Sugar manufacturing poses a challenge to valve makers. The characteristics of the material to be handled, fluctuating pressures and high temperatures and viscosities present great demands to valve engineering.
Due to the competitive market situation in the world of sugar, nowadays the responsible factory managers of sugar factories are required to pay increasing attention to all available options of rationalization and cost savings. The availability of all system components has been especially scrutinized. Thinking in terms of life cycle cost and cost of ownership is gaining significance. While in the past many system components such as pumps and valves were simply replaced after the campaign, they now require much higher durability.
According to the sugar factory managers a high reliability and long service life, service friendliness and functional reliability are just as much on the priority list as the potential for automation. However, the most important element during the campaign is service around the clock. Most of the times the sugar factories expect service by mobile phone from the supplier any time of the day and night. Of course, all this also applies to the numerous valves and fittings. Valves are used everywhere in sugar production: From juice production to juice purification, juice concentration and sugar crystallization. While a typical production facility (referring to a 10,000-ton factory) has “only” 200 to 220 pumps, valves (typically: butterfly valves) can be found much more often. A beet processing factory of 13,000 tons/ day is estimated to utilize approximately 3,000 installed valves. With roughly 1,000 valves in the beet end (that is one third of the total number) most valves are used here; large quantities can also be found in the evaporation crystallizers in the sugar house, in the power station and especially in waste water treatment. When the factory is running sugar juices at the crystallization point, even the smallest temperature variations or thermal bridges are enough to crystallize the medium. A regular valve would clog immediately. Butterfly valves are not as sensitive and can be heated more easily.” Butterfly valves therefore cover the largest application scope of most media handled in the sugar factory.
Section of a soft sealing flucon shut-off valve, series, series 23/24. The fact that the elastomer (EPDM-H) is vulcanized onto the support ring can be clearly seen.The high temperatures and especially the vacuum are extremely critical for the valves used here.
The soft sealing flucon series 23/24 butterfly valve with replaceable EPDMH liners (resistant up to 130°C) by Airpower, showing best results in many evaporation crystallizers worldwide, provides the solution. With the flucon butterfly valves the elastomer is permanently vulcanized on the interchangeable support ring thereby ensuring a vacuum tight housing liner; the elastomer cannot be deformed caused by the vacuum. These valves are therefore particularly suitable for vacuum processes. Combined with the robust twintorque pneumatic actuators on/off or control valves offer the perfect solution for most critical applications in the sugar factories.
Sampling Ball Valve…a special design for special demands!
Sampling valves are commonly used in various industries, everywhere from chemical plants to food industries. It is a type of valve that allows taking a sample of a fluids (either liquid or solids) so it can be tested for its quality. Main purpose for such valves is quality control. This also applies for the sugar industry: Sampling valves are being used at the vacuum pans in sugar factories/refineries where the quality of the sugar juice is being tested for its pureness.
When the sugar is obtained from the thick juice (sugar content 65–80%) by repeated crystallization at elevated temperature and negative pressure, the intermediate product is called “magma”, which is a mixture of thick juice and granulated sugar.
During the crystallization, a crystal suspension is created in the “vacuum pans”. The boilers are heated with vapors from the evaporation station and are under vacuum to ensure energy-saving evaporation of the water at low temperatures. This means the clarified juice must be evaporated for the sugar to crystalize. The vacuum pans are big vessels where the syrup is boiled under vacuum, and since they are under vacuum, it is very important to install a sampling valve that can fulfill this vacuum-resistance. Airpower Europe has come up with the idea of this sampling ball valve upon request from various sugar factories, where the sampling process was rather problematic due to the difficulty of taking clean samples.
For this purpose Airpower Europe GmbH has designed a special sampling ball valve that is being used and appreciated by many sugar factory workers worldwide. Today this sampling valve is being used in sugar factories in Germany, Mexico, Cuba, Guatemala, Turkey, Pakistan, Poland etc. It consists of a 3 piece stainless steel ball valve, with a closed ball on one side. Nominal diameter is DN50 with a pressure range of PN40. Temperature range is from -10°C to +200°C. The operation of the valve is being handled through a hand lever. For further information please contact Mr. Murat Erol at firstname.lastname@example.org or feel free to visit our website www.airpower-gmbh.com
Proportional valves with linear motors in the medical industry
The Precision Fluidics Division of Parker Hannifin, the global leader in motion and control technologies, announced the release of their new Parker LM-Pro linear motor proportional valve targeted at the respiratory and anaesthesia markets.
