Mbl Volkmann Che Mag Is
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Transcript of Mbl Volkmann Che Mag Is
Part 1.: Vacuum Conveying and the applications for bulk materials in thechemical-, pharma-, and food-industries
Suction/Aspiration, conveying and loading with dust s, powders & granules
Dipl.-Ing. B.Eng.(Hons) Thomas Ramme, Soest
Table of Contents
* Pneumatic Conveying in comparison to mechanical conveying
* Vacuum Conveying in comparison to positive pressure conveying
* Flexible Configurations and diverse applications of Vacuum Conveying Systems
* Powder Transfer Solution Examples, integration into all solids process systems
* Silo Loading, big-bag discharging, drum filling, reactor loading, hopper discharging etc.
* Examples of materials to be conveyed and powder transfer parameters
* Dilute-phase, dense-phase and plug-flow with Vacuum Conveying
* Analysis of components (Vacuum pump, receiver vessel, filter systems)
* Cyclic powder transfer with Multiple-Jet-Vacuum-Pumps versus electrical mechanical pumps
* How to adapt the Vacuum Conveyors to the wide variety of applications
VOLKMANN GmbH Vakuumtechnik Schloitweg 17 D-59494 Soest Germany
Phone: ++ 49 (0) 29 21 / 96 04 – 0 Fax: – 900 [email protected] www.Volkmann .info
How do you transfer your bulk materials?
Mechanical Transport
Hopefully not like that!
Back-falling material
Flammable materials
Conveying Screw
High friction
Open rotating parts
EX-risk powder
layers (cloud
building)
EX-risk overheating
EX-risk electric sparks
Wear
Cross contamination because large
residuals remain in screw
Blockages
Not dust-freeTEL +97235464578 fax: +97235464569 [email protected]
Example Positive Pressure Conveying
Transfer of bulk materials - pneumatic
Pressure rated sending vessel
Receiving vessel
Filter
I
Discharging valve
Loading vessel
- Pressure rated vessel necessary
- Powder has to be loaded into a pressure rated vessel
- Complex installation
- Tends to block at higher pressures and longer distances (esp. on fibres..)
- Often bypass system necessary
- Pressurised system, small leakages lead to large dust clouds
- Accumulation of electrostatic charges / blowing into large volumes
- For small/medium conveying rates more expensive than Vacuum Conveying
- Possible heating of powder at the feeding point
TEL +97235464578 fax: +97235464569 [email protected]
Material flow in a Vacuum Conveying System with fee ding and discharging locations
Various pick-up and loading options
Suction / Emptying of:
• Hoppers
• Big-Bags / FIBCs
• Silos
• Sacks
• Drums
• Trays
• Dryers
• Sieves
• Mills
• …
Powder supply to /
Loading
• Reactors
• Stirring vessels
• Weighing containers
• Tablet presses
• Mills
• Mixers
• IBCs
• Capsule filling ma.
• Dosing units
• Packaging ma.
• Centrifuges
• …
Powder Transfer Solutions
Vacuum Transport System
Vacuum Conveyors in the pharmaceutical industries
Vacuum Conveyor for the discharging of drums (various powder-like raw materials) and loading of a mixer.
Discharging of Fluidised-bed-dryer andloading of drums with the same, mobileVacuum Conveyor.
Powder Transfer Solutions
Vacuum Conveyor for
dust-free loading of drums with
Palladium-oven ash
(Catalyst-Recycling)
Powder Transfer SolutionsTEL +97235464578 fax: +97235464569 [email protected]
Loading of a Toner powder-
filling machine
Discharging of Big-Bags in
the room next door
Capacity: 1,100 kg/h
Toner powder for photocopiers
with fine content up to app.
0.1 µm, sensitive against
mechanical loads, aggressive to
special plastics
Powder Transfer Solutions TEL +97235464578 fax: +97235464569 [email protected]
Silo loading in general bulk industry
Conveying of iron sulphate powder
Total distance: 20 m
Height: 12 m
Capacity: 3000 kg/h
Conveyor: VR 450
Vacuum Transport System
Discharging location
Powder Transfer Solutions
Silo loading in general bulk industry
Powder feeding station / hopper
Replacement of mechanical conveying system
Feeding location
Vacuum Pick-up point
Powder Transfer Solutions
Big-Bag (partial)unloading, loss in
weight dosing & silo loading
Load cell
Feeding Point
Powder Transfer Solutions
API‘s (Active Pharmaceutical Ingredients)
Reactor Loading
in the pharmaceutical & chemical industries
INEX
Inert System for the Loading in zone 0
Pressure rated Vacuum Conveyors
Powder Transfer Solutions
Stirring vessel loading
in the paint & dye industries
INEX
Inert System for the Loading in zone 1
Pressure rated powder locks
Double valve powder locks
TEL +97235464578 fax: +97235464569 [email protected]
Vacuum Conveyors
in OEL relevant
applications
Filling of IBC
through split valve
to maintain OEL
level during container
handling
Powder Transfer Solutions
Mixer loading
Tablet press
feeding
Mixer loadingVessel loadingPowder (raw materials)
dosing and charging
into IBC (with in-line safety
sieving (cone-mill)).
