Predictive Valve Maintenance: The Future Is Now For

VACUUM CONVEYORS: POWDER HANDLING’S INCREASE PLANT INSIGHTS BY LEVERAGING www.processingmagazine.
com
ANTIDOTE TO SOARING POST-PANDEMIC COSTS PAGE 18 INSTRUMENT DIAGNOSTIC DATA PAGE 48 MARCH 2023
The future is now for

PREDICTIVE
VALVE
MAINTENANCE
SPECIAL SECTION
PAGES 34-47
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CONTENTSMARCH 2023 | VOL. 36 | NO. 3
COLUMN: Food & Beverage
12 Controlling food production costs

made simple with NIR analysis
How food processors are navigating rising prices with
proven quality assurance applications.
COVER STORY
14 The future is now for

predictive valve maintenance
14
Advances in digital valve controllers, diagnostics software and
network communications are enabling significant reductions
in maintenance costs and unplanned outages — resulting in
enhanced service life, increased productivity and cost reduction.
POWDER & BULK PROCESSING
18 Vacuum conveyors: Powder handling’s antidote

to soaring post-pandemic costs
Automating powder handling with vacuum conveying systems is
one of the fastest and most economical ways for manufacturers and
processors to mitigate skyrocketing labor, energy and material costs.
22 Combustible dust hazards of dilute phase

pneumatic conveying systems
Proper design, operation and maintenance are critical to
minimize dust explosion hazards when pneumatically conveying
combustible dusts and particles.
30 Different ways to charge material in a

pneumatic conveyor
This article explores the most common types of pneumatic conveying
system line chargers and their usual applications and limitations.
18
WATER TECHNOLOGY
34 Efficiently measuring and accounting

for cooling water
The right instruments ensure that building and maintaining a
reliable cooling water system can be realized with a minimum
of upsets or process fluctuations.
36 Industrial water and steam treatment will be

important for a long time
The first installment in a four-part series examining modern
water treatment and chemistry control/monitoring technologies.
36 48
www.ProcessingMagazine.com Facebook Twitter LinkedIn

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2 Processing | MARCH 2023

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CONTENTS
WATER TECHNOLOGY DEPARTMENTS
42 A closer look at National Beef’s

new wastewater treatment plant
Beef producer constructs wastewater treatment plant to meet
6
8
Editor’s Note
Industry News
state standards and reduce its dependency on local aquifer with
water reuse for agricultural irrigation. 28 Powder Show preview
46 Case study: Ensuring compliance and

continuous water quality monitoring
Chemical manufacturer uses KETOS SHIELD to improve water
54
55
Classifieds
Advertiser Index
quality and ensure regulatory compliance.
56 ProcessingMagazine.com
FEATURES
48 Increase plant insights by leveraging

instrument diagnostic data
By examining data that is frequently already available, food
VACUUM CONVEYORS: POWDER HANDLING’S INCREASE PLANT INSIGHTS BY LEVERAGING
ANTIDOTE TO SOARING POST-PANDEMIC COSTS PAGE 18 INSTRUMENT DIAGNOSTIC DATA PAGE 48
PREDICTIVE
www.processingmagazine.com
MARCH 2023
and beverage processors can increase batch yields, reduce VALVE

MAINTENANCE
downtime and increase proactive maintenance.
SPECIAL SECTION
PAGES 34-47
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EDITOR ' S NOTE

CONTENT
Chief Editor Jesse Osborne
[email protected]
Managing Editor Daniel Gaddy

[email protected]
Senior Editor Nate Todd
W
[email protected]
elcome to the March issue of Processing. Art Director Ryan Carlson

[email protected]
First off, some exciting news to share: This
issue features our first special section fea- Production Manager Josh Troutman
[email protected]
turing content from sister brand Water
Technology. Articles and case studies
focused on industrial water and wastewa-
ADVERTISING
ter will be featured in the pages of Processing on a quar- District Manager Jay Haas
281-980-5831 | [email protected]
terly basis this year, with additional special sections
planned for the June, September and December issues it meet regulations and reduce its dependency on a Account Manager Lisa Williman
518-322-6691 | [email protected]
in 2023. local aquifer.
The Water Technology section starts on Page 34 of this Lastly, KETOS founder and CEO Meena Sankaran
issue with an article from Emerson’s Cheng Vue that provides a case study that outlines how the company
MARKETING
discusses how the right instruments help to efficiently helped a major chemical manufacturer ensure regula- Digital Product Director Nick Phillips
[email protected]
measure and account for cooling water. tory compliance via continuous water quality monitor-
Vue writes: “There are different systems that require ing at one of its production facilities. Digital Operations Manager Mary Beth Romano
[email protected]
cooling, whether in power generation or chemical pro- I hope you find this content both interesting and infor-
cess applications, and knowing the water used for the mative. For more content related to industrial water and Marketing Manager Lexi Richards
[email protected]
process of cooling and temperature regulation allows wastewater, please visit www.watertechonline.com.
for accurate accounting and reporting. Considering Audience Development Manager Anna Hicks
[email protected]
that most often the water used in these instances “The Powder Show” returns April 25-27
comes from municipal sources, it stands to reason a The International Powder & Bulk Solids Conference Endeavor business media
facility wants to know how much they are using and & Exhibition returns to the Donald E. Stephens CORPORATE
where the wastewater goes after it has run through the Convention Center in Rosemont, Illinois, from April
process. Accounting for wastewater is also required for 25-27. Turn to Page 28 for a brief preview of this year’s CEO Chris Ferrell
environmental reporting.” “Powder Show” to find out more about this year’s event. President June Griffin
Next, Brad Buecker and Katie Perryman team up on Be sure to check out www.processingmagazine.com in CFO Mark Zadell
the first installment of a four-part series that will exam- the weeks leading up to the show for more information, as COO Patrick Rains
ine modern water treatment and chemistry control/ well as brief video interviews with subject matter experts Chief Administrative and Legal Officer Tracy Kane
monitoring technologies. Part 1 takes a closer look at who are presenting educational sessions at the event.
EVP/Industrial Group Mike C. Christian
makeup water treatment. They write: “Inattention to
makeup water system operation and maintenance Sincerely,
can cause serious deposition and corrosion issues in
steam generators. Subsequent failures can be costly and Processing (ISSN 0896-8659, print; 2641-6581, digital) is published monthly by Endeavor
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EDITORIAL ADVISORY BOARD Email: [email protected]
Christine Banaszek, Sales Manager, ROSS Mixers | Frederic Baudart, CMRP, Senior Product Application Specialist, Fluke Accelix
Eric Maynard, Vice President, Jenike & Johanson | Jack Osborn, Senior Engineer, Airdusco | Colin Barbeau, Bulk Materials Handling Specialist, Hatch
Todd Smith, Manager, Kansas State University Bulk Solids Innovation Center | Bill Bremer, Principal, Food Safety, Kestrel Tellevate
Robert Rogers, Senior Advisor for Food Safety & Regulations, METTLER-TOLEDO | David Brewer, Mid-Atlantic Regional Manager, Sealing Equipment Products Co. (SEPCO)
David W. Sptizer, PE, Spitzer and Boyes LLC | Mike Klimes, Applications Engineer, Tsurumi (America) Inc.

MARCH 2023 N E W S, N OT E S A N D I N S I G H T S F R O M A C R O S S T H E P R O C E S S I N D U S T R I E S processingmagazine.com
INDUSTRY EVENTS
PACK EXPO Las Vegas 2023 on track to be

largest show in its history
In keeping with industry growth, PACK EXPO Las
Vegas 2023 (Sept. 11-13; Las Vegas Convention
Center) is on pace to be the largest, most com-
prehensive edition of this trade show since its
inception, according to show producer PMMI,
The Association for Packaging and Processing
Technologies.
As the premier destination to explore cutting-
edge packaging and processing solutions, PACK
Image courtesy of Honeywell

EXPO Las Vegas will include more than 2,000 sup-
pliers, as well as new and growing show features
that address key industry trends.
PACK EXPO Las Vegas has already surpassed
final exhibition space for PACK EXPO Las Vegas
2019 and continues to increase. Industry growth
is driving the expansion, with 60% of consumer
packaged goods (CPG) companies indicating that
their investment in packaging machinery will
EXXONMOBIL to deploy Honeywell increase in 2023 and 64% saying their scheduled
projects will increase, according to PMMI’s 2023
carbon capture technology Purchasing Plans and Priorities report.

“Our industry is stronger than ever and posi-
tioned for unprecedented growth, making the
H
kinds of connections and innovations that come
oneywell announced that ExxonMobil ExxonMobil's Baytown integrated complex is
from a world-class trade show more crucial than
will deploy one of Honeywell's carbon home to the largest olefins plant in the United
ever,” says Jim Pittas, president and CEO, PMMI.
capture technologies — Honeywell's States. The site is located on approximately
“PACK EXPO Las Vegas will provide unrivaled
CO 2 Fractionation and Hydrogen 3,400 acres along the Houston Ship Channel.
opportunities to move projects forward, forge rela-
Purification System — at its integrated "ExxonMobil's investment in carbon capture
tionships, and gain valuable insights on industry
complex in Baytown, Texas. This tech- technology shows our commitment to sup-
trends — all in one place.”
nology is expected to enable ExxonMobil to cap- porting customers in their decarbonization
Due to a significant increase in demand, The
ture about 7 million tons of carbon dioxide (CO2) efforts and to reducing emissions at our own
Processing Zone is currently 44% larger than it
per year, the equivalent of the emission of 1.5 mil- operations," said Dan Ammann, president of
was in 2021 and growing. This growth tracks with
lion automobiles for one year. ExxonMobil Low Carbon Solutions. "The scale
the increase in processing suppliers joining PMMI,
Honeywell UOP's carbon capture tech- of this project is expected to enable up to 30%
with 27% of companies joining in the last two
nology will be integrated into the design of of Scope 1 and 2 emissions from our Baytown
years offering processing solutions.
ExxonMobil's low-carbon hydrogen production facility by switching from natural gas as a fuel
PACK EXPO Las Vegas is filled with several
facility and enable it to capture more than 98 source to low-carbon hydrogen."
must-see features addressing critical industry
percent of associated CO2 emissions. The cap- "The use of Honeywell's technology enables
needs, such as a brand-new show floor destination
tured CO2 is expected to be sequestered and ExxonMobil to reduce CO2 emissions at a large
focusing on sustainability. The Logistics Pavilion
permanently stored by ExxonMobil. scale," said Barry Glickman, vice president
will make its Las Vegas debut nearly double the
ExxonMobil's Baytown low-carbon hydrogen, and general manager, Honeywell Sustainable
size it was at PACK EXPO International 2022. The
ammonia and carbon capture facility is expect- Technology Solutions. "Our ready-now carbon
Containers and Materials, PACKage Printing and
ed to produce around one billion cubic feet of capture technology works to decarbonize pro-
Healthcare Packaging Pavilions are also larger
low-carbon hydrogen per day, making this the duction processes and is effective because it can
than previous shows, offering even more targeted
largest low-carbon hydrogen project in the allow for significant emissions reduction that
solutions in easy-to-navigate show areas.
world at planned startup in 2027-2028. can play a major role in the energy transition."
“We are excited to be offering such a compre-
hensive show with features directly addressing the
trends, opportunities and challenges facing our