“The Parker LM-Pro miniature proportional valve utilizes a patent pending linear motor actuation technology to enable flow up to 540 slpm in a very compact and energy efficient package, while providing an unparalleled, controllable range to allow for use across multiple respiratory applications,” says Beth Young, division marketing manager at Parker Precision Fluidics.
A critical feature of the LM-Pro valve is the valve’s linear motor actuation technology that provides exceptional resolution over a longer stroke and lower power consumption than traditional solenoid or voice coil actuation designs. With a linear controllable flow range from 0.5 to 540 slpm, pressure capability up to 100 psi (6.9 bar), and typical power consumption of less than 2 Watts, the LM-Pro valve enables very precise flow control throughout the full performance range of the valve. The LM-Pro valve allows for simple, closed loop feedback, giving the customer precise pressure or flow control. This ensures accurate and safe delivery of precise gases to patients, from neonates to adults. Typical applications will have power usage of less than 2 Watts, giving the customer longer battery life or ability to use a smaller battery to save size and weight. Typical hysteresis of <10% (full scale), coupled with a fast response time of <20 msec (full cycle), give the customer the ultimate in low and high flow rate and precision control proportional valve performance.
The Parker LM-Pro is a true, one-size-fits-all, proportional valve. Its unrivalled performance capability combined with the simplicity of a face mounted/ported design make the LM-Pro valve an ideal solution for varied applications with dynamic flow control needs. “It is ideal for customers who are trying to increase performance while continuing to decrease the footprint of their products,” says Paul Nierman, division engineering manager at Parker Precision Fluidics.
As systems become smaller and more portable, power concerns and accurate flow control at both the high and low ends of the spectrum are vital. The Parker LM-Pro linear motor proportional valve is a great example of the portfolio of products at the Precision Fluidics Division of Parker Hannifin that lead the market in miniature, low power, light weight, high performance fluidic products.
Visit the link to find more information of the Parker LM-Pro linear motor proportional valve: https://discover.parker.com/LM-Pro
Airpower Series 35 Double Eccentric Butterfly Valves
The Series 35 Double Eccentric Butterfly Valves also known as High Performance Butterfly valves from Airpower Europe GmbH are generally used in the sugar industry where you require valves resistant to higher temperatures or also in the cogeneration facilities, pulp and paper, chemical etc.
They are characterized by their long-service time, low maintenance and reduced friction between seal and the gasket. The airpower Europe GmbH Series 35 valves are available from DN50 (2”) up to DN1000 (40”). The body is made of Ductile Iron GGG40 (EN-JS-1030) (EN-GJS-400-15) but can also be offered as Stainless steel 1.4408 version (CF8M) or carbon steel A216 WCB.
The disc is offered as a standard in the stainless steel CF8M version. Alternatively, it can be offered as well with 304 stainless steel or Ductile Iron 1.0619 discs. The media temperature for the body coatings is -30°C up to +200°C for RPTFE.
The body length is in accordance with API609 and the mounting flange standard is ISO5211. For all nominal sizes the bearing is maintenance-free. The bearing is for exact centering of the disc. The valve disc itself is double eccentric mounted.
All sealing surfaces are machined. Major advantages here are the low torque value and the low wear. The bolt itself is secured by a locking plate. An additional sealing ring ensures that the inner area of the bolt is protected against dirt and liquids.
The seat ring inserted with a positive fit ensures absolute tightness and compensates for wear. Replacement is possible without disassembly of shaft and disc. The removable retainer ring protects against abrasion and erosion whereas the continuous shaft ensures high stability. The Series 35 double eccentric butterfly valves can be combined with twintorque series pneumatic rotary actuators from airpower Europe GmbH, either single or double acting type.
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