cpp – Process technology for the chemical industry 02.2020

02-2020 

20 COVER 

QUICK ACCESS TO 

ALL LEVEL DATA 

14 PLANT PROTECTIVES 

CHOOSING THE RIGHT 

MILL CAREFULLY 

42 I/O SOLUTION 

FOR INTRINSICALLY 

SAFE APPLICATIONS 

44 DIGITAL TOOLS 

SMART PRODUCTION OF 

TABLETS AND CAPSULES 

PROCESS TECHNOLOGY FOR THE CHEMICAL INDUSTRY 

WWW.CPP-NET.COM

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cpp 

EDITORIAL 

LET US FILL YOUR 

REQUIREMENTS, TOO! 

Corona accelerates 

digitalisation 

Rapid delivery 

Made in Germany 

ISO 9001 

Swift conversion, cross-machine control and reliable remote maintenance: 

in exceptional times such as the coronavirus crisis, it becomes 

apparent just how fast and comprehensively pharmaceutical 

manufacturers need to react to volatile production conditions. Demand 

and availability can change at any time. These agility requirements 

can be organised more efficiently using digital tools. For 

example, it is more important than ever to be able to use live 

chats and video conferencing for remote maintenance as well as 

augmented reality applications for increased precision. Fette Compacting 

is now making a comprehensive set of digital solutions 

available for tablet and capsule production. You can learn more 

about these solutions in an article on page 44. 

Digitalisation doesn’t stop at Ex zone 1. Comprehensive networking 

in the sense of Industry 4.0 can offer the process industry significant 

advantages when it comes to efficiency, specifically with regard 

to integral data processing, system and remote monitoring, predictive 

maintenance or intelligent diagnostics. Jürgen Wenzel, Business 

Development Manager, and André Fritsch, Remote I/O Product 

Manager, of explosion protection specialist R. Stahl provide a 

glimpse into technological developments at the company in our 

interview on page 30. 

Finally, a brief comment on the title article of this issue, which 

deals with quick access to all level data at Georg Oest Mineralölwerk, 

based in Freudenstadt, Germany. Thanks to the Vega Inventory 

System, the company has fast access to both current and historical 

consumption data. You can find out more about this technology in 

an article on page 20. 

Multi-purpose 

laboratory pump 

The compact, standardized Gather gear 

pump is designed for metering and recirculation 

from 0 °C to 85 °C against 10 bar. 

Proven Gather quality at budget prices. 

• For lubricating and non-lubricating liquids 

• Pulsation-free pumping action 

(0.6 to 180 l/h) 

• CIP capability (cleaning in place) 

www.gather-industrie.de 

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

Günter Eckhardt, Editor-in-Chief 

cpp 02-2020 3 

Pump/Metering/Coupling Technology

cpp CONTENTS 02-2020 

20 Cover At the production 

facility of Oest, 

Vega sensors monitor the 

mixing of oils and keep 

track of stock levels. 

8 A research team, with 

a leading role played by 

Evonik, has achieved a 

breakthrough in the 

field of carbonylation 

chemistry. The team 

succeeded in the double 

carbonylation of a conjugated 

diene using a new 

catalyst. 

26 In spring this year, 

KSB presented several 

new models for the water 

and waste water industry. 

The highlight of the 

spring offensive was the 

new Amarex series of 

submersible motor 

pumps, which are offered 

in different versions. 

PROCESS ENGINEERING 

8 A dream reaction achieved with the right catalyst 

Successful direct carbonylation of 1,3-butadiene 

10 Green engineering for green chemistry 

More sustainability in the chemical industry 

12 All-purpose process tool 

Cylindro conical dryer with wide range of applications 

14 Dry fine grinding of plant protectives 

Choosing the right mill carefully 

INSTRUMENTATION, CONTROL, AUTOMATION 

20 COVER Quick access to all level data 

Good lubrication makes everything run better 

24 Explosion-protected housings are the solution 

Factory automation sensors make their way into 

hazardous environments 

ENVIRONMENTAL TECHNOLOGIES 

26 High-efficiency waste water pumps 

Submersible motor pump brings life to waste water 

28 Intelligence for pumps, agitators and mixers 

Decentralised drive systems for process and 

waste water engineering 

FOCUS: SAFETY AND SECURITY 

30 Systematic digitalisation in hazardous areas 

Process automation: safely networked up to Ex zone 1 

33 Safety as a building block for success 

A transformation of safety culture at Rain Carbon 

36 From centralised to decentralised design 

The protection of power distribution systems 

is changing 

38 PRODUCTS 

40 Functional all-rounder for safety 

High-performance, configurable small controller for 

efficient automation projects 

42 Reliable implementation of the NOA concept 

I/O system extended to include modules for the 

Ex i zone 

PLANTS, APPARATUS, COMPONENTS 

44 Full speed ahead for smart solid formulation 

production 

Digital tools optimise performance of tablet presses 

and capsule filling machines 

46 Monitoring of the bearings of the centrifuge bowl 

Danger recognised, bearing damage averted 

48 Precise metering needed 

Diaphragm metering pumps in use in 

battery production 

4 cpp 02-2020

33 In 2016, the number 

of reportable injuries was 

already at a low level, but 

that was not enough for 

Rain Carbon. With the 

help of Dupont Sustainable 

Solutions, Rain Carbon 

has moved closer to 

zero, beginning with a 

pilot project at its Castrop-Rauxel 

site. 

44 Even before the 

spread of Sars-CoV-2, it 

was clear that digital 

tools are decisive factors 

for the success of future 

pharmaceutical production. 

Now corona has significantly 

increased the 

necessity of such aids. 

COLUMNS 

3 Editorial 

4 Contents 

6 News 

17 PRODUCTS 

50 List of Advertisers 

50 Contact to the Editors 

50 Imprint 

WWW.CPP-NET.COM 

More news, facts, products and 

solutions for the process technology 

in the chemical industry can be found 

on our internet page! 

www.cpp-net.com 

SOME THINK 

THAT STACK 

QUALITY 

AND HIGH 

THROUGHPUT 

ARE MUTUALLY 

EXCLUSIVE. 

WE THINK 

DIFFERENT. 

cpp 02-2020 

beumer.com 5


NEWS 

Group increases incoming orders, sales, profits and headcount in the 2019 

ENDRESS+HAUSER WELL POSITIONED FOR THE FUTURE 

Picture: Endress+Hauser 

Dr. Klaus Endress (left), President of the 

Supervisory Board, and Matthias Altendorf, 

CEO of the Endress+Hauser Group 

Endress+Hauser performed well across all 

fields of activity, industries and regions in 

2019. The Group created hundreds of new 

jobs, invested record amounts and improved 

in the area of sustainability. According to 

CEO Matthias Altendorf, the family company 

is thus in a strong position to address 

the challenges of the corona crisis. “2019 

was a solid year for Endress+Hauser,” emphasised 

Matthias Altendorf. “Growth was 

broad-based and balanced.” 

The measurement and automation technology 

specialist for process and laboratory applications 

increased net sales by 8.0 % to 

2.652 billion euros, despite a weakening 

economy. During the annual media conference 

on financial statements in Basel, the 

CEO explained that instead of large-scale 

orders, this growth was driven by smaller 

and medium-sized projects. 

According to the CEO, this success is also 

tied to the company’s undiminished innovative 

spirit. In 2019, Endress+Hauser filed 

318 patent applications and invested 7.6 % 

of sales in research and development. More 

than 1100 people are working on new 

products, solutions and services. By the end 

of 2019, Endress+Hauser had 14,328 

employees worldwide. 400 new jobs have 

been created within one year. 

Endress+Hauser started 2020 with a further 

increase in incoming orders. However, the 

coronavirus pandemic makes it massively 

more difficult to achieve the original goals. 

“Although we are still unable to predict the 

economic impacts of the crisis, we and our 

customers will certainly feel the effects,” 

underlined CEO Matthias Altendorf. The 

Group responded early to the spread of the 

virus and used all means at its disposal to 

protect people’s health and continue to 

offer customers solid support. 

“We bridge the physical distance through 

digital and emotional proximity,” said 

Matthias Altendorf. The CEO has been 

driving digitisation at Endress+Hauser for 

years. Customers can use the website to 

order instruments or track orders, and an 

online tool enables remote support aided by 

video. 

Picture: Evonik 

Membrane reactor on its way to being an industrial scale 

EVONIK LAUNCHES MACBETH PROJECT 

Involved in the Macbeth project: Dr. Marc- 

Oliver Kristen, Dr. Frank Stenger, Prof. Dr. 

Robert Franke (from left to right) 

Evonik is continuing to strengthen its position 

as one of the leading companies in the 

field of C4 chemistry. Macbeth (Membranes 

And Catalysts Beyond Economic and Technological 

Hurdles), the largest EU-funded 

project coordinated by Evonik to date, was 

recently launched. The aim is to develop a 

new process for catalytic synthesis with appropriate 

separation equipment in a single, 

highly efficient catalytic membrane reactor 

(CMR). Macbeth is the follow-up project to 

the Romeo project (Reactor Optimization 

by Membrane Enhanced Operation), which 

was completed in September 2019. 

The newly founded project consortium consists 

of 24 partners from ten different countries. 

It brings together expertise related to 

catalysis to membranes, carriers, reactors, 

engineering, modelling as well as the perspective 

of the end user. 

„It is crucial that we think beyond the 

boundaries of chemistry, share knowledge 

and exploit synergies. One individual company 

could never achieve this. Our consortium 

brings together the know-how that is 

essential for the desired breakthrough in 

catalytic synthesis,“ says Dr. Marc Oliver 

Kristen, Head of the Innovation Agency at 

Evonik and Project Manager Macbeth. 

In individual sub-projects, the concept of 

the new reactor is now being applied to 

various chemical reactions and put into 

practice. This includes hydroformylation for 

specialty chemicals, hydrogen production 

for the transport/electricity generation sector, 

propane dehydrogenation (PDH) for 

large-volume chemicals and biocatalytic oil 

cleavage for biotechnologically manufactured 

products. 

Evonik’s focus of the project is on the hydroformylation 

reaction. In this catalysis, 

which is traditionally carried out homogeneously, 

synthesis gas is used to convert 

olefins into aldehydes. Sustainability is a key 

driver here: the planned reduction of greenhouse 

gas emissions in large-volume industrial 

processes will be up to 35 % and the 

increase in resource and energy efficiency 

up to 70 %. 

Back to work 

HOW TO REBOOT IN A 

POST-COVID WORLD 

Finding the right exit strategy after the 

corona crisis is not an easy task for many 

companies 

As many lockdowns around the world begin 

to ease, Bain & Company’s research, Back to 

Work: Advance, Retreat, Adapt, Recover, 

offers a guide for how to think through 

some of the most critical questions that 

businesses will face when operating in a 

radically different environment. Returning 

to work will be far more complex than 

turning the lights back on and restarting 

operations. Companies will need to face 

questions that confront every business 

founder: What are the customer needs that I 

serve? Where is the demand and how will 

we configure the business model to meet it? 

Evaluating the demand side of the equation 

can offer a starting point to gauge workforce 

needs and the urgency of returning 

different groups of workers. 

Picture: duncanandison – stock.adobe.com 


New hotspot for the digital ecosystem 

DIGITAL HUB AT ACHEMA 2021 

Bild: Dechema 

Digitalisation is one of the main topics of 

Achema2021. Therefore the Digital Hub 

will be established. 

The process industries are going digital – 

and they need specialised partners to get the 

best out of digitalisation, big data and artificial 

intelligence. This is why Achema 2021 

is introducing the Digital Hub – a place for 

digital players and process industry experts 

alike. The chemical, pharma and food industries 

are building on plant automation to 

bring digitalisation to the next level with 

predictive maintenance, flexible production 

and new digital business models. “To be 

able to use this potential, however, a close 

exchange between industrial companies and 

providers of digital solutions is essential. 

The Digital Hub offers the perfect framework 

for this,” said Dr. Klaus Schäfer, CTO 

of German chemical producer Covestro. It 

combines interaction and inspiration, enabling 

the forging of new business links and 

the development of novel ideas in an inspiring 

atmosphere. The Digital Hub provides 

more than an additional exhibition area: To 

promote interaction, a new concept integrates 

an exhibition with a centre stage that 

offers space for presentations and discussions. 

The concept of the Digital Hub at 

Achema 2021 has been developed in close 

conjunction with renowned experts. Four 

dedicated access points focus on logistics 

and supply chain, research and innovation, 

cyber security as well as engineering and 

operations. The Digital Hub showcases digital 

solutions such as cloud and infrastructure 

offerings, software and tech tools while 

providing the opportunity for networking. 

Next environmental trade fair in Munich from May 30 to June 3, 2022 

IFAT 2020 TO BE CANCELLED 

Picture: Messe München 

The next Ifat will take place in May 2022 

In consultation with the Executive Board of 

the Exhibitors’ Advisory Board and the 

conceptual partners of Ifat, Messe München 

conducted a survey among the Ifat exhibitors, 

revealing that most respondents are 

against holding Ifat from September 7 to 

11, 2020. Hence, at the planned time it 

would be unacceptable not only for Messe 

München but also for the trade fair participants. 

In order to provide all customers with 

a reliable basis for planning and in close 

consultation with the Executive Board of the 

Exhibitors‘ Advisory Council, Ifat now is 

canceled for this year. The fair had already 

been postponed from May to September. 

“We therefore cancel the alternative date 

with a heavy heart. The next Ifat will take 

place from May 30 to June 3, 2022,” says 

Stefan Rummel, Managing Director of Messe 

München. Even in this turbulent time, 

Messe München and the Ifat team see themselves 

as partners of the industry: “We will 

continue to develop and digitally complement 

our platform in order to add fresh impetus 

to the environmental industry – at our 

home base in Munich and internationally.” 

cpp NEWS TICKER 

30 years of experience, Michael 

Clark is internationally recognised 

in the process automation 

sector for his expertise in Industrial 

Control System (ICS) fieldbus 

protocols. 

specialty fleet of returnable 

cylinders. TEAL is a metal alkyl 

essential in the production of 

high-volume plastics including 

polypropylene and polyethylene. 

The acquisition is the latest in a 

series of moves Nouryon has 

made to increase its footprint in 

the metal alkyls market, following 

an expansion of production capacity 

at its Rotterdam site and 

the acquisition of metal alkyls 

producer Zhejiang Friend in 

China. The transaction is expected 

to be finalised during 

the second quarter 2020, after 

which Nouryon will gradually 

move production to its site in 

Rotterdam. 

Picture: OPC Foundation 

OPC Foundation with new 

Director of North America 

The OPC Foundation is pleased 

to announce the appointment of 

Michael Clark as the Director of 

OPC Foundation North America. 

Mr. Stefan Hoppe, President and 

Executive Director, selected 

Mr. Clark to serve in this capacity, 

to support OPC North American 

membership, and to function as a 

spokesperson for the Foundation 

throughout the region. With over 

Picture: Flender 

New Flender CEO 

Flender Group, part of Siemens 

AG Portfolio Companies, has a 

new CEO. As of April 1, 2020, 

Andreas Evertz has been appointed 

as additional Managing 

Director and has succeeded 

Picture: Nouryon 

Nouryon to acquire metal 

alkyls business from Sasol 

Nouryon has entered into an 

agreement to acquire the merchant 

triethyl aluminium (TEAL) 

business of Sasol, including its 

retiring Stefan Tenbrock as CEO 

effective June 1, 2020. Evertz 

worked for the former Flender 

Group in Bocholt and Tübingen. 

At last he was CEO at Schenck 

Process Group. 

cpp 02-2020 7



Successful direct carbonylation of 1,3-butadiene 

A dream reaction achieved 

with the right catalyst 

A research team, with a leading role played by Evonik, has achieved a breakthrough 

in the field of carbonylation chemistry. The team succeeded in the double carbonylation 

of a conjugated diene using a new catalyst. Science and industry had been 

searching for more than 60 years for a way to realise this newly successful reaction 

step. 

Cost is a critical factor in the large-scale 

production of fine chemicals and the demand 

for efficient synthesis routes is correspondingly 

high. The optimisation of 

chemical reactions and industrial processes 

using catalysis as a key technology enables a 

more sustainable use of raw materials and 

energy sources as well as loss-free utilisation 

of the raw materials. A tailor-made 

catalyst accelerates the reaction, prevents the 

formation of by-products, and thus reduces 

the energy requirements of the entire process. 

Carbonylation reactions are among the 

most important applications of industrial 

catalysis. The catalysed introduction of the 

CO group takes place through the use of 

carbon monoxide (CO), which, as an important 

C1 building block of the chemical 

industry, can be extracted both from fossil 

resources (coal and gas) and from renewable 

sources (CO 2 or biowaste). Carbonyl 

compounds (aldehydes, acids, esters) are 

produced annually on a scale of several million 

tonnes and are used for numerous consumer 

goods. 

A research team from Evonik and the Likat has succeeded in directly double carbonylating 

the raw material 1,3-butadiene 

Pictures: Evonik 

Direct carbonylation of 1,3-diene 

Despite the discovery of homogeneously 

catalysed carbonylation processes almost 

eighty years ago, challenges remain unsolved, 

especially the direct dicarbonylation 

of 1,3-dienes. This reaction is a so-called 

dream reaction and enables a more environmentally 

friendly, atomically efficient production 

of adipate diesters, which are produced 

on a large scale as building blocks 

for polyamides and polyesters. In particular, 

adipate diesters are used in plasticizers, perfumes, 

lubricants, solvents and active pharmaceutical 

ingredients. A further application 

is the production of nylon. Currently, 

adipic acid diesters are produced industrially 

by oxidising a mixture of cyclohexanol 

and cyclohexanone with an excess of 

nitric acid. The resulting adipic acid is esterified 

with the corresponding alcohols. 

