cpp – Process technology for the chemical industry 02.2021

02-2021
24 COVER
EXPLOSION SAFETY FOR
SPRAY DRYING SYSTEMS
08 DIGITAL TWIN
ADDING MORE VALUE
FOR PLANT OPTIMISATION
36 INCREASED EFFICIENCY
INTER LOCKING CONTROL
FOR COMPRESSORS
42 EFFICIENT INTERFACE
END-TO-END AUTO-
MATION OF TANK FARMS
38 TREND
CIRCULAR
ECONOMY
PROCESS TECHNOLOGY FOR THE CHEMICAL INDUSTRY
WWW.CPP-NET.COM

Reliable. Tested. Safe.
Radar for exact levels in bulk solids applications
From simple to challenging: With radar technology that is highly robust, flexible and economical all
at the same time, VEGA is putting things on track to ensure more reliable and efficient production
processes involving bulk solids – of any kind and any grain size.
Decades of experience means that we understand the requirements of the industry quite well. That’s
why VEGAPULS level sensors are able to deliver exact measured values even when conditions get
extreme because of dust, noise or buildup.
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www.vega.com

cpp
EDITORIAL
High-performance
plastics for valves
and fittings
A new look at
plastic waste
Plastics are indispensable nowadays, but all too often plastic
products become waste at the end of their lives and end up as huge
carpets in the world’s oceans. This is something that has to change.
One way out of this dilemma is the so-called circular economy.
Circular economy is defined as a model for production and consumption
which involves sharing, leasing, reusing, repairing,
refurbishing and recycling existing materials and products for as
long as possible. This will become increasingly important in the
future, as natural resources such as crude oil or certain minerals are
limited on our planet. Reusing plastic waste will therefore be an
essential building block for a sustainable economy. The article
“New life for old plastics” starting on page 38 deals with the topic
of plastics recycling. It provides an overview of the various methods
that exist and shows what new approaches are currently in place at
Covestro, one of Germany’s leading polymer manufacturers.
In our cover story on page 24 we take a look at explosion pro -
tection. One measure for constructional explosion protection is
explosion suppression. The Q-Bic extinguishing barrier for this
purpose takes particular account of the hygienic requirements of
spray drying systems. A practical example shows how Q-Bic can be
used to create economical concepts for demanding applications.
Furthermore, you will find a selection of pumps and compressors
for daily work in the chemical industry in our focus topic starting
on page 27. I hope you enjoy reading this issue.
We offer a broad range of customized
solutions to meet your complex sealing
and bearing requirements:
• Made of Polytetraflon-PTFE and
thermoplastic materials
• Based on our in-house compound
and product development expertise
• In GMP-certified quality
www.ek-kt.de/product
mech-engineering@elringklinger.com
Phone +49 (0)7142 583-0
Daniela Held, Editor
cpp 02-2021 3

cpp CONTENTS 02-2021
24 Cover One
measure of constructive
explosion protection is
explosion suppression.
Rembe has developed the
Q-Bic extinguishing barrier
for this purpose,
taking particular account
of the hygienic requirements
of spray drying
systems.
10 EagleBurgmann CEO
Dr. Andreas Raps talks
about the development
of digital products using
agile methods, the
requirements for me -
chanical seals and the
robust mechanical seal
for high-pressure ranges.
18 It is absolutely crucial
to supply very dry air
to sulfonation processes.
Dew points of up to
-80 °C are normally
achieved in such plants.
With Sorbead R/WS adsorbents
users can save
operating costs in air
dryers designed for these
desiccants.
PLANTS, APPARATUS, COMPONENTS
8 Digital twin: adding more value
How the plant twin not only preserves values,
but creates new ones
10 Maintenance concepts from the digital laboratory
Developing digital products and services with
agile working methods
PROCESS ENGINEERING
18 Dry compressed air for sulfonation plants
Use of high-performance adsorbents pays off
20 All depends upon the mixer
Possibilities and limitations of fixation of
mix components to agglomerates
SAFETY
22 Efficient process reliability management
Software suite combines engineering data with IT
and OT data
24 COVER Explosion safety for spray drying systems
An economical concept
FOCUS: PUMPS AND COMPRESSORS
27 All-round metering pumps
Dosing solutions for liquid products
28 Digital pump pioneers
IoT solution enables live monitoring of
mechanical pumps
30 Submerged pumps for hazardous media
Designed to meet specific requirements
32 PRODUCTS
34 Oil-free compressed air for the laboratories
Bergische Universität Wuppertal installed new
compressed air treatment systems
36 For greater efficiency
Intelligent interlocking control of air compressors
TREND CIRCULAR ECONOMY
38 New life for old plastics
Plastic waste is a valuable resource
INSTRUMENTATION, CONTROL, AUTOMATION
42 End-to-end automation of tank farms
Explosion-proof components guarantee high
system availability
44 Everything from a single source
HMI platform for Atex, IECEx zone 2/22, UL division 2
and non-hazardous areas
46 Safe and effective interface technology for Ex areas
S electing devices and designing intrinsically safe circuits
4 cpp 02-2021

28 With Tim-IoT a
digital solution is
available that enables
location-independent
monitoring in real-time
and predictive mainte -
nance of pneumatic
double diaphragm
pumps.
46 When interconnecting
equipment with type
of protection Ex i, the
user must provide proof
of intrinsic safety and
should take this into account
when selecting the
equipment. Ex i isolators
are particularly important
here.
The all new CleanLine C5
Pioneering process technology
meets Hygienic Design
COLUMNS
3 Editorial
4 Contents
6 News
13 PRODUCTS
49 PRODUCTS
50 Contact to the Editors
50 List of Advertisers
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
One-Pot universal machine
Mixing | Granulating | Coating
Kneading | Dispersing
Maschinenfabrik Gustav Eirich GmbH & Co KG
www.eirich.de
cpp 02-2021 5

cpp
NEWS
Pathway to net zero
LYONDELLBASELL PLANS NET ZERO EMISSIONS BY 2050
LyondellBasell’s Houston, Texas, refinery is among North America’s largest full-conversion
refineries capable of processing significant quantities of heavy, high-sulfur crude oil
LyondellBasell announced its ambition of,
and approach to, achieving net zero
emissions from global operations by 2050.
As an interim step toward 2050, the company
also announced a strategy to achieve
an absolute reduction of 30 % in scope 1
and scope 2 emissions by 2030. These
targets are consistent with efforts to support
the Paris Agreement‘s goal of limiting
climate change by achieving net zero for
global greenhouse gas (GHG) emissions
by mid-century. LyondellBasell‘s approach
to achieving net zero emissions for its scope
1 and scope 2 emissions by 2050 will build
upon the progress achieved over the balance
of this decade. In addition to these strategies,
the company has begun evaluating a
portfolio of technology options that could
be deployed across the company‘s manufacturing
footprint, including cracker electrification,
use of hydrogen, carbon capture and
storage, and carbon use. In addition, the
company is actively embedding emissions
reduction efforts into certain business
processes including long-range planning
and risk management, and identifying
collaboration opportunities across multiple
sectors.
Picture: LyondellBasell
World forum for the process industries
ACHEMA 2022 ON-SITE IN
FRANKFURT AGAIN
After Achema Pulse 2021 – the pioneering
digital event for the process industry –
Achema 2022 will be back on the Frankfurt
Fairground from 4 to 8 April 2022. A comprehensive
hygiene concept ensures that
personal exchange and networking are once
again possible in safety on site. “After a
two-year dry spell, the need for intensive
technical and personal exchange is palpable“,
says Dr Thomas Scheuring, CEO
Dechema Ausstellungs-GmbH. This is also
reflected in the increasing exhibitor demand:
currently, more than 2400 exhibitors
have already registered, who will present
their range of products, solutions and services
for the process industries on more
than 100,000 m 2 . Trendsetting technology
and global networking will continue to
characterise the world‘s leading trade fair in
2022. Manufacturers and service providers
from almost 50 nations will present their
products for the chemical, pharmaceutical,
biotechnology, energy and environmental
sectors. Focus topics of Achema 2022 will
be: “Modular and Networked Production”,
“The Digital Lab” and “Product and Process
Security”. The megatopics of digitalisation
and climate neutrality are also moving even
more into the focus of Achema with the
“Digital Hub” and the “Green Innovation
Zone”.
Platform for automation industry exchange
SPS 2021 WILL BE HELD AS ON-SITE EVENT
Around 750 exhibitors are expected to SPS Smart Production Solutions in
Nuremberg from 23 to 25 November 2021
SPS Smart Production Solutions remains one
of the most important highlights in the
automation industry calendar. Around 750
exhibitors are expected in Nuremberg from
23 to 25 November 2021 to present their
Picture: Mesago
products and solutions for smart and digital
automation. This on-site event will be combined
with a supplementary digital offering.
“In these times when everything is different,
one thing has remained constant: the
need for innovation and personal inter -
action within the automation industry. We
will finally be able to cater to this need
again in 2021 and take a step towards a new
normal despite the coronavirus,” says Martin
Roschkowski, President of Mesago Messe
Frankfurt, the organiser of the trade fair.
In addition to numerous product presenttions
and intelligent solutions, visitors to
the SPS will benefit from direct personal
discussions and professional exchanges with
experts. Presentations and live demonstrations
round off the trade fair visit. Attendees
can also obtain extensive insights into specific
topics and ask providers for advice on
their particular requirements at the “Automation
meets IT” shared booth in Hall 6.
For the first time, the German industry
associations VDMA and ZVEI will hold the
trade fair forum together in Hall 3.
6 cpp 02-2021

Confidence despite corona
JUMO DEFIES THE CRISIS WITH INNOVATIONS
Jumo management: (from left) Bernhard
Juchheim (managing director and shareholder),
Dimitrios Charisiadis (managing
director), Michael Juchheim (managing
director and shareholder).
Picture: Jumo
During a virtual press conference, Jumo
GmbH & Co. KG reviewed the past months
and gave an outlook on the future of the
company. Despite corona, the overall balance
of the managing directors was positive.
“2021 was a year of restrictions, and even
this year we have not yet reached the end of
the tunnel with regard to the corona pandemic,”
said managing director and partner
Bernhard Juchheim, summarising the situation.
He added that Jumo has so far come
through the crisis generally unscathed.
Economically, the corona pandemic nevertheless
left a clear mark: “We ended 2020
with a drop in sales of around 6 % compared
to the previous year. In 2021, we
were able to start a race to catch up with
above-average order intake and sales figures,
but we are currently feeling the global
material shortage all the more”, managing
director Dimitrios Charisiadis said. Overall,
the forecast for the current year is nevertheless
positive.
For the future, Jumo is focusing on clear
strategic goals, which managing director
Michael Juchheim explained: “On the one
hand, we will supplement and round off
our portfolio with new measurement variables
on the basis of a very clear industry
focus. Secondly, as a solution provider for
the automation industry, we want to drive
forward the digitalisation of our customers.
The third pillar of growth is the expansion
of service and training offerings for our
customers.”
A large number of new products show that
Jumo has not sat back and taken it easy,
even under pandemic conditions. In addition
to various measurement technologies,
the company presented the browser-based
Jumo Smartware Evaluation software, which
enables intuitive evaluation and visualisation
of process data from the Varitron
automation system.
Pumps and valves from Frankenthal
KSB IS CELEBRATING ITS
150TH ANNIVERSARY
The Frankenthal-based pump and valve
manufacturer KSB SE & Co. KGaA celebrated
its 150th anniversary on 18 September
2021. Johannes Klein founded the company
in Frankenthal back in 1871 together with
fellow businessmen Friedrich Schanzlin and
Jakob Becker. Initially a 12-man operation,
the company has since developed into a
global group with over 15,000 employees,
27 production locations, companies and
sales agencies in 100 countries and a sales
revenue of 2.2 billion euros. Over the
course of the company’s history, KSB has set
numerous technical benchmarks. The Eta
type series which was launched on the market
in 1935 is still the leading product in its
class. Today considered to be the mother of
all standardised pumps, the Eta type series
has made industrial history. Another
example are the CPK standardised chemical
pump and its successor, Mega-CPK. They are
among the most used standardised chemical
pumps in the world. The company has always
attached great value to sustainability. It
has been a member of the United Nations
Global Compact since 2010, committing the
company to the fundamental principles of
socially and environmentally responsible
corporate governance. Due to the coronavirus
pandemic, the festivities have been postponed
until 2022.
cpp NEWS TICKER
tered in Huddersfield (UK), and
which took nearly two years to
Extract Americas (Formerly,
complete, includes a new produc-
Dec Group acquires
Extract Technology
The Dec Group completed the
acquisition of the Extract Technology
business from US-based
Wabash National Corporation.
Extract Technology is a leading
provider of containment and
aseptic systems for the pharmaceutical,
biotech, nuclear and
Picture: Extract Technology
chemical markets. The acquisition
Walker Barrier Systems), located
in New Lisbon, Wisconsin (USA),
and supports Dec’s strategic approach
to complimentary technology
acquisition.
Endress+Hauser expands
production in Maulburg
Endress+Hauser has invested
roughly 46 million euros in the
Picture: Endress+Hauser
tion and office building with
more than 17,000 m 2 of space,
plus a parking garage. The expansion
was in response to
strong growth in the area of level
and pressure measurement technology.
With roughly 2000 employees,
Maulburg is one of the
Endress+Hauser Group’s largest
locations. “The new buildings will
allow us to cope with the growth
stemming from previous years,”
said Dr Peter Selders, managing
director of Endress+Hauser
Level+Pressure in Maulburg. A
generous amount of space and a
Picture: Beumer
Beumer with new
managing director
Beumer Maschinenfabrik GmbH
& Co. KG, the German regional
company of Beumer Group in
Beckum, has a new managing director.
Dr Jörn Fontius succeeds
Norbert Stemich, who after eight
years in this position is now focusing
on the activities in the
product business area.
includes the Extract Technology
expansion of its Maulburg,
modern infrastructure will now
businesses which is, headquar-
Germany, location. The project,
help to meet the demand.
cpp 02-2021 7

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PLANTS, APPARATUS, COMPONENTS
How the plant twin not only preserves values, but creates new ones
Digital twin:
adding more value
In plant engineering, millions of data are generated, changed, updated and documented
through the years. This costs a lot of money, time and know-how. And then
what? The plant is delivered and in operation, but the documentation lies dormant
in various files or even cardboard folders. With every repair or plant optimisation
that is not added, the plant loses more of its value. Yet up-to-date plant data opens
up a wealth of opportunities for value creation.
For Reinhard Knapp, Head of Global Strategies
at the software provider Aucotec, the
most important prerequisite for being able
to use these opportunities is the principle of
data instead of documents. This requires a
single source of truth (SSoT), in which all
data from basic, process and detail engineering
to the control system configuration
are united in a versatile model – this is the
only way that documentation can become a
comprehensive digital twin. “It not only
maps the entire plant reality with all logics
and associations across all disciplines, but
can also grow consistently in the lifecycle of
the plant with all its physical changes,” says
Knapp. Every entry, which includes every
change, is immediately visible to all those
involved, without manual transfer or interfaces.
“A digital twin that is only a static
snapshot would do as little justice to the
value of the data as keeping it in disciplineoriented
containers,” he points out.
Half the reality – twice the work
Still widespread are chains of special tools
that can give a discipline-specific representation
e. g. only P&IDs with containers,
pipes and flanges or only the electrical
model including wiring. A tank with a sensor
and pump, but without an associated
loop and without the knowledge from and
up to what value the pump should operate,
only shows half the reality. And it takes
twice as much work to plan it as it does to
operate it, because in a tool chain, each
compartment system must be fed individually,
even with the inevitable changes. Interrelationships
are not recognisable, not to
mention consistent data navigation. The
maintenance staff must later gather the relevant
information from several sources.
Tool chains are also the reason why the inevitable
plant changes, for example due to
repairs, often do not reach the documentation
at all or only inadequately. Consistent
updating in various special tools is very
time-consuming and error-prone. If only
paper documentation or dead PDFs are
available, and these are already overloaded
with the red entries of previous changes,
the current status can be hard to discern.
This is particularly fatal in the event of an
incident, but also when a conversion is
pending or a new operating licence is due
after a shutdown phase.
From the FEED phase and P&IDs to detail engineering and automation, the digital twin
grows together in EB’s central data model
Pictures: Aucotec
Unity in the data model
For this reason Aucotec has developed a cooperation
platform that with its versatile
data model combines all core engineering
disciplines in one SSoT. Each item exists
only once in the Engineering Base (EB)
library and each discipline can specify it
from its perspective at any time. At the same
8 cpp 02-2021