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available packaging and processing solutions and correctly. tainability in all areas of its business and contin-
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ence of PACK EXPO Las Vegas.” — how remote condition monitoring provides assist process manufacturers in their efforts to
Attendee registration for PACK EXPO Las Vegas valuable insights and reduced costs. meet these same environment, social and gover-
will open April 3. For more information visit nance (ESG) criteria.
www.packexpolasvegas.com. Each day of the EASA Convention features the
Solutions Expo where the industry’s leading man- Water technology company Aquafortus
EASA announces program for 2023 ufacturers and service providers showcase the lat- raises $17M in funding
Convention & Solutions Expo est developments in electric motors, drives and Aquafortus, a water technology company that
The Electrical Apparatus Service Association controls, generators and other equipment and ser- purifies high-salinity brines and derives valuable
(EASA) will hold its annual Convention and vices for the electromechanical industry. metals and minerals from them in the process,
Solutions Expo on June 24-27, 2023, at the Gaylord For the complete program, exhibitor listing and recently announced the closing of a $17 million
National Resort & Convention Center in National to register, visit www.easa.com/convention. oversubscribed Series A1 financing.
Harbor, Maryland. The 2023 Convention theme is Until now, brine desalination has been pro-
“Together Towards Success.” hibitively expensive: thermal-based evaporation,
EASA’s 2023 Convention education line-up fea- COMPANY NEWS the most common technology today, is highly
tures a wide-ranging program designed to address energy-intensive. Aquafortus uses a non-thermal,
all areas of the electromechanical sales and repair eschbach Awarded Bronze Sustainability zero-liquid-discharge recovery and crystallization
business. This year’s featured keynote speaker, Rating from EcoVadis approach that uses 90% less energy, costs 60%
Connie Podesta, will kick off the convention by Global software developer eschbach, the provider less, and turns 98% of high salinity brine into fresh
bringing her message “Together for Success! Really? of Shiftconnector enterprise software platform water, while extracting lithium, copper, magne-
But Life Would be Easy If It Weren’t for Other for process manufacturing, recently announced sium salts and other metals and minerals.
People” challenging and empowering attendees to that it has received a Bronze Sustainability Rating Aquafortus targets industries that produce sig-
understand and get along better with the people in from EcoVadis, which ranks the company in the nificant volumes of hypersaline water: mining,
their life. More than 30 education sessions are avail- top 50th percentile of organizations rated across oil and gas production, chemical manufacturing,
able throughout the convention, including: the world. Achieving such a high ranking from and power generation. The financing will allow
EcoVadis, the world's largest and most trusted the construction and deployment of a relocatable
• Sustainability: Emerging and Developing provider of business sustainability assessments, demonstration unit and commercial pilot across
Opportunities in the Motor Service Industry reinforces eschbach's commitment to sustainabil- major U.S. oil and gas basins and operators, as well
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COLUMN: FOOD & BEVERAGE
Controlling food
production costs
By Chris Pike made simple with NIR analysis
KPM Analytics
Chris Pike is the senior global
business development director for
How food processors are navigating rising prices
NIR products with KPM Analytics. with proven quality assurance applications.
A
s the global food market name a few. In most cases, food proces- etc.). Most NIR instruments will provide
becomes more specialized sors take suppliers at their word regard- comprehensive data in under 30 sec-
and competitive, processors ing the quality of their ingredients. onds and in-process instruments can
are feeling the pressure to Once in production, however, they may transmit data in real time.
innovate while meeting the find that their ingredients may affect the
high expectations set by their processing of the food product, and poten- Customized calibrations to
consumers. However, with inflation tially yield a poor-quality final product. analyze ingredients or product-
impacting the food industry hard today, Then, for various reasons, ingredient specific traits
these pressures are compounded. properties can change during the food NIR is not a new technology. Because of
From flour to seasoning sprays, food production process. Routine at-line or this longevity, NIR calibrations for vari-
ingredients have always been among in-process product quality analysis is ous food products have become more
the highest routine expenses for any also necessary to maintain high stan- repeatable due to continued research
food processor. These ingredients are dards and avoid over-formulating (or and application customization.
generally sold to food processors based overusing) costly ingredients. Every NIR calibration is a mathemat-
on the availability of specific qual- ical correlation between raw NIR data
ity parameters such as moisture, fat/ Few options to control taken from a sample compared with
oil content, protein and crude fiber, to essential parameters a chemical constituent or property of
One option is to submit ingredient or interest. The product samples used to
product samples to external quality create a calibration should represent
laboratories for analysis. Over time, this future samples in all areas of potential
can become quite costly; sample analy- variability, including range(s), origin,
sis typically costs an operation between seasonal variation and others. Also,
$20 and $50 per sample. Also, it can it is possible to transfer the same NIR
take days to receive results, which calibration to multiple instruments or
means the ingredients or food products production sites. Companies can com-
could have been used in production mand consistent product quality no
and distributed to consumers. matter where the product is produced.
As an alternative, more food proces- As many companies have found, the
sors are investing in near-infrared (NIR) flexibility of NIR technologies can help
technologies to help fortify their quality spark new ideas to measure quality at
assurance protocols. In this process, the various stages of the production pro-
instrument transmits near-infrared light cess. For instance, a product calibration
onto a product sample, which absorbs for a benchtop NIR instrument to verify
at various wavelengths. A detector on moisture and fat content could lay the
the device reads the reflected NIR light. framework for an in-process instru-
Then, using a calibration, the instrument to measure product in real time.
ment generates data on a specific qual-
ity parameter (moisture, fat, protein, How food processors are
employing NIR technologies
Analysis of incoming raw ingredients:
 The MCT466-SF on-line NIR analyzer shown here
offers real-time monitoring of moisture and oil content NIR instruments analyze incoming
in various process stages to help operators make data- raw ingredients for compositional and
driven decisions to save costs and improve efficiencies. physical parameters. These data ensure
All images courtesy of KPM Analytics the compositional profile needed to

“monitoring
support final product quality or ensure
ingredients meet contract specifica- Using NIR technology for the at-line or in-process
tions and support claims for out-of-
specification materials.
of food production lines can mediate raw
Chocolate, for instance, is a vital
ingredient for many baked goods and
snack foods. Cocoa liquor is mixed
material costs and ensure consistent product quality.
”
with sugar and cocoa butter to produce ever, that machinery begins to function
chocolate. Cocoa butter introduces fat out of specifications. This can negatively
to chocolate, which influences product impact a company’s bottom line and the
texture and taste. Cocoa butter is also consumer experience.
one of the most expensive ingredients In cereal production, for instance,
in chocolate production. sugar is crucial for customer accep-
It is not uncommon for bakeries or tance. Tumbling applicators are an
snack food companies to struggle with efficient, low-impact way to sugarcoat
the frequent reworking of products entire products in high volumes. The
due to chocolate quality inconsisten- sugar or seasoning adherence on the
cies. These struggles worsen as suppli- final product is a function of many
ers raise their prices due to commodity factors, including moisture in the mix,
pricing increases. humidity and product temperature.
More companies are turning to NIR One cereal producer routinely struggled
technologies to verify incoming choco- with over-formulated final products. As
late’s fat, moisture, sugar and lactose a result, its production crew would com-
content. This analysis helps significantly monly over-formulate sugar added to
reduce instances of rejected or reworked the tumbler by 2% ( from 10% to 12%) to
products while holding suppliers ensure total product coverage. This pro-
accountable for their promise of quality. cess became cost-prohibitive over time.
With the help of an at-line NIR
In-process analysis of moisture and oil: instrument to regularly inspect in-pro- Finding a “sweet spot” for product  Sugar and seasoning additives repre-
NIR analyzers positioned in or over a cess samples, this cereal manufacturer moisture and fat content is challeng- sent some of the highest routine expenses
for food processing companies.
production line provide real-time feed- reduced sugar use by over 15%, saving ing for many food processors. Too little
back to help operators adjust process the operation $3,000 daily. moisture or fat can result in a crumbly
parameters such as oven temperature Another sugar or seasoning applica- texture. Too much moisture or fat can
or conveyor speed. tion method involves spray nozzles, lead to a soggy product and microbial or
For example, crunchy snack foods get which can be positioned at various mold growth.
their texture through a frying or baking points of the production process to Examining products for moisture, fat
process that removes moisture from apply a consistent seasoning mixture. and other parameters before packaging
raw products. Tortilla and corn chips, Operators can adjust the load by regu- can help ensure the best possible custom-
for instance, usually require a moisture lating the sprayer pump, but changes in er experience while improving shelf life.
level between 1% and 2.5% depending the consistency/viscosity of the season- NIR technologies offer a more efficient
on specifications set by the manufac- ing, clogged nozzles and other factors way to verify final products than IR mois-
turer. Fat (oil) content is another essen- can influence seasoning load. ture balances or routine lab analysis.
tial factor that generally needs to stay These changes were a common occur-
within 25% to 35% in the final product. rence for one popcorn manufacturer. Taking advantage of
Quantifiable, real-time data on prod- To address sprayer inconsistencies, proven methods
uct moisture and fat content are essen- the quality control team utilized NIR As the food industry continues through
tial to ensure product consistency technology to analyze grab samples of these tumultuous times, processors —
while reducing energy costs. products after receiving their propri- with the help of NIR technology — can
A tortilla chip manufacturer recently etary seasoning blend. access the data they need to qualify
installed rugged NIR moisture and fat They developed a custom NIR cali- incoming ingredients and confidently
analysis sensors to continually monitor bration to analyze specific parameters reduce ingredient over-formulation
these critical parameters of products of products against parameter read- Using NIR technology for the at-line or
before and after the fryer or oven. With ings from an ideally seasoned product. in-process monitoring of food production
this technology, the operator can opti- This effort has helped the team reduce lines can mediate raw material costs and
mize the cooking oil or energy used in applied seasoning by 5%, saving the ensure consistent product quality.
a production run or adjust temperature company over $1,000 daily.
and belt speed to achieve proper levels.
Final product examination:
Monitoring sugar and seasoning Just as NIR technologies can analyze MORE
application: product parameter quality before and ONLINE Visit processingmagazine.com
Food processing companies employ during production, the same principles for more on food and beverage.
various methods to apply sugar and sea- can apply to qualify final products before
sonings to food products. Suppose, how- packaging.
MARCH 2023 | www.processingmagazine.com 13

VALVES & ACTUATORS
 Smart digital valve controlers, such

as the Fisher FIELDVUE DVC6200
SIS Digital Valve Controller, employ
sensors that detect air, actuator,
packing and valve problems.
All images courtesy of Emerson

predictive valve maintenance
Advances in digital valve controllers, diagnostics software and network communications
are enabling significant reductions in maintenance costs and unplanned outages
— resulting in enhanced service life, increased productivity and cost reduction.
By Saurabh Pathak and Naman Tahan, Emerson
P
rocess manufacturers have pursued the Proactive versus reactive repair perform the repair, and minimize production loss.
elusive goal of predictive maintenance for Automated control and on-off valves are critical The key ingredient that makes this predictive
decades because they know that deploy- components in a vast number of processes, and maintenance possible is data, and ideally the more
ing resources and focusing on equipment their unanticipated failure can cost millions of information one has, the more accurate predic-
that is about to fail, while allowing healthy dollars annually. Unfortunately, many automated tions can be. Historically, automated valve data
devices to remain in service, will save mil- valves offer no obvious hint of developing prob- has been limited to valve position, but with every
lions in maintenance costs. Avoiding unplanned lems. When the PID controller is set to automat- generation of smart diagnostic digital valve con-
outages and shutdowns would undoubtedly save ic, which is typically the case, it compensates for troller, more information has become available.
millions more. It stands to reason that every com- degrading valve performance, so the loop contin- These digital valve controllers employ an array of
pany should be run this way, yet few have accom- ues to function, albeit with reduced performance. sensors to monitor the valve and detect abnormal
plished that goal because predicting the future is Eventually the valve fails completely, upsetting the conditions as they develop. Higher-tier units allow
notoriously difficult. process or forcing a shutdown. both offline and online monitoring. Valve signa-
This article discusses a variety of diagnostic and In reality, there often are hints of an impending tures and as-installed data can be captured and
data-driven initiatives that make predictive mainte- failure, but these signs can be quite subtle (Figure 1). compared with future tests to note discrepancies.
nance possible. These efforts have been years in the Still, if these signs could be detected and acted upon, These types of online measurements capture ongo-
making and are bearing fruit in the automated valve it would be possible to gather the necessary repair ing valve performance and transient problems that
industry, with ongoing development underway. components, schedule a brief outage or bypass to can otherwise be difficult to detect.