This process requires special equipment 

due to the corrosive effect of the acid. It 

also releases nitrous oxide (laughing gas), 

which on the one hand binds stratospheric 

ozone and on the other hand is 300 times 

stronger as a greenhouse gas than CO 2 . 

Therefore, the work of the scientists at the 

Leibniz Institute for Catalysis (Likat) – 

Prof. Dr. Matthias Beller, Dr. Ralf Jackstell, 

Dr. Helfried Neumann, Jiawang Liu, JiYang 

– in collaboration with Prof. Dr. Robert 

Franke, Evonik Performance Materials 

GmbH and Associate Professor of Chemistry 

at the Ruhr University Bochum, has great 

potential for carbonylation chemistry. They 

developed a palladium catalyst with a 

specially designed pyridyl-functionalised 

bisphosphine ligand that enables the highly 

selective and efficient double alkoxy carbonylation 

of 1,3-butadiene into adipic 

acid esters in a single step. The key to success 

was the ligand design. The combination 

of a bidentate phosphine ligand 


Complex network of reactions involved in the synthesis of adipate diesters from 1,3-butadiene, 

carbon monoxide and alcohol 

Comparison of the different phosphine ligands with regard to reactivity and selectivity 

with a basic pyridyl substituent on the 

phosphorus and a palladium precursor delivers 

a yield of ≥95 % and selectivity of 

≥97 % in the dicarbonylation of 1,3-butadiene 

dialkyl adipates. 

The right catalyst is key 

The difficulty lies in the complexity of the 

dicarbonylation reaction, which usually 

tends to form numerous by-products. The 

simultaneous introduction of two CO 

groups presents several challenges in this 

catalytic process: 

• The simultaneous production of two different 

carbonylation reactions on a diene 

substrate (no other research group has 

been successful before) 

• The selective formation of the linear dicarbonylation 

product, although the isomerisation 

of the originally formed monocarbonylated 

intermediate to the terminal 

olefin is thermodynamically particularly 

unfavorable 

• The suppression of other side reactions 

such as telomerisation, hydroalkoxylation 

and (co)polymeridation 

For the development of a suitable catalyst, 

palladium-coordinated, base-modified derivatives 

of the 1,2-bis[(di-tert-butylphosphino) 

methyl] benzene ligand (L1, dtbpx), 

which is used for the large-scale production 

of methyl methacrylate, were chosen. First 

optimisation studies with this ligand 

showed low activity but good selectivity. 

The incorporation of suitable basic groups 

leads to a significant increase in activity. 

However, as the direct comparison between 

L1 and the doubly base-modified L4 shows, 

this is at the expense of selectivity. The solution 

was to combine both structural elements. 

The specially developed L5 (HeMa- 

RaPhos) combines the excellent selectivity 

of L1 with the high reactivity of L4. 

Supplementary studies on the performance 

and optimisation of the catalyst system now 

allow the direct dual carbonylation of 

1,3-butadiene to adipate diesters with high 

catalyst conversion rates (>60 000), yields 

of up to 95 % and an outstanding selectivity 

of over 97 %. The catalyst system can also be 

transferred to other dienes, paving the way 

for a completely new synthesis route for the 

production of many fine chemicals. 


Online search: Evonik 

AUTHOR: 

PROF. DR. 

ROBERT FRANKE 

Head of Hydroformylation 

Research, 

Evonik 




More sustainability in the chemical industry 

Green engineering for 

green chemistry 

The topics of climate change, resource conservation and energy efficiency are shaping 

the political and economic debate worldwide. In the current competitive market 

situation each company has to focus on sustainable products and processes. The 

chemical industry in particular has unused potential that should be taken into account 

already in the stage of plant design. Experienced partners such as the plant 

designer VTU Engineering offer the necessary support for doing just that. 

Strict environmental regulations, a market 

geared towards more sustainable products 

and processes, and high competitive pressure 

from emerging markets, especially for 

bulk quantities at low manufacturing costs – 

the challenges the European industry is 

facing today are far from trivial. While Europe 

has already lost the battle for many 

low-cost base chemicals, now the fight is 

for the future of fine chemicals with higher 

profit margins. 

More than 20 years ago, the American 

chemists Paul Anastas and John Warner published 

the book „Green Chemistry: Theory 

and Practice“ (Oxford University Press; 

1998), in which they describe twelve characteristics 

of sustainable chemical syntheses 

(see also text box). Starting from research 

and development at universities and in the 

pharmaceutical sector, green chemistry has 

now become a powerful tool for technological 

innovation in the chemical industry. 

Green engineering 

Green chemistry for a more compatible design 

of chemical syntheses is primarily developed 

by the R&D units of such companies 

that own the production technology. 

However, the industrial success of a new 

process depends profoundly on a planning 

partner who guarantees the technological 

and economic feasibility from the beginning 

to shorten the time to industrial implementation. 

It also requires a special ap- 

Picture: VTU Engineering 

View into the VTU Engineering pilot plant in Graz 


proach to process engineering, an approach 

which can be defined as "green engineering": 

Engineering in the service of green 

chemistry. 

The implementation of the twelve principles 

requires, for example, that process 

engineering goes back to the laboratory and 

promotes a proactive and highly interdis - 

ciplinary exchange between chemists and 

engineers. 

Energy efficiency 

Improving energy efficiency is no easy task 

for a chemist who develops and evaluates 

alternative syntheses on a gram scale in the 

laboratory. Here, the engineering tools of 

predictive modelling (including the analysis 

of energy flows and optimisation) and process 

simulation are helpful. These instruments 

are already available for an initial 

concept study to obtain information on the 

energy needs, environmental impact and 

economic conditions of the synthesis to be 

developed. This allows for important decisions 

to be made pro-actively and as early 

as in the R&D phase, which will have a 

positive impact on the industrial implementation 

(e.g. evaluation of alternative separation 

processes to increase yield at lower 

costs). 

VTU has extensive experience in the field of 

increasing the energy efficiency of chemical 

plants. Thanks to the know-how of the process 

engineers, numerous improvements 

have become possible that go far beyond 

simple heat recovery or known measures 

such as pump control. The greatest potential 

usually lies in process management. For 

example, simple mechanical changes to 

guide different feed streams in evaporation 

or distillation plants can result in high savings. 

At Borealis in Linz, Austria, CO 2 capture 

in the feed gas for ammonia synthesis 

was increased by simple means, resulting in 

considerable energy savings. The project was 

awarded a prize by the Austrian Ministry of 

Agriculture, Regions and Tourism. 

Monitoring of process parameters 

Real-time analysis of process parameters 

allows for the timely remedial action to 

meet production requirements, reduce byproduct 

formation and increase yield, 

which is one of the targets of a green process. 

The effects of relevant measured and 

manipulated variables are determined by the 

engineers during the development phase, so 

that they can then implement optimal and 

robust strategies for monitoring process 

parameters in the plant. VTU Engineering 

successfully uses the combination of quality 

SUSTAINABLE SYNTHESIS: 

Twelve principles characterise 

sustainable syntheses (Anastas 

and Warner, 1998): 

• Prevent waste 

• Atom economy – the product 

of a chemical reaction should 

have a molecular weight as 

close as possible to the sum of 

the molecular weights of the 

starting products, so that few 

by-products are formed 

• Select new, less dangerous synthesis 

pathways 

• Prefer syntheses of new molecules 

without risk to humans 

and the environment 

• Use solvents that are harmless 

to humans and the environment 

by design (QbD) and process analytical 

techniques (PAT). With QbD, a test matrix is 

specified for relevant measured or manipulated 

variables, which is statistically evaluated 

with PAT and used for predictions. This 

allows for the influences and weighting of 

the process variables on, for example, reaction 

time, yield, formation of by-products 

and, finally, quality to be determined and 

validated. QbD and PAT have become widely 

used in the pharmaceutical sector as they 

make an important contribution to speeding 

up and rationalising expensive experimental 

campaigns. The advantages of these tools can 

also be proven in any other context. 

Flexibility is imperative 

Process engineers today have sufficient tools 

available to meet the challenges of green 

chemistry. However, project planning must 

be reviewed on an ongoing basis and 

adapted to the results achieved after each 

development stage. Where appropriate, 

more flexibility should be adapted to improve 

the process as well as to evaluate ways 

that are unknown, in order to be able to implement 

the project competitively on an industrial 

scale. VTU has a consolidated concept 

for sustainable process plants, which 

makes use of their many years of experience, 

e.g. with biotechnological processes or 

energy recovery. The engineering tools are 

adapted to the specific requirements of the 

respective project. There are many examples 

of how this flexible VTU approach proved to 

be decisive for increasing client sustainability, 

including: 

TWELVE CHARACTERISTICS 

• Consider energy efficiency in 

new synthesis pathways 

• Use renewable raw materials 

• Reduce derivatives and intermediates, 

e.g. avoid protective 

groups through better regio - 

selectivity or stereoselectivity 

• Prefer (bio-)catalytic over stoichiometric 

reactions 

• Consider later degradation of 

new molecules – after use, 

products should be able to degrade 

naturally 

• Use real-time monitoring during 

production, e.g. to prevent 

contamination in the process 

• Consider safety aspects to prevent 

accidents and avoid dangers 

• A process evaluation for fuel-from-CO 2 

• Plants for solvent recovery (e.g. ethanol in 

pharmaceutical quality, NMP, DMSO) 

• The planning of a demonstration plant for 

on-site on-demand H 2 production 

• Lithium-ion battery recycling 

• The biocatalytic production of plastics 

• Processes for the treatment of bio-based 

oils for use in hydrogenation plants 

As a planning partner, VTU also focuses on 

research and cooperation. With its own 

technical centre and close cooperation with 

various institutions, including the Graz University 

of Technology, the engineers are constantly 

striving to broaden and improve 

their know-how. 


Online search: VTU Engineering 

AUTHOR: 

WOLFRAM GSTREIN 

Managing director, 

VTU Engineering 

Deutschland 

AUTHOR: 

ALESSANDRO 

ROSENGART 

Process Engineer, 

VTU Engineering Italia 




Cylindro conical dryer with wide range of applications 

All-purpose process tool 

The Bolz cylindro conical dryer CCD is an all-rounder. With its flexible design, 

different agitators and material grades, it can be adapted to almost any process 

requirement in the chemical, fine chemical, pharmaceutical and food industry. It 

is used as vacuum contact dryer and evaporator as well as steriliser or alkaliser, 

providing the highest quality and short drying times. The products processed 

range from slurries and pastes to filter cakes, granulates and powders. 

The cylindro conical 

dryer CCD has a central 

shaft agitator and is 

designed for gentle 

drying of solids in the 

chemical, fine chemical, 

pharmaceutical 

and food industries 

Constantly increasing demands on quality 

and economic efficiency call for innovative 

solutions in the manufacture of end and intermediate 

products in the chemical, fine 

chemical, pharmaceutical and food industries. 

Especially where products for the 

building material, adhesives and sealants 

sectors are concerned, functional additives 

such as chalk, carbon black or calcium carbonate 

are essential. Their moisture content 

should be as close as possible to zero, preventing 

unintended reactions with other 

product components from impacting on 

quality. This is where conventional drying 

systems reach their limits. Bolz fulfils these 

demanding requirements with its cylindro 

conical dryer CCD. The gentle yet intensive 

mixing ensures short drying times without 

Pictures: Bolz 

significant product debris. Drying is effected 

at a very low pressure of less than 

30 mbar absolute and the final moisture 

content is no more than a few ppm, depending 

on the application. 

The efficient cylindro conical dryer is often 

used after mechanical solid-liquid separation, 

but can also be operated without a 

preceding mechanical separation stage. It is 

an all-purpose dryer which meets various 

process requirements due to the different 

agitator designs including helix, double 

helix, paddle or segmented helix. Different 

application-specific materials are available 

for the product contacted parts, from stainless 

steel to (super) duplex, Hastelloy or titanium. 

Thanks to its flexibility, the Bolz cylindro 

conical dryer can be used for vacuum 

contact drying as well as for evaporation, 

sterilisation and alkalisation or as a reactor 

handling slurries, pastes, filter cakes, granules 

and powders. 

Sophisticated functionality 

The central mixing helix is the core technology 

of the Bolz cylindro conical dryer 

with its central shaft agitator. Precisely 

adapted to the vessel design and running 

close to the wall, the helix guarantees optimum 

mixing of the product. The mixing 

helix feeds the product upwards along the 

heated vessel wall, while in the centre of the 

vessel vertical mixing is ensured by gravity. 

Rotation results in a horizontal flow component. 

The three-dimensional mixing principle 

means new material is continuously 

fed to the heated vessel wall, leading to a 

homogeneous temperature in the dryer. In 

combination with a heated mixing helix, 

the optimised agitator achieves perfect mixing 

results and reduced drying times. 


The mixing helix of the cylindro conical dryer CCD ensures short drying 

times 

The vapour filter is jet-cleaned to rule out product deposits on the filter 

elements 

The vessel including the dished cover is 

heated by a jacket, half-pipe coils or pillow 

plates using heat carriers such as hot water, 

(saturated) steam or thermal oil, which can 

be heated to temperatures of up to 400 °C. 

By heating the complete dryer, the 

formation of cold spots is prevented. In addition, 

an insulating jacket keeps the heat 

inside the dryer and at the same time offers 

operator protection against injury. 

A ball segment valve with an inflatable, 

sanitary lip seal is normally used as an emptying 

device at the cone’s central outlet, 

guaranteeing maximum tightness in vacuum 

or pressure operation. It allows the lowest 

helix segment to be adapted exactly to 

the ball segment’s geometry, thus minimising 

unmixed zones and product residues. 

The cylindro conical dryer is often used as a 

vacuum contact dryer for increased 

throughput as well as gentle product drying 

at low temperatures. A vacuum pump provides 

the required vacuum, producing an 

operating vacuum in the dryer in the range 

from 5 to 100 mbar absolute. As a result, 

moisture evaporates at lower temperatures, 

throughput is higher and energy losses are 

reduced. The lower process temperatures 

have a positive effect on the quality of the 

end and intermediate products, particularly 

when handling temperature-sensitive substances 

such as enzymes. 

For easy and hygienic cleaning, the Bolz cylindro 

conical dryer features WIP or CIP 

nozzles. At the end of the drying process 

and before the next drying batch starts, 

cleaning liquid can be sprayed into the interior 

of the dryer under (high) pressure 

while the agitator is rotating. After the 

cleaning liquid has been completely discharged, 

the dryer is heated and the remaining 

moisture evaporates. 

Vapour filter 

Like every Bolz dryer, the cylindro conical 

dryer CCD also has a vapour filter to prevent 

product particles from escaping into the environment 

or the connected vacuum pipeline 

during charging or discharging. The 

filter surface, filtration efficiency and material 

are always adjusted to the dryer size, 

the operating parameters and the product. 

To avoid condensation of the vapours and 

thus sticking and blocking of the filter elements, 

the vapour filter is heated and insulated. 

The vapour filter is jet-cleaned to rule 

out product deposits on the filter elements. 

Wide range of applications 

The Bolz cylindro conical dryer is not only 

used as a vacuum contact dryer. It demonstrates 

its flexibility and versatility in the 

production of cocoa, for example. First, the 

fermented cocoa beans, broken into cocoa 

nibs, are heated in the central shaft dryer by 

the addition of steam. An alkaline solution is 

then also added by means of overpressure 

and temperature, reducing the bitter flavouring 

components, raising the pH to approximately 

7, washing out unwanted bitter 

substances and adjusting the cocoa’s colour. 

This process includes operation under vacuum, 

use as an overpressure reactor, homogeneous 

mixing and sterilisation of the 

broken cocoa nibs. The Bolz cylindro conical 

dryer is moreover ideal for sterilising spices 

by adding superheated steam as well as for 

evaporating liquid or pasty products, which 

are difficult or impossible to filter due to 

their low solids content, meaning that no 

mechanical solid-liquid separation can be 

installed upstream. 


Online search: Bolz-Summix 

AUTHOR: 

FRANK BESSNER 

Product Manager, 

Bolz Process Technology 




Choosing the right mill carefully 

Dry fine grinding of plant 

protectives 

The production of plant protectives is currently gaining in strategic importance. It 

needs to be re-evaluated to put more emphasis on environmental restrictions, both 

during the chemical production process and in agriculture when spreading on crops. 

When optimising the production processes for herbicides, fungicides and pesticides, 

the selection of the most suitable mill technology plays a vital role. 

In crop protection products, it is important 

that the active molecules act on the right 

target (insects, weeds or fungi) with the 

right intensity and at the right time, 

namely when the crop actually needs protection. 

Crop protection products therefore 

contain different components: 

• Active ingredients, of which a formulation 

can contain one or more 

• Dry fillers such as clay, talc, kaolin or silica 

to dilute the active material 

• Adjuvants and additives giving certain 

qualities (stabilising, wetting or antifoaming 

agents, repellents, …) 

The pesticide production process starts 

with dosing of the ingredients and intensive 

mixing. The various mills presented 

below are required at the next stage. The 

aim is to obtain homogeneous sizing of all 

the different particles from the various ingredients 

as well as end fineness compatible 

with the final application. After milling 

and safety sieving to eliminate possible 

oversized particles, a second mixing step 

re-homogenises the product and mixes the 

added ingredients which do not need to be 

ground. 