Reinhard Knapp is Head of Global Strategies at Aucotec
A digital twin that is only a static snapshot does not do justice to the
value of the data
time, everyone sees what the other
disciplines have already worked on and
builds directly on it. Whether it’s the drive,
flow stream or wiring: the platform automatically
shows all the consequences of
changes because it knows the interrelationships.
“In this way, the digital twin with all
its aspects from the FEED phase to commissioning
grows consistently into a single unit
that continuously reveals the enormous
treasure trove of plant knowledge,” explains
Knapp.
Twin instead of older sister
This unity in EB’s data model also makes it
considerably easier to keep the as-built
documentation alive and up-to-date as a
digital twin. Technicians can use EB Mobile
View, a web service-based app, to pull all
the relevant data for each area of the plant
onto a mobile device in an instant instead of
having to painstakingly search for it. In addition,
the app allows change information
to be entered directly on the objects via redlining
and fed back to engineering, “so that
the twin does not become the older sister of
the plant with only a sorry resemblance, but
earns its name,” emphasises the Aucotec
strategist. If OPC UA-capable devices are installed
in the plant, they can even communicate
directly with EB and thus report their
existence or modification to the digital
twin. This means that the service is always
up to date. And a team does not have to scan
the actual state of the plant and then add it
before any conversions.
To ensure that this procedure is also open to
operators of older plants with corresponding
documentation, Aucotec has developed a
migration concept for EB that checks existing
data during its transfer, in some cases
supplements or merges it and thus raises it
to a digital twin level. An Aucotec customer
once put the value of the existing data for a
chemical plant at around five million euros.
Preserving it was an important reason to
switch to EB.
From data model to business model
But it is not only unnecessary to accept the
loss of value of documentation, but also not
to use the added value that up-to-date,
easily accessible and usable existing data
offers. With the data model in EB, manufacturers
can become full-service providers, for
example. Who knows a product better than
its producer? And where, if not in the system
with which a plant was developed, is
the data on this most precise and comprehensive?
A compressor manufacturer, for
example, no longer sells the system, but the
compressed air. It operates the sub-system
itself; its know-how, manifested in the data
model, is a guarantee for quality and reliability.
The burden on the overall plant operator
is significantly relieved and it is more
likely to continue to rely on this supplier in
the future.
Aucotec’s developers have also equipped EB
with web service technology that allows the
system to be supplemented with browserbased
front-end products for individual
special tasks, i. e. apps that open up possibilities
for further business models. This is
where the SSoT, the central data model,
comes into play again, making the objects
directly usable, including for analyses and AI
use. In this way, maintenance processes can
be supported via the app or actual conditions
in the plant can be recorded and
optimisation solutions for the operator can
be developed from this. Monitoring for
specific target groups is also possible or the
support of predictive maintenance. EB is
able to do this because the system also
manages abstract objects, so-called inter -
pretations, which do not even appear in
conventional documents. For example,
measurement types for the functional
description of a sensor. This enables a predictive
maintenance system to automatically
interpret condition data from the running
plant correctly. With tens of thousands of
signals, this is an enormous time-saver.
“As long as the digital twin remains a living
image, growing with ‚its‘ plant, a lot of
added value can be derived from it, instead
of the value being exhausted in the documentation,”
concludes Reinhard Knapp.
www.prozesstechnik-online.de
Online search: Aucotec
AUTHOR:
JOHANNA KIESEL
Public Relations Manager,
Aucotec
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PLANTS, APPARATUS, COMPONENTS
Pictures: EagleBurgmann
Dr. Andreas Raps is the Chairman of the Management Board of EagleBurgmann
Developing digital products and services with agile working methods
Maintenance concepts
from the digital laboratory
At the Achema Pulse, EagleBurgmann presented itself with several topics. We spoke
to the CEO of EagleBurgmann, Dr. Andreas Raps, about the development of digital
products using agile methods, the requirements for mechanical seals and the brand
new robust mechanical seal CobaDGS for the high-pressure range up to 160 bar.
Dr. Raps, is your company suffering greatly from the Corona
pandemic?
Dr. Andreas Raps: I would say that we have come through very well
so far. However, due to the economic crisis, large chemical companies
had to reduce plant operations or even shut down entire plants.
In addition, our service personnel could not visit the companies
due to the corona-related access restrictions. Of course, all this had
a negative impact on our service business and ultimately led to a
loss of sales. There are currently also some challenges in the area of
supply chain.
An important topic not only in the pandemic is digitisation. What
goals does your company pursue in this area?
Dr. Raps: In our comparatively conservative industry, we want to be
the first mover in digitisation. The aim is to offer customers a digital
customer experience. That is why we are currently in the process
of consistently establishing digital sales channels and business models
that complement our traditional portfolio.
And how does EagleBurgmann intend to achieve this ambitious
goal?
Dr. Raps: For this purpose, we founded the EB Digital Lab in 2019.
This is a very young and innovative organisational unit in the company
that develops digital products and services and makes them
marketable. In doing so, we rely on agile working methods.
What does that mean?
Dr. Raps: The colleagues work detached from everyday routines and
constraints. They have their own generously furnished area that offers
space for interaction and discussion. Among other things, working
methods that have proven themselves in software development
are used. I am thinking, for example, of agile project management
10 cpp 02-2021

according to the Scrum method. It is based on a self-organised and
interdisciplinary team in order to cover as many competencies as
possible.
Sounds a bit like a start-up feeling.
Dr. Raps: Right. However, the Digital Lab is not located in a chic loft
in Berlin, but at our headquarters in Wolfratshausen. This ensures
traction and proximity to the core business. This is not about detached
ideas, but about digital products and services that are developed
from the customer‘s perspective.
How many employees work in the Digital Lab?
Dr. Raps: Currently 20 people. In addition, there are so-called split
heads. These are people who are actually based in a different organisational
area and work project-related or only for a certain period
of time in the Digital Lab.
„Pain points in the Digital Lab language
stand for the very critical aspects. We want
to know where our users are most pressed.“
I suppose these will be very young people?
Dr. Raps: Compared to the rest of the workforce, the employees in
the Digital Lab are significantly younger. Ultimately, it depends on
the right mix because experience is also needed.
Which projects are currently being worked on in the Digital Lab?
Dr. Raps: Digital maintenance concepts, i.e. condition monitoring
and predictive maintenance, as well as an innovative customer portal.
We not only want to use the latter as a digital sales channel, but
also to provide our customers with a wide range of information
about the seals they use. This also includes data that is recorded directly
in the seal via condition monitoring on site at the user‘s site.
Did I understand this correctly: You integrate operating and status
data recorded at the customer into the customer portal?
Dr. Raps: In principle, yes. You have to think of condition monitoring
and predictive maintenance as a precursor to our customer
portal. With condition monitoring, we continuously record the data
of a seal that is in use by the customer. This data will be processed.
The evaluation provides us with an overview of the performance of
the product used, from which the condition of the seal can be derived.
If, for example, a product reaches a critical condition or the
end of its service life, the ordering process of a spare part or product
can be initiated directly via the customer portal.
The central intersection for the entire process is therefore your
customer portal. What will be possible here?
Dr. Raps: In the future, we want to give the user a complete overview
of all EagleBurgmann products used. In the customer portal,
they can manage their products, check performance, automate orders
or place service orders.
The EB Digital Lab in Wolfratshausen has a start-up feeling
The prerequisite for this scenario is the recording of the operating
and condition data of the seals. What paths are you treading here?
Dr. Raps: Here we rely on sensors that are integrated into the seal.
To achieve this, however, some constructive challenges must be
overcome. On the one hand, the sensors must be so small that they
fit into the seal. On the other hand, the seal design must be adapted
to such an application. And last but not least, the entire unit of seal
and sensor must withstand aggressive media, high temperatures, vibrations,
etc.
At what stage of development is the whole thing?
Dr. Raps: At the moment, we in the Digital Lab are dealing with the
question of how we can obtain the necessary data. Ultimately, it‘s
about finding the right sensor or sensors that provide us with the
appropriate data in the demanding environment of a mechanical
seal. In addition to test runs on our test bench, we are already testing
in the first pilot applications. I am optimistic that more pilot
applications will be added in the course of 2021. We expect the
right series maturity in the next three years.
EAGLEBURGMANN:
FACTS AND FIGURES
EagleBurgmann‘s product range for the chemical industry
ranges from mechanical seals for pumps, agitators
and compressors to magnetic couplings, gaskets and
carbon floating ring seals. In addition, there are sealing
supply systems and expansion joints. The medium-sized
company also has various sealing series in its portfolio
for the pharmaceutical industry. These include, for
example, the Agitator seal of the MR-D series or the
dead- and gap-free SRG1 pump seals with electropolished
surfaces.
EagleBurgmann employs around 5,700 people worldwide.
In Germany, about 1,600 people work for the
company; most of them at the headquarters in Wolfrats -
hausen. Sales in 2020 amounted to approximately 800
million euros. In view of the economic impact of the
corona pandemic, only a slight increase in sales is expected
for 2021.
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PLANTS, APPARATUS, COMPONENTS
Can Cobaseal and CobaDGS seals be combined?
Dr. Raps: Yes. The combination of the two seals always makes sense
when there are increased pressure requirements and a significantly
increased sealing performance is required. However, both variants
have different functions in one application. In combination, the CobaDGS
acts as the main seal, while the Cobaseal is then suitable as a
bearing seal.
Can you specifically name an application in which the CobaDGSsealing
system can be used?
Dr. Raps: A good example is Liquified Natural Gas. The use of this
seal significantly reduces the escape of methane gas. If all compressors
in LNG pipelines in Germany were equipped with the
CobaDGS sealing system, emissions in the order of 770,000 households
could be saved. Another application example is the propylene
oxide compressors used in the chemical industry.
The CobaDGS turbo compressor seal is based on the Cobaseal seals and is
a gas-lubricated mechanical seal in the coaxial version
Surely you also work together with other partners during development.
Dr. Raps: Yes. Internally, the Digital Lab cooperates very closely with
the Research & Development department of EagleBurgmann, externally
also with research institutions such as institutes and universities.
But the most important thing is that we are in close contact
with our customers. We need to understand what solutions they expect
from us and where their so-called pain points are so that we
can address them.
What points please?
Dr. Raps: Pain points. In the digital lab language, they stand for the
very critical aspects. We want to know what the customers’ biggest
challenges are and how we can help them to make life a little easier.
Did your new CobaDGS turbocompressor seal also emerge from
such a pain point?
Dr. Raps: In a way. Compressor manufacturers are confronted with
ever higher pressures in applications. These can no longer be mastered
with conventional seals. A solution had to be found.
What type of seal is this?
Dr. Raps: The CobaDGS turbocompressor seal is based on the Cobaseal
series. This is a gas-lubricated mechanical seal in the coaxial
version. Coba stands for Coaxial Barrier Seal. The seal consists of a
rotating and a static ring. The rings form the gas-lubricated sealing
gap, usually 0.003 to 0.005 mm. A sealing gas,usually nitrogen, is
fed through the static ring into the sealing gap and then forms a
barrier layer. The CobaDGS works analogously, but is characterised
by changed materials and an optimised design. For example, components
were reinforced, the geometry of the rings improved and
the gas-transporting grooves redesigned. As a result, much higher
pressures are possible. We are talking about over 160 bar versus
10 bar before. Silicon carbide is used for the rotating ring. An important
criterion in the development was that as little nitrogen as
possible is consumed or escapes into the process.
You describe the CobaDGS as a zero-emission solution. Can you
please explain that?
Dr. Raps: In the mechanical seal, the sealing gas in the sealing gap
prevents the leakage of process gas. In the case of CobaDGS, the reverse
even occurs. Instead of the process gas or sealing gas escaping
into the environment, sealing gas enters the process in minimal doses.
That‘s why we call this seal a zero-emission solution. Such a solution
is particularly useful for the transport of environmentally
harmful gases.
Are there any other advantages?
Dr. Raps: In addition to zero emissions, the issue of clean nitrogen
in the sealing gap plays a particularly important role. The fact that
there is no contamination in the sealing gap increases the service
life of the seal and makes it less susceptible to interference.
When will you launch the product on the market?
Dr. Raps: We officially presented the CobaDGS at Achema Pulse. It is
already in use by some customers and the response to the seal is extremely
positive. Above all, the robustness was convincing in the
test runs. We are here at the right time with the right product and
we are very pleased that we as EagleBurgmann can also make our
contribution to reducing CO 2 on the way to carbon neutrality.
www.prozesstechnik-online.de
Online search: EagleBurgmann
THE INTERVIEW WAS CONDUCTED BY:
LUKAS LEHMANN
Editor-in-Chief
12 cpp 02-2021

cpp
PRODUCTS
Electronic flow switch with display
Wika’s FSD-4 electronic flow
switch offers full flexibility in
monitoring and controlling
flow based on the velocities of
liquid media. The switch points
of the model FSD-4 can be
freely configured very easily via
the 3-button operation directly
on the instrument or optionally
via IO-Link.
The FSD-4 can output both absolute
values in various units
and relative flow values and display
them on the digital indicator.
While a flow rate value is
assigned to the first switch
point, it can be defined at the
second switching output
whether the switch should
switch at a second flow value or
at a specific temperature value
for the medium.
In addition, the FSD-4 can be
fitted with an analogue output
for flow or temperature values.
The wide range of parameterisation
options makes the model
FSD-4, with only three basic
variants, an economical flow
switch for a wide variety of applications
and installation situations.
www.cpp-net.com
Online search: Wika
Every child
is one of a kind and unique. Each child needs
individual support according to their needs.
Please help us by donating. Thank you!
Picture: Wika
Tel.: 0800/50 30 300 (free of charge)
IBAN DE22 4306 0967 2222 2000 00
BIC GENO DE M1 GLS
www.sos-kinderdoerfer.de
2016/1
Valve inspection as digital service
SOSKD_Anzeige_Fingerabdruck_E_92x133_4c_RZ.indd 1 29.03.17 09:12
SEAL TECHNOLOGY
PREMIUM QUALITY SINCE 1867
Before industrial valves are used
they must be thoroughly tested.
The various test procedures include
destructive and non-de -
structive testing procedures.
AS-Schneider has the necessary
equipment and qualified personnel
to carry out all test procedures
in-house in accordance
with the standards. Even pres -
sures above 1000 bar and various
process liquids and gases
can be used without any problems.
Valves and manifolds can
be inspected before shipment
and even during assembly,
Picture: AS-Schneider
which is great for customers,
because they can save capacities.
The company also offers the independent
inspection in digital
form: customers and external
auditors have the ability to attend
the tests and review the results
online via Microsoft Teams,
Gotomeeting, Skype or other
platforms. Upon request, AS-
Schneider will also take photos
and create video recordings to
document all processes and results
in a verifiable manner. AS-
Schneider discusses the exact
scope of the inspection individually
with the customer in advance
so that he receives exactly
the information he needs.
All test results are transparent
and traceable to meet even the
highest quality assurance stand -
ards.
www.cpp-net.com
Online search: AS-Schneider
COG MAKES ITS MARK:
The world‘s
largest O-ring warehouse.
Precision O-rings in 45,000 variants ready for delivery.
www.COG.de
cpp 02-2021 13

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PRODUCTS
Laboratory homogenisers
Laboratory mixers with IoT compliance
Industrial gear unit for mixers
Picture: GEA
GEA has recently extended its
range of homogenisers with the
GEA Ariete Homogenizer 3160
and the GEA Triplex Panda Lab
Homogenizer for the dairy,
beverage, food, pharmaceutical,
chemical and cosmetics industries.
The Ariete Homogenizer
3160 completes the series for
medium and large sized process
lines and closes a gap in this
series: it features up to
1500 bar, with significantly increased
flow rate capacity between
200 and 1200 bar. Like all
Ariete homogenisers, it can be
customised with more than 300
options for easy integration into
any sanitary or aseptic process
line. With their wide range of
available materials, low running
speed and linear plunger velocity,
the Ariete models perform at
their best even with abrasive
and viscous products. Adding
options from GEA – such as the
patented homogenising valve
Nano Valve or the Oil Pure System
for measuring condensed
water and oil – lowers power,
water and lubrication oil consumption,
delivering further
production cost savings.
www.cpp-net.com
Online search: GEA
The Hauschild Speedmixer
Smart DAC Series combines
craftsmanship with smart features
like real-time temperature
control, vacuum-robotic, sensor
integration, variable counter rotation,
IoT compliance, QR-code
reader, remote control, and
automatic pot cooling system.
Furthermore, the manufacturer
increased the capacity of its
Speedmixer, offering more
choices for specific applications.
The Smart DAC series allows
mixing from 250 g up to 1,5
and 2 kg. All Smart DAC will be
available with mixing volumes
from 310 ml up to 2.8 l. Up to
20 % more powerful versus the
standard LR version, the Smart
DAC features variable counter
rotation, increased mixing
weight and volume and allows
up to 30 minutes of mixing
time. The improved structure
also allows mixing at very low
speeds without the risk of high
vibrations. Features like the control
of the jar’s temperature in
combination with an automatic
cooling programme or the
adaption of specific volume
requirements make the series
capable of mixing components
that were previously considered
immiscible. A robotic version is
available for highly automated
laboratories and small batch
production.
www.cpp-net.com
Online search: Hauschild
Picture: Hauschild
Maxxdrive industrial gear units
with the Safomi-IEC adapter are
specifically developed for
mixers to improve operational
reliability and reduce the need
for the replacement of wearing
parts. In combination with the
Nordac Flex SK 200E frequency
inverter for the power range up
to 22 kW, a flexible unit with
low maintenance is offered.
Maxxdrive industrial gear units,
an integral part of the Nord
portfolio, offer high output
torques from 15 to 282 kNm
and ensure smooth operation
even under demanding conditions.
The compact design enables
operation under ultimate
external loads. For agitation applications,
a combination with
the Safomi (Sealless Adapter For
Mixers) IEC adapter is recommended,
in which an oil expansion
chamber is directly integrated.
Safomi is available for
Maxxdrive parallel gear units in
the sizes 7 to 11 and covers
maximum output torques from
25 to 75 kNm.The adapter impresses
with its compact and
simple design and integrated oil
equalisation volume, which
means that there is no need for
oil tanks and hoses or the shaft
sealing ring between the gear
unit and the IEC cylinder, which
is prone to leakage and wear.
Using the Safomi-IEC adapter
instead of the standard IEC
adapter on the agitator drive increases
operational reliability
and lowers maintenance costs.
www.cpp-net.com
Online search: Nord
Picture: Nord Drivesystems
Digital total pressure vacuum gauges
Pfeiffer Vacuum has added additional options to the
Digiline range of digital total vacuum pressure gauges
to keep abreast of changes in market requirements. This
means that Digiline is now also available with the industrial
Ethernet interfaces Profinet and Ethercat. In
comparison to conventional fieldbuses, these offer the
advantage of very fast data rates and a significantly
higher number of participants, which makes them an
important factor in implementing Industry 4.0.
In addition, the capacitance gauge types, CCT, which
were previously supplied only with an analogue output,
are now also available in the Digiline series. These highprecision
measurement instruments can be used independently
of the type of gas, and find applications in
the precise control of coating processes, for example, as
well as in freeze drying and in calibration laboratories.
The tried-and-tested ceramic technology in the CCTs
has the advantages of good chemical resistance and a
very low zero point deviation. The CCTs are available as
a temperature-compensated version and a 45 °C heated
version.
www.cpp-net.com
Online search: Pfeiffer Vacuum
14 cpp 02-2021