The next generation of digital valve controllers
are already well into the design stage, and they
will provide even more data that can be utilized
to monitor valve operation, packing performance,
system integrity and much more. New software
apps will automatically analyze all available data
to provide insights and recommendations.
Data is only useful if you use it

Data is certainly a key requirement to enable pre-
dictive maintenance, but no predictions are pos-
sible unless a knowledgeable entity receives that
data and properly evaluates it to draw accurate
conclusions. The whole process is stymied by a
host of problems.
• The currently installed valve controller may be
an older model lacking the ability to sense and
capture the necessary data.
• The digital valve controller may capture the
data, but it has no way to serve up the data,
unless a technician goes to the valve and
accesses the information directly.
• The digital valve controller may be tied to some
type of maintenance network and the data trans-
mitted to a common location, but there are no
 Figure 1: A valve will often exhibit subtle signs of degradation well in advance of outright failure
resources to look at the data. Even if resources If these conditions are noticed and appropriate actions are taken, unplanned outages can be avoided.
are available, they may lack the experience and
knowledge to accurately interpret the informa-
tion and draw actionable conclusions. in development. Higher-tier digital valve control- tion that can automatically perform scheduled
lers have multiple options for transmitting the online testing of each valve as it operates, as well as
These issues are being addressed in a number of data via a number of different wired and wireless continuously monitor and alarm issues with air pres-
ways. The first problem is resolving itself with time. communication protocols (Figure 2). sure, performance degradation and packing. Future
As older valve positioners fail, most users are replac- Predictive maintenance is only possible if the software enhancements will use software apps with
ing them with diagnostic digital valve controllers, data can be continually accessed and monitored built-in machine learning and artificial intelligence to
which have improved sensors and advanced com- in near real time. Therefore, the most successful flag developing problems and suggest solutions.
munication technologies. However, there are tiers plants have some means of pulling the data up If the plant lacks the resources to monitor valve
of performance with these devices, with higher-end through the control system and transmitting it to a information, it can securely transmit the data
equipment providing out-of-service and in-service central location where it can be reviewed, or trans- to trained automation experts located remotely,
diagnostics, as well as partial stroke testing. mitting the data directly from the digital valve con- who can serve as an extension of on-site staff. The
If a company wishes to position itself for predic- troller to its intended destination. experts can communicate developing long-term
tive maintenance, it may need to invest more in issues to plant personnel, as well as problems
the digital valve controller for any repaired or new Transforming data into savings requiring immediate response (Figure 3).
valves. This is particularly true of any valve that Perhaps the most difficult aspect of a predictive These services free plant resources to perform
is critical to production or operates in severe ser- maintenance system is finding a knowledgeable other tasks by detecting degrading performance
vice. Higher-tier digital valve controllers for these resource that can assess the information, detect and impending failures before operations are
valves will almost always pay for themselves in developing issues and initiate actions that can impacted. They also provide plant personnel with
short order due to improved diagnostics capability, address the problems in advance of outright fail- access to valve experts on an on-going basis for
lower maintenance costs and increased uptime. ure. Fortunately, a number of solutions are already consultation on performance, along with recom-
The second issue, that the data is captured but in place, with several more in development. mended corrective measures.
not transmitted anywhere, has been addressed in a Valve data management packages, such as Fisher
variety of ways, with further improvements already FIELDVUE ValveLink software, are an on-site solu- Data investments pay dividends
A herbicide plant used advanced control valve
diagnostics to transition from reactive to predic-
tive maintenance, reducing annual maintenance
 Figure 2: One costs by $230,000. In one case, the plant saved
common method
of valve data nearly $100,000 an hour by detecting and address-
capture utilizes ing a developing control valve issue before it shut
the control system down the unit.
connections to
transmit the A refinery identified 26 critical valves in their
information to a hydrocracker unit that could cause unplanned
maintenance shutdowns. The plant lacked resources, so they
database, which
monitors for engaged their valve vendor to provide remote ser-
problems. vices for continuously monitoring these valves and

reporting issues. The service detected a develop-
ing air leak on a large anti-surge valve, as well as
issues with several heating valves. Using this infor-
mation, all repairs were planned and executed
without production impact, avoiding a $5.6 million
unplanned outage, and saving $400,000 a year by
improving performance of the heating unit.
A combined cycle power plant saved $68,000 in
one outage after installing a number of upgraded
digital valve controllers and implementing diag-
nostic alert software, enabling the facility to focus
repair efforts more efficiently. Annual mainte-
nance cost reductions totaled $33,500, and plan-
ning for outage repairs was significantly improved,
particularly by ordering repair parts in advance.
Conclusion
Predicting the future is not easy, but it is pos-
sible when the right data can be gathered and
reviewed by a knowledgeable entity. Many exist-
ing digital valve controllers can provide the
required data, and next generation digital valve
controllers will gather even more data. Once
captured and transmitted to the right repository,
advanced software tools and remote experts can
translate the information into specific actions
 Figure 3: When a plant lacks the proper knowledge or resources, critical valve that can be taken to resolve problems and avoid
data can be securely transferred to remote experts for continuous monitoring. unplanned failures.
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Significant advances in digital valve controllers — including newer commu-
nication technologies such as Ethernet APL and local real-time control — are Valves for a Wide Range of
already in progress, rapidly improving prediction accuracy to cut maintenance
costs and increase uptime. Processing Applications
Wise investments in equipment upgrades or new equipment specifications,
along with remote expert services when needed, will pay big dividends in the future.
Predictive maintenance is finally possible, and it will only improve with time.
For over 75 years,

Saurabh Pathak is the digital valve global marketing director at Emerson Automation Magnatrol has been
Solutions, with global marketing responsibility for next-generation product development of
valve prognostics, hardware and sensor-based technologies that tie into analytics-based
manufacturing high quality,
valve management software. He has been with Emerson for 16 years, working across general purpose, two-way
North America, Asia-Pacific and the Middle East, where he is currently based. Pathak holds bronze and stainless steel
a bachelor’s degree in Electrical & Computer Engineering from Queensland University of Technology in Australia.
solenoid valves to control
Naman Tahan is the director of engineering and operations for Digital Valve Services at the flow of oil/fuel oil,
Emerson Automation Solutions, with global responsibility for all deployment and perfor- biofuel, natural gas,
mance aspects of the company’s valve condition monitoring remote services. He has
been with Emerson for the past 28 years in various sales, operations and project man-
solvents, hot liquids
agements roles, and he is currently based in Houston, Texas. Tahan holds a bachelor’s and gases, corrosive
degree in Electronics Engineering from Aleppo University in Syria. fluids, water, steam,
Emerson and other sediment-
www.emerson.com free fluids.
• Flanged ends
or NPT threads
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67 Fifth Avenue • Hawthorne, NJ 07507

 A sanitary vacuum
conveyor keeps a
tablet press filled in
a pharmaceutical
environment.
All images courtesy
of Vac-U-Max
Vacuum conveyors:
Powder handling’s antidote to
soaring post-pandemic costs
Automating powder handling with vacuum conveying systems is one of
the fastest and most economical ways for manufacturers and processors
to mitigate skyrocketing labor, energy and material costs. | By Doan Pendleton, Vac-U-Max
M
anufacturers and processors have labor shortage — all converging at the same time,” conveyors. Floor space is already a focus point for
survived economic downturns and notes Matthew Moore, executive vice president plant managers, and that will most likely intensify
market shifts since the beginning and president of underwriting for Liberty Mutual as manufacturers reimagine just-in-time (JIT) sup-
of the industrial revolution. Even in Global Risk Solutions.1 In the “landscape of turbu- ply chain approaches.
good times, cost control and efficien- lence” described by Moore, automating processing Vacuum conveyors are the most hygienic meth-
cy have always been, and will always and packaging lines with vacuum conveyors is log- od for transferring powders and bulk solids. The
be, reigning topics in manufacturing. ical because it cuts costs in many ways. systems are fully enclosed, which protects mate-
The COVID-19 pandemic — much like the Great Mechanical conveyors, such as aero-mechanical rials from air, dirt and waste. Because material
Depression and World War II — tested manu- and flexible screw conveyors, are cheaper on the does not escape from a vacuum conveying system,
facturing processes in the extreme, highlighted front end but may be more expensive when con- particulates that can endanger worker health, jam
shortcomings in current practices and challenged sidering the total cost of ownership. Mechanical expensive equipment or result in cross contamina-
manufacturers and processors to rethink standard conveyors have more moving parts than vacuum tion do not escape into the environment.
operating procedures to maximize efficiency. conveyors and require regular downtime for main- Automating powder transfer with a vacu-
“We’ve never experienced inflation, recession, tenance and replacement parts. Mechanical con- um conveying system — whether it is a com-
pandemic, supply chain issues, social inflation, and veyors also require more floor space than vacuum plex PLC-controlled, computer-compatible,

multi-ingredient storage batching and processing  Starting with a
system, or a simple “up-and-in” material transfer properly designed
pickup point with
system — reduces labor costs, reduces injury and phase-density control
its associated costs, increases throughput, fortifies impedes future
quality, and allows manufacturers to rethink how issues with line plug-
ging and inconsistent
they purchase raw materials. material flow.
Conveyor components and design

Versatile, small-footprint vacuum conveying systems
easily integrate with existing processes by routing
conveying lines between floors, through partitions or
around machinery, and they can be easily rerouted to
accommodate process modifications.
Vacuum conveyors are fairly simple systems
comprising four basic components — a pickup
point, a power/vacuum source, a vacuum receiver
(also called a filter receiver) and a control panel —
which work together to gently transfer powders
and bulk solids through convey tubing. Each com-
ponent must complement the others. If one com-
ponent is too large or too small, it will keep the ual loading of powders and bulk solids. Any time
system from working properly. Vacuum receivers powders or bulk dry materials are open dumped
must be able to handle the airflow provided by the into a process, whether it is a blender, a hopper, or
vacuum source, and the correct air-to-cloth ratio a packaging machine, a puff of dust is generated,
for the filters is crucial to prevent the filters from launching particulates into the air and creating
shredding or blinding. fugitive dust.
As simple as vacuum conveying systems are, In environments where combustible dusts are
design variations are nearly endless. This is present or materials have the potential to cause
because each manufacturing process is unique respiratory injury to workers, vacuum conveying
and requires a system engineered to that specific mitigates fugitive dust hazards and reduces house-
process. Factors such as material bulk density, keeping requirements.
material characteristics, conveying distance, con- According to the CDC, “Musculoskeletal dis-
veying rate, industry and upstream/downstream orders are associated with high costs to employ-
equipment all influence a system’s design, making ers such as absenteeism, lost productivity, and
vacuum conveying more art than science. increased health care, disability, and worker’s com-
While the industry may dictate a system’s materi- pensation costs.”2
als of construction (such as stainless steel for food Avoiding manual scooping, lifting and dumping
and pharmaceutical applications), vacuum conveying of materials not only eliminates costly work-relat-
technology and techniques are not consigned to a par-  A mobile vacuum ed musculoskeletal disorders (WMDS) but also
ticular industry but are adaptable across industries. conveying system eliminates the possibility of dust entering work-
conveys material from
Expertise in vacuum technology, knowledge of the floor up and over ers’ airways during manual dumping of powders.
production equipment and processes, and a full processing or packaging More often than not, the need to wear respiratory
understanding of material characteristics, are equipment. The vacuum protection during powder transfer is not necessary
receiver is easily low-
essential to designing a system that truly benefits ered to floor level for with vacuum conveying systems.
the bottom line. easy sanitation.
Reduced downtime and maintenance
Reduced labor costs workers to climb up and down ladders to manually “Next to a safety or environmental mishap,
Without question, reduced labor is where companies dump materials into equipment. unplanned/unscheduled downtime represents
achieve significant savings when going from manual Most facilities experience an immediate 50% one of the costliest events at any industrial or
material loading to automated vacuum conveyors. reduction in labor for material transfer when tran- manufacturing plant,” according to the Forbes
Surprisingly, however, reducing labor costs is not sitioning from manual handling to vacuum con- article, “Unplanned Downtime Costs More Than
usually the main impetus for purchasing a vacuum veying. This increases manufacturers’ ability to You Think.”3 Mechanical conveyors contain more
conveyor. Two of the most common reasons compa- expedite the shift to a skilled workforce. moving parts than vacuum conveyors, and there-
nies automate powder transfer are when changes in Some systems perform more like a set-it-and- fore maintenance costs are higher, and machinery
demand make manual transfer unfeasible and when walk-away scenario. Systems such as this allow is more susceptible to unscheduled downtime.
they need to mitigate safety hazards. businesses to achieve significant labor savings, More moving parts also means that mechani-
Most often, manually transferring materials since workers no longer need to remain at a sta- cal conveyors are more difficult to clean than
into process or packaging equipment requires two tion for the duration of the process. vacuum conveyors, making mechanical conveyors
workers for safety and efficiency, as most equip- less desirable in sanitary conditions. With virtu-
ment is located above workers’ heads, requiring Improved safety and cleanliness ally no moving parts, vacuum conveying systems
lifting and climbing. Vacuum conveyors facilitate The enclosed nature of vacuum conveying systems are more economical when it comes to cleaning
loading from ground level up into process and reduces the amount of housekeeping needed to and preventative maintenance, needing minimal
packaging equipment, eliminating the need for mitigate fugitive dust that is inherent with man- attention a couple times a year to check oil levels