Chemie Pharma Food Diverse
TiO2 Laxative granule Icing sugar Toner powder
Flame soot Paracetamol powder Cocoa Aluminium dust
Sulphur Pharma capsules Garlic powder Blood powder
SiO2 St. John's wort (drug) Apple sauce Al2O3-Powder
Talcum Acetylsalicylic acid Cream-fat-powder Magnesium swarfs
Zinc oxide Ascorbic acid Bacon pieces Casting powder
Silicon carbide Sterile caps "Milk" Mussel shell
Bentonite Cellulose powder Wheat starch PE-granule
Activated carbon Plant drugs Desiccated coconut Stront ium Ferrite powder
Resin granule Barium sulphate Mixed spices Colour pigm ents
Sodium cyanate Magnesium powder Chanterelles Palladium ashes
Ethylene-Poly. Tablets Gelee granule Electro waste (sh redered)
Powder Transfer Solutions
Chemical Pharmaceutical Food Divers
Influences on the design of a pneumatic Vacuum Conv eying System
Powder Transfer Solutions
2. Basic Theory 2.1 General Pressure drop for air flow ∆pL
(2):
2
2w
d
lp L
LL ∗∗∆∗=∆ ρλ [Equation 1]
λL = pipe friction coefficient for air flow ∆l = pipe length in m d = pipe diameter in mm ρL = density of air in kg/dm3
w = air velocity in m/s
υdw ∗=Re
[Eq. 2] υ = kinematic viscosity
of air in m2/s Suspense velocity vS from equation 3. gravity force = lifting force + resistance force
−∗∗∗= 1
3
4
L
K
wKS c
gdv
ρρ
[Eq. 3]
dK = corn diameter in mm g = gravity acceleration in m/s2
cw = drag coefficient ρK = corn density in kg/dm3
Powder Transfer Solutions
Conveying conditions
Dilute phase conveyingw = 18 up to 35 m/s
v/w < 1
µ = 10 (...30)
Dense phase conveyingw < 20 m/s
v1 (top) > v2 (bottom)
v/w < 0,7
Plug conveyingw = 3 up to 10 m/s
v/w < 0,5
µ = 10 – 100
w = air velocity
v = product velocity
Qs = product mass flow
Ql = air mass flow
µ = product load = Qs / QLPowder Transfer Solutions
3. Principle design of a
modular
dense phase / plug flow
Vacuum Conveyor
Conveying cycles:
1. Suction / Vacuum
2. Filling
3. Aspiration / Filter cleaning
4. Discharging
Vacuum generator
Filter
Discharge system
Separator container
Powder Transfer Solutions
Vacuum generation
* Side channel blower (in suction operation)
* Oil sealed rotary vane pumps
* Multiple stage, compressed air driven vacuum pumps
* Liquid ring vacuum pumps
* Roots vacuum pumps
* Ejectors.
The multiple stage, compressed air driven vacuum-jet pumps offer a wide application
range because high amounts of suction-air for dilute phase conveying and also big
pressure differences for plug flow conveying can be achieved.