Rugged, smart pyrometers
Small and compact R&D mixer
Fluke Process Instruments expands its Thermalert 4.0 pyrometer
series, adding intrinsically safe models and Hart
protocol as an additional interface option. The rugged, intelligent
and compact infrared temperature sensors in an
IP 65-rated stainless-steel housing are easy to connect via
2-wire installation. The series provides a future-proof, Industry-4.0-ready
solution for non-contact, automatic, realtime
temperature monitoring. Various spectral models
cover a large measured temperature range from -40 to
2300 °C. The intrinsically safe models rated Ex ib now add
infrared thermometer options for use in hazardous environments
with potentially explosive gas or dust atmospheres
(zones 1 and 21). Accordingly, all models are optionally
available with an Atex/IECEx/CCC-IS certification.
www.cpp-net.com
Online search: Fluke
Picture: Fluke
To discover new ways to create
renewable energy sources, a
company in the chemical sector
approached Dinnissen to come
up with a solution to test their
ideas on renewable energy. Their
very specific chemical process
requires that a batch is mixed
continuously for 24 hours with
exactly 1 g of additives, while
temperature and humidity are
controlled. For this project, Dinnissen’s
engineers developed a
very compact Pegasus R&D
mixer in which all raw materials
can be kept in motion for long
periods of time and can be
tested in small batches. Using
the proven Pegasus mixing technology
as a basis, Dinnissen designed
just the right system for
this testing procedure. The first
results of these tests show enormous
potential. This R&D mixing
installation has the potential
Picture: Dinnissen
to grow into large-scale chemical
processing lines that will have a
positive impact on the global
production of renewable energy.
Further features of this mixer are
a compact and mobile design,
precise mixing technology and a
precise temperature control of
both mixer and products.
www.cpp-net.com
Online search: Dinnissen
cpp 02-2021 15

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PRODUCTS
Flame detectors with enhanced performance
Data management simplified
Spectrex announced the launch
of its next-generation Sharpeye
40/40D and C series flame detectors
that provide optimum
protection against hydrocarbonbased
fuel and gas fires, hydroxyl
and hydrogen fires, and
metal and inorganic fires. These
detectors provide early warning
of fires at long distances in record
time and with high immu -
nity to false alarms.
PCB terminal blocks for Profinet
Picture: Spectrex
Featuring Quadsense technology
with enhanced performance, the
Sharpeye 40/40D offers long
distance detection of hydrocarbon
fires at up to 90 m in under
50 ms. The new series can be
used in a variety of industries
and applications, including oil
& gas installations and pipelines,
petrochemical and chemical
plants, storage tank farms,
power generation facilities, fuel
and gas processing and storage
facilities. The Sharpeye 40/40D
and C are easy to install and
maintain and come with universal
wiring and multiple output
options for maximum flexibility
and compatibility.
www.cpp-net.com
Online search: Spectrex
Emerson’s Plantweb Optics Data
Lake, an enterprise-level data
management software solution
helps manufacturers reduce data
complexity so that they can
fully leverage operations data
across a production site or from
multiple sites to improve profitability
enterprise-wide. This advanced
data management solu -
tion securely identifies, collects
and contextualises disparate
data, at scale, either on-premises
or using cloud technology.
Today, this valuable manufacturing
data is often in different
formats and siloed across a
plant, posing significant impediments
to a company’s digital
transformation initiatives. By
effectively unifying this data,
companies can establish a sound
data foundation that can be
leveraged by various digital so -
lutions.
For example, Emerson’s data
lake software, which is integrated
into the Plantweb Optics
platform, can seamlessly work
with advanced analytics appli-
cations powered by machine
learning and artificial intelligence
– or connect with other
providers’ analytics and dashboard
toolkits – to drive performance
improvement and increase
revenue.
Emerson’s Plantweb Optics Data
Lake runs on various cloudcomputing
platforms, enabling
companies to implement a wide
range of use cases from analytics
applications that make use of
machine learning to KPIs and
dashboards, digital twins and
other applications for improving
reliability and sustainability. Effectively
bridging the gap between
OT and IT domains, this
software seamlessly consolidates
manufacturing data from a va -
riety of systems, protocols and
data architectures – even legacy
systems – across a plant and
multiple facilities by moving it
into the cloud and ensuring that
it is ready for use.
www.cpp-net.com
Online search: Emerson
Phoenix Contact is extending its portfolio with PCB terminal
blocks for Profinet-compliant data transmission.
Each of the 4-position PCB terminal blocks have been designed
specially for the connection of twisted pair cables
with cross-sections of 0.14 to 4 mm². The conductors are
connected via spring or screw connection technology.
Printed or colour-coded connection points allow easy assignment
of the conductors. With horizontal, vertical, and
angled conductor connection directions, the PCB terminal
blocks are suitable for a variety of device designs.
All versions satisfy the requirements of the Profinet directive,
Rev. 05/2017, and are therefore suitable for secure
CAT5 data transmission in accordance with EN 50173 and
ISO/IEC 11801. Some versions are also certified for use in
potentially explosive areas in accordance with IEC
60079-7.
www.cpp-net.com
Online search: Phoenix Contact
Picture: Phoenix Contact
Catalysts for isopropyl alcohol producers
BASF’s new range of catalysts includes
catalysts to produce isopropyl
alcohol (IPA) more efficiently,
a crucial ingredient in
hand sanitisers. BASF’s high performance
oxo alcohol catalyst
Ni 3354 E combines high activity
with high selectivity. The
catalyst has been tested and
qualified to produce IPA
through hydrogenation of ace -
tone. Ni 3354 E allows IPA producers
to operate at high
Picture: Emerson
throughput rates and temperatures
without a drop in selectivity
thus increasing productivity.
BASF also qualified chromiumfree
copper extrudate catalysts
such as Cu 0560 E to further
broaden its hydrogenation catalyst
offering, enabling IPA producers
to select the most suitable
product solution for process
requirements.
www.cpp-net.com
Online search: BASF
16 cpp 02-2021

Explosion isolation valve
Low-maintenance seat valves
Rico has launched the next
generation of the proven Ventex
explosion protection valve. The
valve now features a flow
velocity of at least 30 m/s in all
nominal sizes, thus ensuring an
even higher level of process reliability
and flexibility. The valve
can be placed directly upstream
Level measurement in liquids
Picture: Rico
or downstream of pipe bends in
the pipeline; double pipe bends
or combinations of pipe bends
in different directions are also
no problem. For processes involving
metallic dusts, the
Ventex is also certified in nominal
size DN 400. Moreover, the
new generation also achieves up
to 20 % better values in terms of
pressure drop. In addition, Rico
has responded to customer suggestions:
the DN 250 nominal
size, which previously was not
offered yet, has been added to
the Ventex portfolio and is now
available as standard.
www.cpp-net.com
Online search: Rico
The LCR radar sensor from Pepperl+Fuchs is suitable for continuous,
non-contact level and flow measurement especially in
storage tanks, containers, open basins and pump lift stations.
The hermetically sealed housing allows the use under rough
process conditions. Commissioning is possible via Hart, wireless
with the P+F Level App and Bluetooth.
The signal curve can be displayed with the Level app on any
Bluetooth-enabled smartphone or tablet (iOS, Android). Due to
the innovative chip design and the compact design, the device
fits perfectly in applications with limited space.
www.cpp-net.com
Online search: Pepperl+Fuchs
Low-maintenance on/off and
control valves are essential in
the food and process industry.
They control the flow of gases,
steam or liquids, for example in
auxiliary processes such as CIP,
reverse osmosis or temperature
control. Bürkert now offers a
wide range of electric motor
and pneumatically operated on/
off and control valves specially
suited for these applications,
with extended pressure and
temperature ranges. Thanks to
special sealing materials, the
valves with stainless steel valve
bodies work without any problems
with media up to 25 bar
gauge pressure and temperatures
between -40 and +230 °C.
The rated service life at 200 °C
is more than one million
switching cycles.
Sealing materials and lubricants
suitable for foodstuff, fuel gases
or oxygen allow the valves to be
Picture: Bürkert
used with other media, for
example for cleaning and flushing
purposes, for heat carriers
or saturated steam at 20 bar and
215 °C. So they can be used to
switch and control all common
gases and liquids for heating
and cooling purposes in the
specific process as well as in
traditional CIP processes. It is
also possible to use them with
heat transfer oils.
The valves are available in different
versions with straightseat
on/off and control valves as
well as with angle seat on/off
and control variants. The stainless
steel bodies offer flange,
weld, thread or clamp connections
in DNs from DN 10 to 100
or NPS 3/8 to 4". Design details
take into account the special
requirements of the areas of application.
www.cpp-net.com
Online search: Bürkert
MY DRIVE IS FROM NORD!
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Customisable modular system
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Getriebebau NORD GmbH & Co. KG | Fon +49 4532 289-0 | info@nord.com | www.nord.com
cpp 02-2021 17

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PROCESS ENGINEERING
Use of high-performance adsorbents pays off
Dry compressed air
for sulfonation plants
It is absolutely crucial to supply very dry air to sulfonation processes. Dew points of
up to -80 °C are normally achieved in such plants. The high dew point in air results in
quality problems in the sulfonation process and promotes corrosion of the process
equipment due to formation of sulfuric acid. With Sorbead R/WS adsorbents users
can save operating costs in air dryers designed for these desiccants and reduce the
total capital costs of a new plant by up to 15 %.
Sulfonation and sulfation are major industrial
chemical processes used to make a diverse
range of products, including dyes and
colour intensifiers, pigments, pesticides and
organic intermediates. Although there are
different kinds of sulfonation processes
available which differ primarily in the sulfonating
agent used such as oleum, chlorosulfonic
acid or SO 3 , SO 3 -based sulfonation
is the dominant process for modern plants.
The SO 3 /air process has been shown versatile,
able to produce abroad range of high
quality products and cost-efficient. Among
View of one of BASF’s sulfonation plants
such processes sulfur burning systems
where sulfur is used as SO 3 source gained
substantial importance on the market due to
distinct safety advantages and wide solid
sulfur availability. The process flow scheme
normally involves solid sulfur to SO 2 oxidation,
SO 2 to SO 3 conversion, sulfonation
of organics and effluent gas clean-up systems.
As mentioned before very dry air has
to be supplied to the sulfonation process.
Dew points of at least -60 °C and often up
to -80 °C are normally achieved in such
plants.
Pictures: BASF
Air dryer in a sulfonation plant
The typical air supply system in a sulfonation
process uses ambient air which is first
compressed to 15 to18 psig (0.5 to 1.2 bar)
pressures and cooled in a chiller to ~5 to
7 °C (45 °F). Air precooling is necessary to
reach very low moisture content in the
compressed air at low pressures. The chilled
air is dried in two parallel desiccant-adsorbers
to a dew point of -60 to -80 °C
(-112 °F). Another important aspect of dry
air supply systems in a sulfonation plant is a
necessity to exclude dew point peaks and air
flow variations. Pulsing will immediately affect
the SO 3 /organics mole ratio (i.e. SO 3
mole ratio) which is the major parameter in
a production process. A stable SO 3 mole
ratio ensures designed product yield, optimal
sulfonation efficiency and always needs
to be sustained when the plant is running.
This is also the reason why deep bed cooling
with ambient air is employed on regenerating
beds. Reducing the bed temperature
to an acceptable level prior to bringing the
regenerated air dryer back on-line is important
to avoid dew point spikes.
Sulfonation plants that use SO 3 from sulfur
burners do not require external heat
sources to heat air for beds regeneration.
Hot air is supplied from SO 3 coolers where
SO 3 produced in SO 2 converters cooled to
almost ambient temperature to be further
processed. The abundance of heat energy
generated upon sulfur and SO 2 oxidation is
an important advantage of the sulfur burning
sulfonation process. Other process variations
where oleum-derived SO 3 or liquid
SO 3 is used as sulfonation agent require ex-
18 cpp 02-2021

ternal heating to produce high temperature
air for regeneration.
High-performance adsorbents
Adsorbent used in compressed air dryers installed
in sulfonation plants plays an important
role in ensuring cost-efficient and
robust operation of the air supply system
which also affects efficiency of the production
process. Conventional adsorbents for
compressed air dryers include activated
alumina, silica gel and molecular sieves.
Since an air supply system is offered as part
of the sulfonation plant, process licensors
are normally responsible for selecting and
qualifying certain adsorbent types for their
plant dryers. BASF offers high-performance
Sorbead R and Sorbead WS adsorbents
which are uniquely suited for demanding
conditions in sulfonation plants.
The adsorbent Sorbead WS is acid-resistant and
mechanically stable
Stability towards acidic components
SO 2 and SO 3 (i.e. SO x ) are highly acidic and
highly reactive gases. Even at ppm concentrations
SO x reacts with a variety of inorganic
oxides to produce sulfates or sulfites.
Aluminum oxide is susceptible to such reactions
which are strongly promoted by
moisture loaded on the adsorbent bed during
the air drying process. The formation of
surface sulfates/sulfites contributes to adsorbent
deactivation and degradation and might
result in more frequent adsorbent replacement
or operational issues in a plant. This effect
could also be pronounced for silica gel
materials with high aluminum content.
While aluminum is added to improve hydrothermal
stability of certain silica gels, its
excessive amounts negatively impact material
resistance towards acidic components. Sorbead
is an acid-stable material maintaining
its properties and activity in a presence of
high levels of acidic impurities in air. It has
been designed to optimise its dehydration
efficiency and mechanical stability yielding
very stable and performing adsorbent.
Robustness and mechanical stability
As the adsorbent is subject to multiple adsorption/regeneration
cycles – it ages and
has the tendency to lose efficiency but also
mechanical stability. Low-grade silica gel
materials often exhibit higher attrition and
poor mechanical integrity when subject to
multiple adsorption/desorption cycles. This
could lead to downstream filters plugging
with adsorbent fines, higher pressure drop
across the adsorbent layer and non-uniform
temperature profiles throughout the bed.
Sorbead is designed to maintain exceptional
mechanical integrity under aggressive operating
conditions and was shown to be
highly resistant to hydrothermal aging.
Sorbead WS is a liquid water stable adsorbent
which is often used as a protective
layer on top of Sorbead R to ensure the
highest possible efficiency of the dehydrogenation
process. The presence of liquid
water in desiccant beds negatively impacts
the performance but also substantially contributes
to hydrothermal aging of adsorbents.
Significant amounts of liquid water
in a bed could result in a complete shutdown
of dryers.
Performance and energy efficiency
Desiccants are characterised by dynamic
moisture uptakes. Sorbead R/WS are high
capacity desiccants that overperform most
of the commercially available market adsorbents.
Higher dynamic moisture uptakes
allow to utilise adsorbent volume more efficiently
but also ensure less frequent regeneration
limiting adsorbent aging and wearing.
It is important to emphasise that Sorbead
WS is not only water-stable but also
exhibits similar dynamic water uptakes as
Sorbead. It is high performance and high
reliability that make Sorbead adsorbents the
perfect choice for compressed air dryers.
Because of high adsorption dynamic water
uptakes and the energetically favorable regeneration
conditions to achieve low pres -
sure dew points Sorbead is the first choice
for low-energy consumption heat-regenerated
adsorption dryers. Sorbead adsorbents
need lower regeneration temperatures than
most conventional adsorbents but are still
able to deliver very low moisture dewpoints
(down to -80 °C) under conditions normally
used in sulfonation plant dryers. While
in certain designs of sulfonation processes
there is an abundance of heat energy available
for regeneration of dryers, the efficiency
of the bed cooling is mostly defined by
the highest temperature achieved on regeneration
of the adsorbent – regeneration
temperature implies much faster and more
economic cooling. Higher dynamic capacity
allows sulfonation plant users to extend the
cycle length and, thus, limit the number of
regeneration cycles which contribute to adsorbent
deactivation/degradation.
www.cpp-net.com
Online search: BASF
AUTHORS:
ARTEM VITYUK
Global Market Manager for Alumina, Catalyst
Intermediates and Compressed Air,
BASF
ARNO GÖRTZ
AirConsultant, Consultant for Compressed Air
drying,
BASF
cpp 02-2021 19