STRENGTH
AND ENDURANCE.
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GRADE MAGNETIC METAL
SEPARATORS.
Designed for your process
application and built to last.
 RA25 or lower finish

and passivation are
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“increasingly
With material costs skyrocketing, facilities are
looking for systems that can reclaim
expensive materials and automatically cycle them
 LEARN MORE 
back into the system. ”
MORE LESS and motor health. Compressed air-powered venturi systems require even less
maintenance — simply keeping the compressed air line clean and dry.
» Captured Metal » Maintenance Costs Furthermore, the ability to change out a vacuum conveying system’s hoses
» Product Purity » Plant Downtime and filters between batches results in faster changeovers and increased
uptime. In sanitary environments where cleaning takes place several times per
» Equipment Protection » Headaches day, this time-saving technique can save thousands of dollars each day.
» Employee Safety
» Plant Uptime Other benefits
Additional savings when changing from manual powder transfer to automated
vacuum conveyors come from reduced materials costs — either through dis-
counted pricing for bulk quantities, reclamation and reuse of materials, or both.
With material costs skyrocketing, facilities are increasingly looking for systems
HACCP International Certified and that can reclaim expensive materials and automatically cycle them back into the
USDA AMS Accepted Equipment. system. Ancillary equipment and innovative system engineering can even turn
the task of straightforward dust collection into fully integrated systems designed
to reclaim expensive ingredients and preserve quality formulations.
Vacuum conveyors further contribute to higher quality formulations since
weighing and metering with an automated system eliminates the possibility of
TOLL FREE 888.582.0821 human error during hand scooping.
[email protected] Vacuum conveying systems are available with a range of power options that
fit within an organization’s energy management program and are capable of
operating within sustainable industrial solar-powered environments.
magnetics.com
Industrial Magnetics Inc.
1385 S M-75, Boyne City, MI 49712
PHONE: 1.231.582.3100 Selecting a vacuum conveying system
Properly designed vacuum conveyors have a high ROI. These systems maximize
throughput, have minimal maintenance requirements, reduce safety costs, cut

“fabrication
...work with an experienced supplier with
abilities and the know-how to
anticipate challenges ahead of time...”
changeover downtime, and improve product quality. 2. https://www.cdc.gov/workplacehealthpromo-

When selecting a vacuum conveyor for your application/health-strategies/musculoskeletal-disor-
tion, work with an experienced supplier with fabrica- ders/evaluation-measures/index.html
tion abilities and the know-how to anticipate challeng- 3. https://www.forbes.com/sites/forbestechcoun-
es ahead of time to ensure that the system operates cil/2022/02/22/unplanned-downtime-costs-
flawlessly for decades.
more-than-you-think/?sh=44521d3036f7
Be sure to examine the equipment’s robustness,
ease of cleaning, energy consumption and warranties,
because cheaper upfront does not always mean cheap-
er in the long run. Saving several thousand dollars on Doan Pendleton is president of Vac-U-Max, Belleville, NJ (800-822-
the front end may end up costing tens of thousands of 8629; [email protected]). The company manufactures pneumatic
dollars over the life of the system. Be sure to compare systems and support equipment for the conveying, weighing and
apples to apples and not apples to oranges. batching of dry materials.
References Vac-U-Max
1. https://business.libertymutual.com/insights/ www.vac-u-max.com
economic-uncertainty-and-risk-management-
resilience-in-2023-3-trends-to-watch/
 Stainless-steel tube hopper vacuum receiver features a straight-sided

discharge hopper for fast, efficient handling of non-free flowing materials.
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2203PRO_CollinsInstrument.indd 1 MARCH 2023 | www.processingmagazine.com 21

1/20/22 1:14 PM
Combustible dust hazards of

dilute phase pneumatic
conveying systems
Proper design, operation and

maintenance are critical to
minimize dust explosion
hazards when pneumatically
conveying combustible dusts
and particles. | By Jack Osborn, Airdusco EDS
D
ilute phase (versus dense or semi-dense
phase) pneumatic conveying systems
have been used for many decades in
industry to transfer many types of mate-
rials from one or more locations to a
single or multiple locations. Vacuum (or
negative pressure) dilute phase systems are best
used to convey from one or more locations to a
single destination (Figure 2), while positive pres-
sure systems are best used to convey from a single
source to one or more locations (Figure 3), though
there are exceptions.
Unlike dense and semi-dense phase pneumatic
conveying systems, dilute phase systems are designed
to provide sufficient airflow and velocity to keep the
material being conveyed airborne (i.e., suspended
within the piping/duct). This is basically correct
whether the system pressure is negative or positive.
When properly designed, operated and maintained,
dilute phase pneumatic conveying systems are one of
 Figure 1: Where an explosion hazard exists, filter receivers used in dilute

phase pneumatic conveying require explosion protection and isolation.
Courtesy of Airdusco
 Figure 2: Schematic of a typical vacuum conveying system.
the safest methods for conveying combustible dusts bustible dust. Unless electrical spark is of con- positive pressure system, air (and potentially com-
and particles. However, combustible dust hazards do cern, the test should be without inductance in bustible dust) will leak outward into the workspace.
exist in these systems, and each system must be ana- order to determine the material’s sensitivity to Also, when multiple material feed sources into
lyzed and evaluated for its own unique hazards. electrostatic discharge. the system are required, vacuum conveying is more
• In some cases, it can be advantageous to test easily adaptable. However, if the system requires
Determine the material’s for charge relaxation duration. This is the time discharging the material to multiple locations, a
explosive characteristics required for a generated electrostatic charge positive pressure system is more easily adaptable.
According to NFPA 652 Fundamentals of in a material to dissipate. Examples of where The owner/operator must determine which is
Combustible Dust (2019 version) the owner/opera- this can be important include stearates, resins best for the application.
tor of a facility handling a potentially combustible and sulfur compounds. A long charge relax-
dust is responsible for determining the explosive ation duration (hours or more) can mean that Properly bond and ground the piping/
characteristics of that dust (Section 4.1). The fol- the conveyed material will retain a significant tubing and components
lowing is the minimum information needed to suf- electrostatic charge when in storage. Confirmed and documented (at least yearly, but
ficiently determine how the material’s combustible more often for high-risk materials) bonding (i.e.,
dust characteristics will affect the design, operation, Other test parameters can be considered, but it continuity of the current carrying of the assembly)
maintenance and explosion protection of a typical should be up to the owner/operator to determine and grounding (to earth of the bonded compo-
dilute phase pneumatic conveying system. whether they will be of value. nents) is required (NFPA 652, Section 9.4.7). This is
• Determine the material’s Kst and Pmax values. The dust’s explosivity characteristics are not my minimum recommendation.
These are necessary to determine any explosion the only properties that should be considered as The main concern is the generation of a propagat-
protection and isolation requirements for the fil- important. Examples include whether the material ing brush discharge. This type of electrostatic dis-
ter receiver(s) and possibly other portions of the is cohesive and/or adhesive; whether the material charge is created by the “brush off ” of a layer where
system. Isolation is necessary to prevent the pres- is friable or subject to significant attrition, which a charge exists, allowing the stored charge to be dissi-
sure wave and fireball from an explosion propa- can lead to significant increases in combustible pated as an electrostatic discharge. This can occur in
gating back through the system and possibly dust mass when conveyed or handled; angle of any dilute phase pneumatic conveying system where
causing secondary explosions and/or flashfires. repose, which affects the design of storage vessels, components are not properly bonded and grounded.
• Determine the material’s minimum explosive etc.; and moisture content, as some drier materials Such electrostatic discharges can reach 1,000 milli-
concentration (MEC) value. The MEC is the tend to be greater risks than materials with higher joules, which is more than sufficient to act as an igni-
minimum amount of combustible dust, usually moisture content. tion source for most combustible dusts. This is also a
in grams per cubic meter, necessary to support The need to know your material cannot be over- concern where hoses are used, as the inside of a hose
an explosion or flashfire. This is imperative to emphasized. is often not designed to be conductive. Multiple ven-
show that a relatively small amount of combus- dors supply hoses that will rapidly dissipate electro-
tible dust, when suspended in air around an Convey using negative pressure static discharges from the inside of the hose.
ignition source, represents a high-risk situation. when possible
• Determine the material’s minimum igni- I tend to recommend vacuum (or negative pressure) Consider isolating the material
tion energy (MIE) value. The MIE is the low- dilute phase conveying systems for combustible feed location(s)
est energy, usually measured in millijoules, dusts. This is because if there is a leak in the system, Isolating the material feed location(s) is often not
required to ignite a suspended cloud of a com- a vacuum system will leak inward, whereas with a considered, especially with a negative pressure

 Figure 3: Schematic of a typical positive
pressure pneumatic conveying system.
system. If, during the analysis and evaluation of source. An explosion event in the hammermill or Protect and isolate the filter receiver
the various material feed locations (singular or its components (such as a dust collector) could A filter receiver (also called an air-material sepa-
multiple), a combustible dust hazard exists, then transfer to the pneumatic conveying system if no rator or AMS) is basically a cylindrical dust col-
this hazard should be isolated from the rest of the method is used to isolate the feed. A screw con- lector designed to operate at higher differential
pneumatic conveying system. veyor does not provide isolation. Using a Class pressures and material rates. Although not every
An example would be where a screw conveyor 1 rotary airlock at the screw conveyor discharge filter receiver used in dilute phase pneumatic con-
is being used to feed material from a hammer- (designed to shut off feed should an event occur) veying requires explosion protection and isolation
mill, which is considered a high-risk ignition would provide isolation. (e.g., ingredient transfer systems, NFPA 61), where

SLICE IT.
an explosion hazard exists, such protection should be provided (NFPA 652,
Section 9.7). Figure 1 shows a typical method of explosion venting plus a Class
1 rotary airlock valve (isolation is not shown). Figure 4 shows passive and
active isolation methods to prevent propagation of an explosion event inside
DICE IT.
PASS IT.
the filter receiver.
Examples of hazardous applications include conveying from the previously
mentioned hammermill material discharge, where embers are possible; con-
veying material where foreign objects could be present; and conveying mate-
rials with low MIE values such as sulfur, resins or stearates. Some materials
will become self-heating if they accumulate for long periods within the filter
receiver. Also, it is important to note that, with or without bonding wires, most
filters are insulators and will hold an electrostatic charge. ERADICATOR PLUSTM ––
Make sure the designer, provider and installer know what they GORMAN-RUPP’S NEW
are doing SOLIDS-HANDLING
Any dilute phase pneumatic conveying system can become an unwanted combus-
tible dust hazard if it is improperly designed or installed or is the wrong equipment TECHNOLOGY.
for the application. There are highly qualified equipment suppliers that can both
design and provide the proper equipment. Some can also install and commission
the system. It is up to the owner/operator to make sure the company or compa- EXTRA-THICK,
AGGRESSIVE,
nies selected for each part of the system’s development know what they are doing. SELF-CLEANING
A failure in any phase of system creation can result in an unacceptable increase in WEARPLATE
combustible dust hazards.
SHIMLESS
Provide training in proper system operation and maintenance ADJUSTMENT
DESIGN
One can have the best possible dilute phase conveying system for an applica-
tion, but if it is not properly operated and maintained it will quickly become a
greater combustible dust hazard. First, make sure the system supplier provides
a usable and complete operation and maintenance manual. Second, require
HEAVY-DUTY
that same supplier (or another viable source) to train your personnel in the CONTINUOUS
operation and maintenance requirements for the system. This should be done VANE IMPELLER
with all shifts, and a repeat training session after several months of operation
is also recommended.
Continuously monitor system performance parameters

