geräte GmbH, Hattert 7<br />

Georg Schünemann GmbH, Bremen 22<br />

VACUUBRAND GmbH & Co. KG, Wer<strong>the</strong>im 3<br />


Schul<strong>the</strong>is GmbH & Co., Offenbach 31<br />

Witte Pumps & Technology GmbH, Tornesch 30<br />

ystral GmbH, Ballrechten-Dottingen 45<br />

60 <strong>cpp</strong> 03-2019

www.jesspumpen.com<br />

&<br />

robust<br />

powerful<br />

Pumps<br />

Please visit us!<br />

K-fair<br />

Düsseldorf 16.<strong>–</strong>23.10.2019<br />

Hall 12 C45<br />

parts2clean<br />

Stuttgart 22.<strong>–</strong>24.10.2019<br />

Hall 3 E03<br />

Made in<br />

Germany<br />

ATEX<br />

2014/34/EC<br />

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Electric and air operated drum pumps<br />

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Air operated diaphragm pumps<br />

Horizontal centrifugal pumps with<br />

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Vertical centrifugal pumps<br />

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Accessories such as<br />

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and nozzles<br />

Filling systems accord-<br />

ing to customer request<br />

est<br />


Jaegerweg 5 <strong>–</strong>7<br />

D-85521 Ottobrunn<br />

Phone: +49 (0) 89 - 66 66 6 33 400<br />

Fax: +49 (0) 89 - 66 66 33<br />

3 411<br />

info@jesspumpen.de<br />

www.jesspumpen.com<br />

Pumps<br />

und systems<br />

<strong>for</strong> almost all<br />

media<br />

<strong>cpp</strong> 03-2019 61

Ei: Intrinsically safe Pressure Transmitter<br />

For strong hazardous areas (Zone 0)<br />

For industrial applications (Gas Group II)<br />

For Ex II 1G Ex ia IIC T4…T6 Ga<br />

Series 4 LD Ei…9 LD Ei<br />

«The Heart»<br />

Ø 11 mm…Ø 19 mm<br />

Series 20 D Ei<br />

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3 bar to 1000 bar<br />

Series 21 D Ei<br />

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Series 23 D Ei<br />

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300 mbar to 1000 bar<br />

Series 26 D Ei<br />

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300 mbar = ca. 3 mH2O<br />

Optimised <strong>for</strong> battery-operated applications<br />

Total error band: ± 0,7 %FS @ -10…80 °C<br />

I 2 C microcontroller interface<br />

1,8…3,6 V / 20 μW @ 1 SPS<br />

62 <strong>cpp</strong> 03-2019<br />


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