cpp
PROCESS ENGINEERING
Possibilities and limitations of fixation of mix components to agglomerates
All depends upon the mixer
Agglomeration processes can considerably improve the product properties provided
that the firmness of the product is sustainable. That is why in the field of build-up agglomeration,
the selected machinery will have to ensure highest mixing quality taking
into consideration the individual product and application. Lödige Process Technology
offers mixing systems that guarantee the permanent stability of agglomerates.
In many industries and applications, powdered
or fine-grained substances are hardly
suitable as intermediates or end products.
They are prone to create dust, to stick or to
segregate. Agglomeration is therefore a process
alternative which consists in bringing
together disperse substances to build agglomerates.
These show – on the contrary to
the disperse original substances – nearly the
same specific surfaces. At the same time, they
have the advantage in offering much improved
product properties like better flowability,
simpler dosability, optimised transportability
as well as a dust-free handling. In
terms of ecology and user safety, the agglomerated
product is superior to the initial
particles: less dust means that the maximum
allowable concentration levels at workplaces
in production areas are easier to meet in a
reliable manner.
Definition of agglomeration
This process can be used for a wide variety
of applications. Nevertheless, or perhaps just
because of that, there are always terminological
discrepancies when dealing with
the basic operation of agglomeration. Agglomeration
is often confused with the comprehensive
term granulation. However,
granulation only refers to the form of the
end product (granum, lat. grain) but does
not indicate how the granulate has been
achieved.
This is different in the case of agglomeration:
agglomeration consists in bringing together
disperse substances to form bigger
particles. This implies bonding mechanisms
between the particles whereby one can differentiate
two sorts of bonding: direct adherence
mechanisms without product bridging
(van der Waals and electrostatic forces) and
indirect adherence mechanisms with product
bridging (viscous and hardening binding
agents, liquid bridges, cristal bridges, etc).
These bonding mechanisms can be globally
generated in three different manners: by introducing
heat (fusion granulation), by
mechanical compaction (press granulation)
or by build-up granulation.
Ploughshare mixer working according to the mechanically generated fluid bed principle introduced to
mixing technology by Lödige
Pictures: Lödige
Build-up granulation process
Build-up granulation is an interaction between
adherence and separating forces
(mechanisms counteracting the sticking together
of the particles) generated by a mutual
interaction of particles, agglomeration
seeds and agglomerates. The selection principle
will apply in this case i. e. the weak
bondings are broken and only the stronger
ones remain.
The achieved firmness depends therefore on
the strength of the bonding forces, the intensity
of the separating forces and time
subjected to these forces. The quantity of
binding agent generates the product bridging
between the particles. By increasing the
liquid quantity in the pore space between
20 cpp 02-2021

The ringlayer mixer Corimix meets the highest requirements in
terms of profitability and availability.
Universal mixer KUM with vertical, cylindrical mixing vessel
the particles, one can go through different
states of saturation leading to different
bonding strengths. In any case the firmness
of the agglomerates is an important requirement
to preserve the product properties in
the long run – for example in case of longer
storage.
Suitable mixing systems
The success of agglomeration in a mixer
depends on three factors: the construction of
the mixing system, its operating parameters
and the method of introduction of the liquid
binding agent. In case of shovel mixers (in
batch and continuous operation) and vertical
high speed mixers, the liquid binding agent
is introduced either via lances into the turbulent
zone of the choppers (homogenisers)
or directly into the product area. In case of
ringlayer mixers, the binding agent will be
introduced via nozzles into the annular layer
generated by the mixing tools. The desired
product form and quality will determine the
necessary retention time. The limit of size for
agglomerates is approximately 3000 µm for
build-up agglomeration in mixers, the size
distribution is about 1:5 at d80.
Lödige Process Technology develops application-specific
solutions for a wide variety
of agglomerates with top product quality.
These solutions include ploughshare mixers
for batch operation and for continuous operation
using the mechanically generated fluid
bed system introduced to mixing technology
by Lödige. Ploughshare shovels rotate as
mixing elements in a horizontal, cylindrical
drum close to the walls; the basic shape of
the shovels was patented by the German
manufacturer in 1949.
A further machine suitable for build-up
agglomeration is the high speed, continuous
ringlayer mixer Corimix. The high peripheral
speed of the mixing tools generates a
centrifugal force forming a concentric annular
layer of product. The product moves
through the mixing chamber in a plug-like
flow manner under constant energy input.
The high speed difference causes intensive
mixing within the product layer and this
creates particularly short residence times.
Depending on the product up to 175 kg/
dm 3 can be processed per hour.
Though the mixer is quite compact, it is designed
for high and very high specific
throughputs. Having a working volume of
5 to 3000 l, this machine meets the highest
requirements in terms of profitability and
availability.
Other solutions that can act as powerful agglomerators
include the type KUM universal
mixer and the type MGT mixing granulator,
a vertical mixing system with low energy
input and low temperature increase but high
mixing power. Available in different sizes,
the machines are characterised by a vertical,
cylindrical mixing vessel and are operated in
MGT mixing granulator, a vertical mixing system with low energy
input and low temperature increase but high mixing power
a batchwise manner. A three-bladed mixing
element rotates close to the wall and with
minimum clearance to the bottom of the
vessel.
The special shape of this element and its peripheral
speed are coordinated in such a way
that the mixing product is circulated as a
vortex and thereby accelerated horizontally
and vertically. A high speed chopper is
placed above the mixing element, i.e. in the
product vortex, directly in the turbulent area
where agglomeration can proceed.
www.cpp-net.com
Online search: Lödige
AUTHOR:
REINER LEMPERLE
Head of Marketing and
Sales,
Lödige Process Technology
cpp 02-2021 21

cpp
SAFETY
Software suite combines engineering data with IT and OT data
Efficient process reliability
management
Safetyinsight, a suite of digital software applications, helps businesses in the process
industry manage their process reliability across a system’s entire lifecycle. It not only
makes it easier for system operators to comply with documentation regulations, it
also helps cut maintenance costs, reduce production losses, and above all, ensure
process reliability for people and the environment.
Functional safety is crucial to the process
industry due to the strict guidelines the sector
must follow and because it is the key to
protecting people, systems and the environment.
This makes functional safety arguably
the most important factor in system availability
and investment protection. Complex
workflows place high demands on process
reliability. Managing this safety begins with
three key questions:
• What can go wrong?
• Which systems can prevent this from happening?
• Do they work?
ABB’s software suite Safetyinsight helps
answer these questions.
Designed as a central source of information,
the software digitalises early Engineering
Technology (ET) data to create a digital map
for process reliability. This information creates
the context for the tremendous volume
of data generated by information technology
(IT) and operational technology (OT)
systems.
During the engineering phase, companies in
industries that use systems with high risk
potential in particular invest a great deal of
time and money in developing fundamental
safety and security principles. However, this
elementary knowledge often remains tucked
away and unused, while operations and
maintenance teams must repeatedly reanalyse
the hazards and risks associated with
their processes. Using Safetyinsight changes
all this. The software suite combines IT and
OT data with ET data, thus enabling enterprises
to digitalise valuable engineering information
(like the HAZOP analysis and
LOPA analysis). The data is then made available
to operations and maintenance personnel
in simplified, intuitive and easy-tounderstand
visual formats. This makes it
possible to perform ongoing risk assessments
with digital safety information.
Thanks to a software extension that includes
IT/OT data, updates are possible almost in
real time. The cumulative effect of operations
and maintenance tasks can be visualised
in a dynamic risk matrix, making performing
risk assessments and managing operational
risks that much easier.
ABB is digitalising process reliability management with the Safetyinsight software suite
Pictures: ABB
Advantages for validation
Engineering technology data such as digital
twins must be validated. Safetyinsight also
simplifies this task by making it possible to
capture actual operations and maintenance
data in the context of early design assump-
22 cpp 02-2021

Safetyinsight combines IT and OT data with ET data, making it possible to digitalise valuable engineering information
tions. This enables operators to identify and
deploy improvements – thus closing the
process reliability management loop. These
improvements not only enhance safety, they
also help minimise production losses and
cut maintenance costs. The software package
includes process reliability dashboards that
provide the right people with the right information
at the right time so they can
make well-informed decisions.
Safetyinsight and other ABB applications for
information management systems have already
delivered proven performance in
major process industry businesses. In one
specific case, the suite helped increase system
availability to over 99 %. Another international
corporation was able to reduce
time and effort spent on annual safety system
valves inspections by 30 %.
Safety for connected systems
The rise in networked systems in the process
industry and increasing Internet connectivity
have made plants more vulnerable
than ever. Implementing a management system
for information security (ISMS) in accordance
with ISO 27001 or using other industry
standards such as IEC 62443 in risk
analyses or deploying a suitable architecture
such as the ABB cyber security reference
architecture are practical measures – and
not just for critical infrastructures.
According to the 2021 Global Risks Report,
cyberattacks are among the top five greatest
threats to the global economy. All the more
reason to ensure the appropriate cybersecurity
measures are in place and not to rely
too heavily on past actions. In practice,
threats can come in many different forms.
ABB’s cybersecurity portfolio is built on
three key pillars: Foundation, Services and
Operations, all of which address exactly
these issues.
On the one hand, there is a steady stream of
cyberthreats; simple countermeasures such
as regular patches or other “Foundational
Controls” can help mitigate these risks. On
the other hand, precisely targeted attacks –
also known as Advanced Persistent Threats
(APTs) – are also being carried out. Here attackers
attempt to work their way through
to the process control system in a series of
steps. Countermeasures that exploit knowledge
of the attacker’s approach and defend
against it help mitigate attacks against companies
in the industrial sector and individual
plants and systems.
An example of an effective defensive strategy
is detecting and observing an attacker
in the early stage of target selection or in
the choice of attack and adapting to the specific
characteristics of the identified attack
to prevent the attacker from reaching important
assets and information. Availability,
process continuity and process reliability are
absolutely essential to the process industry.
This is why it is advisable to keep pace with
every version step by performing smaller
updates throughout the entire life cycle of
the system, including the implemented security
controls to keep cybersecurity risk
and the risk for upgrade projects or even
system stops for major IT changes as low as
possible.
The ABB Ability Collaborative Operations
Center (COC) for cybersecurity enables experts
to respond immediately to problems
and threats in customer systems. Specific
parameters are monitored to report
anomalies to the COC. This allows experts to
proactively inform customers and take immediate
action. Remote Services from ABB
help users transfer cybersecurity tasks to
ABB experts in an effective and timely
manner. This makes it easier to make the
right decisions quickly and investigate existing
security issues. The ability to effectively
network with experts facilitates quick action,
thereby boosting the efficiency and reliability
of system operation.
www.cpp-net.com
Online search: ABB
AUTHOR:
STEPHAN BOY
Technical Sales Support,
ABB Energy Industries
AUTHOR:
TOBIAS NITZSCHE
Cyber Security Practice Lead,
ABB Process Automation
cpp 02-2021 23

cpp
SAFETY
Pictures: Rembe
An economical concept
EXPLOSION SAFETY FOR
SPRAY DRYING SYSTEMS
One measure of constructive explosion protection is explosion
suppression. Rembe has developed the Q-Bic extinguishing barrier
for this purpose, taking particular account of the hygienic requirements
of spray drying systems. A practical example shows how
Q-Bic can be used to create economical concepts for demanding
applications, taking into account current research findings.
24 cpp 02-2021

Explosion vents differ in shape and structure depending on the application
Extinguishing barrier Q-Bic
Explosion protection involves reducing the effects of an (inevitable)
explosion and is the central, most frequently applied explosion
safety concept. Certified protective systems are used to safeguard
employees, affected plant components and the entire environment.
One option is explosion suppression. In this case, the
idea is to eliminate the explosion before it can fully form. This is
made possible by detectors that use sensors to detect pressure or
flames and immediately trigger the extinguishing agent canisters
that are also installed in the system. The latter disperse a highly effective
extinguishing agent within milliseconds and thus nip the
explosion in the bud. If required, an explosion suppression system
can also be used for explosion isolation.
Rembe’s Q-Bic extinguishing barrier was developed in strict compliance
with the hygiene requirements for spray-drying plants.
Thanks to the convex dirt protection cap, neither water nor dust deposits
can accumulate on the Q-Bic. The blue-green QXP extinguishing
powder prevents cross-contamination and the patented
SJX nozzle ensures optimum application of the extinguishing
powder. The Q-Bic is particularly suitable for large pipes attached to
dryers and filters or complex shaft geometries such as conveyors
and elevators.
Protection of spray dryers and cyclones – a case study
In a production plant for pharmaceuticals, a spray dryer and a
connected cyclone, through which the product is discharged, were
to be protected. The most important technical data of the plant at a
glance:
• Drying temperature: 90˚C
• Dust specifications: organic dust St1, K St value: 150 bar*m/s,
P max : 8 bar
• Lower explosion limit: 255g/m 3
• Strength of all system elements: tested P design of minimally 0.3 bar
A safety concept was required that incorporates as few explosion
safety products as possible. This is a common requirement; however,
it can only be met by considering the plant as a whole and taking
all technical specifications into account, as well as the latest research
findings.
In the present case, explosion isolation of the spray dryer from the
cyclone is not necessary. At first glance, this contradicts the statement
that isolation is absolutely necessary to prevent an explosion
from propagating. However, scientific evidence shows that decoupling
can be dispensed with if a P red of maximally 0.3 bar is determined
for the entire plant, since any hazardous pre-compression in
the neighbouring equipment can then be ruled out.
Protection for the spray dryer
VDI guideline 2263, or more precisely sheet 7.1, states that under
the following circumstances a reduced volume can be assumed
when calculating the necessary vent areas/protective systems:
• No integrated fluid bed
• No recirculation of fine dust into the head of the spray dryer
• The average dust concentration inside the spray dryer is lower
than the lower explosion limit of the dust
If these three conditions are met, as in the present case, either a reduced
volume of 1/3 of the total volume or the volume of the cone
can be assumed. The larger volume must be selected in each case.
For the spray dryer in question, 1/3 of the total volume, i.e.
19.85 m 3 , was selected.
Observance of VDI guideline 2263, sheet 7.1. allows an additional
reduction in addition to the volume, resulting in smaller required
vent areas. If it can be assumed that, due to the process, the optimum
dust concentration for an explosion will never be present, the
protective systems can be designed with a reduced K St value. Due to
the nature of the process – the product is to be dried after all – it
cpp 02-2021 25

