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.
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.
New control heads extend the life of process valves
Investing in high-quality process control valves have several operational advantages, including an extended service life. However, when just the valve actuators reach the end of their service life, the options can be limited, especially when the OEM parts are obsolete.
Fortunately for a UK based malt processer Bürkert has been able to provide a cost-effective retrofit solution for two hundred third-party valves, upgrading them with Bürkert Type 8691 control heads to keep the full complement operational for years to come.
The food and beverage industry uses process control valves extensively to manage the flow of liquids and gases throughout the manufacturing process. As such, their reliability is essential to the continued operation of the food manufacturing process: keeping sufficient spare parts available is therefore an important task.
However, as equipment ages, the original equipment manufacturer (OEM) may no longer support the product. At this point, maintenance managers can be left with just their own stock of spare parts, which will, inevitably, run out at some point.
In this case, the food manufacturer took the opportunity to investigate the alternatives, starting with replacing the control valves completely. With over 200 process control valves affected, replacement would be a substantial investment and the payback period would have been longer than desired.
At the same time, Bürkert, as an existing supplier to the company, was invited to offer a solution. Craig Kerr, Sales Manager at Bürkert, explains: “We were provided with a spare control valve from the production line and asked to deliver a proposal that would resolve the issue of ageing controls, while retaining the value in the valve body.”
As a major manufacturer of process control valves, Burkert could have offered a complete replacement valve, but having assessed the condition of the valve body decided that just the control head needed attention. The obsolete pneumatic actuator could be replaced with Bürkert’s Type 8691 control head with the simple addition of an adapting bracket to attach it to the legacy valves.
Plug & Play
Craig continues: “The manufacturing process operates a decentralised control system using ASI, with the valves either open or closed. Bürkert’s suggested solution would provide a simple, plug-and-play control head that would easily attach to the control valve body.”
In all, it would take less than an hour to replace each control head. This includes assigning an address for the PLC and using the tuning function where the operator presses the buttons to open and close the valve. The integrated valve position sensor registers these points and stores them to ensure reliable valve operation.
The Type 8691 is ideally suited to the food and beverage industry; being constructed from stainless steel, with excellent ingress protection ratings, it is easy to clean and has excellent chemical resistance properties. In addition, it is equipped with bright, coloured LED status indicators that show the position of the valve at a glance. Craig concludes: “The customer had the first unit on trial for a short period before ordering a further one hundred units. These were all installed and commissioned by the customer and one year on, they are all continuing to function reliably. This solution has been very cost-effective, saving thousands in process hardware and replacement costs by allowing the customer to retain the original valves and minimise any potential downtime from the upgrade.
Burkert Fluid Control Systems is one of the leading manufacturers of control and measuring systems for fluids and gases. The products have a wide variety of applications and are used by breweries and laboratories as well as in medical engineering and space technology. The company employs over 2,500 people and has a comprehensive network of branches in 36 countries world-wide.
New hydraulic tipping valve will increase productivity in tipping operations
Edbro is introducing a new hydraulic valve for tipping trucks, which will allow faster lowering than was previously possible. This will lead to a quicker turnaround time of tipping operations and therefore increased productivity.
Edbro, a member of the JOST World since 2012, is a highly regarded leader in the manufacture of on-vehicle hydraulics systems. It maintains its position at the forefront of the tipping market by always working to increase payloads, reduce tipping times and provide “fit and forget” solutions that require little or no servicing over their entire working life.
Replacing the incumbent CT range of valves, the UT valve is completely interchangeable with the older part. This ensures that vehicle operators can continue to maintain their existing hydraulic kits without any issue. Like its predecessor, the UT valve increases safety during lowering and offers lightweight performance.
The UT range introduces an optimised internal oil flow which reduces flow restrictions. As a result, the maximum lowering speed of the valve has been increased, reducing the time taken per tipping cycle. While this will be appreciated by all users, it will be particularly useful in quarrying and other operations where multiple tippings are made each day – the time savings on each cycle adding up so that the trucks can complete more runs per shift.
Danny Broomfield, Sales Director for UK & Ireland, comments: “The Edbro slogan is Lighter, Faster, Stronger. We achieve these goals by maximising the performance capabilities of every components found in our systems. The introduction of the UT valve will play its part in making sure our customers have the fastest and safest tippers on the market.”
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