sentry equipment corp sampling solutions specialty heat exchangers bulk solids sampling applications...
TRANSCRIPT
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Bulk Solids Sampling Bulk Solids Sampling Applications II Applications II
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Applications ReviewApplications Review
• Cement • Dairy • Chemical • Plastics
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Cement ApplicationsCement Applications
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Cement – Process flowCement – Process flow
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Process Flow Description Process Flow Description
• 4 main ingredients: – Calcium (limestone) – 90% – Alumina (flyash) – 3%– Iron – 2%– Silica (sand) – 5%
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Process Flow DescriptionProcess Flow DescriptionRaw Mill Raw Mill
•Ball mill combines/mills proper proportion of limestone, flyash, iron and sand
•Sent to rotary kiln after mixing in homogenizing silos
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Process Flow DescriptionProcess Flow DescriptionRotary KilnRotary Kiln
• Mixture is heated to 2700°F temp to create “clinker” through a process known as calcination
• Clinker is then stored until needed
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Process Flow DescriptionProcess Flow DescriptionFinish Grinding Finish Grinding
• Combine clinker with gypsum – Limestone for mortar products
• Mixture delivered to roller presses then ball mills for finish grinding
• Discharge from the finish grinding mill is separated into finished product
– Larger particles returned to mill
• Cement is transported to silos prior to bulk shipping (rail, truck, barge)
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Process Flow DescriptionProcess Flow DescriptionBarge Load Out Area Barge Load Out Area
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Process Flow DescriptionProcess Flow Description ISOLOK®ISOLOK® SAK Sampler on Load out AirslideSAK Sampler on Load out Airslide
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Why Sample in a Cement Why Sample in a Cement Plant? Plant?
• Quality control of finished product – 325 mesh/45 micron (94% passing)– Blaine – (determines total surface area in square cm per
gram of cement) – Chemistry
• Finished product is discharged from multiple silos into one shipment – needed to assure consistency
• Provides data for report to terminal, tech reps / sales reps
• Custody transfer– Provides sample for archival purposes
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Challenges With Sampling in a Challenges With Sampling in a
Cement PlantCement Plant
• Direct sampling method is messy and dangerous– No good location for manual sample collection in
load out area
• Material particle size cannot be significantly degraded while collecting the sample
• Minimize human variances • Dozens of sampling points result in high
labor costs for manual collection of samples
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• Automatically takes sample of material taken at fixed time intervals
• Simple, safe, and reliable• Uniformity and consistency of sample
– (Elimination of human error)
• Clean (eliminates material dusting / spillage)• VERY low labor costs
– Eliminates time consuming manual sampling process
• Compact design of ISOLOK allows for direct attachment on moving load out air slide
• Model RX can penetrate the Airslide membrane to sample from the center
Why Sentry Samplers? Why Sentry Samplers?
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Dairy ApplicationsDairy Applications
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Dairy ProcessDairy Process
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Typical Sampling Points Typical Sampling Points
• Drying process– Models SAK, B1 and PR
• Bag filling stations -custody transfer– Models SAK and B1
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Milk Drying ProcessMilk Drying Process
• Milk drying is a three step process:– Multistage evaporator– Spray dryer– Fluid bed dryer
• In multistage evaporator initially milk is concentrated up to about 48%
• During drying in spray dryer, the excess water present in free form between the particles of the dry solids get evaporated easily
• These last drops of water are removed in a fluid bed dryer
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Milk Drying ProcessMilk Drying Process• Produces powder with extremely good
solubility– Instant powder
• Drying:– Extends the shelf life of milk apart from– Reducing the weight and volume– Lowers the cost of transportation
• Final moisture in the powder ranges between 2.5% and 4%
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Bag Filling ProcessBag Filling Process
• ISOLOK® model SAK mounted in bag filling system
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Bag Filling ProcessBag Filling Process• Many sample systems
incorporate an indexing system for lot archiving
• Models SAK and B1 are often used
• SAK seals have been supplied with springs that are impregnated within them – Can be detected in metal
detectors
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Foss Moisture AnalysisFoss Moisture Analysis• Dairy application
analyzing whey powder• Model PR mounted in a
pneumatic convey line• Extracted a fixed volume
of sample and introduced to analyzer
• After measurement sample was purged into the bottle for additional off-line analysis
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• Butter fat content• Bacteria• Hormone levels (BGH)• Antibiotics• Moisture content
Why Sample in Dairy Why Sample in Dairy Applications?Applications?
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Challenges With Sampling in Dairy Challenges With Sampling in Dairy ApplicationsApplications
• Equipment must be 3-A approved (section 59-00 or 81-00)
• Sample should be taken from various types of processes– Fluid bed dryers– Pneumatic conveying systems– Gravity chutes– Bag filling systems
• Samplers need to be compact and easy to clean
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• Model B1 and ISOLOK® SAK compact– Easy removal and cleaning– Reliable and consistent
• Model PR– Installations in pneumatic convey lines– Integrate moisture analysis– Easy removal and cleaning– Reliable and consistent
Why Sentry Samplers?Why Sentry Samplers?
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Plastics ApplicationsPlastics Applications
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Plastics Process FlowPlastics Process Flow
• Natural Gas is sent through a cracking unit which produces a feedstock
• Feedstock is combined with hydrogen, catalysts into a reactor which precipitates a white powder known as “Fluff”
• The Fluff is then passed through a catalyst deactivation unit – fluid bed vessel using
nitrogen as the fluidizing medium
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Plastics Process FlowPlastics Process Flow• After deactivation, Fluff is
pneumatically transported to silos
• Fluff is fed into continuous blenders where blend additives are introduced
• Blended material is heated, extruded through a die plate, chopped into pellet form and cooled
• Finished pellet is screened an pneumatically conveyed to loading silos where it is bulk shipped by rail or truck
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Typical Sample PointsTypical Sample Points
• Inlet of catalyst deactivation unit
• Outlet of catalyst deactivation unit
• Discharge of continuous blender
• Finished pellet
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Why Sample Plastics?Why Sample Plastics?
• Monitor product composition and quality– Melt index tests – Check ethylene and rubber content – Catalyst residue (outlet of catalyst deactivation
unit)
• Provide feedback for process control• Check to ensure volatile organic compounds
(VOC) levels are within acceptable limits • Custody transfer
– Provides sample for archival purposes
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• Extraction of representative sample from pressurized line without allowing dust and gas to escape
• Sampler must handle pressure surges well above process pressure
• May need to have food grade wetted components if process line produces material that will go into FDA approved containers, bottle caps, or closures
• Minimize labor cost, material waste, safety and cleanup concerns
Challenges of Sampling PlasticsChallenges of Sampling Plastics
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• Automatically takes fixed volume of material taken at fixed time intervals– Provides accurate verification for plant control
• Closed sampling – Eliminates material spillage/waste– Extracts sample without releasing gas/dust to
atmosphere – Built-in nitrogen purge port can connect to gas
collection system to reclaim unreacted hydrocarbons – Keeps operator out of harms way
• Food grade 316 SS and EPDM elastomers
Why Sentry Samplers?Why Sentry Samplers?
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Questions?Questions?
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Applications/PricingApplications/Pricing
• Quote Templates– Blank Template - SEC Terms and Conditions– Quote Templates
•Standard & [optional] model information•Copy verbiage onto blank template form•Delete [optional] verbiage•Use Qty & Pricing info from price
worksheets
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Questions?Questions?