cpp
SAFETY
Protection systems for the spray dryer in comparison
Protective systems
in use
Explosion vents, free
venting to outside
areas
Flameless
explosion venting
Combination of vent
ducts and explosion
vents
Suppression
Conventional design
4 EGV HYP hygienic explo sion
vents (586 x 920 mm) (with
EHEDG-approval)
5 Q-Box 586 x 920 with EGV
HYP hygienic explosion vent
5 EGV HYP hygienic explosion
vents (586 x 920 mm) (with
EHEDG approval)
+ duct cover
3 Extinguishing agent bottles
(45 l)
Design according to the
latest research findings
1 EGV HYP hygienic explosion
vent (586 x 920mm) (with
EHEDG approval)
2 Q-Box 586 x 920 with EGV
HYP hygienic explosion vent
1 EGV HYP hygienic explosion
vent (586 x 920mm) (with EHEDG
approval)
+ duct cover
2 Extinguishing agent
bottles (45 l)
has been scientifically proven that a maximum concentration of
250 g/m³ cannot occur in the spray drying system.
The inclusion of the latest research results and current guidelines in
the design thus leads to a reduction in the volume to be considered
and the K St value. This in turn allows the creation of a safety concept
that is not only safe but also cost-effective. By comparison, without
taking these reductions into account, the vent areas for the spray
dryer to be protected would have been up to 340 % larger. From the
operator’s point of view, this would be over-engineering, because
larger relief areas always mean greater effort to modify the respec -
tive plant components and, last but not least, higher acquisition
costs.
The table shows how the protection system for the spray dryer
under consideration might look with and without the described design
requirements. For round vessels such as spray dryers, selected
flameless explosion venting systems, e. g. the Q-Box, can be installed
by means of an adapter flange. Since the entire plant is located
inside a building and the operator wanted an explosion protection
system with the lowest possible maintenance requirements,
flameless venting was chosen in this example.
Protection for the cyclone
For the associated cyclone, the original safety characteristics of the
dust in question must be taken into account. Cyclones are usually
vented via the vortex finder, which must be included in the design
as a vent duct. Therefore, it is also crucial to know the exact dimensions
of this plant component. In this particular case, the cy -
clone is protected by a DN 800 Q-Rohr equipped with an ERO
hygienic explosion vent. By ensuring that the smooth surface of
the explosion vent faces the processing area, all hygiene requirements
from production are met.
The product discharge area below the cyclone is equipped with an
explosion-proof and flame-proof rotary valve.
Risk of tampering with safety systems
Even the highest quality protective systems can only do their job if
they are installed correctly and protected against tampering. The risk
of tampering is an important issue, and also one that is sometimes
ignored.
Recently, Rembe engineers have found indications of such deficiencies
increasingly frequent during plant inspections. For example,
safety devices are disabled, electronic signalling and warning devices
are bridged, mechanical elements are secured with too few
fasteners and bolts. The reasons for this are complex and certainly
not easy to understand.
Rembe’s protective systems are therefore designed from the ground
up to ensure a high degree of in-built safety that is immune to tampering.
For example, screw connections are replaced by non-deta -
chable riveted connections; bolts are designed to be self-locking
and captive.
This is particularly essential for more complex components such as
devices for flameless venting. These systems are typically installed
indoors, but always in locations where free venting, e.g. via explosion
vents, is not possible. However, if the part responsible for
flameless venting fails or has any weak points, this could have devastating
consequences for the surrounding area, which would be
left defenceless against the flames and pressure of an explosion.
www.cpp-net.com
Online search: Rembe
AUTHOR:
GERRIT FIKSE
Senior Consultant Explosion Safety,
Global Sales Explosion Safety,
Rembe Safety + Control
26 cpp 02-2021

cpp FOCUS PUMPS AND COMPRESSORS
Dosing solutions for liquid products
All-round metering pumps
Doseuro metering pumps work reliably even under harsh conditions. The piston metering,
hydraulic diaphragm and mechanical diaphragm pumps offer a wide range of
applications through individualisation. In demanding applications, the Just- switch-on
system and the Rapida 2.0 series ensure optimum metering results.
Doseuro pumps and systems for dosing
chemical, acidic and basic liquids have been
part of the FPZ Group since 2017. The
chemical dosing pumps are available in three
main versions: plunger pumps with packed
plungers, plunger/hydraulic diaphragms, or
mechanical diaphragms. High pressure
pumps are available, too. The range also includes
various driving methods, such as electric
motor or electromagnetic solenoid operation.
The company also manufactures complete
dosing packages, electric mixers, and
fully automatic plants for the dissolution and
mixing of polyelectrolyte, both as powder
and emulsion.
All Doseuro pumps are fitted as standard with
4 pole electric motors that comply with
Unel-Mec standards, and range from 0.09 to
4.0 kW and are available with motor ratings
from 0.09 to 4.0 kW at standard European
three-phase voltages of 230/400 V at 50 Hz.
The motors are also available in many alternative
specifications, including explosionproof,
Atex-compliant designs. The dosing
quantity is fully adjustable by means of a
manually controlled eccentric mechanism
with spring return or positive return according
to API standard 675. Automatic adjustment
is possible by means of servo-control
motors, pneumatic control or motor frequency
control, via a Profibus interface if
required. The reduction system, consisting of
an endless screw coupled to a worm wheel,
makes the gearbox robust and durable. To ensure
higher dosing accuracy and chemical
cost savings, Doseuro has developed the Justswitch-on
(JSO) system and the Rapida 2.0 -
dosing pump. The Just-switch-on panel is a
prefabricated system that includes single or
double metering pumps and inlet and outlet
piping on a robust PP frame (1.5 cm). The
inlet piping is equipped with an isolation ball
valve, a Y-filter and a calibration pot, and
shut-off ball valves, pulsation dampeners, a
back pressure valve, a relief valve and a pres -
sure gauge with isolator are located on the
outlet piping. This preconfi gured solution is
easy to install and ready for immediate use.
The Rapida 2.0 metering pump is equipped
with a six-button digital control panel, providing
the ability to measure actual chemical
consumption and instantly change pump settings.
Alternatively, it can be controlled via a
0/4...20 mA or 0/2...10 V signal, Modbus
RTU or Profibus. The pump has a three-phase
asynchronous electric motor and an inverter
board, and is designed so that the motor
speed can be varied. It can operate from 0.25
to 0.75 kW and has a base frequency of 6 to
60 Hz, which can be extended up to 100 Hz.
The motor has a timing mode that allows delaying
the start and defining a specific working
period, a flexible management of the acceleration
and deceleration ramp, a working
Picture: FPZ
Doseuro metering
pumps work reliably
even under harsh
conditions
hour counter and a correction factor of the
flow curve.
www.cpp-net.com
Online search: FPZ
AUTHOR:
FERDINAND RUCKER
Country Manager DACH
Region,
FPZ
AUTHOR:
ANDREAS GÖTZ
Product Specialist,
FPZ
cpp 02-2021 27

cpp FOCUS PUMPS AND COMPRESSORS
IoT solution enables live monitoring of mechanical pumps
Digital pump pioneers
With Tim-IoT a digital solution is available that enables location-independent
monitoring in real-time and predictive maintenance of pneumatic double diaphragm
pumps. Plant operators benefit from a significantly higher level of process reliability,
minimisation of downtimes and cost savings due to better predictability.
Modern plants are highly complex
systems. Many plant parameters are already
being monitored today – however pumps
are usually the exception. Even though
pumps are frequently the heart of a plant
and thus a crucial element in the process
chain. Consequently, failures can result in
considerable financial losses. With regard to
maintenance times or a replacement, to
date, users have been compelled to rely on
empirical values. For pneumatic double
diaphragm pumps in particular, previously
it has scarcely been possible to collect
production data. Pump specialist Timmer,
based in Neuenkirchen, Germany, has met
this challenge with its Tim-IoT solution. It
enables read-out and extensive statistical
analysis of pump data. The Tim-IoT system
structure is quite simple: first, the pump
must have an intelligent sensor; since
1 May 2021, an intelligent sensor has been
integrated in most of Timmer’s double
diaphragm pumps, as standard equipment.
Then the sensor is linked to the Tim-IoT
Smartbox, which transmits all data to the
cloud. The data are visualised and analysed
on freely selectable end devices, such as PC,
smart phone or tablet. Such a simple
structure, yet such complex technology
inside. The Timmer solution works with
particular precision: a measuring point is
set, i. e. information is generated, every
one-hundredth of a second. Unlike the
processes with big data, where frequently
all of these large data volumes are transmitted,
Timmer uses edge computing. First
the system analyses and bundles the data
from the pump in the Tim-IoT Smartbox,
and only thereafter it sends the most
important information to the cloud. This
saves resources, since data transfer is
significantly reduced. However the
advantages of big data volumes are not lost
when edge computing is used, on the
Tim-IoT enables read-out and extensive statistical analysis of pump data and it can also
be integrated in Timmer double diaphragm pumps and electric piston pumps
Pictures: Timmer
contrary: the flexibility of the solution also
allows users access to extensive status
reports by means of so-called snapshots.
Snapshots generate a 20-second recording
with approximately 2,000 measuring
points. If a fault occurs or if a threshold is
exceeded, the system even saves all the
measured data retroactively and notifies the
plant operator. By virtue of this function,
users can analyse deviations with onehundredth
of a second precision.
Custom control
Precisely when a notification should occur,
and precisely which parameters require
special observation, can be adjusted
individually via the user interface. Plant
operators are in a position to specify a
number of tolerances and causalities, and
add notifications to them if certain values
are exceeded or are not reached. For
example, such values include precise
thresholds for a number of parameters – including,
pressure, frequency, flow and
frequency ratio. The more values that are
defined, the closer the mesh of the
monitoring grid for the pump’s run
behaviour. If a value exceeds or does not
reach the specified tolerance, the plant
operator receives a notification immediately.
In addition, Tim-IoT has other useful tools,
such as maintenance planning, a mainte -
nance calendar as well as user-friendly
management of service reports and pumpspecific
documentation. Data protection was
one of Timmer’s design priorities for its
standalone solution, this is also explicitly
demanded by the industry. This aspect is
considered in the data transmission
possibility via separate LTE router, which
works independently of the company
network, and it is also taken into account in
the processes overall: the system receives
only the data of the pump; it has no view
28 cpp 02-2021

has the
solution!
Tim-IoT consists of an in -
telligent sensor for data
acquisition and the Tim-IoT
Smartbox
whatsoever of other parameters or processes
beyond the pump data. Using the pure
pump data can indeed provide indications
that faults may be present in the process
chain, due to the changing information. But
only the user himself has the big picture
required for understanding and interpreting
the overall work chain. Nevertheless, even
the pure pump information alone can be
decisive for detecting errors and thus
preventing production downtimes, for
instance.
Reliable real-time monitoring
With meaningful data, plant operators can
more efficiently organise processes in
practice and make well-informed decisions.
Parameters, such as pump frequency,
number of strokes, or pressure curves, are
permanently visible. Predictions concerning
wear and scheduling of repair measures
become significantly more precise – this
precision ensures optimal use of the pumps
over their entire service life. Moreover,
statistical analysis of production data
facilitates calculation of operating costs and
optimisation of plant use. Frequently plant
operators service all pumps at the same
time, even though some of the pumps have
only reached a fraction of their service life –
over time this can amount to a significant
but needless expense. In addition, predictive
maintenance minimises maintenance downtime
and damage, yet it increases process
stability and machine availability. By means
of health data, such as average frequency
range, stroke count and operating hours,
precise conclusions can be drawn regarding
necessary dimensioning of the pumps.
These values must always be considered in
relation to each other. For example, if the
pump is relatively new, but is constantly
running in a very high frequency range,
then not only is service life reduced, this is
The intelligent sensor has been integrated
in most of Timmer’s double diaphragm
pumps as standard equipment since 1 May
also a high-probability indicator that a
larger pump would be better suited for the
process. Most recently the corona pandemic
has clearly shown that the old model – yet
still frequently used in practice – of handwritten
records of pump and maintenance
information on a warning tape, can cause
real problems. Here is a specific example: a
Timmer customer services his pumps every
six months according to that customer’s
empirical values obtained over many years.
However, due to the corona pandemic and
its economic consequences the customer’s
plant was not always used to capacity and
even ceased production for several days. This
renders the customer’s reference data
obsolete – all of the empirical values
worked out over the years were irrelevant
within a few months. The plant operator
does indeed know that the pump was
serviced six months ago. But he does not
know how many hours it has been in use
since then, due to the irregular operation.
This example and other practical cases
illustrate the benefits that monitoring has to
offer: if the pump is process-relevant, then
it must be monitored for safe and economical
operation.
www.cpp-net.com
Online search: Timmer
AUTHOR:
Frederic Engels
Sales Engineer,
Timmer
Dose with
System!
GATHER metering systems
according to customer
specification
+ ATEX Zone 1 and 2
+ GATHER Metering box 5000
as universal controller
+ Stand-alone systems
or integration
Learn more!
GATHER Industrie GmbH
D-42489 Wülfrath
Made in Germany
NEW
cpp 02-2021 29
+ conveying + coupling + metering

cpp FOCUS PUMPS AND COMPRESSORS
Designed to meet specific requirements
Submerged pumps for
hazardous media
Submerged column pumps are used for the disposal and further processing of mixtures
of boiling, solids-laden or even toxic liquids that need to be pumped out of containers
and tanks. Failure and consequential damage must be avoided wherever possible.
Bungartz designs all submerged pumps according to the specific requirements as single
pumps or as small series, so that a wide range of applications can be covered.
Standard submerged pumps whose slide
bearings are flushed by the pumping liquid
or other media often generate difficulties
for the operator. They are not safe to run
dry. Dry-running damage to the slide bearings
can also occur if gas fractions or solids
get into the pump, or accumulate in the
bearing area during standstill. In practice,
such hydraulic malfunctions regularly cause
severe damage, and this can become particularly
dangerous in the case of explosive
substances or hazardous combinations of
pumping media, which are frequently
found in the chemical and petrochemical
industries.
The submerged column pumps from Bungartz
are designed specifically for these or
other such difficult pumping tasks. All
pumps from this manufacturer have a hydrodynamic
seal, which prevents the secondary
sealing (e. g. packed gland, double
mechanical seal, magnetic drive etc.) from
coming into direct contact with the pumping
medium. One advantage here are the
grease-lubricated rolling bearings, which
are not in contact with the product and are
lubricated for life. A rolling bearing service
life of more than five years of continuous
operation is the norm here. Instead of relying
on sensitive mechanical seals as the primary
seal, Bungartz, as a manufacturer of
special centrifugal pumps, likewise works
with various concepts in its submerged column
pumps.
The submerged pumps for hazardous and toxic media are designed according to the specific
needs as a single pump or as a small series
Pictures: Paul Bungartz
Importance of the immersion depth
The immersion depth of a pump (e.g. the T,
T-AN or F-T pumps, all three of which have
a cantilever shaft design) is dimensioned on
a requirement-specific basis. The guiding
factor for pumps with a cantilever shaft design
may be the deflection of the shaft
under operating conditions. The critical
speed is also significant. This is the speed at
which the natural frequency of vibration of
the shaft coincides with the shaft speed. This
frequency has at least 20 % margin of safety
relative to the desired operating speed. The
shaft length of submerged column pumps
with a cantilever shaft design can reach up
to 1.5 m, measured from the lower rolling
bearing to the impeller. This is dependent
on the speed. Depending on the fluid level,
the area of the bearing bracket can be used.
In addition, the suction pipe extension can
be used for deeper suction.
Depending on the requirements, the T-AN,
for example, can be used as a self-regulating
pump in the pit area – without shaft seal
and with an overflow opening for backpressure
relieving. This pump is also in use
as an external pump (add-on) with a support
pipe as an overflow connection. It is
also suitable for installation in a container,
in which case an additional pipe is added
for pressure compensation. In installations
of this type of pump, the bearing is never
located in the pumping liquid – not even in
pumps with shaft bearing below the liquid
level in the container surrounding the
pump. And they share more common features
with other pump types from the
manufacturer: low operating and mainte -
nance costs.
30 cpp 02-2021