At the end of the production line are the 

Industrial process for the production of plant protectives: 1 – Container for pre-dosed raw materials, 2 

– Dosing screws, 3 – Pre-blenders, 4 – Air jet mill, 5 – Blower, 6 – Filter, 7 – Post-blenders, 8 – Container 

for final product 

Pictures: Netzsch Trockenmahltechnik 

final products: wettable powders (WP) are 

produced ready for packing. If a supplementary 

pelletising or granulation stage is 

added, the final product is referred to as 

water-dispersible granules (WG). 

Reducing active ingredients 

A finer powder helps make the action of the 

pesticides on targets more efficient. The 

same result after treatment can then be 

achieved using a smaller number of active 

ingredients in the formula. This is beneficial 

for safety, environmental and economic reasons. 

Furthermore, pesticide powders without 

oversized particles simplify the end application 

on the crop by the farmer: 

• Before application, the powder is dispersed 

in water. The suspension is more 

stable if the particles are finer and no sedimentation 

occurs during operation. 

• Spreading on crops is carried out by a 

spraying system with a series of nozzles. 

Clogged nozzles due to oversized particles 

prevent regular spraying and can even 

make it impossible. 

Based on the fineness and specifications requested 

by the producers of plant protectives, 

Netzsch has developed various technologies 

for dry grinding. Condux mechanical 

impact mills are well adapted for pregrinding 

and relatively coarse milling. The 

CSM type classifier mill is recommended 

for a perfect top cut without oversized particles. 

The CGS fluidised bed jet mill offers 

key advantages for the production of highquality 

pesticides, namely higher fineness, a 

final product free from oversized particles 

and optimal preservation of the active ingredients. 


Typical particle size distribution with a sharp top cut from a CGS type fluidised bed jet mill 

Mechanical impact mills 

Rotary impact mills are used for fine grinding 

of soft and medium-hard materials. The 

typical fineness range for the mean particle 

size is between 20 and 500 μm. Circumferential 

speeds of between 25 and 150 m/s 

are achieved. A version is also available for 

counter-rotating operation at up to 

250 m/s. The air flow, which depends on 

the type of rotor, ensures temperature-stable 

grinding. The rotor is mounted on a horizontal 

fly shaft arrangement. The high circumferential 

speeds at the shaft enable sealing 

with contact-free labyrinths. 

Mechanical impact mills can be equipped 

with a variety of grinding tools. This 

allows them to carry out two different 

tasks on plant protectives. The Condux mill 

version featuring a blast rotor in combination 

with a stator (screen or grinding 

track) is often used for pre-grinding. These 

grinding tools produce a blowing effect 

with a high air flow and only a very small 

temperature increase. The efficiency of the 

thermo-sensitive active ingredient is thus 

maintained. The fineness which can be 

achieved with this combination is typically 



Milling of two herbicides with a CGS 16 fluidised bed jet mill: the particle size distribution varies depending on the classifier speed 

CGS 50 fluidised bed jet mill 

without tools in the air jet and a dynamic 

classifier limits the maximum particle size. 

The particles are finely ground due to the 

high 500 to 600 m/s velocity of the air jets 

at the nozzle outlets inside the grinding 

chamber. The high level of available energy 

and the speed of the impact between particles 

in the fluidised bed enable a d50 fineness 

of 1 to 5 μm. 

One very interesting point for plant protection 

applications is that the energy received 

by the product for breaking the particles 

does not generate any heat. The expansion 

of the air physically induces a reduction in 

its temperature. Therefore, despite the heat 

which is produced when the particles impact 

each other and break, the two phenomena 

are balanced and the temperature remains 

constant, so that the active molecules 

are not damaged. 

Classifying takes place in the top part of the 

CGS mill, in a quiet zone well separated 

from the milling zone. The specific design 

of the Convor wheel makes it possible to 

achieve a sharp top cut even if the particles 

are only a few microns in size. The easy 

control of the rotating speed by a frequency 

converter means the CGS mill has a wide 

range of possible finenesses. 

Safe and easy to clean 

Regardless of the milling technology, attention 

should also be paid to the design of the 

complete grinding plant. Two aspects in particular 

must be considered: safety in relation 

to the dust explosion risk and cleaning to 

limit contamination. 

In most cases, pesticides include organic 

components which present a risk of dust 

explosion. The characterisation of the complete 

formula by a certified laboratory defines 

the relevant dust explosion values. 

These mainly concern the minimum ignition 

energy, the ignition temperature and 

the K St 

value. Depending on this data and 

when the limits are exceeded, the milling 

system must be adequately protected. A 

pressure shock-resistant plant design, including 

specific elements such as explosion 

valves and rupture discs, has the advantage 

that it brings down production costs and 

keeps operation simple. A second solution is 

to grind under inert gas while monitoring 

the oxygen content in the plant. An explosion 

suppression system using fire extinguishing 

powder sprayed into the installation 

is the third option. 

Very often, the same plant is used for several 

products with completely different formulas 

and possibly antagonistic active ingredients. 

In such cases, pesticide manufacturers clean 

their milling equipment especially carefully 

between two campaigns. 

As a market leader for processing technology, 

Netzsch has worked intensively on the 

design of its grinding plants. Internal parts 

are readily accessible thanks to a cover 

which opens completely as well as optimally 

positioned doors. The stainless-steel mill 

structures, fine polishing and bottom discharge 

valve enable simple washing with 

water. 


Online search: Netzsch 

AUTHOR: 

MICHEL HAMELIN 

Technical Sales, 

Netzsch Trockenmahltechnik 



PRODUCTS 

4-channel measurement and control device 

Efficient sludge dewatering 

Picture: Ecolab 

In May 2020 Flottweg has complemented 

its decanter centrifuge 

portfolio with the top of 

the range X7E. The newest Xelletor 

development has a capacity 

of up to 130 m 3 /h and is therefore 

suitable for medium to 

large sewage treatment plants. 

Since its launch in 2018, the 

Xelletor series has achieved impressive 

results in terms of 

throughput, polymer consumption 

and energy requirements. 

In comparison to other currently 

available machines, it 

offers up to 15 % more 

throughput, up to 2 % higher 

dry solids content and up to 

20 % savings in flocculant and 

energy consumption. 


Online search: Flottweg 

The measurement and control 

device Versatronic from Ecolab 

provides in addition to the 

simultaneous processing of up 

to four measurement and control 

channels, also various communication 

interfaces such as 

RS 485, Profibus, USB, Ethernet. 

System states can be called-up 

via remote access at any time by 

an integrated web server. A paperless 

recorder (optional) is 

able to record all measured 

values and switching states during 

a period of up to one year. 

By using an extensive evaluation 

software, the recorded data can 

be analysed and visualised comfortably. 


Online search: Ecolab 

Picture: Flottweg 

Digital output module 

Picture: B&R 

B&R’s digital output module 

X20DO4332-1 has integrated 

pulse width modulation and is a 

cost-effective alternative to 

motor modules. 

In addition, the module offers a 

dither function that prevents 

valves from sticking. Pulse width 

modulation (PWM) is mainly 

used for controlling larger 

loads, such as motors. Instead of 

using electronics to regulate a 

continuous input voltage down 

to the desired motor voltage, 

the motor is controlled by the 

width of the switching pulses. 

This process saves a considerable 

amount of energy. With its 

dither function, the module also 

prevents valves from sticking. 

This is particularly common 

when valves are held for extended 

times at a constant position, 

especially in liquids. The 

dither function oscillates the 

valve slightly around the position 

setpoint to prevent it from 

sticking. The X20 module is 

equipped with four outputs 

with three-wire connections 

and offers a nominal output 

current of 2 A. 


Online search: B&R 

Vacuum distillation system 

Sustainability is the hot topic of our time. Through sustainable 

waste water treatment with H2O’s Vacudest 

vacuum distillation systems, industrial productions protect 

the environment and save money at the same time. 

Leading companies already rely on Vacudest systems – 

the results achieve high standards thanks to patented innovations. 

For example, the Clearcat technology produces 

crystal clear, oil-free distillate, which is ideally 

suited for a reuse in the production process. This reduces 

disposal costs enormously. It also ensures that no 

residual impurities are released into the environment 

and valuable fresh water resources are conserved. 


Online search: H2O 

Picture: H2O 




Pictures: Pepperl+Fuchs 

The R2000 2-D Lidar scanner monitors the position of the fall protection device 

Factory automation sensors make their way into hazardous environments 

Explosion-protected 

housings are the solution 

Implementing automated processes in a plant requires suitable tools and components. 

Reliable sensors are among the most important of these tools. For example, 

these sensors help to monitor processes, detect and pass on information regarding 

errors, and control process flows. To enable customers to use Pepperl+Fuchs 

sensors in explosion-protected areas, the company has made a range of selected 

factory automation sensors suitable for use in zones 1 or 21, and 2 or 22. 

Advancements in the automation of process 

plants have resulted in changes to customer 

requirements. It is becoming increasingly 

common for plants to be networked 

and automated, which subsequently 

increases the complexity of explosion 

protection. The complex requirements 

for explosion protection are not due 

to changes in processes in particular, but 

rather they are due to the changes in technical 

capabilities in general. In turn, this 

means that approaches to problem solving 

are constantly changing, thus increasing 

the need for solutions that use tried-andtested 

industrial sensor technology, including 

explosion protection. One thing that is 

clear is that sensors that increase the productivity 

and safety of plants in factory 

automation can also be used in process 

automation. Difficulties implementing this 

technology are often due to the significant 

purchase and maintenance costs of sensors, 

and especially the complex approvals and 

certifications required for explosion protection. 

Customers often want sensors to 

be fitted in potentially hazardous locations, 

posing even greater challenges. Based on 

this premise, Pepperl+Fuchs engineers 

have developed a solution for optimising 

customer processes. 

Sensor for fall protection device 

This is demonstrated by a project undertaken 

with a manufacturer of fall protection 

systems for filling tankers with liquids. Fall 

protection systems are necessary because 

the process of filling tankers with liquid 

chemicals is not fully automated – instead, 

it is always carried out by workers on a 

platform. This means that one wrong decision 

by an individual can have far-reaching 

consequences for people and the environment. 

Pepperl+Fuchs helped these customers 

to implement the existing process for 

non-hazardous areas in hazardous areas. 

During this process, the R2000 2-D Lidar 


With explosion protected housings factory automation sensors can make their way into hazardous 

environments 

Stationary code reading device OPC120W 

sensor in explosion protected housing 

scanner monitors the position of the fall 

protection device. The scanner is mounted 

under the platform railing and scans the 

area below the device. Before the filling 

process, if the personnel lower the lifting 

platform too close to the tank carriage 

below, the scanner triggers a dual warning 

signal – a flashing light and audible signal. 

In addition, the movement of the platform 

is automatically stopped to allow the personnel 

to react and use the controls to move 

the lifting platform into the right position. 

This eliminates the risk of damage to lifting 

platforms and railings and even eliminates 

the risk of crashes, which often result in injury 

to personnel. This process was implemented 

in hazardous areas by housing the 

scanner in an Ex d aluminium housing with 

an integrated viewing window. The scanner 

is installed in the housing at a 15° angle to 

prevent refraction from scattering and distorting 

signals. This guarantees that the 

scanner is fully functional. The solution was 

approved for hazardous zones 1, 2, 21, and 

22. This solution allowed the customer to 

maintain existing structures on the plant 

and, in turn, enabled its customers to safely 

monitor the filling process for chemical 

substances, even in hazardous areas. 

Application on an oil platform 

Another example is an oil platform in Malaysia. 

To increase safety for its employees, 

the oil company was searching for a so - 

lution that was capable of enforcing access 

restrictions for critical areas and documenting 

employee locations. Pepperl+Fuchs developed 

a solution by working together 

with a tracking software company that 

specialises in this type of application. The 

software is visualised using a human machine 

interface (HMI) device that is connected 

to the central computer. Persons are 

recorded by a radio frequency identification 

(RFID) system, which is housed in an Ex d 

housing and is therefore specially approved 

for use in potentially explosive environments. 

Just like in any production facility, 

employees must first register their presence 

using a tag to access each area of the oil 

platform. All process-related information is 

stored locally on the tag itself, thus enabling 

track-and-trace applications. Unique identifiers 

allow raw materials, products, or, in 

this case, personnel, to be assigned and 

tracked. The backend software determines 

whether the employee is authorised to access 

the area in question. If so, the software 

unlocks the relevant cabinets and doors. The 

software simultaneously documents the employee‘s 

current location. This is particularly 

important in emergency situations. When an 

alarm is triggered, information about the 

exact location of personnel is essential for 

evacuation purposes. 

Determine the fill level 

Other sensors are also suitable for use in 

hazardous areas – for example, sensors 

using pulse ranging technology (PRT) for 

object detection. This same technology is 

also used by the R2000. The sensors are installed 

in Ex d housings to allow them to 

monitor a wide variety of different processes. 

A powerful light source in the sensor 

emits short pulses that are reflected by the 

target object and then captured by a highly 

precise, light-sensitive receiver element. The 

distance to the target object is then calculated 

from the values recorded. A Norwegian 

manufacturer of hoses and flexible tubes for 

oil production uses this technology to de - 

termine the fill level of its storage facility – 

as you would expect, this involves hazardous 

areas. The VDM28 sensor installed in the 

Ex housing enables a measuring range of up 

50 m from the reflector. If the fill level is not 

reached, this triggers automatic processes 

for filling the position or ordering more 

materials. The list of examples is endless. 

Pepperl+Fuchs offers a selection of 

standardised and certified sensors that are 

permitted for use in zones 1, 21, 2, and 22. 


Online search: Pepperl+Fuchs 

AUTHOR: 

ALEXANDER AUST 

Product Marketing Manager 

EPE & Solutions, 

Pepperl+Fuchs 




Pictures: Vega 

Good lubrication makes everything run better 

QUICK ACCESS 

TO ALL LEVEL DATA 

For more than 100 years now, oils from Oest have ensured that 

processes and machines of all kinds run smoothly. In the current 

production facility, Vega sensors monitor the mixing of oils and 

keep track of stock levels, thus helping the operators maintain a 

good overview of the many different products and processes. 


The Georg Oest Mineralölwerk based in Freudenstadt is the heart of the Oest group, which also includes part of the Avia network of petrol stations 

The origins of Oest go back more than 100 years. It all started in 

1915, when a factory for the production of technical oils and lubricants 

was founded in Dornstetten in the Black Forest. In the following 

years, the scope of products was continuously increased in 

order to meet very different customer requirements. By combining 

various base oils in different ways, the company added many new 

items to its product range: drive belt wax, drilling oil, leather oil, 

carriage grease, anti-rust grease, ski wax, sewing machine oil, turbine 

oils, transformer oils, milling oils, among many others. Not 

every one of these products is still produced today, though special 

classic car oils are still in demand, albeit in small quantities. 

The product portfolio is now broader than ever. Over the years, the 

company has systematically expanded the development, production 

and distribution of industrial lubricants. Today, the Georg Oest Mineralölwerk 

(mineral oil plant) based in Freudenstadt is the heart of 

the Oest group, which also includes part of the Avia network of petrol 

stations. 

Not only was the laboratory expanded and the staff increased at the 

Freudenstadt location, the storage areas were also gradually enlarged. 

The requirements on the various production processes are 

very different. “Some require nitrogen blanketing, others have to be 

temperature controlled, and yet others require special safety 

measures for explosion protection. In addition, the requirements of 

the Water Resources Act (WHG) must be taken into account, as well 

as the EU chemical classification Reach or the specifications mandated 

by TÜV,” says Thilo Reich, Head of Engineering at Georg Oest 

Mineralölwerk, describing the extensive requirements. 

Fulfilling customer requirements 

High-quality petroleum raffinates, the base oils, are the basis for the 

wide range of products. The Black Forest company is constantly 

working on new developments, for example bio-lubricants, which 

are quickly biodegradable and based on renewable raw materials. In 

the company’s own laboratory, the special mixtures are carefully 

examined and tested so that the resulting lubricants are optimally 

adapted to each application. Of course, the laboratory is also responsible 

for quality assurance, so every batch is checked before 

packaging. 

The development of lubricants is one thing, but Oest‘s job also includes 

mixing, filling containers and storing the various components. 

Therefore, about two years ago, the company built a new 

warehouse and logistics centre at the Freudenstadt site, enclosing a 

total area of about 3500 m² with space for more than 4000 pallets. 

“The requirements in the market have changed, today you have to 

deliver much faster,” explains Reich. 

Reliable monitoring of stocks 

Employees at Oest are supported by the most modern production 

and mixing technology available on the market. Stainless steel production 

vessels with various agitators in sizes from 400 to 52,000 l, 

as well as automatic filling systems, ensure that special requests can 

be fulfilled even on short notice. Incidentally, such requests do not 

always concern the composition of the lubricant, but sometimes 

also the size of the package or container the product is delivered in. 

Vega sensors have been used in the numerous storage and mixing 




Thilo Reich, Head of Engineering at Georg Oest Mineralölwerk, on the roof of the storage tanks. 

Vega sensors monitor the mixing of oils and keep track of stock levels. 

tanks for many years. Although the mixing processes are simple and 

the storage tanks are not particularly complex from the point of 

view of level measurement and contain no disturbing internals, the 

sensors nevertheless have to be robust. Among other things, they 

must be able to withstand temperatures of up to 100 °C and in 

some areas also meet the requirements for use in potentially explosive 

atmospheres. WHG approval is also very important – with Vega 

sensors, for example, operators can carry out a function test with 

just the push of a button. However, the most important requirement 

is: “We need sensors that provide us with reliable measured values 

over a long period of time and this is exactly what Vega sensors do,” 

says Reich, referring to Vega sensors installed almost 30 years ago 

that are still operating flawlessly. 