Separator container systems
* one-piece containers
* one-piece containers in pressure rated design
* containers consisting of several parts
* modular containers consisting of several parts
(modular construction system)
* separator containers made of special materials:
e.g. stainless steels in different qualities and alloys,
coatings or special linings, glass containers
Filter systems
* Deep filtration:
e.g. sintered candle filters, plastics, stainless steel,
cellulose, bag filters, tube filters
* Surface filtration:
Membrane filters, e.g. PTFE coated filters
* Primary / secondary filters
Classification of vacuum pumps acc. to DIN 28400, part 2
Hubkolben-Vakuumpumpe
Membran-Vakuumpumpe
Oszillationsverdränger-Vakuumpumpe
Vielzellen-Vakuumpumpe
Drehschieber-Vakuumpumpe
Sperrschieber-Vakuumpumpe
Wälzkolben-Vakuumpumpe
Kreiskolben-Vakuumpumpe
Flüssigkeitsring-Vakuumpumpe
Rotationsverdränger-Vakuumpumpe
Verdränger-Vakuumpumpe
Molekular-Vakuumpumpe
Turbo-Vakuumpumpe
Gasring-Vakuumpumpe
Mechanisch-kinetischeVakuumpumpe
fraktionierendeDiffusionspumpe
selbstreinigendeDiffussionspumpe
Diffusions-Pumpe
einstufigeEjektorpumpe
MULTIJECTORVakuumpumpe
mehrstufigeEjektorpumpe
Gasstrahl-Vakuumpumpe
Dampfstrahl-Vakuumpumpe
FlüssigkeitsstrahlVakuumpumpe
Treibmittelstrahl-Vakuumpumpe
Diffusions-Ejektorpumpe
TreibmittelVakuumpumpe
Ionentransfer-Pumpe
KinetischeVakuumpumpe
Gastransfer-Vakuumpumpe
Kondensator
Kyropumpe
Getterpumpe
Adsorptions-Pumpe
Gasbindende-Vakuumpumpe
VAKUUMPUMPEN(Funktionsprinzip)
TEL +97235464578 fax: +97235464569 [email protected]
Principle design of a multiple-stage, gas-jet driven Vacuum Pump
Compressed air
Suction air
Exhaust air
Powder Transfer Solutions
The Laval nozzle
Sonic speed
Supersonic speedSubsonic speedNorm nozzle Diffusor
Applications for
Multijector
Vacuum pumps
MULTIJECTOR©
Vacuum Pumps
M-RVA / M-RVAC
• multiple stage
• compressed air driven
• completely made out of
stainless steel
• Viton / EPDM gaskets
• max. Vacuum -96 kPa
• CIP-able
Vacuum Conveyor with electric-driven, oil-sealed ro tary vane Vacuum Pump
continuous energy consumption…Powder Transfer Solutions
Comparison:
- electric - mechanical
Vacuum Pumps
(here two dry running pumps)
- Multijector Vacuum Pump
jet-pump (type G 4500)
Receiver- and collecting containers for Vacuum Conveyo rs
Throughputs
from 10 kg/h
to up to
8000 kg/h
All ATEX certified by TÜV
Pneumatic Pharma Conveyors (PPC):
+ GMP-suitable, smooth, polished, gap-free, WIP / CIP
Modular container design:1. Highest flexibility by modular construction system
2. Different flow conditions during suction
Loading of a can-filling machine
Dependency of transfer throughput from bulk density
For approx. 10 m conveying distance. Attention: Each bulk material may show different behaviour.
Bulk density in kg/dm³
Thr
ough
put i
n t/h
Conveyors:
Vacuum Conveyor in one-piece design, Pneumatic Pharma Conv. (PPC):+ GMP-suitable, smooth, polished, gap-free, WIP-suitable
Manual drum discharging by suction -lance and loading of a mixer
ETFE (FDA)-coating
Qualification of Vacuum Conveyors
Steps of a Qualification / Validationprocess:
1. User requirement specification (URS)
2. Functional Specification3. Design qualification(DQ)4. Installation qualification (IQ)5. Operation qualification (OQ)6. Performance qualification (PQ)7. Validation
PPC 315 acc. to FDA
Washing in Place:
1. Wetting cycle
Washing in Place:
2. CIP cycle
Modules for CIP Cleaning of a
PPC 170 K
on top of a tablet press
Loading of tablet pressesIndependent institutes, tablet manufactures and contractors confirmed that there is norelevant separation/segregation if VR and PPC Vacuum Conveyors are used.