Section 9.3.3.1.3 of NFPA 652 (and all combustible dust standards) requires that
pneumatic conveying systems have adequate conveying velocity to prevent the
accumulation of combustible dusts and/or particles in the conveying piping/
tubing. For pneumatic conveying, this requirement seems obvious, but it is not
the case in many systems. Usually, by continuously monitoring certain param- REMOVABLE, LIGHTWEIGHT
INSPECTION COVER
eters, it is possible to know if the system is operating properly and predict the
need for preventive maintenance. Examples of parameters to monitor include: Flushable wipes, trash bags, mop heads, rags and other
• Monitor the negative or positive pressure at the inlet to the blower package. stringy materials can be hard on pumps – that’s why your
By using a transmitter and sending the signal to a control system or area, facility needs a dependable solution for handling solids-laden
the differential pressure (compared to atmosphere) can indicate the sys- wastewater. Gorman-Rupp is now offering Eradicator PlusTM
tem “condition.” For example, when no material is in the line (conveying air solids reduction technology for 3”, 4” and 6” Super T Series®
only), the resulting differential pressure should be low. If this value increases self-priming pumps to help tackle municipal wastes, industrial
(more pressure or more vacuum) without material, this likely indicates an by-products and a variety of other aggressive applications.
accumulation in the piping or possibly a problem with the filter receiver. If The extra-thick, self-cleaning wearplate is designed to cut
the value increases and decreases in a yo-yo pattern during conveying, this and shred organic solids entering the pump, while the rugged,
continuous vane impeller prevents the build-up of debris and
may indicate too much material feed or insufficient performance.
keeps your pump operating at peak efficiency.
• Monitor the pressure differential across the filters of the filter receiver.
Exceeding the value that the system can handle will lead to reduced per-
For more information, call Gorman-Rupp at 419-755-1011
formance from the blower package and possible plugging of the conveying
or visit GRpumps.com to find a distributor near you.
line. Excessive differential pressure often indicates that the filters need to
be replaced, the automatic filter cleaning system is not working properly, 603 © 2023 The Gorman-Rupp Company Gorman-Rupp Pumps USA is an ISO 9001:2008 and an ISO 14001:2004 Registered Company
or material is accumulating inside the receiver to a level that is inhibiting

filter performance.

• For positive pressure systems as well as some
vacuum systems, a static filter is installed
before the inlet to the blower to prevent dust
from entering. If this filter becomes blinded,
the blower package will be “starved” of inlet
air, leading to a major upset condition.
By following the recommendations outlined in

this article, you can ensure that your dilute phase
pneumatic conveying system is compliant with
combustible dust standards and performs success-
fully for years.
Jack Osborn ([email protected]) is a senior

project engineer at Airdusco Engineering and Design
Services and a member of Processing’s edito-
rial advisory board. He has more than 47 years of
experience in dust collection systems, centralized
vacuum cleaning systems, pneumatic conveying systems, and all types
of bulk handling systems and is a participating member of all six NFPA
combustible dust committees (61, 484, 652, 654, 664, and Correlating).
Figure 4: Isolation devices for preventing the
propagation of an explosion event inside a filter receiver. Airdusco EDS
Courtesy of CV Technology www.airdusco.com
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International Powder & Bulk

Solids Conference & ExhibiTION
returns April 25-27
The expo will feature new and interactive programs designed to
give industry leaders and newcomers a holistic learning experience.
T
he International Powder & Bulk Solids span all three days of the expo and pair profes- & Feeding; Dust Control; Fundamentals; and
Conference & Exhibition, also known sionals just starting their dry processing careers Processing & Quality. Sessions include:
as “The Powder Show,” will take place with industry veterans, allowing intimate time • Effective Specification of a Bulk Handling
April 25-27 at the Donald E. Stephens with seasoned experts on all things powder and System; presented by Todd Smith, K-State
Convention Center in Rosemont, Illinois, bulk solids. Bulk Solids Innovation Center
near Chicago. The Powder Show is North Guests can also “Ask the Experts,” where attend- • Basics of Storage and Flow of Powders and
America’s largest event dedicated to powder and ees can approach experts on the show floor to talk Bulk Solids; presented by Eric Maynard, Jenike
bulk solids handling and processing. The event about current challenges and get advice on solu- & Johanson
will feature more than 350 exhibitors showcasing tions. These experienced leaders then will take • Feeder Selection and Design; presented by
the latest manufacturing technology and offering registrants out on the show floor to use exhibiting Scott Miller, Solids Handling Technologies
product demos across the full spectrum of bulk booths as examples, making the show more inter- • Combustible Dust Standards & Regulations;
solids processes. active than ever. presented by Ghose Dastidar, Fauske &
Attendees of the three-day expo can watch free “We want our guests to not only see what the 2023 Associates, and Jeramy Slaunwhite, Rembe
educational sessions at the Center Stage and Tech iPBS show has to offer, but for them to apply what • Basics of Thermal Processing of Solids; pre-
Theater and learn from industry leaders about they’ve learned through quality meetings and expe- sented by Karl Jacob, University of Michigan
topics such as pneumatic conveying, storage, 3D riences with the industry’s leading experts,” says • And many more.
Top: Images courtesy of Informa Markets
printing, and more. Steve Everly, Group Event Director. “We now have
brand new networking and leadership programs to In the weeks leading up to the Powder Show,
New interactive experiences aid everyone in the industry, from newcomers to Processing is speaking with conference presenters
This year’s expo will feature new interactive veterans. The educational content available is more about their sessions.
experiences where attendees can learn about interactive and hands on than ever before.” Be sure to visit www.processingmagazine.com to
the latest trends and innovations in the powder watch these interviews and get more details about
and bulk solids industry. Registrants who want Education conference the presentations.
more in-depth insights on the powder and bulk The two-day technical conference features six
solids trade can sign up for the new Granular tracks covering Bulk Solids Storage, Retrieval, and For more information and to register,
Guides mentorship program. The program will Logistics; Combustible Dust Safety; Conveying visit www.powderandbulkshow.com.

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and have more inventory available.
Different ways to charge material in a
pneumatic conveyor
This article explores the most common types of pneumatic conveying
system line chargers and their usual applications and limitations. | By Colin Barbeau, Hatch
A
simple pneumatic conveying system is • Accelerated line charger wear, which can lead in relation to the material’s saltation velocity dictate
comprised of five main components: to unplanned system shutdowns, extra oper- whether the material will be transported in dilute or
the gas mover, the product feed, the line ating costs or excessive gas leakage. dense phase. Also, dense phase conveying usually
charger, the pipeline, and the product • Excessive gas leakage, which can lead to requires a high gas pressure, and since some types
receiver (Figure 1). The line charger has reduced system capacity, plugging in the pipe- of line chargers have limited pressure differential
a very critical role: it needs to charge the line or excessive dust emissions. ratings, they are not typically associated with dense
convey line at a metered rate while minimizing the • Bridging/arching of material above the line phase conveying.
escape of pressurized gas (in positive pressure sys- charger feed point, which causes convey line The mode of conveying is typically one of the
tems). In this application, the line charger is serv- material starving or intermittent feed. first decisions made with regard to system design,
ing as both a feeder and an airlock. with decisions such as the best line charger made
Pneumatic conveying systems use several differ- Before looking at the different line charger types, subsequently.
ent types of line chargers. Depending on the appli- it is important to settle a widely held misconcep-
cation, one might be a better choice than others. By tion. While it is true that some types of line char- Types of line chargers
understanding the differences between the different gers are most commonly used in either dilute phase The following is a list of the main line charger
line charger types, you can make an informed deci- or dense phase systems, the line charger does not types used in the industry. Please note that many
sion about which line charger to select for your sys- dictate the mode of conveying in the pipeline once variations of each type exist, and it would be difficult
tem. Selecting a wrong line charger for your system the material is mixed with gas. The material-to-gas to execute a summary of all of them in a single article.
can cause many problems, such as: ratio and the velocity of the material in the pipeline
Rotary airlocks
Rotary airlocks (Figure 2) are the workhorses of the
industry as they are simple, compact and widely
 Figure 2: Rotary airlock. available. They can provide an almost continuous
Courtesy of Carolina Conveying Inc. product feed, as the pocket discharge cycle rate is
short compared to other line chargers.
Rotary airlocks are not typically recommended
for use with coarse and/or very abrasive materi-
als, as the internals can wear out rapidly. However,
versions are available that include various forms of
abrasion resistance to extend the component’s life.
Rotary airlocks have a limited pressure differ-
ential rating since there is a gap between the rotor
blade and the casing. This is why they are usually
used for dilute phase systems at low to medium
pressure differentials. Some specialized models can
handle higher pressure and can be used as line char-
gers for continuous dense phase or high-pressure
dilute phase systems, for low-abrasion applications.
Double dump valves

Double dump valves consist of two valves posi-
tioned one on top of the other and separated by
an accumulation chamber (Figure 3). The valves
open alternatively in cycle, allowing material to
pass through while keeping gas updraft to a mini-
mum. The valves are never opened simultaneously.
Different types of valves can be used depending on
 Figure 1: Basic pneumatic
conveying system components.
Courtesy of Hatch
 Figure 3: Double dump valve.

Courtesy of Plattco Corporation
the application, such as flapper valves, ball valves, used in dense phase systems. They can however be Eductors must be used with free-flowing mate-
slide gates, spherical valves, and others. used in dilute phase systems if a higher pressure rials and are limited to low-capacity/low-pressure
Double dump valves can handle high-tempera- is required for the application or when handling systems. They provide low flexibility for flow rate
ture applications. Some models allow gravimetric extremely abrasive materials. control. For this reason, they can be coupled with
feed of material with load cells positioned on the a metering device upstream if an accurate control
accumulation chamber. Since double dump valves Screw pumps is required.
don’t provide a continuous discharge (long mate- A screw pump (Figure 5) is basically a heavy-duty Eductors generate a high-pressure differential,
rial discharge cycle rate), they are usually not used screw feeder with the pitch of the screw dimin- meaning that the total system pressure will be
in dense phase systems. ishing between the material inlet flange and the higher than with other line chargers.
screw discharge. This diminution in screw pitch
Blow tanks compresses the material and creates a gas seal Lock hoppers
A blow tank (Figure 4) is basically a pressure vessel between the low-pressure screw inlet and the Lock hoppers are in a class of their own as they
used to push material inside the convey pipeline. It is high-pressure screw discharge. Screw pumps are are not line chargers per se but can be used in
equipped with many monitoring devices and instru- equipped with a non-return valve at their dis- conjunction with other line chargers to achieve
ments to optimize the material discharge cycle. charge end that closes when no material is in the an optimized solution when applicable. Lock hop-
Once the bottom valve on the blow tank is screw to prevent gas leakage. pers are accumulation hoppers with an isolation
opened, it stays open until all the material is fed A screw pump’s seal quality is highly depen- gate at their inlet flange and a line charger at their
into the convey pipeline. Blow tanks are not dis- dent on the bulk material properties, and they are discharge flange. Once the lock hopper is filled
charged by gravity; the pressure differential inside therefore generally recommended only for free- with material, the inlet valve closes to isolate the
the tank helps to push the material out. Some flowing materials with a small mean particle size. upstream equipment from the convey pipeline
models are equipped with fluidizing air to help dif- With the right bulk materials, high pressure seals pressure. This keeps the line charger at the lock
ficult, less free-flowing materials flow. can be obtained, and screw pumps can be used in hopper’s discharge from being exposed to a pres-
Blow tanks have a long cycle time and can’t be dense phase systems. Screw pumps are not recom- sure differential. Only the lock hopper inlet valve
filled during their pressurization and discharge mended for extremely abrasive materials. is exposed to the pressure differential. Lock hop-
cycle. For this reason, if the process upstream pers, therefore, eliminate the pressure differential
requires a continuous material flow, two blow Eductors to which virtually any line charger can be exposed,
tanks are used, with one being filled while the Eductors create a vacuum at their inlet throat expanding the range of convey line pressures they
other is discharging material into the pipeline. from a positive pressure airflow using the Venturi can operate in.
Alternatively, an intermediate hopper above the effect. This vacuum charges the eductor with bulk Individual lock hoppers do not operate continu-
blow tank can be used as a holding tank to receive material, which is then mixed with the airflow in a ously but in batches. Therefore, if the upstream
the continuous process discharge while the pres- pressure pneumatic conveyor. process requires continuous operation, two lock
sure tank below is in the discharge cycle. Eductors basically solve the problems associ- hoppers are required, with one being filled while
Blow tanks are designed to operate at higher ated with line charger air leakage in pressure sys- the other is discharged into the pneumatic con-
pressure differentials and provide a high material tems. They are small and compact as well as reli- veyor downstream. Dual lock hoppers can be
-to-gas ratio. For this reason, they are most often able, since they have no moving parts. positioned on top of each other to reduce the total