So for him, it’s only logical that Vega sensors have been installed in 

almost every one of the approximately 70 tanks. For one thing, they 

measure the level in the numerous storage containers, ensuring reliable 

inventory monitoring and delivery to customers. And for another, 

they protect against tank overfill. About a year ago, new overfill 

protection equipment in the form of Vegaswing was installed in 

the raw material storage facility. Oest has been very satisfied with 

Vega‘s support and service for many years now. Thanks to Plug & 

Play, setting up and commissioning Vegaswing is unbelievably easy. 

Maintaining a good overview 

Inventory monitoring has assumed an important role because the 

requirements in terms of delivery times have changed so much. 

“On the one hand, we are faced with the challenge of having to 

react much faster than before and also deliver widely varying quantities. 

And on the other, we have to keep certain products constantly 

in stock for some Asian customers. What is more, we have to keep 

an eye on the prices in the raw material markets so that we can always 

buy our basic raw materials at favourable prices,” says Reich, 

explaining the complexities of the task. 

Inventory data acquisition, visualisation and delivery planning have 

therefore increasingly become an important part of the business. 

These are based on automated inventory monitoring. For this, Oest 

had relied on Vegalog for many years, but it had become outdated 

and was discontinued. Today, the company is supported by Vegamet 

and Vega Inventory System (VIS), which allow it to visualise inventory 

for pre-planning and control production processes. The sensors 

and controllers from Vega collect all measurement data, which Vega 

Inventory System then makes available in a form that enables good, 

effective planning. 

Vega Inventory System reports the need for replenishment fully 

automatically and in good time. To this end the software draws not 

only on current measurement data from the inventory, but also on 

empirical data gathered from consumption history. Analysis and 

planning tools enable optimised material requirement, inventory 

and delivery planning. Bar charts and tank symbols provide the user 

with a constant overview of current stock levels. 

Conclusion 

Thanks to Vega Inventory System, Georg Oest Mineralölwerk has 

quick access to current as well as historical consumption data. The 

level values are used as a reference. “Calibrated meters are used 

when filling the tank lorries, but the data from the Vega sensors are 

very important for comparison. Even the old sensors still deliver 

very accurate values.” Managers can view the stock levels at any 

time and intervene if necessary. This not only optimises operational 

processes, it also enables cost-effective production and inventory 

planning. In short: “The service and support we get, as well as the 

price-performance ratio and quality of Vega sensors, are simply excellent,” 

says Reich in conclusion. 


Online search: Vega 

AUTHOR: 

CLAUDIA HOMBURG 

Marketing, 

Vega 



PRODUCTS 

Ultra-compact weighing electronics 

Vibronic point level detector 

Picture: Siemens 

Siwarex WP351 is Siemens’ new 

solution for intelligent weighing 

automation. Measuring 

20 mm width by 65 mm height, 

the module is one of the smallest 

weighing electronics units 

available. The device’s 1,000 Hz 

sampling rate and processing 

time combined with a digital 

output response time of less 

than one millisecond guarantee 

highest accuracy and repeatability. 

This capability represents especially 

in case of checking 

scales and high performance 

filling machines a big advantage, 

as even within very short 

weighing times the dosing devices 

are controlled in an optimal 

way. 

As an integral part of Simatic 

ET 200SP, Siwarex WP351 can 

be seamlessly integrated into Simatic 

and non-Simatic automation 

systems, making it a 

clever alternative to traditional 

weighing terminals. The intelligent 

firmware gives users the 

ability to control weighing processes 

directly from the module, 

thereby reducing the load on 

the connected PLC. 

Compatible with almost all analogue 

strain gauge load cells, Siwarex 

WP351 is a versatile solution 

for demanding weighing 

applications such as mixing, filling, 

bagging, checking, or totalising. 


Online search: Siemens 

The Liquiphant FTL51 is used in 

storage tanks and pipelines for 

level measurement of any 

liquids. The device has already 

been developed according to 

IEC 61508 and the “safety by 

design” principle and is therefore 

designed for use in SIL2 

and SIL3 applications. 

Operators can now communicate 

with the Liquiphant FTL51 

and the Smartblue app from 

Endress+Hauser. The app provides 

access to all product and 

diagnostic data. Especially in 

hard-to-reach areas, where scaffolding 

has to be provided for 

maintenance, this speeds up the 

inspection of systems considerably. 

The new Liquiphant displays 

the status of the level 

switch via LED or via the diagnostic 

function of Heartbeat 

Technology in the Smartblue 

app. In addition, verification via 

Heartbeat technology enables 

complete documentation. The 

newly implemented SIL wizard 

also guides the user through the 

recurring test in an uncomplicated 

manner. 


Online search: Endress+Hauser 

Picture: Endress+Hauser 

HOW EFFICIENT IS YOUR 

AERATION REALLY? 

LET’S TALK 

Markus Leidinger, Application Specialist, Wastewater Technology 

+49 175 9335602 markus.leidinger@aerzen.com 

Real efficiency means operating the load profiles in wastewater treatment plants with precision. 

Aeration consumes up to 80% of the total energy requirements. The greatest savings 

potential can therefore be found here. With our Performance³ product portfolio, consisting of 

Blower, Hybrid, and Turbo, we always find the most efficient and tailor-made solution for you. 

Benefit from up to 30% energy savings! LET’S TALK! We’ll be happy to advise you! 

www.aerzen.com 



PRODUCTS 

GET READY FOR THE UNEXPECTED 

Pump for use in analytical laboratories 

With the Ecodry series, Leybold 

offers a clean, silent, compact 

and low-maintenance pump for 

use in analytical or research laboratories. 

This pump class lies 

exactly in the transition area between 

small laboratory devices 

and large machines. However, 

the most significant innovation 

is undoubtedly the reduction of 

the noise level. The Ecodry plus 

was developed exactly in line 

with the requirements of systems 

such as mass spectrometers 

and electron microscopes. It is 

therefore also suitable for use in 

large accelerators, because there 

is no contamination by dust or 

oil. It offers users a high degree 

of comfort, pumping speed performance 

and flexibility. 

Equipped with two flexible interfaces, 

the pump can also be 

remote-controlled. When used 

in commercial analysis systems, 

it is often integrated into the 

plant control system and can be 

started, stopped, varied in speed 

and also monitored as required. 


Online search: Leybold 

Picture: Leybold 

INSPIRING 

SUSTAINABLE 

CONNECTIONS 

World Forum and Leading Show 

for the Process Industries 

ACHEMA is the global hotspot for industry experts, 

decision-makers and solution providers. Experience 

unseen technology, collaborate cross-industry and 

connect yourself worldwide to make an impact. 

#ACHEMA21 

14 – 18 June 2021 

Frankfurt, Germany 

Are you ready? 

Join now as speaker or exhibitor! 

Multifunction four-wire transmitter 

The Jumo dTrans T06 Ex multifunction 

four-wire transmitter in 

a mounting rail case is suitable 

for use in challenging SIL and Ex 

applications. Its measurement 

input features 22-bit resolution 

with selectable noise suppression 

and is extremely precise. The SIL 

option fulfills the requirements 

of SIL2/SIL3 according to DIN 

EN 61508 and PL c/PL d according 

to DIN EN ISO 13849. The 

dTrans T06 Ex also meets the 

Atex and IECEx requirements up 

to zone 0. 

A particularly high galvanic isolation 

guarantees excellent signal 

Picture: Jumo 

stability, even when measuring 

conditions are difficult. Reliable 

SIL configuration is facilitated by 

an easy-to-use setup programme. 

The device can be used with RTD 

temperature probes, thermo - 

couples, resistance transmitters, 

as well as voltage and current 

signals. It converts the input 

signal into an output signal 

(0(2)...10 V or 0(4)...20 mA). 

The compact mounting rail case, 

which has a design width of just 

22.5 mm, and the encoded plugin 

terminals enable the device to 

be quickly installed into control 

cabinets. In addition, the device 

can be reliably replaced when 

performing calibration and 

maintenance work. All the important 

information regarding 

the transmitter can be queried 

and visualised via an RS485 interface. 


Online search: Jumo 

www.achema.de 


Software for flow measurement 

Most precise measurement and 

control of LOWEST LIQUID 

FLOW RATES 

Picture: Emerson 

Mass flow from 100 mg/h up to 600 kg/h 

Volume flow from 2 μl/min up to 10 l/min 

Coriolis, thermal and ultrasonic measuring principles 

Compact dosing solutions with control valves and pumps 

Digital interfaces available (PROFIBUS DP, PROFINET, Modbus, 

CANopen and more) 

Emerson has released Micro Motion Processviz, a standalone, 

cost-effective software solution for flow meter 

process data visualisation. The software supports the 

Micro Motion Coriolis transmitters with data historian 

output capabilities such as the 5700 and 4200 models, 

and provides a snapshot of a moment in time in the 

flow process. A technician or plant manager won’t need 

to manipulate data to see what is happening in the flow. 

The data is available in a usable format that allows the 

user to identify and analyse process issues. 


Online search: Emerson 

www.bronkhorst.com 

Mobile table series for lab devices 

SEAL TECHNOLOGY 

PREMIUM QUALITY SINCE 1867 

Picture: Sonation 

COG MAKES ITS MARK: 

The world‘s 

largest O-ring warehouse. 

The modern laboratory is home 

to a range of different devices 

that vary in size and build. As 

this equipment is often extremely 

heavy and to be used in 

multiple labs at a given institute, 

it is best to set it up on a mobile 

workbench specially fitted for 

the device. The workbench 

should also offer sufficient flexibility 

so, for example, coworkers 

of different heights 

could all use it comfortably. For 

these reasons, Sonation has developed 

a new series of tables 

specifically designed to meet 

such challenges presented by lab 

equipment. The models’ reinforced 

base provides secure positioning 

for the apparatuses without 

sacrificing flexibility in daily 

lab work. Additionally, a chemical-resistant 

tabletop prevents 

solvents and scratches from 

doing any permanent damage. 

The table can be fitted for use in 

any work situation thanks to its 

electric and infinitely variable 

height adjustment with freely 

configurable position memory, 

plus its modular design and 

optional expansions. 


Online search: Sonation 

Precision O-rings in 45,000 variants ready for delivery. 

www.COG.de 




Submersible motor pump brings life to waste water 

High-efficiency 

waste water pumps 

In spring this year, KSB presented several new models for the water and waste 

water industry. The highlight of the spring offensive was the new Amarex series of 

submersible motor pumps, which are offered in different versions. One special type 

is the Amarex KRT with jacket-cooled drive motors. 

The KSB submersible motor pumps in the 

Amarex type series are employed in applications 

like waste water and sludge treatment 

as well as stormwater transport. They 

can handle waste water with long fibres and 

solid substances, fluids containing gas or 

sludges, service water and grey water and 

are equipped with either free-flow impellers 

(F-max) or open, two-vane impellers 

(D-max). Customers can thus choose the 

right impeller type depending on their 

requirements: low waste water flow rates at 

high heads or high flow rates at lower 

The KSB Group’s new Amarex 

waste water pump stands out 

due to its high level of hydraulic 

efficiency combined with a 

high-efficiency motor 

heads. Pump variants featuring D-max impellers 

are optionally available with a 

D-flector, which significantly increases resistance 

to clogging. A multitude of material 

and mechanical seal variants ensure that 

users can transport a wide range of corro - 

sive and abrasive fluids. 

Non-clogging design 

The impellers’ non-clogging feature 

markedly reduces maintenance requirements 

compared with conventional designs 

while the pumps’ high levels of hydraulic 

Pictures: KSB 

efficiency combined with high-efficiency 

IE3 motors make for low energy consumption 

during operation. The type series has a 

maximum head of 42 m and a maximum 

flow rate of 320 m 3 /h. When designing 

Amarex, the engineers attached great importance 

to the pumps achieving a long service 

life. This is ensured by a generously 

dimensioned motor, robust rolling element 

bearings and a corrosion-resistant stainless 

steel shaft. 

An environmentally friendly, non-toxic oil 

fill provides continuous lubrication of the 

mechanical seal. As is common practice 

with this type of pump, installation in the 

pump sump is effected via a duckfoot bend. 

A large range of adapter claws also allows 

the use of such bends from other manufacturers, 

so that a change of make is possible 

without requiring any major installation effort. 

Sealing between the duckfoot bend and 

the pump discharge flange is by a newly developed, 

absolutely water-tight and durable 

U-profile ring. Users also have several options 

when choosing the arrangement for 

placing the pump on the duckfoot bend: 

they can opt for a guide hoop, guide wire, 

single guide rail or twin guide rail arrangement. 

For high ambient temperatures 

One highlight of the Amarex type series is 

the KRT range of submersible motor pumps 

featuring jacket-cooled drives. They are designed 

to transport untreated waste water 

for municipal and industrial waste water 

management. The new pump sets are available 

with drive ratings from 10 to 30 kW 

and are suitable for vertical or horizontal 

dry installation. Since the pump motors remain 

fully operational when not sub- 


nals from these sensors can be analysed by 

the Amacontrol III protection module, 

which can send the data collected to either 

a data recording system or a cloud. 

The Amarex KRT jacket-cooled submersible motor pump from the KSB Group 

with the Amaslide maintenance aid 

merged, the pump sets can also be used in 

pump sumps when water levels have 

dropped. Thanks to the IP 68 enclosures, 

these pumps additionally offer trouble-free 

continuous operation when flooded. The 

pump sets meet all explosion protection 

requirements set out in the Atex, FM and 

CSA standards. 

The motor is cooled via a closed circuit to 

avoid contact between the circulating waterglycol 

mixture and the fluid handled. This 

simultaneously rules out any risk of contaminants 

in the fluid impairing cooling of 

the motor. The cooling liquid is circulated 

by a special impeller, which the pump’s design 

engineers have integrated into the cartridge 

seal. 

This double mechanical seal is a proprietary 

development of the pump manufacturer, 

which has been producing its own mechanical 

seals in-house for several years. This cartridge 

can be replaced as a complete unit, 

facilitating and substantially accelerating 

servicing work. 

The pumps are able to transport fluids with 

a temperature of up to 40 °C and operate in 

environments with a temperature of up to 

55 °C. This enables them to be used in hot 

countries where they are often dry-installed 

in air-conditioned rooms. Convection cooling 

via the surface of the pump casing 

would place an enormous thermal load on 

the air-conditioning system and have a 

negative effect on power consumption. 

Monitoring as standard 

The sensor package installed as standard includes 

monitoring of the motor temperature 

via a PTC chain, a leakage sensor inside 

the motor and monitoring of mechanical 

seal leakage via a float switch. Users can also 

optionally order up to three Pt100 sensors 

for bearing and motor temperature monitoring 

as well as a vibration sensor. The sig- 

Only one person needed 

Another optional feature is the Amaslide 

maintenance aid for horizontal pump installation. 

With its help, only one person is 

needed to open an Amarex KRT and perform 

work such as impeller inspections. 

Cranes or lifting equipment are not 

required. Service engineers only have to remove 

the bolts between the pump casing 

and the discharge cover. They can then remove 

the back pull-out unit comprising the 

impeller, shaft, bearing, seals and motor 

from the casing. The latter remains in place, 

attached to its suction and discharge lines. 

Once the back pull-out unit has been removed, 

the impeller is freely accessible. 

Maintenance work can then be carried out 

without any problems. After completion, the 

service engineer simply pushes the back 

pull-out unit back into position. 


Online search: KSB 

DR. BERND RADEMACHER 

Editor 

 

 

 

 

 

 




Decentralised drive systems for process and waste water engineering 

Intelligence for pumps, 

agitators and mixers 

As a drive specialist, Nord Drivesystems uses intelligent and networkable drives 

with scalable functions and performance. This concept also offers clear advantages 

for pumps, agitators and mixers in process and waste water technology. To some 

extent, pumps can organise themselves to ensure reliable around-the-clock operation. 

As the demands on the components’ durability are as high as those on their reliability, 

the suitability of mechanical design and equipment are of equal importance. 

Single-stage Nordbloc.1 helical in-line gear unit with an energyefficient 

motor and a Nordac Flex frequency inverter 

Pump systems, as well as mixers and agitators, 

are elemental components in process 

and waste water engineering systems, and 

ensure the smooth operation of sewage 

treatment plants, waterworks, production 

plants, cooling systems or conveyor lines. 

They often have to circulate large volumes 

of liquid or highly viscous substances. 

Therefore, availability, reliability and a long 

service life are the top priorities. As a system 

supplier, Nord offers fully matched drive 

systems consisting of gear unit, motor and 

frequency inverter that are tailored to the 

respective requirements of the customer application. 

Nord drive solutions can be networked, 

operate autonomously, and their 

functions and performance are scalable. In 

the course of the advancing digitalisation of 

industrial production, the pump industry is 

also moving away from central control towards 

decentralised intelligence that controls 

processes autonomously, identifies 

faults and independently solves problems. 

The decentralised drive systems form 

master-slave groups that intelligently communicate 

with each other, and autonomously 

monitor and control the entire 

pump system. 

Pictures: Nord Drivesystems 

PLC performs control functions 

The frequency inverter is the brain of the 

drive. In decentralised concepts, it is directly 

mounted on the geared motor. As standard, 

it is equipped with a PLC that can autonomously 

perform control functions and reduce 

the load on the higher level control 

system. Thus, among other things, the frequency 

inverter can adjust pressure and 

flow rates of the pumped liquids in line 

with the actual requirements. In this way, 

no excess energy is wasted on valves and 

flaps. The frequency inverter perfectly adjusts 

the performance to the actual demand, 

regardless of whether a fixed setpoint has 

been set, or whether it is manually adjustable. 