Specialist for toxic media
This also applies to the specialist in the
submerged column pump range, the
MPCT-AN. It is approved for hazardous and
toxic media, and even for Atex zone 0. Its
pump hydraulics– specifically the pump
casing and impeller – are indeed submerged
in the pumping liquid at startup.
However, in contract to submerged motor
pumps, the drive motor is located above
the dome of the container. On the one
hand, and like the other pumps from this
manufacturer, the safety concept is based
on the total hydrodynamic seal by means
of impeller back vanes. On the other hand,
gas barriers (sealing gas) protect the bearing
unit against penetration by product
vapours. The bearings and sealing unit run
without product contact, and are thus dry
at all times. The dry-running vortex-free
magnetic drive (through a ceramic containment
can) has no contact with the
pumping liquid or its gases. The pump is
likewise hermetically sealed.
The vertical design of the pump is also an
advantage. The design itself thus prevents
the seal and the lifetime-lubricated bearing
from coming into contact with the pumping
medium, even at a standstill. As with
all pumps in the V-AN series, the self-regulating
behaviour of this pump ensures
adaptation to changing feed rates. This
type of pump does not use suction, but
automatically regulates its speed to the
feed flow of medium. Fluctuating feed
rates, sporadic use, and in particular the
total emptying of tanker trucks and tank
wagons are therefore amongst their
specialities.
The MPATAN submerged column pump is
suitable for use in Atex zone 0, 1 or 2 in the
storage tank, with boiling, gaseous and/or
toxic media as well as with media containing
solids
----A---WORLD------
--------LEADER---IN---
---CHEMICAL------
SOLIDIFICATION-----
-----AND--------
-----HANDLING-----
---SOLUTIONS-----
Use of the pump in a container. An additional
pipe is used for pressure equalisation.
Granulation, solidification and
handling systems for different kinds of
chemicals like resins, waxes, hot melts,
antioxidants and residuals.
Everyday pumping application
A light oil processing plant produces waste
water containing hydrocarbons. The slop
medium – waste water and hot liquid hydrocarbons
– is collected in separate containers.
The liquid fraction is collected in a
single tank. At long intervals, the submerged
column pump installed in the container intermittently
pumps the material collected in
the container to a disposal facility. Thanks to
the two-part shaft seal system of the pump,
consisting of a magnetic drive to hermetically
seal out the atmosphere and a mechanical
seal to protect the pump shaft‘s rolling
bearings against the ingress of the liquid
from the container, the pumping process is
safe at all times. The pump has been running
trouble-free for years.
Special tasks like this and others are what
has gained this company its reputation as a
problem-solver. The engineers and their colleagues
at the pump manufacturer provide
comprehensive advisory services and individual
recommendations. They support customers
through the entire process, starting
from the reliable design of the pump,
through to the commissioning process and
beyond.
www.cpp-net.com
Online search: Bungartz
AUTHOR:
FRANK BUNGARTZ
Managing Director,
Paul Bungartz
IPCO offers:
• High productivity – on-stream factor
of 96%
• Proven Rotoform technology – nearly
2000 systems installed
in 30+ years
• Complete process lines or retrofit of
existing equipment
• Global service / spare parts supply
Read more at ipco.com/applications
cpp 02-2021 31

cpp FOCUS PUMPS AND COMPRESSORS
Powerful turbo blowers
Atex scroll pump
The Aerzen Turbo G5plus series
is one of the most compact and
efficient turbos in its class. The
newly developed AT 60 size
brings with it numerous innovations.
In addition to increased
system pressure, the new turbo
also scores with an extended
control range and an efficiency
increase of up to 10 %.
Picture: Aerzen
The powerful turbo blowers of
the Aerzen Turbo series are especially
suitable for applications
in industrial wastewater treatment
plants and now, with 19
different models available, cover
a volume flow range from 300
up to 16,200 m 3 /h and system
pressures of up to 1,000 mbar.
The Aerzen Turbo AT 60-0.9S is
designed for volume flows from
900 to 2640 m³/h and assembly
capacities of up to 50 kW. Thanks
to a completely new motor design,
the maximum differential
pressure has also been opti -
mised to 900 mbar. For a turbomachine
of this size, the Turbo
AT 60 also has a very high control
range of 35 to 100 %.
www.cpp-net.com
Online search: Aerzen
The pumps in the Hiscroll Atex
range from Pfeiffer Vacuum
meet the requirements of the
European directive 2014/34/EU.
The Hiscroll Atex conforms to
equipment category 3G based on
contact with the pumped substance
and meets temperature
class T4. This allows all gases up
to and including explosion
group IIC to be pumped. It is
even possible to pump hydrogen.
With these properties, the
Hiscroll Atex covers many applications
in the field of analytics,
industry or research & development.
Explosion-protected devices
are used in many sectors,
including industrial processes
such as generating and pumping
hydrogen. The Hiscroll Atex
is also used in laboratories for
pumping solvent-based liquids
and gases which can produce
combustible vapours. The Atex
certification is awarded since
the Hiscroll Atex has no sources
of ignition for potentially hazardous
gas mixtures.
www.cpp-net.com
Online search: Pfeiffer Vacuum
Robust circumferential piston pump
Picture: Pfeiffer Vacuum
Dry screw vacuum pumps
The screw vacuum pumps Dryvac DV 500 and DV 800 compress
completely dry. Thanks to their screw design with a
specially adapted variable pitch, they work efficiently due to
their low power consumption. The robust screw vacuum
pump is also characterised by high particle and condensate
compatibility. The pumps are equipped with an easily adaptable
and networkable frequency converter and IE3 motors.
Monitoring via a cloud platform can also be easily implemented
on request and is available as standard from Q3.
www.cpp-net.com
Online search: Leybold
Picture: Leybold
With a robust construction, the
Alfa Laval Duracirc circumferential
piston pumps feature a high
efficiency design, wide performance
envelope and low net
positive suction head (NPSH)
requirement. With flow rates of
up to 150 m 3 /h, the pump is
capable of handling operating
pressures of up to 40 bar. Optional
ports make it easy to replace
existing pumps from Alfa
Laval and other brands with the
Duracirc, without having to
Picture: Alfa Laval
adapt pipework. Certified to
meet EHEDG guidelines and 3-A
Sanitary Standards, the Duracirc
pump assures process integrity
and product quality. For a crevice-free
design with no dead
zones, all product-wetted elastomers
are made of FDA-conforming
materials and profiled
and defined compresssion as
standard. Seal positioning with
seal faces fully immersed in the
pumped media further boosts
cleaning efficiency. Additionally,
the all-stainless steel construction,
suitable for hygienic washdown,
ensures a cleaner environment.
www.cpp-net.com
Online search: Alfa Laval
T +49 2961 7405-0 | hello@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
32 cpp 02-2021

Solenoid driven diaphragm metering pumps
The solenoid driven diaphragm metering pumps gamma/
X and XL use all the advantages of their patented, regulated
solenoid drive. The power consumption of the solenoid
coil (pressure information), and the position of the diaphragm,
allow direct conclusions to be drawn about the
dosing behavior at any time during the pressure and suction
strokes.
By comparing target values with the measured values even
gas bubbles can be precisely identified and selectively
monitored. The air bubble detection and the model-based
control behaviour of the solenoid-driven metering pump
in combination with a special pressure valve enables air
bubbles to be pre-compressed by the system pressure even
before the actual pressure stroke and to be released into
the metering line during the pressure stroke. The intelligent
control ensures that exactly the required quantity is
metered even during pressure compensation. It adapts the
number of strokes and the duration of the compensation
to the number and size of gas inclusions.
This ensures that the dosing capacity is reliably maintained
even if several gas bubbles occur one after the other in the
suction line. Compared to conventional solutions, the
required dosing accuracy is maintained.
www.cpp-net.com
Online search: Prominent
Cryogenics pumps
Vanzetti Engineering’s cryogenic
pumps make it possible to meet
all the application needs of the
small scale industrial sector. The
latest model of the Artika series,
Artika 300 meets application
needs to transfer liquefied natural
gas in small and medium
size terminals.
Available in 1 or 2 stage configuration,
the Artika 300 can
reach up to 270 m 3 /h of flow
rate, thus completing the range
Picture: Vanzetti
of submerged pumps for LNG.
The built-in features of these
pumps include the seal-less concept,
with motor bearings permanently
lubricated by LNG,
which allow a permanent cold
condition for quick and efficient
start and stop operations and
extremely low need of service
and maintenance.
www.cpp-net.com
Online search: Vanzetti
HOW SAFE AND CLEAN IS YOUR
PROCESS AIR REALLY?
LET’S TALK
Dirk Koob, CEO AERZEN Deutschland GmbH & Co. KG
+49 5154 815666 dirk.koob@aerzen.com
With an extensive portfolio in the area of low pressure, AERZEN offers you individual solutions
for the various, sensitive applications in food technology.
Our innovative, ATEX-certified blower and compressor packages guarantee 100% product
purity and safety. Thanks to the patented absorption-free silencer technology, contamination
of the material is excluded.
www.aerzen.com
cpp 02-2021 33

cpp FOCUS PUMPS AND COMPRESSORS
Bergische Universität Wuppertal installed new compressed air treatment systems
Oil-free compressed air for
the laboratories
Autosamplers, sterilisers, rheometers et cetera – many laboratory applications need
compressed air. In view of the sensitive environment, the risk of oil ingress should
definitely be minimised. The University of Wuppertal plays it safe and has equipped
all its compressed air stations with treatment technology from Beko Technologies.
The most important component of each system is a Bekokat catalytic converter for
constant oil-free compressed air.
The University of Wuppertal operates six
compressed air stations with oil-lubricated
screw compressors to supply the buildings
on campus, including its laboratory facilities.
From these stations, a large compressed
air network is fed that extends over
the entire area of the university. To ensure
that the high-quality laboratory equipment
remains undamaged and the sometimes
very sensitive long-term measurements of
the faculties are not affected, the compressed
air must be absolutely oil-free and
also dry. Each of the six compressed air
stations has its own treatment line. The laboratories
still use an additional final station
filtration and/or drying for special requirements.
The Bekokat catalytic converter is the central element of each of the new
compressed air treatment systems
Picture: Beko Technologies
Customised treatment concept
Compressed air treatment of the six compressed
air stations used to be provided by a
refrigeration dryer and double filtration in
each case. “After an oil contamination occurred
in one of the less sensitive laboratory
facilities with fortunately benign consequences,
we wanted to proactively increase
safety and optimise the complete treatment,”
reports Joachim Conrad from the
Technical Facility Management of the University
of Wuppertal. Now, catalytic technology
predestined for sensitive applications
was to be used, which surpasses conventional
systems for oil-free compressed air,
such as the use of oil-free compressors or
activated carbon, in terms of effectiveness.
Following an on-site analysis, Joachim Conrad
and Beko Technologies designed a customised
treatment concept for the six com-
34 cpp 02-2021

Picture: Beko Technologies
Picture: Bergische Universität Wuppertal
Typology of compressed air treatment: Bekokat catalytic technology
framed by two Clearpoint 3Eco fine filters and Drypoint RA refrigeration
dryers
The laboratories at the University of Wuppertal benefit from particularly
high-quality oil-free compressed air
pressed air stations. The university initially
wanted to procure the treatment technology
for two compressed air stations where the
most urgent need for action was seen due to
their typology. Following a public tender,
the Beko Technologies components went
into operation in April 2019.
In the two modernised compressed air
stations, the treatment follows the same pattern.
After the oil-lubricated compressors, a
Clearpoint W water separator with the high -
est separation rates is installed in each case.
This is followed by a Drypoint RA refrigeration
dryer, which was the only component
already integrated in the old treatment system.
In the Drypoint RA refrigeration dryer
series, the pressure drop was reduced to an
absolute minimum for energy efficiency
reasons. Key elements here are the flowoptimised
heat exchanger, a demister for
reliable separation, and generously dimensioned
components that ensure a low pres -
sure drop of 0.16 bar on average in fullload
operation. Subsequently, a Clearpoint
3Eco fine filtration unit achieves aboveaverage
separation performance in an energy-saving
manner with minimum differential
pres sure.
Catalytic converter
The heart of the new compressed air treatment
system is the Bekokat catalytic converter.
The system converts the hydrocarbons
present in the compressed air into carbon
dioxide and water in a single process
step by total oxidation. To do this, a special
granulate is heated to a temperature of
around 150 °C in the pressure vessel and the
compressed air flowing past the surface of
the granulate is completely converted to carbon
dioxide and water. Completely de-oiled
and germ-free compressed air emerges from
the Bekokat the condensate produced when
the compressed air is cooled down after the
converter is also oil-free and can be discharged
into the sewage system without
treatment. An integrated heat exchanger
ensures maximum energy efficiency. Downstream
of the Bekokat are an oil-free dust
filter type Clearpoint 3Eco and an oil-free
cleaned refrigeration dryer Drypoint RA for
a constant moisture level below 5.95 g/m³
water content. The treatment is completed
by an oil-free ultra-fine filter of the Clearpoint
3Eco series for filtering out particles
down to 0.01 µm.
Thanks to the new treatment process, the
University of Wuppertal achieves consistently
oil-free compressed air with a maximum
residual oil content of a barely
measurable 0.003 mg/m³. In addition, the
compressed air processed for the laboratories
is sterile. Compressed air class 1.4.1
according to ISO8573-1 and the sterility of
the air are confirmed by TÜV Nord and a
validation certificate and can be remeasured
temporarily and stationarily at
any time.
The additional decentralised compressed air
treatment systems in the laboratories are still
in use because the contamination that used
to build up in the pipelines of the compressed
air network is only slowly degrading.
However, the replacement intervals of the
filter inserts will be significantly extended,
which will reduce maintenance costs.
More process reliability
“The good experience with the Beko Technologies
systems prompted us to immediately
implement the renewal of the other
four compressed air stations,” says Joachim
Conrad. In August 2020, these treatment
systems were also installed, thus fully completing
the designed project. Joachim Conrad
sums up: “The catalytic process with
Bekokat offers our laboratories the greatest
protection against oil in the compressed air.
By investing in the new equipment, we
increase process reliability and avoid high
costs that even a single fault at a sensitive
point in the laboratories would cause. ”
www.cpp-net.com
Online search: Beko Technologies
AUTHOR:
RAINER STÜTZEL
Manager Corporate Identity
& Relations Marketing,
Beko Technologies
cpp 02-2021 35

cpp FOCUS PUMPS AND COMPRESSORS
Intelligent interlocking control of air compressors
For greater efficiency
Using state-of-the-art compressor technology is not enough to obtain maximum efficiency.
Rather, it is the perfect interaction of the compressor and the higher-level control that
guarantees the optimal performance of the compressed air systems at all times. How impressive
this relationship can be, is demonstrated here by combining screw compressors
from the S-4 series and the Airtelligence provis 3 interlocking control.
For years, compressed air specialist Boge
has focused its research and product development
on the efficiency and cost effectiveness
of its compressors, closely followed by
reliability and quality. The S-4 series is one
example of how tried-and-tested technology
has been kept constantly under review
to achieve new milestones when it comes to
efficiency. The screw compressors from the
55 to 160 kW performance classes feature
an airend developed in-house for mainte -
nance-free operation and high efficiency.
This “Integratedrive” airend is impervious
to dusty environments and works with
minimal loss. By making the airend bigger
and thus slower, Boge has been able to
achieve optimal peripheral speeds. “There is
less wear and tear and the compressors have
a longer service life,” explains Frank Hilbrink,
Team Leader of Product Management
at Boge. “This pays off because these
measures help us to improve efficiency by
up to 15 %.” Large components, for
example coolers or pipe systems, result in
much lower internal pressure losses, which
in turn leads to a reduction in energy consumption
and costs. The efficiency of the
airend also essentially depends on how
much oil is injected. Boge sets the optimum
amount of oil to be injected for each of the
available main drive ratings according to the
various maximum pressures to ensure high
efficiency. The stepless speed control of the
oil-injection cooled screw compressors
allows the free air delivery to be set and adjusted
according to the current demand for
compressed air. In this way, Boge has kept
switching operations and no-load losses to a
minimum. Energy consumption is also reduced.
Intelligent control system
However, the increase in efficiency is not
down to compressor technology alone. The
integration of individual compressors in the
compressed air network and the cross-system
control are also key factors. The idea is
to make compressed air management as
Pictures: Boge
The oil lubricated S-4 screw compressor from 55 to 110 kW is also available with an integrated
dryer. Users benefit from very low pressure losses and high reliability.
36 cpp 02-2021

BUNGARTZ
MASTERPIECES
The Airtelligence provis 3 interlocking
control allows flexible and effective
compressed air management
The Airtelligence provis 3 smart control can
manage any number of compressors,
dryers, other components and even entire
compressed air networks – proactively and
based on consumption
flexible and as effective as possible. Boge
has mastered this with its Airtelligence provis
3 interlocking control.
Whereas conventional control systems only
control a certain number of compressors
and accessory components, this smart interlocking
control can manage any number of
compressors, dryers, other components and
even entire compressed air networks –
proactively and based on consumption.
Multiple functions and a 15.6” screen provide
a clear display of the pressure gradient,
operating statuses and other parameters,
while communication by Ethernet based on
Modbus TCP ensures faster data exchange
between several subscribers at the same
time.
The Airtelligence provis 3 can be used to
create individual profiles, for example for
the perfect configuration on individual days
of the week, at certain times of the day or at
weekends. Control algorithms optimally set
compressors for a certain operating point.
Before the pressure limit is even reached,
the appropriate compressor is activated and
the system pressure is controlled within a
defined pressure range. The control, however,
can also be programmed according to
machine priority, free air delivery or run
time optimisation. Boge’s Airlogic 3 software
module offers maximum flexibility as
the supply air, circulating air and exhaust air
valves can be controlled according to status
or temperature. The additional pro-FU option
allows several frequency-controlled
compressors to be operated at the same percentage
load. This prevents energy losses,
which can have a positive impact on the efficiency
of the compressed air system as a
whole. “Improving efficiency is what Boge
is about,” says Juliana Sträter, Product Manager
at Boge. “By decreasing the pressure
range by 1 bar for example, our Airtelligence
provis 3 has already reduced energy
costs by up to 10 %.” An integrated energy
reporting system breaks down the costs of
each connected component in detail.
It’s all in the combination
Boge compressors are particularly ideal for
3-shift operation in sectors such as the
chemicals and pharmaceuticals industry. The
compressed air machines come into their
own in applications involving dusty or polluted
air. Thanks to their direct drive and
sealed mechanical components, they are unlikely
to experience glitches.
They offer high quality compressed air, process
reliability as well as robust operation,
and can be precisely controlled via the interlocking
control. Users benefit from optimised
run time, shorter start-up and followup
phases and avoid idle capacity costs. Expensive
machine configurations are a thing
of the past, and there is no over-compression.
The pressure is within the defined
pressure range and is thus always set exactly.
The Airtelligence provis 3 also integrates
compressors by different manufacturers as
well as the corresponding peripheral equipment,
and even entire compressed air networks.
www.cpp-net.com
Online search: Boge
AUTHOR:
ANJA EHRMANN
Specialist journalist
THE POWER
OF REGULATION
Representing the groundbreaking
special centrifugal pumps
from the Bungartz collection,
series production
A top-class factory expertly
picks up on the current
movement towards pure
autonomy.
The dry-running centrifugal
pump VAN regulates
itself and requires no
interference. It works free
of cavitation, which makes
it even more fascinating.
When working with toxic
media it unfolds its full
potential.
An asset for many
companies!
More under
+49 211 577905 - 0
and online at:
www.bungartz.de/
masterpieces5
Visit uns at ACHEMA 2022,
Hall 8, Stand C 1
cpp 02-2021 37
1784491-2.indd 1 14.10.21 13:29

cpp TREND CIRCULAR ECONOMY
Picture: Matthias Krüttgen – stock.adobe.com
Plastic waste is a valuable resource
NEW LIFE FOR
OLD PLASTICS
Plastics are indispensable nowadays. They are light, stable and resistant.
Yet it is the latter property in particular that also creates the biggest problem
with this universal material. All too often, plastic products become
waste at the end of their lives and end up as huge carpets in the world’s
oceans. This is something that has to change, because used plastics will be a
valuable resource in the future.
38 cpp 02-2021

