Sentry Equipment Corp Sampling Solutions Specialty Heat Exchangers Bulk Solids Sampling Applications...

Sentry Equipment CorpSentry Equipment CorpSampling Solutions • Specialty Heat Sampling Solutions • Specialty Heat ExchangersExchangers

Bulk Solids Sampling Bulk Solids Sampling Applications II Applications II


Applications ReviewApplications Review

• Cement • Dairy • Chemical • Plastics


Cement ApplicationsCement Applications


Cement – Process flowCement – Process flow


Process Flow Description Process Flow Description

• 4 main ingredients: – Calcium (limestone) – 90% – Alumina (flyash) – 3%– Iron – 2%– Silica (sand) – 5%


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


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


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)


Process Flow DescriptionProcess Flow DescriptionBarge Load Out Area Barge Load Out Area


Process Flow DescriptionProcess Flow Description ISOLOK®ISOLOK® SAK Sampler on Load out AirslideSAK Sampler on Load out Airslide


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


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


• 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?


Dairy ApplicationsDairy Applications


Dairy ProcessDairy Process


Typical Sampling Points Typical Sampling Points

• Drying process– Models SAK, B1 and PR

• Bag filling stations -custody transfer– Models SAK and B1


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


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%


Bag Filling ProcessBag Filling Process

• ISOLOK® model SAK mounted in bag filling system


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


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


• Butter fat content• Bacteria• Hormone levels (BGH)• Antibiotics• Moisture content

Why Sample in Dairy Why Sample in Dairy Applications?Applications?


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


• 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?


Plastics ApplicationsPlastics Applications


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


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


Typical Sample PointsTypical Sample Points

• Inlet of catalyst deactivation unit

• Outlet of catalyst deactivation unit

• Discharge of continuous blender

• Finished pellet


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


• 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


• 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?


Questions?Questions?


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


Questions?Questions?

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