The integration of the PLC into the frequency 

inverter enables the Nord drives to record 

the drive and pump data (e.g. flow rate, 

pressure, pressure difference and temperature), 

to evaluate all of the available sensor 

and actuator data, to provide optimised 

diagnostic facilities and to communicate the 

data to the higher level control system or a 

cloud solution via the bus system. Continuous 

monitoring of the field level and linkage 

of communication, sensors (temperature, 

current consumption), process data 

(torque, acceleration, speed) and vital parameters 

of the drive allow for the implementation 

of a condition monitoring using 

Nord drive systems. This is the basis for a 

status-oriented maintenance with the aim of 

reducing unscheduled downtimes, lowering 

service and maintenance costs, and increasing 

the service life of the drives and connected 

pumps. 


Advantages for agitators 

Especially for agitators and based on its 

comprehensive modular geared motor system, 

Nord delivers complete drive solutions 

covering wide speed ranges with great costefficiency 

from one source. Thanks to the 

easy to clean and corrosion-resistant aluminium 

housing, they achieve a better heat 

dissipation than drives with other housing 

materials. High process-related radial and 

axial loads occur in pump, mixer and agitator 

applications. The Nord Drivesystems 

range includes optional versions so that the 

drive can optimally absorb the occurring 

forces. They comprise an agitator version 

(VL2 bearing) with increased bearing spacing 

and reinforced output shaft bearing, as 

well as a Drywell version (VL3 bearing) 

with additional oil drip plate and leakage or 

oil sensor. For the VL2 and VL3 bearings, the 

bearing spacing is increased with attached 

components whereas the gear unit size remains 

unchanged. This enables maximum 

radial and axial load capacities and a higher 

service life of the gear units. Nord also 

offers bearings that were intentionally oversized 

to meet the requirements of applications 

such as pumps or agitators. 

Higher operational safety 

For agitator applications, the industrial gear 

units can also be equipped with a Safomi- 

IEC adapter. Safomi is available for parallel 

gear units and in the sizes 7 to 11, i.e. for 

maximum output torques from 25 to 

75 kNm. Safomi is the abbreviation for Sealless 

Adapter For Mixers. The compact combination 

of Maxxdrive industrial gear units, 

Safomi-IEC adapter and drive motor is the 

best choice for mixer and agitator applications 

to reduce wearing parts and attached 

components. The Safomi-IEC adapter 

has a compact and simple design, and is 

equipped with an integrated oil expansion 

volume. Oil tanks and hoses as well as the 

radial shaft seal that is subject to leakage 

and wear between gear unit and IEC cylinder 

are not required. As standard, the combination 

of a parallel gear unit and Safomi- 

IEC adapter is only installed in installation 

position M5, i.e. with an output shaft pointing 

downwards. The change to a Safomi-IEC 

adapter instead of the standard IEC adapter 

on the agitator drive increases operational 

reliability and lowers maintenance costs. The 

oil level as well as the required oil volume is 

lower and thanks to fewer attached components, 

the installation space is also reduced. 

Networked, autonomous, scalable: Nord drive units are Industry 4.0 ready. The PLC in 

the frequency inverters independently performs control functions and communicates 

with the external environment. Nord drive units operate with all common bus systems. 

SERVICE: 

Conclusion 

Chemical, pharmaceutical, food or waste 

water industry – the robust drive solutions 

from Nord Drivesystems offer top reliability 

and ensure smooth operation. Reinforced 

and larger output shaft bearings allow the 

gear unit to absorb the high axial and radial 

forces and thus prolong the service life. In 

combination with the decentralised frequency 

inverters and their options of intelligent 

control, networking and diagnosis, 

drive solutions from Nord Drivesystems are 

Industry 4.0 ready and suitable for all future 

APP FOR MOBILE USE 

The Nordcon App and Nordac Access BT 

offer a mobile commissioning and service 

solution for all Nord drives 

With the Nordcon App and the 

Nordac Access BT Bluetooth 

stick, Nord Drivesystems now 

offers a mobile commissioning 

and service solution for all Nord 

electronic components. It is 

used for drive monitoring via 

dashboard, drive analysis via a 

convenient oscilloscope function 

and the drive parameterisation 

of Nord drive systems. 

The dashboard-based visualisation 

can be used for drive 

monitoring and fault diagnosis. 

With a help function and rapid 

access to parameters, parameterisation 

of drive units is 

simple and easy. In stand-alone 

operation, the Nordac Access BT 

can also be used for backup and 

recovery of drive parameters. 

The Bluetooth-stick is available 

from the Nord sales department 

and is used directly on the frequency 

inverter. Users therefore 

have practical access to the drive 

data and remain in full access 

control. The free of charge app 

is available for iOS and Android 

operating systems from the App 

Store or in Google Play. 

requirements of process and waste water 

engineering systems. 


Online search: Nord Drivesystems 

AUTHOR: 

JÖRG NIERMANN 

Marketing Manager, 

Nord Drivesystems 


cpp FOCUS SAFETY AND SECURITY 

Pictures: R. Stahl 

R. Stahl designs and manufactures certified system solutions in customer-specific versions for process automation throughout the 

entire explosion protection sector 

Process automation: safely networked up to Ex zone 1 

Systematic digitalisation 

in hazardous areas 

Comprehensive networking in the sense of Industry 4.0 can offer the process 

industry significant advantages specifically with regards to integral data processing, 

system and remote monitoring, predictive maintenance and intelligent diagnostics. 

Jürgen Wenzel, Business Development Manager, and André Fritsch, Remote I/O 

Product Manager, from explosion protection specialist R. Stahl provide a glimpse 

into technological development. 

Mr Fritsch, Mr Wenzel, why does R. Stahl stand out as a system 

solutions provider for process automation in hazardous areas? 

Jürgen Wenzel: First and foremost, we have over 90 years of experience 

in explosion protection – everything, from the relevant preconditions 

to development, implementation and specific industry 

requirements. Many system suppliers underestimate the work that 

goes into development, engineering and ongoing product maintenance 

in demanding hazardous areas. Our expert sales and applications 

engineers support our customers from consultation to developing 

their ideal solution and, finally, to commissioning. But we 

don’t stop there – even after this stage, our customer service team is 

always available to advise our users. We see ourselves as a partner 

whose strengths lie in explosion protection; we work hand-in-hand 

with engineering firms and planning companies who process entire 

projects. 

André Fritsch: Users want to be able to install and use explosionprotected 

systems without having to spend too much time and 

effort. This is why we aim to design solutions that are not significantly 

more complex than comparable systems for non-Ex areas in 

terms of their function, mounting, handling and maintenance. By 

and large, we achieve this using three methods: Ex protected enclosure 

and connection technology, Ex protected product ranges such 

as our Remote I/O for zones 1 and 2, and energy-limited signals 

and interfaces. Correspondingly, we offer a comprehensive portfolio 

of globally certified products that ranges from individual components 

for signal and data transmission to visualisation, operating 

and camera technology. This enables us to take on complex assignments 

in process automation and to offer tailor-made solutions 

that allow our customers to transmit their process data for plant 

control systems from hazardous areas to control systems that control 

and visualise processes via HMIs in the field and can perform 

camera monitoring. 


What does this mean for technology and product development? 

Jürgen Wenzel: During product development and system construction, 

we take an entirely modular approach. This allows us to 

combine our components in the manner that best corresponds to 

the customer’s specific intended purpose. Explosion protection 

should restrict functionality as little as possible. This requires us to 

have comprehensively mastered all types of protection. We cannot 

restrict ourselves or our customers to just one or two specific types 

of protection in the construction design process – we construct systems 

with the degree of protection most suited to their application. 

Our wide range of innovative products has made us a technology 

leader. The most recent example is our patented Expressure technology, 

with which we have introduced the entirely new ignition 

protection concept of pressure relief. As a sole provider, we are in a 

position to produce Ex d certified enclosures in regular control cabinet 

sizes – this enables switching system layouts to be transferred 

from safe areas to hazardous areas without any additional engineering 

work. 

What do users expect from R. Stahl as a system provider? 

André Fritsch: Generally, users don’t immediately think in Ex protection 

categories – they‘re focussed on their core business. Explosion 

protection is a complex, safety-critical speciality that requires 

“André Fritsch: For Ex protected data 

transfer, we offer everything from fieldbus 

connections to fibre optics and from Ethernet 

to Wi-Fi communication” 

well-founded specialist knowledge and experience. Staying up-todate 

with the latest technology in this sector requires significant 

effort. Our customers cannot be experts in every standard- and 

technology-related area. They therefore expect us to provide them 

with a solution that meets their specifications, is certified according 

to applicable standards and has been tailor-made to suit the specific 

conditions of use on-site. 

Jürgen Wenzel: As a certified manufacturer, we are authorised to 

construct Ex systems designed to customers’ specifications and to 

certify systems without external test bodies. This saves our customers 

lots of time and money. This also includes solutions for hazardous 

areas that are classified as zone 2 by system operators. In this 

sector, we have always held ourselves to a high standard. Nowadays, 

we offer tested, certified device specifications for almost all product 

ranges that completely fulfil all safety criteria. Beyond Ex protection, 

we support users in the process of obtaining further 

certifications such as SIL classification, FDA and GAMP validation or 

granting ship approvals. Since Ex technology is often outsourced to 

specialised manufacturers, comprehensive support with parameterisation, 

installation and commissioning is in high demand. This is 

why we design our systems uniformly so that they are easy and safe 

to install and maintain. 

So how different are the challenges that you face? 

Jürgen Wenzel: Our system solutions are used in every corner of 

the globe. The challenges we face are just as varied as the locations 

where our system solutions are used. We have a global network of 

automation experts with in-depth knowledge of regional requirements. 

This doesn’t just refer to standards, but also specific safety 

and environmental stipulations, as well as the environmental conditions 

at the operating location. Take, for instance, the oil and gas 

industry – oil production platforms and refineries are found in all 

climate zones, from deserts to polar regions. Switching, control and 

communication technology, operating and display units, and 

lighting systems must be designed to withstand corresponding temperatures. 

As a result, we offer product ranges for our entire portfolio 

that are designed for extreme temperature ranges. We also equip 

our explosion-protected switching and control combinations with 

additional heating or cooling units as required. Additional challenges 

arise in the maritime sector due to increased salt content, 

moisture and increased vibrations. Since installation space on ships 

is limited and customers aim to save every gram of weight possible, 

our designs must be particularly compact and lightweight. 

Can you give some concrete examples? 

André Fritsch: For maritime applications, we develop specific system 

solutions in a robust, vibration-resistant and corrosion-resistant 

design. Our Remote I/O IS1+ has already been developed from 

scratch for these operating conditions and is used for intrinsically 

safe signal transmission on tankers. This system enables sensor data 

to be forwarded from gas liquefaction compressors in zone 1 to the 

control room via a bus system. Our solution, which has been perfected 

over time, has been granted twelve different ship approvals, 

from DNV-GL to ABS and ClassNK, for global use and has since 

established a foothold as the standard in the LNG sector. In the 

André Fritsch (left), Remote I/O Product 

Manager, and Jürgen Wenzel (right), Business 

Development Manager from explosion 

protection specialist R. Stahl 



Expressure control cabinets with patented 

pressure relief technology for large-scale 

construction of switching and control 

systems in zone 1 

Completely redundant – IS1+ station for 

external use at refineries in zone 2 

The standard solution on 80 % of LNG 

tankers – the zone 1 Remote I/O with 

compact seawater-, vibration- and EMCprotected 

enclosure integration 

meantime, around 80 % of all liquefied gas tankers use this system 

on board. Thanks to the 8- or 16-channel Ex i modules, it can be 

designed in an especially compact and lightweight version, is easy 

to expand using Plug & Play in continuous operation without any 

complicated procedures, and fulfils strict maritime requirements for 

EMC protection, seawater resistance and vibration resistance. Another 

example can be seen in the chemical industry – in this sector, a 

plant operator had initially opted for one of our competitors’ products, 

only to find that the design of their systems varied hugely 

between zone 1 and zone 2, and that the permissible temperature 

ranges were very different. With our Remote I/O, this customer 

now benefits from a coherent solution with a uniform operating 

concept, manageable number of components and simple spare parts 

management. 

How are you ensuring that the Remote I/O is future-proof with 

regards to new trends in process automation? 

Jürgen Wenzel: Our Remote I/O systems are extremely long-lasting 

and reliable. This is demonstrated by the fact that they have been in 

use in some systems for more than 20 years, only requiring minor 

modifications in this time. If modernisation is then due, operators 

often choose to convert their system to IS1+. This system offers the 

ideal solution for bringing an existing installation into the digital 

Ethernet age without the need for major conversion work. With 

IS1+, we currently offer the latest and most cost-efficient digitalisation 

platform. Preventative diagnostics, IP communication, redundancy 

solutions, extended temperature ranges and additional future 

features have already been installed. And, very importantly for our 

users, it is completely backward-compatible with the preceding system. 

This is always a high priority for us when developing new 

products. Our Remote I/O with Ethernet connection is also popular 

among our customers because it is able to plan the migration path 

and adjust the required communication protocol itself. This means 

that users never need to change everything over from one day to 

the next – they can continue to work with existing solutions until 

the new network connection is available. 

With the advance of digitalisation, more and more IP-based transmission 

paths are being used instead of fieldbus systems. What 

effect does this have on process automation in hazardous areas? 

André Fritsch: For Ex protected data transfer, we offer everything 

from fieldbus connections to fibre optics and from Ethernet to 

Wi-Fi communication – always guaranteeing that the solution we 

provide is optimally suited for the user’s application in terms of its 

function and cost. Just recently, we constructed a wireless system on 

an oil production platform which is so flexible that the customer 

can choose which wireless technology they want to use before they 

even start up the system. Nowadays, digital bus solutions such as 

Profibus DP or Foundation Fieldbus H1 are installed in the majority 

of systems. Industrial Ethernet technology is now taking things to 

the next level. It differs from conventional Ethernet technology primarily 

in its installation technology – all of its components, including 

cables, plug connectors, switches and media converters, need 

to be made significantly more robust. In order to provide our customers 

in the oil, gas, chemical and pharmaceutical sectors with 

Ethernet solutions for hazardous areas, we have developed a wide 

portfolio based on different types of protection. This includes Ex e 

protected connection terminals for copper cabling, as well as isolators 

and splice boxes in Ex op versions for inherently safe fibre optics; 

the range also features intrinsically safe signal and data transmission 

with Ex i protection type, which we also use to control 

antennas for Wi-Fi communication. R. Stahl is involved with a number 

of organisations, with the aim of helping to shape the future 

and drive digitalisation in hazardous areas at the forefront of technology. 

As well as our work with European and international standardisation 

bodies, we are actively working on future technologyrelated 

matters such as Ethernet Advanced Physical Layer (Ethernet- 

APL), Namur Open Architecture (NOA) and the Open Process Automation 

Forum (OPAF). 


Online search: R. Stahl 


A transformation of safety culture at Rain Carbon 

Safety as a building block 

for success 

For Rain Carbon, safety is an important building block for success. In 2016, the 

number of reportable injuries was already at a low level, but that was not enough for 

those responsible. They were aiming for zero. The key to achieving that goal would 

be to develop a more robust safety culture. With the help of Dupont Sustainable 

Solutions, Rain Carbon has moved closer to zero, beginning with a pilot project at its 

Castrop-Rauxel site in Germany. 

Massimiliano Martino, Vice President 

Glob al Safety, Health and Environment at 

Rain Carbon, knows the reasons for investing 

in safety: “To be successful, Rain Carbon 

has to be a world-class performer in terms 

of safety. We cannot compromise when it 

comes to safety and we can only move forward 

as fast as our progress as regards safety 

initiatives and activities.” Rain Carbon’s total 

recordable injury rate is currently less than 

0.4. This is a remarkable achievement, but 

the company will only be satisfied with zero 

incidents. “We have therefore put in place 

stringent programmes and KPIs (key performance 

indicators) to monitor and reduce 

all types of incident. We must do our utmost 

to safeguard communities, employees and 

the environment in order to deliver on our 

commitments as a responsible company”, 

Martino explains. For him, safety is clearly 

one of the building blocks for success. “It 

allows us to increase our productivity and 

operational discipline and it will also add 

value on the path to truly organic growth.” 

Together with Dupont Sustainable Solutions, Rain Carbon launched a pilot project at the 

Castrop-Rauxel site in 2016 to change the company’s safety culture 

Pictures: Rain Carbon 

Project launch in Germany 

Under the direction of Dr. Günther 

Weymans, Executive Vice President Carbon 

Distillation and Advanced Materials, Rain 

Carbon determined in 2016 that its facilities 

around the world needed to develop a more 

mature and sustainable safety culture. The 

company sought assistance from a safety 

and operations management consultancy 

with significant experience in the chemical 

industry: Dupont Sustainable Solutions 

(DSS). Rain Carbon began the cultural transformation 

project at its largest site, the distillation 

and advanced materials production 

facility in Castrop-Rauxel, Germany. The 

total recordable incident rate there had become 

caught in a cycle where the number 

of incidents gradually decreased, crept up 

again, then declined once more without 

ever completely flattening out. 

“It had grown more and more obvious that 

our culture did not promote independent, 

safe decision-making”, recalls Elke Helck, 

then Site Manager. “Instead of pursuing a 

risk-free course of action themselves, people 

relied on rules and regulations to keep safe.” 

The management and their employees had 

widely diverging views on safety. It was 

clear something had to change, but what? 



Various focus areas were defined for the 

Rain Carbon safety project, on which employees 

and managers wanted to work 

Taking back ownership 

An initial assessment by DSS of the status 

quo at the plant confirmed what Rain 

Carbon had suspected. The prevailing safety 

culture was highly dependent on discipline, 

controls and monitoring to prevent incidents, 

whereas Rain Carbon needed its entire 

workforce and management to have a 

more independent mindset if it wanted to 

achieve a sustainable change in safety performance. 