Picture: Covestro
The Covestro process for recycling mattress foam splits the PU foam used back into its original components
Plastics are the material of our time: in the fight against climate
change, for the development of new mobility concepts or to make
our cities more liveable. However, in order to achieve a truly sustainable
future and protect our environment in the long run, our
attitude towards consumption and our understanding of waste must
change. Since 1970, global resource consumption has more than
tripled. The natural resources for the whole of 2020 were already
exhausted after eight months. At the same time, humanity frequently
does not deal with products in a sustainable way. According
to a scientific study, only around 9 % of all plastics manufactured
between 1950 and 2015 have been recycled – 600 million out of a
massive 6.3 billion tons.
Produce, briefly consume, dispose – this pattern has had its day, in
particular with regard to plastics. They must be used more and for
longer. And at their end of life, they should be systematically and
effectively reused and recycled.
Better recycling systems needed
However, much remains to be done to achieve an effective and
resource-efficient circular economy. For example, worldwide waste
and recycling systems must be improved or indeed set up. Currently,
about two billion people – one quarter of the world’s population
– do not have access to regular waste disposal. Yet change can
only succeed if all market players work closely together. The plastics
industry can – and wants – to play a decisive role in this, for instance
in the Alliance to End Plastic Waste, a global coalition of
companies of which BASF, Covestro and Henkel, amongst others,
are members.
As one of the pioneers of the circular economy, Covestro wants to
promote recycling of plastics. In more than 20 projects, experts at
the company are working to make innovative technologies marketready
as soon as possible. In particular, the aim is to reduce the
carbon footprint of production processes and products while contributing
to climate and environmental protection. At the same
time, Covestro is keen to develop new circular business models with
customers and partners.
The newcomer: Chemical recycling
Mattresses give us a comfortable night’s sleep. Unfortunately, at the
end of their lives, they are usually burned or end up in a depot – a
destiny they share with many other plastic products. The average
amount of polyurethane foam in a mattress is round about 15 to
20 kg. But there is hope yet: chemical recycling, which is still in its
early stages, allows such materials to be recycled. During chemical
recycling, foams and other plastics are split into their molecules and
starting materials in order to manufacture new products.
With certain plastics, chemical recycling is the only sensible method
of recycling. It must therefore be further developed and promoted.
This also requires the right political and regulatory framework.
The goal is to make chemical recycling an integral part of the
plastics value chain – with all the advantages and disadvantages that
this technology entails.
Pilot plant for PU foam recycling
Covestro has recently also been operating a pilot plant for flexible
foam recycling, in order to verify the positive laboratory results
achieved to date. Thanks to this project on chemical recycling of PU
mattress foam, the company has made significant progress towards
the goal of a recycling loop. “The project is part of a long-term strategic
programme to fully align Covestro with the circular economy
cpp 02-2021 39

cpp TREND CIRCULAR ECONOMY
THE CIRCULAR ECONOMY:
HOW IT WORKS
Picture: Trueffelpix – stock.adobe.com
Circular economy versus linear: reuse, not throw away
The circular economy is a buzzword that is now an integral
part of company reports and mission statements.
But what exactly is it? In truth, the circular economy is
much more than a buzzword – it is a system philosophy
in which we no longer actually throw anything away.
Instead, materials are preserved through reuse or recycling,
with benefits for society and the environment.
The best way to understand the circular economy is to
look at our current model, which the world has followed
since the first industrial revolution: the linear
economy. This is a “take, make, dispose” model: extracting
resources that are used to produce goods and then
throwing away the waste product. This is not only a
waste of natural resources; it also leaves us with a major
waste problem and leads to ever higher greenhouse gas
emissions.
In short, the circular economy decouples economic
activity from resource use, which harms the planet by
removing waste from the system at every step. In doing
so, the circular economy starts with a product’s design
by ensuring that it is easy to recycle. The aim is to reduce
unnecessary packaging and offer customers more
sustainable options. At the same time, products must be
easy to repair or refurbish, in order to extend their life
and thus reduce waste. By collecting our entire waste
and recycling as much as possible, we can recover the
material value of products and prevent them from ending
up in the environment. Once the material value of
products has been recovered through recycling, the raw
materials can be reused to make new products, reducing
the use of new natural resources.
Implementing a circular economy therefore not only
benefits the environment but also ensures long-term
economic viability, with significant benefits for our society.
Experts estimate that the circular economy will
bring additional annual growth of 0.6 % and reduce
CO 2 emissions by 48 % in Europe by 2030.
Polycarbonate water bottles are particularly easy to recycle mechanically
and be a driving force in value creation”, says Dr. Klaus Schäfer,
Covestro’s Chief Technology Officer. “The development of this innovative
recycling technology and the investment in the pilot plant are
further milestones on the way to closing material loops. Our objective
here is to replace fossil resources in production, reduce the
carbon footprint of our materials and create solutions for dealing
with plastic waste. At the same time, we succeeded in proving that
polyurethanes are recyclable.”
Next-level foam recycling
“Our goal is to industrialise chemical recycling processes for postconsumer
flexible foams, in order to ultimately commercialise both
raw materials derived from recycling mattress foam”, explains
Karin Clauberg, Venture Manager Flexible Foam Chemolysis at
Covestro. “With our technology we’re aiming to deliver a high-purity,
high-quality recycled polyol that fulfils customer specifications
as well as a recycled toluene diamine, or TDA, which is suitable for
further processing to toluene diisocyanate. This isocyanate, or TDI
for short, is used together with the polyol for the production of
flexible foams.”
Furthermore, in collaboration with Recticel and Redwave – a division
of Wolfgang Binder GmbH – and as part of the PUReSmart research
project, Covestro has developed an intelligent sorting solution
to separate the different PU foams efficiently from post-consumer
mattresses. The software uses machine-learning algorithms for
proper recognition of the different types of foam, enabling clean
material inputs for the subsequent recycling process. It represents a
further component of the digitalisation strategy, with associated
new opportunities for the entire chemical and plastic value chain.
The classic: Mechanical recycling has much to offer
Mechanical recycling is the classic recycling method. Polycarbonate,
for example, is predestined for this. It is a particularly light plastic,
shatterproof, perfectly formable and a true all-rounder: polycarbo-
Picture: Covestro
40 cpp 02-2021

Picture: Covestro
Covestro has developed a vehicle headlight that is optimised for recycling
nate is used universally – from lenses to headlights to stadium
roofs. This high-performance plastic, which Covestro manufactures
and continuously develops, has yet another advantage: it is easy to
recycle. After being sorted, cleaned and separated, the used product
is crushed to granules. These granules are then melted and processed
into new plastic. Many Covestro products manufactured in such
a way are already on the market, including polycarbonate blends for
IT applications with up to 75 % recycled materials.
In 2000 in China, for instance, Covestro signed a cooperation agreement
with two companies that focus on making high-quality new
plastic parts from used polycarbonate water bottles. The beverage
manufacturer Nongfu Spring takes the bottles back and delivers
them to Ausell, a recycling specialist, where they are processed into
granules. Finally, Covestro manufactures precursors for electronic
and household appliances as well as car components. The aim is to
recycle one million such 19-liter (5-gallon) water barrels per year.
New ways: Designing products for recycling
With screws, dozens of individual parts and different plastics, car
headlights are usually very complex. This does not make it easy to
recycle them at the end of their life, but Covestro has developed a
concept that makes this possible – with one single type of plastic
and only a few components. This is a good example of a new approach
to the economy, namely to design products from the outset
with the best possible recycling in mind.
The sample headlight is not only lightweight, which amongst other
things increases the range of electric cars or lowers the exhaust gas
output of combustion vehicles. It also consists of much fewer components
than conventional models. And it is based on just one material:
high-performance polycarbonate.
Guide to the electrical industry
In other sectors too, more and more attention is being paid to the
use of recycled materials in end products. This applies, for instance,
to the manufacturers of electrical and electronic equipment and
household appliances. For them, Covestro has published the Circular
Design Guidebook, a booklet produced in collaboration with
Renato lab, the consulting firm, to help designers and developers
make their products more circular.
The book shows which materials are best suited for making products
as resource-efficient and sustainable as possible. It is also
about circular thinking in terms of supply chains and business
models as well as increasing resource productivity.
Conclusion
Companies like Covestro are working hard on solutions for plastics
recycling. Even if many processes are still in their infancy, the first
approaches are definitely recognisable. Overall, however, it will take
a great deal of effort yet before we can speak of a complete circular
economy. For example, many depolymerisation processes require
enormous amounts of energy, which must be made available in a
climate-neutral way. After all, it makes little sense to burn natural
gas in order to break plastics back down into their raw materials.
www.prozesstechnik-online.de
Online search: plastics recycling
DR. BERND RADEMACHER
Editor
cpp 02-2021 41

cpp
INSTRUMENTATION, CONTROL, AUTOMATION
Explosion-proof components guarantee high system availability
End-to-end automation of
tank farms
The New Zealand system integrator Automate-X has used Beckhoff components
to automate the tank farms of a leading global operator. Its aim was to create
an efficient interface between ship and shore while also facilitating agile and
competitive supply chains. The result are state-of-the-art terminals that provide the
tank farm operator’s customers with consistently high quality and safety without
compromising on comprehensive environmental protection.
As the new tank farms for the global operator
in New Zealand have been designed to
store flammable chemicals, they are classified
as plants with high hazard potential.
This poses special challenges for both the
tank farm operator and the system integrator,
as there are stringent requirements
regarding automation when storing potentially
explosive and environmentally harmful
chemicals. For this reason, the engineers
at Automate-X had to take into account
numerous aspects, standards, and special
features of explosion protection, as well as
functional safety, when planning the automation
concept. They were also required to
carry out a comprehensive analysis of the
electrical and safety-related requirements. In
the explosion protection zone, for example,
the hazardous areas had to be defined to
allow suitable explosion-proof components
to be selected. Another factor to consider is
that a high level of plant availability had to
be achieved to prevent a dangerous situation
caused by a plant breakdown.
Pictures: Beckhoff Automation
The PC-based control technology allows the straightforward integration of third-party software and hardware. Ben Haughey shows how
Automate-X was able to integrate Scada software and various drives into the automation system so easily.
42 cpp 02-2021

On a single I/O platform, one can accommodate
digital I/O modules, Twinsafe,
analogue Ex inputs, Namur inputs, HARTs,
and RS232/RS485 – all running on
Ethercat. The Ethercat redundancy ensures a
very high level of availability.
With the intrinsically safe ELX system, the
signals can be acquired and processed directly
from the hazardous area. By using
fibre optic lines with cable redundancy, the
extensive plant sections can be reliably
automated from long distances.
To be able to bridge the large distances of
tank farms, Automate-X relies on fibre
optics with a ring topology. An intrinsically
safe tablet can also be used for mobile
monitoring of the plant.
“We came up with the solution of implementing
a dedicated control system based
on remote I/O couplers connected throughout
the plant by Ethercat. All safety-critical
elements are monitored and controlled via a
CX5130 running Twinsafe, and as a final
safeguard against overfilling, the storage
tanks are equipped with SIL3-certified vibrating
fork probes,” reports Marcel van
Niekerk from Automate-X. He goes on to
explain that: “The gantry area for loading
the tankers features infrared flame detectors
that can trigger a spray foam system in the
event of a fire to prevent a potentially
catastrophic event. Additional safety components
include emergency stop switches,
Namur sensors to monitor valve statuses,
and a connection to fire alarm systems.” In
addition to the safety control system, Automate-X
also installed a separate CX5130 that
handles a number of tasks including regulating
the control of pumps and valves.
Countless benefits
It didn’t take long for the company to decide
in favour of Beckhoff – and therefore
PC-based control technology – because the
open nature of the technology developed by
Beckhoff facilitates straightforward integration
of third-party software and hardware.
This meant the Ignition Scada software
platform could be incorporated into
the tank farm project, and the tank farm operator’s
existing drives were integrated into
the automation system via Ethernet/IP.
Another key advantage for the project is the
wide range of Beckhoff terminals, since the
modular Ethercat I/Os allow for the integration
of safety, communication, redundancy,
and explosion protection components
in a single system. “On a single I/O
platform, we can accommodate digital I/O
modules, Twinsafe, analogue Ex inputs,
Namur inputs, HARTs, and RS232/RS485 –
all running on Ethercat.
Not only does the Ethercat redundancy ensure
a very high level of availability, but no
other platform offers such flexible configuration
options,” explains Ben Haughey from
Automate-X. Intrinsically safe barriers are
not required due to the use of the Ethercat
terminals in the ELX series that feature intrinsically
safe interfaces. This serves to simplify
the electrical design significantly and
makes it possible to achieve high-resolution,
high-precision signal acquisition in
hazardous areas, which is already standard
in non- hazardous areas. The use of Ethercat
single-mode fibre-optic components enables
interference-free communication between
the tank farm operator’s extensive
plant sections. In addition, the implementation
of cable redundancy via a ring topology
is also possible via fibre optics to ensure
a high level of plant availability.
Communication between the various controllers
and the Ignition Scada system is
implemented using OPC UA. Operators can
access the Scada system using intrinsically
safe tablets, allowing them to call up plant
data and control the plant from anywhere
on site. Communication between
Twincat and Scada is seamless via the
Twincat OPC UA standard.
“We are delighted that we have been able to
implement an innovative and, above all,
consistent automation concept for the tank
farms using Beckhoff components specifically
for hazardous areas. Our customer can
benefit from a reliable solution that is sure
to stand the test of time,” reports Marcel
van Niekerk.
www.cpp-net.com
Online search: Beckhoff
AUTHOR:
ANDRES OETKEN
Business Management
Process Industry,
Beckhoff Automation
cpp 02-2021 43

cpp
INSTRUMENTATION, CONTROL, AUTOMATION
HMI platform for Atex, IECEx zone 2/22, UL division 2 and non-hazardous areas
Everything from a single
source
Pepperl+Fuchs has added a new range to its modular Visunet series. With the new
Visunet FLX, the clue is in the name: FLX is short for flexibility, representing the fact
that the user can custom-configure this modular system as required.
In the process industry, the requirements
for product quality are extremely high. HMI
devices, which are used in this sector for
operating and monitoring the processes,
also have to meet the highest demands.
With this in mind, Pepperl+Fuchs already
developed the modular Visunet GXP for
hazardous areas back in 2016. This success
story is now being continued with the new
Visunet FLX for zone 2/22, Class I, II and
III, division 2 and non-hazardous areas.
The modular system is the perfect solution
for demanding application scenarios. The
additional range supplements the existing
Visunet GXP series, meaning a solution can
be used from zone 1 and division 1 through
to non-hazardous areas.
A highly flexible modular system
The fully modular design of the new platform
allows for highly customised configuration
of the HMI systems and enables
fast, simple, and cost-efficient service in
the field. Each user can choose from a
wide range of technologies, mounting
options, and peripheral devices. Every
HMI system consists of at least one computer
and display unit, which can be configured
specifically for the application. In
order to optimally support every possible
application, the Visunet FLX can be purchased
as a thin client, PC, or direct monitor.
It is available in three basic configurations
according to the application
requirement:
• The HMI system or basic configuration 1:
Various display options, including Full
HD, are combined with a thin client, PC,
or direct monitor unit. The housing is
made of stainless steel, with a design that
is suitable for pharmaceutical applications.
Depending on the requirements, the system
can be installed anywhere in the production
plant on a pedestal using additional
adapters or on a wall bracket.
• The panel PC or basic configuration 2:
This allows various display options to be
combined with a thin client, PC, or direct
monitor unit for panel mounting.
• The box PC or basic configuration 3:
This consists of a stand-alone PC or a
stand-alone thin client for direct installation
in a switch cabinet.
For cost-effective thin client applications,
all basic configurations are equipped with
Celeron processing units. For more CPUintensive
applications, i5 processing units
are available from Intel‘s seventh-generation
„Kaby Lake.“ Not only does this computer
technology provide high performance for
future software features, it also allows components
to be easily replaced during upgrades.
Overall, therefore, it is a safe investment
in the future.
Example of custom mounting of Visunet FLX for pharmaceutical applications
Pictures: Pepperl+Fuchs
For any installation situation
The new platform has been perfectly
aligned to the needs of the fine chemicals
and pharmaceutical industry. This means the
Visunet FLX easily meets the high requirements
of one of the most regulated industrial
sectors. For instance, the devices can be
used for producing vaccines in pharmaceutical
clean rooms. To this end, the HMIs
feature special stainless steel housing and
are resistant to a variety of chemicals and
44 cpp 02-2021