Filter systems
* Deep filtration:
e.g. sintered candle filters, plastics, stainless steel, cellulose,
bag filters, tube filters
* Surface filtration:
Membrane filters, e.g. PTFE coated filters
* Primary / secondary filters
Classification - particle air filterVOLKMANN GmbH -- Vakuumtechnik -- 59494 Soest -- www.volkmann.info
NORM Eurovent DIN 24185 DIN DINTest
aerosolFiltration
gradeIEC
average transmittance
grade
Test aerosol
BIATest
aerosol
average transmittance
grade
DIN 24184 EN 779EN
1822[ > % ]
60335-2-69 Annex AA
[ > % ] [ > % ]
EU 1 EU 1 G 1 <65
EU 2 EU 2 G 2 65-80
COARSE FILTERS EU 3 EU 3
G 3 80-90
EU 4 EU 4 G 4 ≥90
EU 5 EU 5 F 5 40-60
EU 6 EU 6 F 6 60-80
FINE FILTERS EU 7 EU 7 F 7 80-90
EU 8 EU 8 F 8 90-95
EU 9 EU 9 F 9 ≥95
EU 10 Q H 10 85
EU 11 R H 11 95
HEPA FILTERS EU 12 R H 12 99,5
EU 13 S H 13 99,95
EU 14 (T) H 14 99,995
EU 15 (U) U 15 99,9995
ULPA FILTERSEU 16 (U) U 16 99,99995
(ULPA = Ultra Low Penetrat ion Air Filter) EU 17 (U) U 17 99,999995
A direct reference from BIA- and IEC-classes to oth er
Attention! class systems is not possible!
* DEHS = Di-ethyl-hexyl-sebacat DOP = Di-octyl-phtalat
(HEPA = High Efficiency Part iculate
Air Filter) Par
affin
e oi
l mis
t
0,05
Qua
rtz
dust
U 5
1
0,5
0,1
S
G
C
DE
HS
alt.
DO
P *
Par
rafin
e oi
l mis
t
H
M
5
0,1
0,005 Paraffine oil mist
synt
hetic
dus
tat
mos
pher
ic d
ust
Qua
rtz
dust
L
Vacuum Conveyor VR 315 with primary filter
- secondary filter afterwards (left)
- then vacuum pump (middle)
- Vacuum control at secondary filter
- Replacement of a screw conveyor that often
caused production-breakdown
Continuous Vacuum Conveying
4. Application examplesMaterial to be
conveyedBulk
Density[kg/dm 3]
Con-veyingHeight
[m]
Con-veying
Distance[m]
Particle size MaterialCharacteristic
Transportingcapacity [kg/h]
Suction- andloading system
1. Dicyano-diamide powder
0,7 2 4 20 up to100 µm
bridging occurs 600 VR 315: Weight=19 kg∅ 345 mm, Height=955 mm
2. Activatedcarbon dust
0,4 3 3 fine dust,5 up to 80 µm
adherent 120 VR 170: Weight=6 kg∅ 180 mm, Height=450mm
3. Placebogranule
0,6 2 4 100 up to1000 µm
very goodflowing
5.000 VR 450: Weight=39 kg∅ 480 mm, H=1.160mm
4. Hexamethy-lenetetramine
0,7 - 0,8 4 12 > 5 µm hygroscopic 1.400 VR 315: Weight=19 kg∅ 345 mm, Height=955 mm
5. Par-acetamol powder
0,8 1,5 3 40 up to200 µm
adherent &bridging
1.000 VR 315: W=19 kg∅ 345 mm, H=955 mm
6. Ferricpowder
3,5 4 5 50 up to100 µm
sensitive,abrasive
180 VR 170: W=6 kg∅ 180 mm, H=450 mm
7. Flamesoot
0,2 5 15 0,1 up to44 µm
bridging,adherent
1.440 VR 450 Contivac(continuous conveying)
8. Titanium-dioxide& dyes
0,85 - 1,4 1,5 3 > 2 µm partial stronglyadherent
600 up to1.628
VR 315: W=19 kg∅ 345 mm, H=955 mm
9. shredded wheatpellets
0,98 5 12 dust content,∅ 2 x 8 mm
sensitive 3.600 VR 450: W=39 kg∅ 480 mm, H=1.160mm
10. Sand-lime-mixture
1,38 0,5 32 400 up to900 µm
badflowing
30,0 VR 170, W=6 kg∅ 180 mm, H=450 mm
11. Toner 0,2 - 0,8 4 5 very fine dust> 0,1 µm
aggressive 1.100 VR 315: W=19 kg∅ 345 mm, H=955 mm
12. Polyurethanegranule
0,9 10 12 1 up to3 mm
goodflowing
1.000 VR 315: W=19 kg∅ 345 mm, H=955 mm
13. Plasticcaps
- 0,5 10 ∅ 40 mm,H=25 mm
sensitive 17.100caps per h
VR 315: W=19 kg∅ 345 mm, H=955 mm
Thank you for your attention !
TEL +97235464578 fax: +97235464569 [email protected]