Only personal engagement, increased 

accountability for each employee’s 

area of responsibility and a change in attitude 

toward individual safety would move 

the plant forward and closer to its goal of 

zero accidents. 

“What we didn’t realise”, Helck admits, “is 

that you don’t just buy a consulting service 

and they do everything for you. You have to 

do things yourself and change. That was 

quite a hard lesson to learn. But we would 

never have managed it on our own. We discovered 

that managers have to leave their 

offices and go out into the production 

shops where the risks are highest. It was incredibly 

helpful to walk around the site 

with a DSS consultant, spotting unsafe activities 

and learning how to address them in a 

positive way. The consultant would ask 

really simple questions.” 

“Initially, employees would react by saying 

‘I have to check if there is a rule for that’”, 

Helck continues. “DSS gently nudged them 

to start thinking for themselves. This approach 

allowed us to take back ownership 

After many ups and downs, the number of days off and incidents with injuries have been decreasing 

since the beginning of the safety project. In 2019, Rain Carbon recorded the safest year in the company’s 

history. 

of our plant. At first, people were rather 

perplexed and sceptical. They naturally want 

to produce more, to be proud of what they 

have achieved and receive praise. It took 

time for them to understand that we were 

not checking up on them and that we mean 

it when we say ‘safety first’. We’ve had so 

many safety campaigns in the past that 

people were a bit weary and wary of them. 

But we’ve sent strong signals that we’re serious 

about safety – such as stopping production 

for safety reasons or investing in train- 

ing – and I continue to push managers out 

into the plant, as that is the only way to get 

everyone involved in safety.” 

Structural changes 

In addition to the initial assessment, which 

included a survey of employees’ safety perceptions 

and help with safety observation 

training (STOP), Rain Carbon and DSS came 

up with a two-year implementation plan 

with prioritised short- and medium-term 

goals and identified a number of quick 


safety. We need agility because timing is 

critical with 24/7 operations across different 

continents and time zones. I am very 

ambitious and want faster and bigger 

changes for the success of the company, but 

if we shake people up too much, they vibrate. 

Since we started working with DSS, 

the changes have been positive and progress 

has been fast. Perhaps even more important, 

the impact is sustainable at all levels of the 

organisation so that real value is added. 

Thanks to DSS, our safety culture has improved 

to become more active. However, we 

are not yet proactive enough. I believe that 

we need to continue accelerating with 

maximum energy to create the highest 

possible momentum and achieve safety excellence. 

We will then see a reduction in all 

incidents globally with stronger organic 

growth for Rain Carbon.” 

The change at the Castrop-Rauxel site is visible: the corporate culture has become much 

more open and employees talk willingly about their behavior 

wins. The transformation of the site culture 

was planned at a joint strategy workshop 

that analysed such issues as what had to 

change and when as well as who had to 

change and how, with clearly defined responsibilities. 

This led to an action plan developed 

collaboratively by Rain Carbon and 

DSS, which considered the site’s starting 

point and ultimate objective. DSS helped 

Rain Carbon to determine the actions which 

would be necessary to move the site from 

one to the other and ensure the company 

took a realistic view of the plant’s readiness 

for change. A safety steering committee and 

support structure were established to enable 

the action plan to be implemented. DSS furthermore 

assisted with coaching for senior 

management in addition to workshops to 

develop management and employee capabilities. 

Insights 

Management at the site has noticed a great 

change since work with DSS began in 2016. 

Thomas Tulkens, former Global Safety Manager 

at Rain Carbon, says that lagging indicators 

and housekeeping have improved and 

levels of engagement and involvement in 

safety are higher, as is visible management 

commitment. “The culture is much more 

open and people are more willing to discuss 

behaviour”, he claims. “That wasn’t the case 

four years ago.” 

Change has not only affected production at 

the Castrop-Rauxel site; the impact can be 

seen in the administrative offices as well. 

Thomas Müchler, the recently retired Vice 

President Corporate Accounting & Tax, admits 

he initially didn’t understand what 

safety had to do with administration. Nor 

did many of the 80 to 90 employees who 

took part in the workshop for administrative 

staff. Yet after that workshop, the 

feedback he received was entirely positive. 

“We have come to realise that safety has 

many different aspects and I think we’ve all 

become far more proactive,” he continues. 

He cites initiatives that employees in his department 

have organised, such as safety 

training for drivers of company cars and activities 

to improve safety on the way to 

work. 

Massimiliano Martino is clear on this issue. 

“We come from a top-down culture. Our 

mindset is still conservative, but we are introducing 

digitalisation and steering committees 

to enable us to communicate, think 

and act quicker in relation to all aspects of 

Conclusion 

This is a clear signal to Rain Carbon’s senior 

management that change is here to stay. 

Today, managers at the Castrop-Rauxel site 

not only track safety performance differently 

from before with a wider range of 

KPIs; they also share what is happening at 

the German plant with employees at other 

Rain Carbon production facilities and offices 

around the world, so they too can 

benefit from the lessons learned during the 

Castrop-Rauxel pilot project. 


Online search: Dupont Sustainable 

AUTHOR: 

HOLGER GRIMM 

Vice President 

Health & Safety, 

Rain Carbon 

AUTHOR: 

LUDWIG GULOW 

Senior Consultant, 

Dupont Sustainable 

Solutions 



The protection of power distribution systems is changing 

From centralised to 

decentralised design 

Requirements of process control and design of production facilities has changed 

significantly over the past few years. Besides machine uptime and a consistently 

high quality of the products to be manufactured, flexibility and data collection 

are getting more and more important. This not only changes the design of plants 

and systems, but also substantially influences the power supply of the electrical 

components. 

In the past, chemical plants used to be supplied 

by centralised control rooms. The generously 

dimensioned rooms offered sufficient 

space for all equipment and at the 

same time allowed enough cooling capacity 

for the components. Temperature rise was 

therefore not an issue. This made planning 

and extension of systems easy. Large battery 

arrays or transformers supplied all components 

of the entire plant. Kilometres of 

copper wire lines were characteristic for a 

24 V(DC) power distribution. The only 

problem was the voltage drop on the supply 

lines and an effective protection of the various 

loads in the field also was a challenge 

not to be underestimated. 

Relocation to the field 

If you look at modern plant construction, 

you will notice that the control components 

are transferred to the field. This allows a 

quicker recording of measuring data and, at 

the same time, prompt access to the control 

components. This decentralised approach on 

the control level then also leads to a decentralised 

approach of the 24 V(DC) power 

supply – including all associated advantages 

and disadvantages. 

A major advantage of a decentralised power 

distribution is the proximity to the process 

and thus significantly shorter cable lengths. 

This allows a better control of the production 

processes and reduces the required wiring, 

saving material costs and installation 

time. But as so often in life, there is no light 

without shadow. Decentralised control cabinets 

offer rather little space, requiring 

small, compact and modular devices. In addition, 

temperature development of the 

components in the control cabinets or distribution 

boxes must be considered much 

more closely than before. Power loss of the 

individual devices and the associated heat 

emissions are an essential factor. 

Today, many process plants feature a decentralised design on the control level. 

Therefore, a decentralised power distribution is very suitable. 

Picture: funtap – stock.adobe.com 

Individual power distribution systems 

Power distribution systems like E-T-A’s 

Module 18plus are exactly tailored to the 

requirements of decentralised systems in the 

process industry. They offer the perfect combination 

of modular design and flexibility 

for setting up a 24 V(DC) power distribution. 

The Module 18plus power distribution 

system consists of three modules. The 

supply module has push-in terminals which 


Picture: E-T-A 



The Module 18plus power distribution system 

holds a compact wiring solution for all 

load and signal lines of the 24 V(DC) control 

voltage 

E-T-A designed the ESX10 electronic circuit 

protectors specifically for potentially explosive 

atmospheres 

The plug-in type modules make the Module 

18plus power distribution system highly 

flexible 

accommodate cable cross sections of up to 

16 mm 2 . This allows the distribution of up 

to 80 A across the entire system. The connection 

modules are added side-by-side to 

this supply module by the plant operator. 

The maximum solution consists of 30 modules 

mounted side-by-side. Each connection 

module can be operated with a max. load 

current of 20 A. The wide range allows the 

best possible distribution of the used loads. 

Each connection module has two each protected 

terminals for the loads as well as two 

terminals for zero volt and functional earth. 

This ensures a clear correlation between the 

different loads and the corresponding circuit 

protector. 

The signalling module completes the system. 

Each circuit protector has an auxiliary 

contact transmitting the status. All circuit 

protectors used are connected in series. If a 

circuit protector trips, this is detected and 

indicated by means of the signalling module. 

A process control system monitors and 

visualises this signal contact. The plant operator 

can quickly gain an overview of the 

status of the 24 V(DC) power distribution. 

Plug-in type circuit protectors 

The plug-in design of the power distribution 

system allows the design engineer to meet 

the requirements of his plant very individually. 

A range of electronic circuit protectors 

is available for the different applications. 

E-T-A designed the ESX10 electronic circuit 

protectors for the specific requirements of 

potentially explosive atmospheres. They 

have various approvals valid for the Atex 

zone 2. This allows the use of decentralised 

solutions and ideally protects the 24 V(DC) 

power distribution. Current ratings are 

available in a range of 0.5 to 16 A and are 

internationally usable with approvals to 

Atex, IECEx and ISA. To meet the rising demand 

for electronic circuit protectors with 

higher current ratings, E-T-A extended its 

portfolio to include a 16 A version. This circuit 

protector meets the requirements of 

protecting the input and output sub-assemblies 

of process control systems. 

The plug-in design supports the system’s 

flexibility. For applications in a standard industrial 

environment, the above described 

approvals are not required. In this case, an 

electronic circuit breaker providing physical 

isolation can alternatively be used. In the 

event of a short circuit or overload, these 

breakers do not only electronically disconnect 

the circuit, but they also ensure physical 

isolation through a mechanical contact. 

In standard electronic circuit protectors, a 

power mosfet disconnects the load circuit. 

In normal duty, it is low-resistance and becomes 

high-resistance when tripped. This 

additional functionality offers extended 

protection to the user. In the event of a 

short circuit, the circuit protector first electronically 

disconnects the load circuit. After 

another five seconds, it will additionally 

physically separate the load circuit. For this 

purpose, a bimetal, which is connected in 

series with the mosfet, is supplied with current. 

When heating up, the bimetal deforms 

and physically isolates the load circuit by a 

clearance gap. This prevents hazardous return 

supply on the 24 V(DC) level and increases 

plant safety. 

Conclusion 

The change from centralised to decentralised 

design in plants of the process industry 

offers many advantages. However, we 

also need to mention that design engineers 

are faced with new challenges. The proximity 

to the plant and the process affects the 

available size of the control cabinets and 

possibly also the safety requirements. A 

possible temperature rise of the devices and 

the compact design become more and more 

important. This must be taken into account 

when selecting the components to be used 

in a 24 V(DC) power distribution. Due to its 

compact and modular design, the Module 

18plus is ideally suited to the task. In addition, 

the plug-in design offers unrivalled 

flexibility regarding suitable circuit protectors 

or breakers. 


Online search: E-T-A 

AUTHOR: 

Thomas Kramer 

Business Development 

Manager, 

E-T-A 



Easy connection in any hazardous area 

Fieldconnex Multi-Input Output (MIO) offers intrinsically 

safe inputs and outputs for discrete signals in 

zone 0 and division 1 and comes with certification for 

installation in zone 1 and division 2. MIO can be set up 

to monitor and control four different types of discrete 

signals via Foundation Fieldbus H1 and Profibus PA 

protocols. It can monitor the status of up to 12 Namur 

sensors, control up to four valves, including position 

feedback and automatic partial stroke test, connect signals 

from vibration limit switches and collect signals 

from pulse and frequency signals. This latest function 

enables users to monitor and detect standstill of motors, 

where this is critical to the process or safety. 


Online search: Pepperl+Fuchs 

Picture: Pepperl+Fuchs 

Laser shaft alignment in hazardous areas 

Maintenance technicians in the 

petrochemical and chemical processing 

industries will now be 

able to use the Pruftechnik 

single-laser technology and a 

ruggedised tablet with touchscreen 

to perform laser shaft 

alignment. Sensalign single-laser 

technology offers a superior 

measurement principle that ensures 

high measurement accuracy 

and repeatability in any situation. 

The measurement setup is 

fast and a machine pre-alignment 

Picture: Pruftechnik 

is not necessary. No matter what 

the distance or length of the 

spacer shaft is, the measurement 

accuracy remains consistent. 

Rotalign touch EX is Zone 1 certified 

according to Atex/IECEx. 

Rotalign touch EX is packed with 

many user-friendly alignment 

features including the continuous 

Sweep mode and the Live Move 

function for simultaneous realtime 

machine corrections. 


Online search: Pruftechnik 

Portable power distribution station 

Monitoring of combustible and toxic gases 

Picture: MSR Electronic 

MSR-Electronic's SSAX1 sensor 

probe effectively protects people 

and equipment in dangerous 

situations when combustible and 

toxic gases escape. In addition to 

the high-quality infrared sensor 

element and the measuring amplifier, 

the SSAX1 contains a 

μController for processing the 

measured values. The IR measuring 

principle with integrated 

temperature compensation ensures 

high accuracy, selectivity 

and reliability. All relevant data 

and measured values of the sensor 

element are stored fail-safe in 

the μController and are transmitted 

digitally via the local bus 

to the controller or the board. A 

signal output via PWM is also 

possible. The remote sensor 

probe with local bus interface 

can be connected to the board 

with a standard Atex cable of 

5 m length for evaluation of the 

measured values. The board is 

mounted outside the hazardous 

areas. Due to the small design of 

the sensor probe, the device can 

be installed almost anywhere. 


Online search: MSR Electronic 

Picture: Larson 

The explosion-proof, temporary 

and portable power distribution 

station from Larson Electronics 

converts a three-phase 600 V(AC) 

electrical current into threephase 

208 Y/120 V(AC). The system 

allows operators to power 

their 120 V equipment from a 

single system. The primary side 

gives operators the ability to 

connect three-phase 600 V linein 

power using a customer-provided 

cord and a secondary side 

that gives access to two explosion-proof 

receptacles for 

120 V equipment. All receptacles 

on this unit are equipped with 

weatherproof covers. 

Larson Electronics’ power distribution 

system is rated for use 

in class I, divisions 1 and 2, 

goups B and C; and class II, 

divisions 1 and 2, groups E, F 

and G hazardous locations. The 

transformer is grounded to the 

frame via a grounding lug that is 

provided. 


Online search: Larson 

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

Gallbergweg 21 | 59929 Brilon, Germany 

F +49 2961 50714 | www.rembe.de 

Your Specialist for 

EXPLOSION SAFETY 

and PRESSURE RELIEF 

Consulting. Engineering. Products. Service. 

© REMBE® | All rights reserved 


ProcessSensing.com 

Vacuum gauge for the Atex area 

Vacuubrand's DVR 3pro measuring device for the vacuum 

range up to 1 mbar can be operated in hazardous 

areas with a 9 V battery. The large display with digital 

and analogue readout makes it easy for the user to read 

off measured values precisely and to record trends 

quickly. The Atex approval (II 2G EX ib IIC T4 Gb) enables 

safe use in hazardous areas of Atex category 2. 

The DVR 3pro is ideally suited for working with aggressive 

gases or vapours: all parts in contact with the medium 

are made of chemical-resistant materials. The integrated 

pressure transducer is also highly corrosion-resistant 

and has long-term stability. With its immunity to 

interference, the DVR 3pro offers a high degree of operational 

safety, even when used in industrial environments. 

Another advantage is the battery compartment 

on the back of the device. The user can easily change the 

battery for power supply outside of the Atex hazardous 

area. 

The DVR 3pro comes with various connectors and 

accessories for flexible use in the laboratory. 


Online search: Vacuubrand 

OPTIMIZE YOUR OPERATIONS, 

SAFETY AND EFFICIENCY 

Sensors | Transmitters | Loggers | Analyzers 

Monitoring Systems ... 

Humidity | Dew Point | Oxygen | Trace Impurities 

Gas Concentration ... 

PST Leading Brands 

Picture: Vacuubrand 

Delivering advertisement 

data simply and safely 

High resolution oxygen sensor 

PDF 

Pewatron's PO2ES-103D is a 

rugged electrochemical cell with 

a weak acid electrolyte that can 

easily be adapted into the application. 

The lifetime of the cell 

exceeds 1200000 % Vol O 2 hours 

and the end of life (EOL) is easy 

to detect. The sensor is lead-free 

Picture: Pewatron 

and is conform to recent RoHS/ 

Reach directives. Most industrial 

requirements for oxygen sensors 

call for a low-drift baseline, signal 

stability and ease of calibration. 

The basic PO2ES-103D 

sensor has a build-in 16 bit AD 

converter that delivers a highly 

stable, temperature independent 

signal with a resolution 


High-performance, configurable small controller for efficient automation projects 

Functional all-rounder for 

safety 

The product range of configurable safe small controllers Pnozmulti 2 from Pilz 

monitors a diverse range of safety functions on plant and machinery and stands for 

maximum safety, including in the process industry. Depending on the application, 

the configurable small controller can cover a safety range up to PL e/Cat. 4 of 

EN ISO 13849-1 and SIL CL 3 of EN / IEC 62061. Pnozmulti 2 is based on a modular 

hardware platform and provides the base units Pnoz m B0 and Pnoz m B1. 