 Figure 4: Blow tank.
required footprint. In this configuration, a single Courtesy of Nol-Tec
line charger is used.
Suction nozzles
Suction nozzles are applicable only to vacuum con-
veying systems. They are basically the air intake
side of the convey pipeline in a vacuum system
that is used to suck material. It is very similar to
a domestic vacuum cleaner. The main difference is
the ability to adjust the air intake near the material
intake to control the material flow. There are also
additional air intakes on the suction arm, down-
stream of the material intake that prevent the line
from being choked and plugged.
Suction nozzles are generally manually oper-
ated to suck material from a bag or a box, but they
can also be used on larger scales to empty trucks,
containers or ships. Since these line chargers are
used on vacuum systems, which have a limitation
in negative pressure (less than one atmosphere of
vacuum), they are usually seen on dilute systems.
Flood fed  Figure 5:

Flood fed line chargers are also only used on vac- Fuller-Kinyon screw pump.
uum systems. This concept is similar to a suction Courtesy of FLSmidth.
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nozzle in that a pipe under vacuum is connected
“operated
to the discharge of a hopper. A partially opened
Suction nozzles are generally manually slide gate can be used to help meter the mate-
to suck material from a bag or box, rial flow rate. Additional air intakes on the convey
pipeline, downstream of the material pickup point,
but they can also be used on larger scales to prevents line plugging by ensuring that the correct
”
rate of air flow is available.
empty trucks, containers or ships.
Selecting a line charger
Table 1 can be used as a guide for selecting the
right line charger for the application. The table lists
which line chargers are best suited for a given sys-
tem conveying mode and phase.
Colin Barbeau is a bulk materials handling spe-

cialist at Hatch and a member of Processing’s
editorial advisory board. He can be reached at
[email protected].
Hatch
www.hatch.com
 Table 1: Line charger suitability by conveying mode and phase.
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2301PRO_ThermalCare.indd 1 MARCH 2023 | www.processingmagazine.com 33

12/22/22 1:49 PM
SPECIALSECTION
PROCESS WATER
Efficiently measuring and accounting for
cooling water
The right instruments ensure that building and maintaining a
reliable cooling water system can be realized with a minimum
of upsets or process fluctuations. | By Cheng Vue, Emerson
A
t first glance, cooling water measure- the cooling process malfunctions. Any significant
ment might not seem to be an essential change in temperature can impact the process at
measurement to power generation or various points down the line.
chemical operations. However, when
delving into the value of cooling and Process control with heat exchangers
temperature control, it becomes clear it Heat exchangers are a critical component in both
cannot be an afterthought. power generation and in processes that require
There are different systems that require cool- temperature regulation, such as chemical, refin-
ing, whether in power generation or chemical ing or food and beverage processes. In chemical
process applications, and knowing the water used processes — similar to food and beverage — for
for the process of cooling and temperature regu- example, there is often a blending stage in the pro-
lation allows for accurate accounting and report- cess. But that blending can only happen if materi-
ing. Considering that most often the water used als or ingredients are at the correct temperature,
in these instances comes from municipal sourc- as temperature can impact viscosity, which will
es, it stands to reason a facility wants to know determine if a material can blend properly. This is
how much they are using and where the waste- one indication of how important a heat exchanger
water goes after it has run through the process. is in regulating temperatures.
Accounting for wastewater is also required for Cooling water is what allows the heat exchanger
environmental reporting. to regulate the temperature by transferring the
If the water used is taken from natural sources, temperature from one fluid to another, in this case
other issues come into play, such as: Will the water to the cooling water.
require filtration? How clean is the water? What Power plants that use hydrocarbon or nuclear
types of particles might be in the water that can materials to generate power rely on heat exchang-
contribute to corrosion of piping, pumps and flow ers to keep the processes running safely by pre-
measurement devices? And how much can partic- venting dangerous temperature excursions.
ulate matter impact accurate measurement? Designs may differ, but heat exchangers in one
A facility will want to look into finding a flow form or another have a long history. Often the
meter that is not significantly impacted by the dif- design features a series of tubes that allow the hot
ferent types of impurities and still able to return liquid or steam to flow through and the tubes are
reliable measurement data. submerged in cold water which cools the material
Efficiently cooling a process or maintaining a in the tubes by taking on the heat.
correct temperature is essential to the quality or That basically describes the most commonly
outcome of the process. Though cooling water used type of heat exchanger — the shell-and-tube
measurement is not generally seen as a critical design. The bundle of tubes that the hot material
measurement, cooling is an important part of goes through is immersed and then enclosed in a
keeping a process running and of what makes a shell designed to let the cooling fluid flow through
heat exchanger a valuable piece of equipment. the spaces between the tubes. In nuclear reac-
Efficiency in cooling is what keeps the process tors, the fuel rods are placed in the tubes in the
from bogging down if temperatures fluctuate or if bundle. Cooling fluid flows around the rods and

 Figure 1: Rosemount magnetic flow meters in the 8700 series are particularly when water is drawn from and
sized to meet a variety of needs. Courtesy of Emerson returned to natural environments, are closely
monitored. The water must be accurately mea-
removes the heat generated by the fission process. sured and accounted for. In addition, cooling
Looking at power plants that use a combustion water that is returned, cannot be hot or even
type of process to create heat, they will often run warm, as it could damage ecosystems in and
the hot exhaust gases through the heat exchanger around the body of water it is returned to.
set up, instead of venting the gas directly to the Complying with regulations requires regu-
outside environment. This way the gas is cooled, lar reporting of volumes of water used and dis-
the heat is recirculated into the process and usu- charged. Having that data easily accessible means
ally the gas is also run through a scrubber before savings in time and personnel needed to physically
being vented to the outside air. check each meter. Having relevant data available
with a few keystrokes ensures accurate reporting.
Magnetic flow meters for efficient
cooling water measurement Modernizing facilities
Cooling water performs an important function Closely tied to having wireless-enabled magnetic
in different industries and processes. To ensure flow meters is the digitalization of data collection,
that the cooling process runs as it should and there storage and use. Wireless transmitters make it
is an accurate accounting of the water used, water easier to install additional flow meters if and when
released — either into the sewer system or back the need arises, ensuring that cooling water flows
into nature — and possible water lost through efficiently and is measured accurately.
leaks, good measurement devices are needed. Accuracy in the cooling of critical processes is not
The magnetic flow meter is ideally suited to mea- an afterthought and is an important component in
sure flow rates and water usage for accurate tem- many types of industrial facilities, bound by regu-
perature control. Operators can track the rate of flow lations and safety requirements to ensure safe and
and collect data on amounts of water used, while reliable results and consistent final products.
controlling temperatures throughout the process. The right instruments ensure that building and
With no moving parts and an obstruction-less maintaining a reliable cooling water system can
design (Figure 1), the magnetic flow meter is low be realized with a minimum of upsets or process
maintenance and efficient. By pairing it with the fluctuations.
ID 17772915 © Vladvitek | Dreamstime.com
right liner and electrode material, the likelihood

of corrosive or obstructive deposits is dramati-
cally reduced. Verifying a meter’s performance Cheng Vue is the global magnetic flow meter
becomes routine with advanced diagnostic capa- product manager for Emerson. Previously, he was
bilities, especially when they are wireless enabled. the global product manager for Emerson vor-
Wireless data collection provides real-time data tex and temperature transmitters and has been
gathering, allowing an operator to respond quickly working with Emerson for eight years.
to changes in flow rate and temperature.
Emerson
Meeting regulatory requirements www.emerson.com
Regulations around water and wastewater,

SPECIALSECTION
WATER TREATMENT
Industrial water and

steam treatment
will be important for a long time
The first installment in a four-part series examining modern
water treatment and chemistry control/monitoring technologies.
By Brad Buecker, Buecker & Associates, and Katie Perryman, ChemTreat, Inc.
A
s wind and solar renewable energy tech- • Cogeneration plants at many heavy industries.
nologies continue to evolve and mature, • Combined cycle power plants that will in part,
fossil-fired power plants, and particular- or eventually in whole, operate with hydrogen
ly coal-fired units, will continue to fade as the fuel.
away. With the loss of coal-fired plants, • Biomass-fired power plants and biorefineries.
there is reduced need in the power • Small modular nuclear plants.
industry for makeup water treatment, steam gen- • Fusion plants sometime in the distant future.
eration chemistry, cooling water treatment and
wastewater discharge cleanup expertise. Yet, as many industry experts can attest from
However, traditional fossil-fueled power plants rep- experience, often the plant staff focuses on pro-
resent just a fraction of the many industries around cess chemistry and engineering to the detriment
the globe that generate steam. Furthermore, other of water and steam systems. That is until a failure
less carbon-intensive energy production methods occurs that shuts down part or all of the plant, or
continue to evolve, where water/steam chemistry — much worse, injures personnel. Some upsets may
and cooling water and wastewater treatment — are also place the plant in jeopardy regarding environ-
and will remain critical. These include: mental regulations.
 Figure 1: Common high-purity makeup system for modern combined cycle power plants. Courtesy of ChemTreat
“makeup
Inattention to
water
system operation
and maintenance
can cause serious
deposition and
corrosion issues in
steam generators. ”
 Figure 2: Abbreviated data for impurity
limits in low-pressure industrial boilers with
superheaters, which shows guidelines as they
relate to boiler operating pressure.
Courtesy of American Society of
Mechanical Engineers (ASME)
This four-part series will examine modern lower-quality makeup water, industry experts
water treatment and chemistry control/monitor- have seen many instances of insufficient
ing technologies to assist current and future plant makeup system operation and maintenance
employees with complex issues, where even seem- that allow poor-quality water to enter boilers
ingly slight upsets may cause major difficulties. The and cause scaling and corrosion. (Impurities
discussion will frequently have a holistic flavor, as in condensate return can cause similar issues,
often a treatment method or operational issue is which will be covered in a later installment of
not confined to one system but can influence mul- this series.)
tiple processes. This first installment will consider
makeup water treatment. The remainder of this article briefly touches on
the first item, but primarily focuses on the second.
A sometimes-overlooked unit operation:
Makeup water treatment Makeup water treatment for
Two recent Water Technology articles have exam- high-pressure power generators
ined particular aspects of makeup water treat- Impurities in high-pressure boilers can cause depo-
ID 59794141 © Jzehnder1 | Dreamstime.com
ment1,2. However, neither completely delved into sition and corrosion and can potentially carry over
two very important aspects of the process, particu- with steam to induce fouling and corrosion in
larly the second item listed below: superheaters, reheaters and turbines. Proper boiler
• The choice and complexity of the makeup water/steam chemistry control requires high-puri-
system is quite variable depending upon the ty makeup, well-designed condensate/feedwater
steam generator(s) served. High-pressure units chemical treatment programs, comprehensive on-
such as those for power production require line analytical monitoring around the circuit and
high-purity makeup, which relies on sophisti- judicious use of blowdown to maintain boiler water
cated treatment methods. On the other hand, contaminant concentrations within limits, with-
simpler makeup methods are often sufficient out wasting energy and water. Regarding makeup
for lower-pressure industrial boilers. system effluent purity, Electric Power Research
• Even though low-pressure boilers can tolerate Institute (EPRI) guidelines recommend3:

 Figure 4: Influence of deposits on boiler tube wall temperatures.
Courtesy of ChemTreat
 Figure 3: Layered boiler tube scale caused by multiple hardness incursions. Courtesy of ChemTreat
• Specific Conductivity (S.C.): <0.1 µS/cm When it comes to low-pressure boiler water Tube overheating is a common outcome from
• Sodium: <2 parts-per-billion (ppb) impurities, the largest potential problem is hard- scale formation. Other deposits may be porous in
• Silica: <10 ppb ness. Note the low feedwater hardness limit of 0.5 nature, which can lead to under-deposit corrosion,
mg/L for even the lowest pressure range of Figure 2. a topic for future discussion.
Guidelines from the International Association For high-pressure units the limit decreases to zero. Accordingly, for low-pressure steam generators,
for the Properties of Water and Steam (IAPWS) The typical result of hardness excursions is a very common core makeup treatment method
replace sodium with conductivity after cation shown below. for years has been sodium softening.
exchange (CACE) to calculate the influence of car- A primary reaction is: A softener contains many millions of small ion
bon dioxide ingress to makeup, which often occurs exchange beads and each bead has an enormous
in vented storage tanks. IAPWS’ recommended number of active sites (typically the sulfonate ion
CACE limit is 0.1 µS/cm4. Calcium carbonate (CaCO3) scale forms per the (SO32-)) which, in regenerated form, have sodium
As previously reported in Reference 2, a very inverse solubility of dissolved calcium and bicar- ions attached. As water passes through the resin,
common configuration for power plant high-puri- bonate alkalinity (HCO3-) with temperature. The sodium is exchanged for hardness and other cations
ty makeup is shown in Figure 1. general effect of scale deposition on tube wall tem- that have a stronger affinity for the exchange sites.
The micro- or ultrafilter minimizes particulate peratures is illustrated in Figure 4. A well-designed and operated softener can
fouling of the reverse osmosis (RO) membranes.
Modern RO units can typically remove over 99%
of dissolved ions, leaving a light load for a down-
stream ion exchange unit or electrodeionization
(EDI) system. The ion exchange polisher or EDI
unit produces the final, high-purity effluent.
Whereas this configuration or something simi-
lar is commonplace for power-generating units,
makeup water requirements for industrial boilers
“low-pressure
When it comes to
boiler
are usually less stringent but still important.
water impurities,
Makeup water treatment for industrial boilers the largest
The American Society of Mechanical Engineers
(ASME) recently revised its long-standing guide- potential problem
lines for industrial boiler water purity5. Figure 2 is
an extract from that guide.
The key point for this discussion is that lower-
is hardness. ”
pressure boilers can tolerate higher concentra-
tions of impurities because of lower heat fluxes
and the reduced potential of solids carryover to
steam. (We will examine such data in more detail
in a later article in this series on boiler water  Figure 5: A common softener vessel design.
chemistry, but encourage readers of this article to Courtesy of ChemTreat
contact the ASME (www.asme.org) to purchase a
copy of the guidelines.)

FEED AND MIX
WATER & WASTEWATER SOLUTIONS
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Conclusion
Inattention to makeup water system operation and
maintenance can cause serious deposition and
corrosion issues in steam generators. Subsequent
failures can be costly and potentially hazardous.
References
1. AlGhamdi, A., “Production of High-Quality
 Figure 6: Calcium
Demineralized Water for Steam Generation
exchange for sodium Units”; Water Technology, July/August 2021.
on active sites. 2. Buecker, B. and K. Perryman, “High-purity
Courtesy of ChemTreat water treatment: Using membranes to pro-
tect membranes”; Water Technology, May/
June 2022.
reduce makeup hardness to very low concentra- Caustic feed to the decarbonator effluent readjusts 3. Comprehensive Cycle Chemistry Guidelines
tions, which leads to a key point of this article. the pH. This fundamental arrangement can reduce for Combined Cycle/Heat Recovery Steam
From personal experience and via reports seen alkalinity to low part-per-million (ppm) levels. An Generators (HRSGs). EPRI, Palo Alto, CA:
from colleagues, a common malady at plants with alternative to the forced-draft decarbonator is a 2013. 3002001381.
boiler tube failures is frequent malfunction or fail- dealkalizer softening arrangement, where a strong 4. International Association for the Properties
ure of the sodium softeners. Inspections of extract- base anion (SBA) unit would follow the soften- of Water and Steam, Technical Guidance
ed failed tubes typically reveal deposits similar to ers. SBA resin, when regenerated with brine, puts Document: Volatile treatments for the steam-
that in Figure 3. Even more disturbing are cases the resin in the chloride cycle where it can then water circuits of fossil and combined cycle/
where operators were instructed to bypass the remove alkalinity. HRSG power plants (2015).
makeup system when the softener malfunctioned The system in Figure 7 does nothing to remove 5. Consensus on Operating Practices for the
and directly feed raw water to the steam genera- other ions including chloride, sulfate and silica. In Control of Feedwater and Boiler Water
tors. Rapid boiler failures were a common out- some cases, it may be beneficial to remove them Chemistry in Modern Industrial Boilers, The
come, with outage and materials replacement from the makeup stream, particularly if conden- American Society of Mechanical Engineers,
costs reaching six, seven or sometimes even eight sate return to the steam generators is of good qual- New York, NY, 2021.
figures. Process engineering and chemistry should ity. In that respect, basic two-stage, single-pass RO
not supersede water and steam system operation is becoming more common as a softener replace-
and maintenance. This is a theme that will run ment. RO will remove 99% or greater of the total dis- Brad Buecker is president of Buecker & Associates,
through this series. solved ions. This allows the boiler cycles of concen- LLC. He may be reached at [email protected].
tration to be raised, resulting in reduced blowdown.
Softening enhancements and alternatives Occasionally, one will see references that call demin- Katie Perryman is manager of the pretreatment
Apart from hardness capture, sodium softening eralized water “hungry water,” implying that it is simi- technical team at ChemTreat.
alone removes no other ions from the makeup lar to acid and will be very aggressive towards metals,
water. In low-pressure boilers with good blow- particularly carbon steel. As has been demonstrated in ChemTreat
down control, most impurities may be manage- the power industry, with proper pH conditioning puri- www.chemtreat.com
able; however, issues regarding alkalinity deserve fied water is not aggressive in that manner.
additional discussion.
In some corrosion control applications, a mild con-
centration of HCO3- may be desirable, as the ions
can form a mild protective layer on metal surfaces
and help reduce the corrosion potential. But HCO3-,
upon reaching the boiler, is in large measure convert-
ed to CO2 via the following reactions:
The total conversion of CO2 from the combined

reactions may reach 90%. CO 2 flashes off with
steam and when it re-dissolves in the condensate,
CO2 can increase the acidity of condensate return
and induce significant carbon steel corrosion.
Accordingly, many softening systems are
equipped with downstream equipment to remove
alkalinity. A common configuration is shown in
Figure 7.
The system includes a forced-draft decarbon-
ator. Acid feed upstream of the tower converts
alkalinity to CO2, which escapes in the tower vent.  Figure 7: A general industrial steam generation makeup system schematic. Courtesy of ChemTreat

SPECIALSECTION
WASTEWATER
A closer look at
National Beef’s new
wastewater treatment plant
By BOB CROSSEN
EDITORIAL DIRECTOR,
Beef producer constructs wastewater treatment plant to meet
ENDEAVOR BUSINESS MEDIA state standards and reduce its dependency on local aquifer with
Bob Crossen is the editorial direc- water reuse for agricultural irrigation. | By Bob Crossen
tor for the Endeavor Business
S
Media Water Group. He has cov-
ered the water and wastewater tricter nutrient removal require- treatment plant that would meet state  An aerial view of the National Beef Wastewater
industry since 2016. ments and planned changes at requirements. Treatment Plant. Courtesy of HR Green
a Kansas wastewater treatment “The plant successfully allows us to
facility pushed National Beef to operate independently of the POTW ary clarifiers, disc filters, aerated sludge
build its own plant. while beneficially reusing up to 9,000 holding and sludge dewatering with
National Beef is a major beef gallons per minute of treated waste- belt filter presses. In total, the new plant
processor located in Liberal, Kansas. water in crop irrigation in partner- treats 4.5 million gallons per day and an
Prior to constructing its own facility, ship with a local farmer,” said David irrigation pump can redirect 9,000 gal-
National Beef pretreated its wastewater Kalscheur, vice president of engineer- lons per minute of flow to the neighbor-
with screening, suspended air flotation ing for National Beef. ing farmland for beneficial reuse.
and anaerobic treatment cells before The heaviest use of the Ogallala The facility still has the option to dis-
being discharged to the publicly owned Aquifer is agricultural irrigation. charge effluent to the POTW during
treatment works (POTW). In con- National Beef sought to reuse its treat- months with low irrigation needs, but
structing the new plant, National Beef ed effluent for that purpose in partner- for the majority of the year, the facility
discovered it could treat the wastewa- ship with a local farmer for crop pro- remains independent.
ter to a higher level and also reuse efflu- duction in addition to use within its “The National Beef Liberal wastewa-
ent, reducing its dependence and pull facility to wash trucks, belt filter press- ter treatment plant project removed
on the Ogallala Aquifer. es and other beneficial reuse options. the industrial wastewater from the pub-
National Beef selected HR Green The construction included a raw lift licly owned treatment works system,”
to assist with the design of a new bio- station, a 5-stage Bardenpho process said Eric C. Staab, P.E., Bureau of Water,
logical nutrient removal wastewater for biological nutrient removal, second- Industrial Program Section, Kansas

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Watch a video interview
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“ The project reduced the nitro-
To meet state requirements, National
gen and phosphorus loading to the
Beef constructed a wastewater treatment
Cimarron River and provides the ben-
plant that not only reduced its reliance
eficial use of wastewater effluent irri-
on the Ogallala Aquifer but also reused
gation onto agricultural land while
water for irrigation of a local farm. David
simultaneously reducing the demand
Kalscheur, vice president of engineering
for groundwater used for irrigation,”
for National Beef Packing Company, and
Staab said.
Eric Staab, professional environmental
Using construction manager at risk,
engineer in the industrial programs
National Beef and HR Green created
group for the Bureau of Water in Kansas
a collaborative environment for the
Department of Health and Environment,
planning, design, construction and
explain the purpose behind the project
value engineering services for the
and how it met state requirements.
entire project. This kept costs low and
reduced scheduling disruptions.
Watch the video by visiting
 Establishing beneficial reuse of Department of Health & Environment. HR Green created a plant opera-
treated wastewater with water reuse https://bit.ly/3IbDrTZ
was a primary goal of the project.
“This allows the new POTW to operate tions manual prior to start-up for
without complications created by the operator review, which helped the
industrial wastewater.” team solve problems with foaming,
The National Pollutant Discharge high oil and grease and filamentous
Elimination System permitting for the bacteria. Additionally, biological seed
POTW influenced the treatment levels was developed organically with the
MORE Visit watertechonline.com
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for National Beef. In turn, it established incoming wastewater for initial start for more on wastewater.
limits of < 10 mg/L of total nitrogen and up due to a lack of biological seed
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SPECIALSECTION
A
Fortune 500 multinational conglomer-
ate that produces over 60,000 products
installed the KETOS SHIELD solution at
a 2,000,000-square-foot chemical manu-
facturing facility for specialty resins and
specialty films.
Challenge
This plant had been cited in litigation related to
health and environmental complaints. As a result,
the plant operations team needed to proactively
understand the composition of its water matrix on
a 24/7 basis.
Staffing and budget constraints made it impos-
sible for operators to be on-site 24/7 to collect
samples and continuously monitor water quality.
In addition, it was impossible to add lab personnel
or lab expenses and achieve real-time water qual-
ity visibility.
The team needed to autonomously monitor
multiple water quality parameters in real-time
to make data-driven decisions and proactively
address potential issues.
Solution
 Ideal for high-frequency water quality sampling,
the KETOS SHIELD solution provides operators with MONITORING The plant’s wastewater treatment process includes
lab accurate results for more than 30 parameters. primary, secondary and tertiary water treatment
Case study:
All images courtesy of KETOS before final discharge to a nearby river. The oper-
ations team implemented the KETOS SHIELD
remote water quality monitoring device at the sec-
Ensuring compliance
ondary treatment phase before the activated car-
bon beds and UV treatment.
The KETOS SHIELD autonomously monitors for
the following parameters:
and continuous water

• Fluoride
• Free chlorine
• Residual chlorine
• Total hardness
quality monitoring
• Calcium
• Magnesium
The plant operations team received access to the

KETOS Smart Water Intelligence platform. And
with the help of the KETOS customer success team,
Chemical manufacturer uses KETOS SHIELD to improve they configured it to meet their operational needs.
Now, if the KETOS SHIELD detects a parameter
water quality and ensure regulatory compliance. | By Meena Sankaran, KETOS that is out of range, the plant operations team receives