The completely modular design of the Visunet FLX allows for highly individual configuration
and enables quick and easy servicing in the field
cleaning agents. They are also suited for
pharmaceutical applications, as the lack of
steps, edges, or horizontal surfaces make
them easy to clean.
Such sites are often multi-purpose production
plants that manufacture a wide range of
products. For instance, solid or liquid raw
materials are mixed in steel-encapsulated
containers, at temperatures from -50 to
160 °C under pressure or in a vacuum, and
react to pharmaceutical products. In order
to monitor these processes, the devices do
not just have to comply with GMP guidelines
– they also need to handle a whole
host of installation situations. The new platform
offers complete installation flexibility
and is therefore able to cover all installation
requirements of the plant with a single-device
series. Generally speaking, ceiling or
wall mounting, panel installation, pedestals,
versions with duplex monitors or even mobile
carts are all possible. Any features not
already covered by the large number of
standard configurations can be implemented
as an individual solution in one of
the Pepperl+Fuchs Solution Engineering
Centers (SECs) located around the world.
Maximum process availability
Plants in the chemical industry usually run
around the clock in three-shift operation. In
order to ensure continuous production, a
key focus within the industry is the availability
of all operator stations and the mean
time to repair. Thanks to its modular design,
the FLX, like the entire Visunet family, has a
clear advantage over monolithic devices. The
latter have to be completely dismantled,
sent in, and repaired or replaced as necessary.
With the modular Visunet device series,
individual components can be replaced onsite
by plant service personnel. This reduces
downtime to a minimum and is extremely
cost-effective. Plant operators can either
stock relevant components themselves or
quickly obtain them from a nearby spare
parts warehouse. By using standard RDP
(Remote Desktop Protocol), the HMIs not
only offer high reliability but also great
flexibility. This makes Visunet FLX compatible
with all standard PCS and MES systems.
Due to its wide range of configuration options,
the FLX is perfect for a large number
of possible applications. The devices were
originally designed for the industrial indoor
applications described above. These include
vaccine production in pharmaceutical clean
rooms and as an operator workstation for
monitoring and controlling processes under
GMP guidelines in batch-oriented production
in the pharmaceutical industry. However,
other versions are available for special
requirements beyond these applications,
which can be used in ambient conditions
up to the extended temperature range:
There are also versions with Zone 2/22 and
Class I, II, III, Division 2 approval for other
applications. Choose between an industrialgrade
HMI for applications at temperatures
from 0 to +40/45 °C, or a panel for operating
temperatures from -20 to +55 °C. Both
are optimally tailored to the needs of the
(petro)chemical industry and to oil and gas
applications.
Investment security
For operators of large processing plants,
backward compatibility is another very important
criterion. Since successor products
are often not compatible with older HMIs,
given the large number of devices installed,
replacements and updates are often an unnecessarily
high cost factor. As with the GXP,
backward compatibility is ensured at all
times in the Visunet FLX, such as through
assembly compatibility and thin client technology,
thereby ensuring a high level of investment
security.
Summary
The new FLX is the ideal complement to the
flexible and cost-effective HMI operator
stations already on offer in the Visunet device
family. This now guarantees a consistent
portfolio from Zone 1 or Division 1 to the
switch room – everything from a single
source. With RM Shell firmware, all thinclient
devices are also based on a common
software philosophy with a focus on reliability
and user-friendliness. Thanks to the
Visunet control center, all HMI systems can
be managed from an incredibly convenient
central point. This ensures simple and uniform
handling of the devices for users
around the world.
www.cpp-net.com
Online search: Pepperl+Fuchs
AUTHOR:
NATALIE WALTHER
Product Marketing Manager
HMI, Process Automation,
Pepperl+Fuchs
cpp 02-2021 45

cpp
INSTRUMENTATION, CONTROL, AUTOMATION
Selecting devices and designing intrinsically safe circuits
Safe and effective interface
technology for Ex areas
Intrinsic safety type of protection has established itself worldwide in the field of
measurement and control technology in systems with potentially explosive areas.
However, when interconnecting equipment with type of protection Ex i, the user
must provide proof of intrinsic safety and should take this into account when selecting
the equipment. The MACX isolators and field analogue devices are recommended
here with properties such as flexibility, efficiency and availability.
The protection principle behind the Ex i
type of protection is based on limiting the
energy that is conducted to the potentially
explosive area and that can be stored there.
This means that the energy from any potential
spark has to be always less than the
minimum ignition energy of the surrounding
potentially explosive atmosphere. In
addition, no impermissibly hot and thus
ignitable surfaces – for example on electronic
components – may be created. As opposed
to all the other types of protection,
Ex i refers not only to a single item of
equipment but to the entire intrinsically
safe circuit, in accordance with IEC/EN
60079-11.
Ex i isolators are mandatory
Intrinsically safe circuits are generally
composed of the following elements:
• The intrinsically safe equipment, i.e., a
load installed in the Ex area (Figure 1),
e. g. an Ex i field device, where all circuits
are intrinsically safe
Figure 1: Whether a refinery, plastics processing or the chemical industry: thanks to their
features, the MACX isolators and Field Analog devices are proven cost-effective solutions
when it comes to explosion protection and system safety
Pictures: Phoenix Contact
• The associated equipment, i.e. a source installed
in the non-Ex area (Ex i isolator),
which contains both intrinsically safe and
non-intrinsically safe circuits
• The connecting line (cable)
Ex i isolators are particularly important here.
In accordance with IEC/EN 60079-11, they
have to be designed in such a way that the
non-intrinsically safe circuits cannot adversely
affect the intrinsically safe circuits, including
by means of safe electrical isolation.
Ex i isolators are therefore mandatory in
every Ex i MCR circuit. Moreover, they limit
the energy conducted to the Ex area, i.e. the
maximum no-load voltage U o , the maximum
short-circuit current I o and the maximum
power P o , to a non-incendive level. At the
same time, via C o and L o , the Ex i isolators
determine which maximum energy storage
elements – concentrated capacitance C i and
concentrated inductance L i in the field device,
line capacitances C c and line induc -
tances L c – can be connected without jeopar -
dising the intrinsic safety of the circuit.
Another important aspect of the Ex i type of
protection is the reliability of the energy
limitation itself under the assumption that
certain faults will occur. For that reason, intrinsically
safe electrical equipment and the
Ex i-related switching parts of the associated
equipment are designed in accordance with
the required safety and divided into different
protection levels, which in turn correspond
with the different zones in the Ex area. The
Ex ia protection level (double-fault tolerance)
is suitable for use in zone 0, the Ex ib protection
level (single-fault tolerance) is suitable
for use in zone 1 and the Ex ic protection
46 cpp 02-2021

level (zero-fault tolerance) is only suitable
for use in zone 2. The following applies accordingly
to areas at risk of explosion due to
dust-air mixtures (zones 20 to 22).
The proof of intrinsic safety
To ensure that the respective connection cannot
produce incendive sparks and incendive
hot surfaces, the user or system operator has
to demonstrate and document “proof of intrinsic
safety” in accordance with the socalled
operator standard IEC/EN 60079-14.
This process offers the user the advantage of
being able to select and combine Ex i field
devices and isolators from different manufacturers
in accordance with the specific
requirements.
Figure 2 shows a typical intrinsically safe circuit
consisting of an associated item of
equipment (source) with a linear or ohmic
source characteristic curve, an intrinsically
safe item of equipment, and the connecting
cables. Also listed are the safety-related
parameters needed to demonstrate intrinsic
safety and the criteria required for compliance
with intrinsic safety. For safe use,
these parameters must be able to be taken
from the user documentation.
Observing the 50-percent rule
In accordance with the current versions of
IEC/EN 60079-11 and IEC/EN 60079-14, an
evaluation must also be carried out to determine
whether the 50-percent rule must be
used. This is because the certified C o and L o
Figure 2: Parameters and criteria of an intrinsically safe circuit
values for the associated equipment may only
be fully utilised in simple intrinsically safe
circuits with no concentrated capacitances (=
C i ) and no concentrated inductances (= L i )
and in a mixed intrinsically safe circuit with
concentrated capacitances and/or concentrated
inductances on condition that L i

cpp
INSTRUMENTATION, CONTROL, AUTOMATION
Figure 3: Example of an intrinsically safe temperature measurement circuit
Figure 4: MACX Analog Ex – comprehensive
product range with 12.5 mm overall width
For that reason, we have provided an
example showing how to verify the intrinsic
safety of an intrinsically safe temperature
measurement circuit which is led into a frequently
occurring Ex atmosphere consisting
of a hydrogen/air mixture (zone 0).
This Ex i measurement circuit consists of an
interconnection between a MACX MCR-EX-
RPSSI-I repeater power supply as the active
associated equipment item with a linear
source characteristic curve and two passive
intrinsically safe items of equipment: an FA
MCR EX-HT-TS-I-OLP temperature transmitter
and an FA MCR-EX-DS-I-I process indicator
(Figure 3).
For the verification of intrinsic safety, the following
criteria must be fulfilled:
• The device protection level (Ex ia, Ex ib, nA
[Ex ia]) or the device category (1G, 2G,
3(1)G) is suitable for use in the corresponding
zone. This criterion in the
example is met by the indication in the EU
examination certificate for the field display
that the device can be used within an Ex i
circuit with ia protection level without this
affecting its level of protection.
• The explosion group is suitable for the application.
All Ex i devices used apply according
to the marking IIC for an Ex atmosphere
consisting of a hydrogen-air mixture.
• The temperature class is suitable for the application.
All Ex i devices used have a temperature
class between T4 and T6, depending
on the permissible ambient temperature,
and are therefore suitable for a hydrogen-air
mixture.
• The five criteria listed in figure 2 regarding
the Ex i parameters are met. This prerequisite
is met in accordance with the Ex i pa -
rameters shown in figure 3. This is a mixed
Ex i circuit for which there is no need to
use the 50-percent rule. Only the process
indicator has an inductance of 35.1 μH to
be considered. Assuming a specific cable capacitance
C c of 140 nF/km and a cable inductance
L c of 1 mH/km, a maximum cable
length of 750 m for the capacitance and
1964.9 m for the inductance is thus mathematically
possible with a C o value of
107 nF and a L o value of 2 mH. Since the
smaller value is decisive, this interconnection
is intrinsically safe with a line length
of up to 750 m.
The proof of intrinsic safety described above
must be implemented separately for the interconnection
of the field-side connections
of the head-mounted transducer with the
thermocouple and the resistance thermo -
meter. Thermocouples and resistance thermometers
are considered “simple electrical
equipment” as defined in IEC/EN 60079-11
and IEC/EN 60079-14.
Consideration of functional data
When choosing devices, the dimensioning of
the functional data must be taken into consideration
along with the proof of intrinsic
safety. For example, the MACX MCR-EX-SL-
RPSSI-I repeater power supply provides the
FA MCR EX-HAT-TS-I-OLP temperature transmitter
with a supply voltage of 16 V at
20 mA. The temperature transmitter in turn
requires a supply voltage of at least 11 V DC.
The slight voltage drop for the FA MCR EX-
DS-I-I process indicator of

cpp
PRODUCTS
Modular photochemistry reactor
Biofouling preventing technology
Syrris’ Asia photochemistry
reactor enables a host of novel
photochemistry applications in
flow across a variety of sectors.
The reactor has been designed
to meet the demands of the
market, with individual, high
powered LED modules available
to provide a variety of wavelengths.
These modules can be
quickly and easily interchanged
for rapid screening and optimi -
sation of conditions, and offer
Picture: Syrris
adjustable light intensities to
help tune reaction rates and increase
production. A built-in,
interlocking cover prevents high
intensity light exposure to ensure
user safety, and the system
also provides precise and accurate
temperature control from
-40 to +80 °C, eliminating the
need for external cooling
sources to maintain optimum
performance.
The Asia photochemistry reactor
is modular in design, flexible
and scalable. The extremely
user-friendly system allows
chemists to control experiments
either manually or using intuitive
automation software, supported
by world-class global
customer care.
www.cpp-net.com
Online search: Syrris
Biofouling is one of the most
common and severe problems
in the operation of a reverse osmosis
(RO) system. Unchecked,
it causes significant operational
problems such as frequent interruption,
damage to the membranes,
intense chemical and
energy use, and regular cleaning-in-place
(CIP) of the RO.
Dupont Water Solutions is
launching a pre-treatment technology
that efficiently elimi -
nates the effects of biofouling in
RO systems. Dupont B-Free so -
lution is the result of a multiyear
research and development
effort that consists of a vesselbased
media technology that
offers a reliable, easy-to-use and
sustainable solution. It is based
on the ability of B-Free pretreatment
technology to create
an instant and sustained bio -
static environment for the
downstream RO operations
without the need for chemicals
and resilient to upstream upsets.
B-Free pre-treatment is the so -
lution designed for customers
suffering from biofouling and
looking for designing, building
and operating reliable RO systems
at an optimised cost of
water and sustainability footprint.
The technology enables a
reduction of CIP frequency by
up to 75 % and may double the
RO membranes and cartridge
filters’ lifetime. The B-Free customers
will be able to achieve a
low-touch and stable plant operation
with up to 50 % lower
operations downtime required.
www.cpp-net.com
Online search: Dupont
Cleaning system for heat exchangers
Active torque control for decanters
No employees are needed to conduct the fully-automated,
patented Jetmaster process. The system’s electronic controller
offers multiple cleaning programmes for heat exchangers
that can be selected easily at the push of a button.
The Jetmaster AS is environmentally-friendly, with jet
widths of 500 mm, for instance, and a water usage of over
240 l per hour. Approximately 100 m 2 of the exchanger’s
surface can be cleaned in just one hour. The system also
produces only a small amount of waste water. The Jetmaster
AS is chemical-free, using only 5 to 7 bar compressed
air and water and delivers a high quality cleaning.
The Mycon Controlmaster algorithm calculates the optimal
times to clean the heat exchangers based on data available
from the customer. This data covers at least the last year,
and preferably the last three years.
Controlmaster reviews and processes data received from
the customer in a fully automated procedure. The required
data and transmission are coordinated with the customer
in advance. Calculations are completed quickly, even for
large quantities of data.
www.cpp-net.com
Online search: Mycon
Picture: Mycon
With its automatic active torque
control (ATC) for CF decanter
centrifuges, GEA makes production
processes more reliable
under stick-slip conditions.
GEA’s ATC solution features onthe-fly,
automated correction of
the differential speed by means
of active torque control to ensure
an optimal working point
while avoiding stick-slip. This
ensures maximum solid yield,
minimum energy costs for thermal
drying and significantly
lower risk of system damage
due to stick-slip.
ATC reliably detects the occurrence
of the stick-slip effect and
makes the necessary adjustment.
A perennial problem for decanter
operators is finding the
Picture: GEA
optimal working point to maximise
dry substance yield while
still avoiding stick-slip. Adding
to the challenge is the fact that –
like for products such as starch
or casein – the optimal working
point often approaches conditions
where stick-slip can occur.
GEA’s ATC solution adds intelligence
to the decanter system so
it can make the necessary adjustments
on the fly for an optimal
working point with optimal
safety and efficiency. GEA offers
its ATC automated monitoring
and control system in new CF
decanter series machines, as
well as the option of retrofitting
existing CF decanters with ATC.
www.cpp-net.com
Online search: GEA
cpp 02-2021 49

cpp
CONTACT THE EDITORS
LUKAS LEHMANN
Editor-in-Chief
Phone +49 711 7594-290
lukas.lehmann@konradin.de
CLAUDIA BÄR
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ISSN 0724–1054
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The Editor cannot be held responsible for unsolicited
reports from industry. Please note that brands
or trade names that are not specifically trademarked
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Printed in Germany
© 2021 by Konradin-Verlag
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cpp
LIST OF ADVERTISERS
Aerzener Maschinenfabrik GmbH, Aerzen 33
AZO GmbH & Co. KG, Osterburken 15
Paul Bungartz GmbH & Co. KG, Düsseldorf 37
C. Otto Gehrckens GmbH & Co. KG, Pinneberg 13
Maschinenfabrik Gustav Eirich GmbH & Co. KG,
Hardheim 5
ElringKlinger Kunststofftechnik GmbH,
Bietigheim-Bissingen 3
GATHER INDUSTRIE GmbH, Wülfrath 29
Getriebebau NORD GmbH & Co. KG, Bargteheide 17
IPCO Germany GmbH, Fellbach 31
Dr. Jeßberger GmbH, Ottobrunn 52
REMBE GmbH Safety + Control, Brilon 32
VEGA Grieshaber KG, Schiltach 2
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