There‘s a wide range of expansion modules 

to cover safety-related requirements. 

For example: monitoring emergency stop, 

safety gates, light curtains, two-hand controls 

and press safety valves, right through 

to motion monitoring functions. In 

particular, the safe analogue input modules 

Pnoz m EF 4AI cover tasks in the process 

engineering sector. With the Pilz analogue 

input module you can safely record and 

monitor any process operations up to SIL 3 

of IEC 61511. The software tool of the configurable 

small controller, the Pnozmulti 

Configurator, provides software blocks for 

analogue input, feasibility, scaling and arithmetic 

functions for this purpose. They not 

only make project configuration simpler, 

but above all faster. Parameters for limit 

values and range monitoring can be set 

with just a few clicks. 

Fast and precise reactions 

The independent module program (mIQ) 

allows fine-granular settings for values, 

which can be processed quickly, directly 

within the module. Processes can also be 

monitored safely and with precision. Pres - 

sure, temperature, flow rate, distance, fill 

level or even rope speed and load are just 

some of the things that can be monitored 

reliably. Process cycles, which include force 

conditions, bending operations or distance 

measurement, are also included. 

Users of the module program mIQ can also 

implement fast reaction times, as all the 

commands are processed decentrally within 

the module. During configuration, the analogue 

measured values can be scaled into 

numeric variables of any unit of measurement. 

Parameters for monitoring the limit 

value, range or work area can be set via the 

software tool. The design guarantees compliance 

with the sensors’ standard measuring 

range, so that established industrial 

standards are easy to apply. 

The small controllers Pnozmulti can be used for project planning, configuration, 

documentation and commissioning. Convenient diagnostic solutions also make troubleshooting 

easier, so reducing plant and machine downtimes. 

Pictures: Pilz 

Diagnostics firmly in view 

The analogue input module provides the 

user with four independent, safe analogue 

current inputs of 4 to 20 mA with signed 

15 Bit resolution. The measuring range is 

0 tp 25 mA. The analogue inputs are suitable 


The analogue input module Pnoz m EF 4AI from the product range of 

configurable safe small controllers Pnozmulti 2 offers faster processing 

and optimised diagnostics 

Despite the expanding machine size and the increasing level of automation, 

user programs can still be manageable with the help of the 

Pnozmulti Configurator and by simulating the application 

for connecting transducers or encoders with 

standardised current signals. Arithmetic 

functions such as averaging and calculating 

differential pressure make application easier 

and enable faster, more precise diagnostics. 

Up to six analogue values per module can 

be transferred to a fieldbus, so it is possible 

to intervene in the process more quickly, if 

necessary. 

Analogue values can also be displayed and 

evaluated in combination with the visualisation 

software Pasvisu, also from Pilz. 

Fewer downtimes are the result, along with 

faster configuration and commissioning. 

Automation projects can be configured and 

visualised with Pnozmulti 2 in conjunction 

with the web-based visualisation software; 

the full function range can be used. Operators 

and service personnel obtain a comprehensive 

overview of the entire plant, including 

numerous diagnostic options, both 

locally and via remote access. As a result, 

faults or malfunctions can be detected and 

rectified quickly, plus downtimes are reduced. 

Potential savings during configuration 

In addition to the analogue modules, the 

software tool Pnozmulti Configurator also 

supports process industry users during configuration, 

documentation and commissioning. 

You simply need to select the necessary 

function blocks in order to establish the desired 

connections via drag & drop. The program 

then checks each action independ - 

ently for plausibility. It also helps with the 

early detection of errors within projects: 

from Version 10.9, an offline simulation 

program in the Pnozmulti Configurator 

checks the completed project on the computer, 

before the newly created program is 

required to prove its functionality on the 

machine. The simulation program detects 

logic errors prior to commissioning. The actual 

procedure on the machine as it is running 

is effectively simulated – offline and 

without hardware, in the office so to speak. 

Simple simulation 

The logic connections are simulated and 

tested to avoid drop out and downtimes and 

to save time when the system is first deployed 

on the plant. The connection line between 

two function blocks may be forgotten 

in one section of the program. Practical 

example: an emergency stop pushbutton as 

an input controls an output in the configuration. 

Other functions, and therefore other 

lines, are planned in between them. If one 

line is forgotten, nothing happens later 

when the emergency stop is operated. So 

the simulation comes into play even during 

development. The opportunity for simulation 

means that users can guarantee that 

the configuration of the safety controller is 

“fault-free” and that the correct functioning 

of the program logic is verified before it is 

used live. Simulation helps users to maintain 

an overview of whether the configuration is 

correct, particularly when there are more 

than two or three safety functions on the 

machine. 

Simple logic elements, counters and operating 

modes such as continuous cycle are calculated 

automatically as a first step. What’s 

more it’s even possible to simulate the entire 

application if elements that cannot be 

simulated are brought to the required state 

by forcing the outputs (fixed signal state is 

specified). Not every input needs to be defined. 

One special feature: in the Pilz simulation 

it is possible to specify a machine’s 

cycle time; there is an integrated time controller. 

Time sequences can be simulated: 

the seconds that an axis needs to move into 

position, for example. 

Whether you have analogue modules for 

safe, precise process workflow management 

or software for simulation: user programs 

must remain clear and manageable, despite 

the expanding machine size and the increasing 

level of automation on the machine. 

Due to their function range, small controllers 

such as Pnozmulti 2 contribute towards 

safety while at the same time being 

easy to use. 


Online search: Pilz 

AUTHOR: 

ANDREAS VOLLAND 

Product Manager, 

Small Controllers 

Pilz 



I/O system extended to include modules for the Ex i zone 

Reliable implementation of 

the NOA concept 

The NOA concept enables data already available in process engineering systems to 

be used to optimise processes. This is why Phoenix Contact has developed an I/O 

solution for intrinsically safe applications, which enables the relevant information to 

be easily read out. In combination with the PLCnext Technology ecosystem, the Ex i 

modules are ideal for NOA applications such as detecting leaks in pipelines, gas 

warning systems, and monitoring tanks, valve positions, pumps or motors. 

Apply new concepts to improve monitoring 

of existing plants and detect malfunctions 

before they occur. When these stand - 

ards are met, the efficiency and availability 

of machines and plants increase. In this context, 

the NOA concept provides a side channel 

for chemical and pharmaceutical industry 

applications that is used to acquire additional 

data from the application to improve 

maintenance and achieve more cost-efficient 

operation. Side channels also enable new 

technologies that do not have a negative effect 

on ongoing plant operation to be used. 

Further, important plant components can be 

continuously checked with the help of 

modern solutions such as cloud connection. 

To ensure greater user benefits, special 

requirements such as industrial compatibility, 

robustness, and reliability must also be 

implemented. Comprehensive data security 

is also a significant factor in both existing 

and new plants. If these general conditions 

do not exist, users will not be able to install 

the technology in their plants. 

The Ex i modules of the Axioline F I/O system are ideal for NOA applications such as 

detecting leaks in pipelines, gas warning systems, and monitoring tanks, valve positions, 

pumps or motors 

Picture: Oil and Gas Photographer – shutterstock.com 

Acquiring additional data 

The NOA concept was introduced at the 

Namur general meeting in November 2016. 

As mentioned above, a side channel was 

created to enable access to all key data of the 

device and provide infrastructure that satisfies 

the wish of operators to gain a deeper 

insight and a higher degree of plant openness. 

What makes this solution special is that 

it is impact-free and critical processes can 

continue to run without interruption. Since 

then new approaches and (further) developments 

have been presented in November 

every year. They practically demonstrate 

how manufacturers and service providers in 

the industry have understood the requirements 

of operators and implemented them 

as products and solutions. 

With the NOA concept, additional data can 

be acquired from field devices, the majority 

of which currently support the proven 

4…20 mA current loop and some of them 

also have a Hart interface. The information 

can be immediately used as part of the 

maintenance and monitoring strategy. When 

it comes to monitoring and operation, in 

addition to important 4…20 mA measuring 


Picture: Phoenix Contact 

Picture: Phoenix Contact 

With the NOA concept, field device data can be read out securely and impact-free, and 

forwarded to a cloud, for example 

The I/O modules of the Axioline F product 

family with IP 20 degree of protection are 

also available for use in Ex i zones 

signals, other types of data can be read via 

Hart communication as a superimposed signal 

from field devices – irrespective of 

whether they are sensors or actuators. Typically, 

Hart functions are only used for replacing 

devices in the field or workbench 

calibration – comparable to measuring 

pulse and blood pressure, which is only 

done during a visit to the doctor. But today 

there are smartwatches that continuously 

log this type of information and can graphically 

present it for an entire day. This capability 

is also desirable in industrial applications. 

Easily integrated 

Using special Hart I/O cards that can be integrated 

into process control engineering 

(PCE) or the distributed control system 

(DCS) for the purpose of using the Hart 

data generates additional costs. Since the 

data are only of interest to maintenance personnel 

for device monitoring, Phoenix Contact 

has developed two solutions for Hart 

transmission that are used in the framework 

of a side channel. Both products can be integrated 

into existing and new process 

plants, and are continuously further developed 

to meet the requirements of users and 

official bodies. 

The first approach is the modular Ethernet 

Hart multiplexer GW PL… bus. It provides 

the option of configuring and monitoring 

Hart devices via Ethernet. Hart devices can 

be integrated into almost any host system 

via industrial Ethernet systems such as 

Profinet, Modbus TCP, Hart IP, Emerson 

AMS, and OPC UA. The analogue control 

system remains fully operational and does 

not even need to be shut down for installation. 

An Ethernet Hart multiplexer consists 

of a head station and up to five four- or 

eight-channel Hart extension modules, so 

that a maximum of 40 Hart devices can be 

connected to the head station and supplied 

with current from it. The modular design 

provides a scalable solution for modern distributed 

control systems and phased rollouts. 

For four years, the Ethernet Hart 

multiplexer has been proving itself worldwide 

in smaller applications. It is ideal for 

installation involving intrinsically safe applications 

and in combination with additional 

signal isolators on the Hart devices for Ex 

zone 2 applications. 

Adapted to harsh environments 

The second solution that was introduced at 

the Namur general meeting in November 

2019 is an extension to the proven Axioline 

F I/O system with IP 20 degree of protection. 

Axioline F features rapid signal acquisition. 

The robust mechanical system 

can withstand the harshest ambient conditions 

due to its excellent shock and vibration 

resistance. In addition, the extended 

temperature range from -40 to 

70 °C also contributes to an increase in system 

availability. And installation time is reduced, 

thanks to fast wiring without tools 

and easy handling. The I/O system has 

been extended to include analogue and 

digital input and output modules for Ex i 

applications. Now Axioline F can be used 

in both hybrid and continuous applications. 

It makes sense to install it where 

intrinsic safety is required but hot-swap capability 

is not necessary. 

The I/O modules can be coupled with the 

industrial controllers and bus couplers in 

the Axioline product family. Users benefit 

from a solution that is less expensive than 

PCE/DCS, although the latter satisfies more 

rigorous requirements and offers PID control 

capability. However, Axioline F provides 

a reliable platform for maintaining 

process field devices that can flexibly adapt 

to specific general conditions and is subject 

to ongoing further development. Alongside 

the standard I/O modules for Hart communication, 

the intrinsically safe variants 

open up new opportunities for use in the 

field. Hart-compatible flow meters deliver 

additional selectable data, including device 

runtime, total flow rate, pressure and temperature. 

As a result, users can implement 

needs-based maintenance measures and 

optimise the relevant process. Since the 

cost of the sensors installed in the process 

environment have become lower, Namur 

sensors can be monitored directly through 

the side channel as discrete signals. 


Online search: Phoenix Contact 

AUTHOR: 

ARNOLD OFFNER 

Strategic Marketing Manager 

Automation Infrastructure, 

Phoenix Contact USA 




Digital tools optimise performance of tablet presses and capsule filling machines 

Full speed ahead for smart 

solid formulation production 

In exceptional times such as the corona crisis, it becomes apparent just how fast and 

comprehensively pharmaceutical manufacturers need to react to changing production 

conditions. Demand and availability can change at any time. Such requirements 

on agility can be organized more efficiently using digital tools. Fette Compacting is 

now making a comprehensive set of digital solutions available for tablet and capsule 

production. 

Even before the spread of Sars-CoV-2, it 

was clear that digital tools are decisive factors 

for the success of future pharmaceutical 

production. Now corona has significantly 

increased the necessity of such aids. For 

example, it is now more important than 

ever to be able to use live chats and video 

conferences for remote maintenance as well 

as augmented reality applications for increased 

precision. 

What helps here are particularly agile 

methods in order to become more flexible 

and deploy resources specifically. Even if the 

main processes associated with tableting 

and capsule filling remain mechanical for 

the foreseeable future, digital solutions will 

mean that all associated processes will, 

however, become more efficient, faster, and 

safer. 

Agile methods for faster development 

The question as to how digital tools can optimize 

pharmaceutical production is a core 

issue at Fette Compacting. On the basis of 

For efficient troubleshooting, a smart remote tool enables personal live chats and video 

conferences with experts 

Pictures: Fette Compacting 

pharmacists’ requirements, a new division is 

developing software solutions for manufacturing 

tablets and capsules. The central focus 

is on improving the efficiency of production 

as a whole in that operators, maintenance 

technicians, and their supervisors are 

supported and data utilized intelligently. 

The new division goes by the name of OSDi 

and builds a bridge between the manufacture 

of Oral Solid Dosages and the digital 

future. The OSDi team utilizes the agile 

methods of Design Thinking and Lean Startup 

which are also widely established in Silicon 

Valley. These methods are linked by the 

fact that they are consistently oriented toward 

the requirements of users. In fact, 

users are included in the development process 

right from the start, particularly operators, 

maintenance technicians, production 

managers, and quality managers. 

In practice, this translates into an agile approach 

entailing the OSDi team initially 

drawing up new product sketches on the 

basis of users’ “pains and gains”. These are 

then sent back to the customer for a second 

opinion. Using the feedback obtained, the 

unit collaborates closely with the customers 

to create a click dummy, a prototype, and 

finally the finished tool. The customer’s 

perspective is decisive at all times. This way, 

ideas with less potential can be detected 

swiftly and rejected if necessary, which 

reduces the development process and conserves 

resources. 

Interactive learning content 

Some digital tools have already been created 

on this basis at Fette Compacting. And they 


In order to keep an eye on the running production at any time and 

anywhere, OSDi provides several apps such as a smart interface and a 

condition monitor 

In a virtual training unit, operators can practice cleaning 

processes at and in the isolator without blocking the real 

machine 

already address a preliminary stage which is 

decisive for success: training new personnel. 

Via an app, experienced trainers make 

3D-animated learning content available. 

Using interactive graphics, animations, and 

detailed instructions, new employees can 

familiarize themselves with the entire process 

of solid formulation production. In 

several modules, the learning platform illustrates 

how individual parts of the machine 

are assembled and protected from wear, for 

example. After each module, the trainees are 

obliged to complete a small test on the 

training content. Their learning progress is 

depicted in an overall summary. 

Fette Compacting is working on a range of 

virtual training units to enable work processes 

to be practiced. The first available 

unit concerns the preparation of an isolator 

for cleaning. Without blocking the real machine, 

employees can practice the process as 

often as they want using virtual glove ports, 

VR glasses, and a gaming notebook. The 

standardized process is supported by an avatar 

and a virtual checklist. Once participants 

feel sufficiently confident, they can move to 

a test mode where they can clean the isolator 

without instructions. Those who pass 

the test receive a certificate. Gaming elements 

such as a high score also make VR 

training more fun and increase the motivation 

of the participants. 

Digital overview 

OSDi also has initial applications ready for 

ongoing production: the team has developed 

a Fleet Manager to provide a swift 

overview of the machines at all locations. 

A single glance at a mobile end device indicates 

which machines are running and 

which ones are down. Users can arrange 

their machine park in the app and focus on 

individual production halls or manufacturing 

lines in particular. 

Those who wish to access machine data live 

without being bound to a cloud solution 

can use a special Fette Compacting interface. 

This permits access to real-time production 

data independent of the respective location. 

The KPI dashboard offers an overview of the 

current production and machine status. The 

monitoring functions can be used for recording 

and exporting all process values. 

Often it is not sufficient to merely know the 

status quo. It is also increasingly important 

to detect possible error sources at an early 

stage. A condition monitor collates production 

and machine data, harmonizes them, 

and visualizes them on any device via a secure 

cloud. Maintenance teams use the app 

to see the real-time status of their machines 

and plants. A comparison with historical 

measurements indicates deviations at an 

early stage and prevents downtimes. It can 

even be used to configure third-party machines. 

The functions of the condition monitor are 

further extended by a performance manager. 

Among others, it visualizes measurements 

and notifications from all connected 

devices – live and chronologically. This way, 

it indicates any statistical deviations and 

communicates performance potentials. 

Swift detection and troubleshooting 

And finally, troubleshooting is also more efficient 

thanks to OSDi tools: with a smart 

guide, operators can remedy frequent errors 

at the instruction of technical experts. The 

app runs on a mobile device or a desktop 

computer. Images, animations or videos 

provide information on the respective error 

and illustrate the steps for a solution. Furthermore, 

users can create their own instructions 

for their machines, regardless of 

the brand. 

If the troubleshooting guide is not sufficient, 

a smart remote tool offers personal 

live chats and video conferences with experts. 

Operators use the app on a mobile 

device and can implement the instructions 

provided by experts directly on the machine. 

Augmented reality increases the 

precision of troubleshooting via visual tools 

such as a “finger pointer”. This remote tool 

saves solution instructions in a customer 

archive enabling users to access it at will. 