• Better ensure wastewater quality and permit
compliance.
• Meet or exceed corporate sustainability
expectations.
• Automate sustainability data dashboards for
enhanced ESG reporting.
• Integrate actionable water metrics along with
other EHS data of importance to the organization.
• Leverage interoperable data to holistically
assess the impact of plant operations due to
water quality — leading to sustainable water
management.
Meena Sankaran is the founder and CEO of

alerts via email, SMS or mobile app. Over time, alert review water quality dashboards. As a result, all KETOS. KETOS is a fully integrated platform
thresholds can be configured and modified to meet stakeholders know the composition and quality that combines hardware, software, connectiv-
the team’s evolving needs. In addition, the tiered alert of water in real time, and the operations team can ity, automated reporting, predictive analytics and
system allows the team to have internal and exter- treat, manage and responsibly discharge water. maintenance to automate water monitoring and
nal metrics with custom treatment planning for both In addition, because the plant team’s ability to testing. KETOS enables water operators to identify and solve mission-
thresholds. As a result, the team is more informed, bet- efficiently treat and recycle water has improved, a critical water efficiency and quality challenges in real-time, or before
ter prepared and able to act proactively. lower percentage of treated water enters the envi- they happen through predictive algorithms, to ensure that water meets
ronment, and chemical costs have decreased. specific quality and safety standards.
Results Over time, because water quality data is col-
After the KETOS installation, plant operators con- lected consistently, the plant team can leverage KETOS
figured water quality dashboards to highlight the historical views, trend analysis and even predictive www.ketos.co
most critical parameters. The plant operations and intelligence to improve site operations and overall
corporate management team could then quickly efficiency. In addition, the team can:

FOOD & BEVERAGE
Increase plant insights by

leveraging instrument
diagnostic data
By examining data that is frequently already available, food and
beverage processors can increase batch yields, reduce downtime
and increase proactive maintenance. | By Ola Wesstrom, Endress+Hauser
F
or decades in the food and beverage indus- 4-20mA primary process variable. This extended  An Endress+Hauser Picomag electromagnetic flowmeter digitally
try, instrument data was constrained to data, transmitted from instruments to host sys- transmits primary and secondary process variable, plus instrument
diagnostic data to a central host system via IO-Link.
single analog process variables communi- tems via digital communication protocols, helps
All images courtesy of Endress+Hauser
cated via individual 4-20mA current loops. plant personnel improve efficiency and avoid
But modern instrumentation advances, unplanned shutdowns by giving them the data variable analog output. Operators interpreting
particularly digital communications, now they need to implement proactive maintenance such a signal received by a programmable logic
provide a wealth of additional diagnostic and other and predictive monitoring (Figure 1). controller, distributed control system, asset man-
information, providing operational insights that Engineers, managers and operators in the food agement system or another host system simply
are not easily obtained using conventional 4-20mA and beverage industry are observing their peers in have no other information regarding its accuracy.
measurements alone. However, a lack of aware- other industries, who are often farther down the Each analog loop scales a single process value as
ness of digital capabilities that are already present path of digital transformation and — encouraged electrical current but is unable to transmit second-
among existing instrumentation has led to a delay by the results — are also beginning to embrace this ary variables, such as temperature on a pressure
in adoption in the food and beverage sector. digitalization trend. instrument. Additionally, communication is uni-
In today’s data-centric landscape, smart instru- directional only, so there is no way to send com-
mentation provides a wealth of diagnostic and Conventional instrumentation challenges mands from a host to the instrument.
other information, empowering plant personnel to Many factors impact and even interfere with the Traditional analog instrumentation also
get far more from their instruments than a single accuracy of a conventional instrument’s process lacks diagnostic information, making it nearly

“instrumentation
impossible to foresee or troubleshoot instrument
failure. Malfunctions cause unplanned downtime In today's data-centric landscape, smart
and costly instrumentation repairs in the best
cases, or catastrophic equipment damage and
provides a wealth of diagnostic
safety hazards in the worst. Bound by analog elec- and other information...”
tronics, traditional instruments must be hardwired
to a host system, sometimes limiting placement in
hard-to-reach areas of a facility. they are unaware of this existing capability.
Transmitting this data is also possible via many
Digital pathways for enhanced connectivity Ethernet-based protocols. These provide several of
HART over 4-20mA the same benefits as HART but typically operate at
For retrofitted and new applications where much higher speeds, enabling the inclusion of more
hardwiring transmitters back to a host system is information, along with faster response times.
existing or convenient, instruments can use the
bi-directional digital HART communication pro- IO-Link
tocol. Data is superimposed on a 4-20mA analog IO-Link possesses a unique set of advantages
current loop, providing two-way communica- — particularly for applications in the food and
tions between an instrument and a host system. beverage industry — combining simple configu-
The exchanged data includes primary process ration, a standardized protocol, fast data trans-
values, one or more secondary process values, mission speeds and cost efficiency. Recognized
diagnostics, calibration, maintenance and other as an international standard IEC 61131-9, IO-Link
information. This wealth of data makes configu- is a bidirectional digital communications proto-
ration easy and improves operational process col that provides measurement and other devices
insights, compared to traditional analog-only with basic functionality, most notably instrument
instrumentation. diagnostic information.
Because HART-enabled instruments can trans- Similar to a remote input/output (I/O) hub, an
mit multiple process values to a controller via a IO-Link “master” device is used to connect mul-
single loop, users gain flexibility to continue using tiple instruments to a host system via an industrial  Figure 2: An Endress+Hauser smart Coriolis flowmeter (middle) and
iTHERM TrustSens temperature probe (left) can digitally transmit primary
existing analog loops for real-time control, while Ethernet protocol, such as EtherNet/IP, PROFINET and secondary process variables, plus instrument diagnostic data to a
taking advantage of additional process and diag- or Modbus-TCP/IP. The master serves as a gate- central host system via HART, superimposed on their analog 4-20mA loops.
nostic data provided to the host system for making way, transmitting diagnostic data, secondary pro-
data-driven decisions within a facility (Figure 2). cess values and host system commands among all popular among machine builders and skid sup-
An estimated 80% of instrumentation used for connected devices (Figure 3). pliers in the food and beverage industry. This
real-time control and monitoring in the food and Integrating IO-Link-capable instruments, using is because basic instruments with support for
beverage industry already supports HART, but M12 washdown-grade connectors and unshield- IO-Link fulfill most operational requirements,
many processors are not using it, often because ed cables up to 20 meters in length, is especially while the diagnostics of IO-Link can drastically
improve troubleshooting efforts when issues
arise. The installation requirements of fieldbuses
add complexity and costs, but IO-Link instru-
ments, by contrast, are about as close to “plug-
and-play” as any come.
Additionally, the majority of IO-Link instru-
ments can be optionally operated in 4–20mA ana-
log mode with simple configuration and wiring
changes, enabling flexible installation and integra-
tion. When ready, facilities can switch the devices
to digital mode to harness the power of remote
configuration, increased instrument diagnostic
data and multiple process variables transmitted
from a single instrument.
Compared to instrumentation with direct
Ethernet connectivity, IO-Link devices are not
directly accessible from an upper-level system,
such as an asset management system. Instead,
users must tunnel through the IO-Link master to
reach them. However, faster data polling speeds
make this quicker than connecting to instru-
ments via HART. But one of the greatest strengths
of IO-Link systems is the simplicity of instrument
configuration and ease of device replacement,
reducing the level of training required to maintain
and service plant instrumentation.
 Figure 1: There is a period in time when proactive diagnostic data monitoring can reveal measurement issues prior to instrument failure.

Ethernet-APL
The Ethernet Advanced Physical Layer (Ethernet-
APL) is a more recent development, providing
the ability to transmit digital data via industrial
Ethernet protocols using a single two-wired shield-
ed cable per instrument, while also providing power
for 4-wire instruments. With the same cable require-
ments as HART — though markedly different gate-
way and termination specifications — Ethernet-
APL can simplify retrofits by eliminating the need to
pull new wires to instruments (Figure 4).
Ethernet-APL is protocol agnostic, and it sup-
ports industrial communication protocols such
as PROFINET, EtherNet/IP, Modbus TCP, HART-IP,
OPC UA and other higher-level network protocols
(Figure 5).
Ethernet-APL provides high-speed data trans-
mission at a 10-Mbit/s data rate, making it possible
to send and receive more data than is possible with
older digital methods. It provides a robust basis
for continuous diagnostics, monitoring, industrial
internet of things connectivity and remote instru-
mentation verification.
Because communication is handled via stan-
dard Ethernet protocols, instrument data routing
among process control systems and asset manage-
ment tools is highly efficient as most control envi-  Figure 3: IO-Link can integrate seamlessly with an existing plant Ethernet network by way of the master
ronments already support these protocols. device that transmits data among connected instruments and host systems, or it can act independently.
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“primary
Food and beverage automation systems regularly use
process data to monitor and control operations, but
Results
Food and beverage automation systems regularly
use primary process data to monitor and control
plant personnel often discard status and diagnostic data.” operations, but plant personnel often discard sta-
tus and diagnostic data. By dismissing this data,
facilities miss out on opportunities to optimize,
simplify and safeguard their operations.
A corn wet-milling facility was experiencing
issues with one of its processes, and it began to
suspect a flowmeter was providing inaccurate val-
ues. However, an online Heartbeat verification of
the installed Endress+Hauser Promag H300 elec-
tromagnetic flowmeter using instrument diagnos-
tic data proved the flowmeter was not the source
of the issue.
The online protocol, leveraging diagnostic
data, saved two technicians six hours of labor,
along with plant downtime, by alleviating the
need to remove, replace and bench test the flow-
meter in question. Within a matter of minutes,
 Figure 4: Ethernet-APL architecture is highly customizable, requiring

only a gateway and power supply to enable data transfer among a wide
range of instruments and various host systems using a single two-wire
shielded cable per instrument. In many cases, cables are already present
in plants with existing analog instrumentation.
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334
food grade seal materials  Figure 5: As a foundational transport layer, Ethernet-APL is capable of carrying any industrial Ethernet protocol.
Endress+Hauser Ethernet-APL instrumentation currently supports PROFINET traffic, with plans to carry EtherNet/
IP, Modbus TCP and additional protocols in the near future.
Flow Patterns
the processor determined the meter was working within specifications, so
2-way, 3-way or Multiport
it moved on to troubleshooting other components. It turned out there was
flow patterns a problem with an upstream valve, causing unexpected flow rates.
Online diagnostics increase

Automation 509 reliability and uptime
Today’s smart instruments provide a plethora of diagnostic data, helping pro-
Electric, Pneumatic and cessors maintain their systems with much greater reliability. The trick is often
Sanitary actuation packages simply realizing the data is available and then adjusting operational workflows
to use it effectively.
Instrument diagnostics and other functions make it easier to detect prob-
Accessories lems, and with quicker troubleshooting and servicing when issues arise.
Sustaining a competitive edge in the food and beverage industry requires top-
Feedback Switches, notch production efficiency, and precise monitoring of variables such as stock,
Solenoids, V Balls, hygiene, safety and inventory conditions is crucial to minimize material waste
Positioners and more and adhere to strict standards.
Digital protocols in general, and IO-Link in particular, can help food and
337
beverage processors, who experience challenges with the constant threat of
product loss and the difficulties of rigorous manual management. These capa-
bilities help expand visibility and generate holistic insights, empowering plant
Visit us on the web at www.ballvalve.com personnel to optimize operational efficiency, maintain product quality and
maximize profitability.
or call us at (800) 568-8998
for immediate assistance
Ola Wesstrom is the senior industry manager of Food & Beverage for Endress+Hauser USA. He is responsi-
ble for the development and implementation of best practice measurement solutions, supporting customers
throughout the industry segment. Ola has a Bachelor of Science degree in instrumentation and automation
from National Pulp & Paper College in Sweden. Since joining Endress+Hauser in 1992, he has held various
positions, focusing on Food & Beverage since 2001.
Endress+Hauser
www.endress.com
ISO 9001 BPE-2002 3

68-00
NSF/ANSI 61 & 372
800 - 568 - 8998 • [email protected] • www.ballvalve.com

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VACUUM CONVEYORS: POWDER HANDLING’S INCREASE PLANT INSIGHTS BY LEVERAGING www.processingmagazine.

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18 Vacuum conveyors: Powder handling’s antidote

22 Combustible dust hazards of dilute phase

30 Different ways to charge material in a

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36 Industrial water and steam treatment will be

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42 A closer look at National Beef’s

46 Case study: Ensuring compliance and

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14 Processing | MARCH 2023

Data is only useful if you use it