All in all, OSDi currently includes eight 

functional applications for solid formulation 

production. The fact that more apps and services 

will follow is clearly foreseeable in 

line with the agile methods already used. 


Online search: Fette Compacting 

AUTHOR: 

BRITTA VON SELCHOW 

Head of OSDi Digital 

Solutions, 

Fette Compacting 




Danger recognized, bearing damage averted 

Monitoring of the bearings 

of the centrifuge bowl 

Flottweg has succeeded in creating digital added value from mechanical vibration 

signals. The Motice Condition Monitoring System monitors the bearings of the 

decanter bowl, thus making predictive maintenance possible. This makes it ideal for 

avoiding plant downtimes. 

Who is not interested in preventing machine 

malfunctions? For Flottweg, the availability 

of machinery and equipment is a 

basic prerequisite for productivity. This is 

taken very seriously and is the focus of a 

strategy to increase availability through the 

use of digital resources. The Motice Condition 

Monitoring System was initially designed 

for bowl bearings. In the future, it 

will also be used to monitor motors and 

chatter vibrations in industrial centrifuges 

and decanters. This system facilitates the 

early detection of sources of potential faults 

and permanently monitors the condition of 

the mechanical components of the machines. 

High bowl speeds and high loads are 

the norm in industrial centrifuges and decanters. 

The bowl‘s bearings are the most 

heavily stressed functional components and 

under continuous load, they can cause premature 

failures and unplanned downtimes. 

The wear becomes visible and measurable 

when the vibration characteristics of the 

bearings change. With the Motice system, 

the bowl‘s bearings can be monitored in 

order to detect bearing damage at an early 

stage. Siemens measurement electronics 

monitor the bearings synchronously and 

continuously. An intelligent evaluation of 

the signals in the measuring module not 

only detects early changes in the condition 

of the bearings, but also monitors and visualizes 

these changes. After authorization by 

the customer, the service staff can quickly 

access the bearing data via a remote diagnosis 

tool and make qualified statements 

about the bearing condition based on the 

measured values. 

Permanent condition monitoring 

Classical measuring methods often reveal 

the overall condition of a machine but 

they do not offer an exact fault analysis. Motice 

focuses on the bowl‘s bearings and 

evaluates important parameters such as 

speed, bearing type and the decanter‘s 

threshold values. Regardless of frequency, 

this leads to a clear and reliable assessment 

of any emerging damage. 

All measurement data is evaluated in the 

Motice module and the user can quickly 

identify bearing faults via a visualization 

system. This data analysis alerts Flottweg of 

an upcoming maintenance appointment. Acceleration 

signals are recorded on all channels 

in the trend analysis, whereby defined 

threshold values facilitate monitoring. Lack 

of lubricant, foreign matter in the bearing 

or bearing corrosion can be optimally visualized 

within the trend profile. Using an 

envelope curve, bearing damage to the 

outer ring and inner ring, the cage and the 

ball bearing can be analysed and separately 

evaluated. Exact bearing damage patterns 

enable specific conclusions to be drawn 

about the remaining service life of the bearing. 

The programmed warning thresholds 

vary as a function of the speed. 

Using a Condition Monitoring System, potential faults in decanter mechanical components 

such as gears and bearings can be detected at an early stage 

Images: Flottweg 

Maximum machine diagnostics 

Up to four synchronous high-resolution 

measuring channels are available, whereby 

the system ensures continuous data acquisition 

without an additional integrated speed 

sensor. With regard to the data, the net- 


operation is still possible. Conversely, abnormalities 

in a system can be directly correlated 

with the health of components, for 

example, whether a temperature increase is 

the result of a defective bearing. 


Online search: Flottweg 

Motice facilitates the digital diagnosis of bearing deterioration in decanters 

AUTHOR: 

FRANK EBERT 

Machine development, 

mechatronic components, 

Flottweg 

work-capable Motice stores the characteristic 

value trends with intelligent data compression 

for up to ten years. The high level 

security of user data is guaranteed, because 

Flottweg only has passive access rights with 

a release clause relating to the data to be 

analysed. This means that the Condition 

Monitoring System can be used independently 

and requires no additional software 

or licenses. 

Monitoring stations always have up-to-date 

information on the status of the bearings 

and, in the event of abnormalities, it is 

possible to quickly estimate how long safe 

AUTHOR: 

NILS ENGELKE 

PR and Communication 

Manager, 

Flottweg 

Versioned catalog production 

intelligent 

Medien 

produzieren 

Perfect project management for highly complex jobs 

Tools for an efficient workflow 

www.konradinheckel.de 




Diaphragm metering pumps in use in battery production 

Precise metering needed 

Ternary oxide systems containing lithium guarantee a high energy density, long 

service life and high number of charge cycles for lithium storage batteries. The 

quality of the precursors required for this depends on the precise and synchronous 

metering of various chemicals. The diaphragm metering pumps in the Gamma/ X and 

Sigma X ranges from Prominent play a key role in this. 

The demand for lithium batteries in the 

communication, tools, automotive and 

energy sectors is high. Becoming increasingly 

lighter and with greater energy density, 

they are replacing heavy lead or nickelcadmium 

batteries in these applications. 

Lithium iron phosphate batteries cannot 

meet the requirements for electric mobility 

and stationary storage as the new generation 

of lithium batteries. Lithium-ion batteries 

with special cathode materials are replacing 

lithium iron phosphate batteries. 

The new power packs have a long service 

life with a high energy density and a large 

number of charge cycles with maximum 

safety. With carbon compounds containing 

lithium, these properties can be put to use 

as anodes and, with a ternary oxide system 

containing lithium, as cathodes. Market researchers 

are anticipating above-average 

growth per year. 

NCA compounds 

Ternary precursors are being used for this. 

These are predominantly manufactured by 

means of reactions of nickel, cobalt and 

manganese solutions through hydroxide or 

carbonate precipitation. In this process, sodium 

hydroxide acts as a precipitant and 

ammonia as the complexing agent. For 

special applications, the manganese is replaced 

with aluminium solutions and receives 

NCA compounds. NCM or NCA precursors 

are obtained by various solutions 

being combined in precisely specified quantities, 

within a specific time frame, at specified 

temperatures, under stable conditions, 

and reacting accordingly. The reactions of 

the chemicals affect the critical properties of 

the precursors, such as the particle size and 

their specific surface. Strict proportional 

control of the reactants directly determines 

the final ternary material properties and 

their quality, as well as the purity of the sintered 

ternary lithium, nickel, cobalt and 

manganese (NCM) compounds. To obtain 

an exact quality in the precursors, and 

above all one that can be reproduced, smart 

high-end metering pumps are increasingly 

being used. These ensure the exact metering 

of the individual heavy metal solutions 

required for the reaction to achieve the 

requisite precursor quality at all stages of 

production. 

Metering station with Gamma/ X solenoid-driven metering pumps and Sigma X motordriven 

metering pumps. Direct input of the required final concentration in concentration 

mode ensures precise volume-proportional metering. 

Pictures: Prominent 

Task of the metering pumps 

Typical production for ternary precursors 

consists of up to 15 different process stages. 

Within the individual processes, solenoiddriven 

metering pumps and motor-driven 

metering pumps are used to precisely meter 

fluoride, liquid metal solutions containing 

amounts of nickel, cobalt and manganese, 

plus sodium hydroxide (NaOH) and ammonia. 

In the key process step, the synthesis 

reaction, ultra-pure water and ammonia are 

added as the base fluid. Depending on the 

pH value, three diaphragm metering 

pumps, for example, synchronously meter 

the various liquid metal solutions at around 


Picture: Prominent 

Gamma/ X solenoid-driven metering pumps provide 

low-pulsation, continuous metering in the production of 

ternary precursors in battery production 

Metering station with six Sigma X motor-driven metering 

pumps. The metering pumps are equipped with a click 

wheel and four additional operating keys on a removable 

operating unit. 

5 to 20 l/min. A NaOH solution is also 

added and mixed with the metal ion so - 

lutions in the reactor. Additional pumps 

meter the precipitant at around 10 to 

40 l/min. The original pH value in the so - 

lution is maintained throughout the entire 

reaction, including all metering and mixing 

processes. After a reaction time of around 

24 h, the pH value is slowly lowered in 

one-hundredth steps (0.01 pH/H) to a specific 

pH value. This is done through the absolute 

and precise addition of NaOH. 

Custom metering behaviour 

The solenoid-driven metering pumps in the 

Gamma product range with regulated solenoid 

drive are ideal for this. Within their capacity 

ranges of 2.3 to 45 l/h or 8 to 80 l/h 

at 25 to 2 bar, the precise quantity needed 

can be set and added to the exact process. 

Their model-based solenoid control records 

varying pressure levels, while automatically 

and precisely adjusting the pump’s metering 

behaviour to the current conditions. In 

other words: The pumps always meter the 

required quantity of the chemical precisely– 

without any additional sensors. Unlike other 

metering pumps, this eliminates unneces - 

sary sources of faults in advance. 

Intuitive operation 

Intuitive operation and simple programming 

of all pump parameters needed are 

key for error-free operation. A minimal 

number of controls on the gamma pump 

ensures rapid adjustment of the individual 

parameters, such as stroke length, frequency, 

and metering profile. 

A click wheel and some push-buttons are all 

that is needed to quickly access parameters 

or functions at different menu levels. Specifying 

the capacity in l/h avoids laborious 

conversions and allows the setting to be 

made quickly and easily. The stroke length 

can be electronically set within the range 

between 0 and 100 %. Another advantage of 

controlled pumps is their continuous metering 

characteristics which ensure the excellent 

mixing of the individual reactants. With 

volume-proportional metering of chemicals 

into a primary flow, elongated metering 

strokes ensure even distribution. There is 

therefore no need for static mixers. After 

completion of the reaction and lowering of 

the pH, product particles with an average 

size of a few μm have formed. After repeated 

washing, these are sedimented, dried 

at temperatures of up to 150 °C and after 

one day, can be extracted as a ternary precursor. 

Adjusted movement profile 

Regardless of the size of the reactors, quantities 

are also needed that exceed the capacity 

range of the Gamma product range. In 

this scenario, Sigma X motor-driven metering 

pumps are used. Depending on the version, 

these ensure accurate metering within 

the range of up to 117 l/h (Sigma1), 

353 l/h (Sigma2) or 1040 l/h (Sigma3). 

They have the same standardised operating 

concept with click wheel and four additional 

operating keys as the Gamma pumps. 

They also provide accurate and complication-free 

metering of media due to their 

broad adjustment range thanks to a combination 

of frequency and stroke length adjustment 

and adjustment of their movement 

profile. 

Real time communication 

Production processes, such as the production 

of ternary precursors for battery cathode 

materials, are extremely challenging for 

operators. It involves maintaining optimal 

conditions, which are dependent on various 

metering processes, over a long period of 

time. The precise quantity of the various 

solutions must still be continuously metered 

in real time throughout the entire production 

period. This requires direct communication 

using corresponding sensors and the 

control system. Integrated Profibus and 

CANopen interfaces enable simple connection 

to process control systems. As smart 

products, the Gamma/ X and XL diaphragm 

metering pumps, and the Sigma X can be 

connected to the Dulconnex web-based 

fluid management platform. This allows the 

operator to monitor, analyse and optimise 

the individual metering processes with ease. 

Each process can be monitored in real time. 

Downtimes and the consumption of raw 

materials used are thus minimised. The result: 

The result: high quality ternary precursors 

which ensure that batteries have high 

energy density and a longer service life. 


Online search: Prominent 

AUTHOR: 

MICHAEL BIRMELIN 

Marketing Editor, 

Prominent 



CONTACT THE EDITORS 

GÜNTER ECKHARDT 

Editor-in-Chief 

Phone +49 711 7594-291 

guenter.eckhardt@konradin.de 

LUKAS LEHMANN 

Assistant Editor-in-Chief 

Phone +49 711 7594-290 

lukas.lehmann@konradin.de 

CLAUDIA BÄR 

Editor 

Phone +49 711 7594-287 

claudia.baer@konradin.de 

URSULA FISELY-BUSTORFF 

Editor 

Phone +49 711 7594-373 

ursula.fisely@konradin.de 

DANIELA HELD 

Editor 

Phone +49 711 7594-284 

daniela.held@konradin.de 

DR. BERND RADEMACHER 

Editor 

Phone +49 711 7594-263 

bernd.rademacher@konradin.de 

ANGELIKA STOLL 

Editor 

Phone +49 711 7594-300 

angelika.stoll@konradin.de 

BARBARA DIVIGGIANO 

Editorial Assistant 

Phone +49 711 7594-415 

barbara.diviggiano@konradin.de 

ISSN 0724–1054 

Publisher: 

Katja Kohlhammer 

Publishing House: 

Konradin-Verlag Robert Kohlhammer GmbH 

Ernst-Mey-Straße 8, 70771 Leinfelden Echterdingen, 

Germany 

General Manager: 

Peter Dilger 

Publishing Director: 

Peter Dilger 

Editor-in-Chief: 

Günter Eckhardt (ec), Phone +49 711 7594-291 

Assist. Editor-in-Chief: 

Lukas Lehmann (le), Phone +49 711 7594-290 

Editorial Staff: 

Ursula Fisely-Bustorff (fi), 

Phone +49 711 7594-373 

Dipl.-Ing. Daniela Held (dh), 

Phone +49 711 7594-284 

Dr. Bernd Rademacher (br), 

Phone +49 711 7594-263 

Angelika Stoll (st), 

Phone +49 711 7594-300 

Editorial Assistant 

Barbara Diviggiano, 

Phone +49 711 7594-415, -1415 

e-mail: barbara.diviggiano@konradin.de 

Desktop Publishing: 

Jennifer Martins, Phone +49 711 7594-262 

Ana Turina, Phone +49 711 7594-273 

Birgit Ender (freelancer) 

Sales Director: 

Andreas Hugel, Phone +49 711 7594-472 

e-mail: andreas.hugel@konradin.de 

Order Processing: 

Andrea Haab, Phone +49 711 7594-320 

e-mail: andrea.haab@konradin.de 

Rate card No. 53, effective October 1, 2019. 

Reader Service: 

Ute Krämer, Phone +49 711 7594-5850 

Fax +49 711 7594-15850 

e-mail: ute.kraemer@konradin.de 

Subscription price: 

Inland 20,70 €, VAT and distribution included; 

Foreign countries 20,85 €, VAT and distribution 

included 

Retail price 5,30 €, VAT included, plus distribution 

International Sales Offices: 

Great Britain, Jens Smith Partnership, The Court, 

Long Sutton, GB-Hook, Hampshire RG29 1TA, 

Phone 01256 862589, Fax 01256 862182, 

e-mail: jsp@trademedia.info, 

Japan, Mediahouse Inc., Kudankita 2-Chome 

Building, 2–3–6, Kudankita, Chiyoda-ku, Tokyo 102, 

Phone 03 32342161, Fax 03 32341140; 

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Inc. Detlef Fox, 5 Penn Plaza, 19th Floor, New York, 

NY10001, Phone 212 8963881, Fax 212 6293988, 

e-mail: detleffox@comcast.net. 

Articles published under the name of an author do 

not necessarily constitute the Editor`s opinion. 

The Editor cannot be held responsible for unsolicited 

reports from industry. Please note that brands 

or trade names that are not specifically trademarked 

may nevertheless be pro tected. 

The Editor reserves the right to condense or enlarge 

manuscripts submitted to him. Proofs can regrettably 

not be sent. 

Place of performance and jurisdiction: Stuttgart 

Printed by Konradin Druck GmbH, 

Leinfelden-Echterdingen 

Printed in Germany 

© 2020 by Konradin-Verlag 

Robert Kohlhammer GmbH, 

Leinfelden-Echterdingen 


LIST OF ADVERTISERS 

Aerzener Maschinenfabrik GmbH, Aerzen 23 

Beumer Group GmbH & Co.KG, Beckum 5 

Bronkhorst High-Tech B.V., NL-Ruurlo 25 

C. Otto Gehrckens GmbH & Co. KG, Pinneberg 25 

DECHEMA Ausstellungs-GmbH, Frankfurt 24 

GATHER INDUSTRIE GmbH, Wülfrath 3 

IPCO Germany GmbH, Fellbach 15 

Amandus Kahl GmbH & Co. Maschinenfabrik, 

Reinbek 52 

Linde GmbH Gases Division, Pullach 27 

Michell Instruments GmbH, Friedrichsdorf 39 

REMBE GmbH Safety + Control, Brilon 38 


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is one of a kind and unique. Each child needs individual support 

according to their needs. Please help us by donating. Thank you! 

Tel.: 0800/50 30 300 (gebührenfrei) 

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www.sos-kinderdoerfer.de 

cpp 02-2020 51 

2016/1

PELLETING: A PROCESS TECHNOLOGY FOR 

ECONOMICAL COMPACTION AND SHAPING 

Transport and storage of bulk and powdery products present a challenge due to their mealy and dusty consistency. 

Whether pigments, talcum, tabletting masses, activated carbon or pharmaceutical raw materials are involved – 

pelleting significantly improves the properties of these substances. KAHL plants for agglomeration by compression 

and pelleting increase the economic efficiency of the production processes as they reduce storage losses and dust 

load and improve the flow properties, proportioning properties and usability, to name only a few advantages. 

For more information please visit akahl.de. 

52 cpp 02-2020 

AMANDUS KAHL GmbH & Co. KG 

Dieselstrasse 5–9 · 21465 Reinbek · Hamburg, Germany 

+49 (0) 40 72 77 10 · info@akahl.de · akahl.de

cpp – Process technology for the chemical industry 02.2020

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