Processing January 2013.9009

S O L U T I O N S F O R T H E P R O C E S S I N D U S T R I E S

January 2013

Guided Wave Radar Technology

VEGA introduces the latest innovation

in guided-wave radar technology, the

VEGAFLEX 80 Series. The unit has sensors

specifically designed for measurement of

liquids or solids, as well

as for hygienic and

high temperature/pres-

sure environments. For

liquids measurement,

level and interface mea-

surement are available

from a single sensor.

Perhaps the most inno-

vative feature of the VEGAFLEX 80 Series is

the user interface. Because one of the most

important aspects of providing a reliable

level measurement is ensuring the sensor is

properly configured, VEGA has introduced

a new guided setup procedure that makes

commissioning simple and safe.

VEGA Americas, Inc.www.ohmartvega.comWrite In 503

Bulk Bag Conditioning System

Discharging bulk bags containing material that has

solidified, hardened or agglomerated can cause seri-

ous operational bottlenecks. Conditioning and empty-

ing bulk bags can be dangerous if the right equipment

isn’t used. A new, patented system uses hydraulically

actuated, twin heavy-wall tubular-steel pivoting con-

ditioning arms. Each conditioning arm features “v-shaped” tubular steel

breaker profiles that safely and efficiently return solidified materials to a

free-flowing state. For more information on powder & bulk solids, turn

to page 44.

Material Transfer & Storagewww.materialtransfer.comWrite In 502

Electric Modulating Actuators

Electric modulating actuators in Rotork’s new CMA series are suitably

sized for linear, quarter-turn and rotary control valve and pump applica-

tions requiring precise position control and continuous modulation. They

can be powered by single-phase or direct current supplies, eliminating

the need for the air hoses and compressors used with pneumatic control

valve actuators. Setup and configuration is easy via pushbuttons and

an internal, six-segment LCD display. Resolution is 0.25% on linear and

quarter-turn applications and 2.0 degrees on the multi-turn configuration.

Other features include a permanently lubricated and maintenance-free

drive train; a 4-to-20 mA loop-powered feedback signal; and digital com-

munication options including HART®, Foundation Fieldbus™, Profibus®,

Pakscan™, RIRO and Modbus®. For more information on valves &

actuators, turn to page 34.

Rotork Controls, Inc. www.rotork.comWrite In 500

Large volumes of ethane obtained as

a by-product in shale gas production

have changed the cost position of North

American cracker operations from an infe-

rior rank to second best. Natural gas is

changing the process industry landscape,

leading analysts and consultants to cat-

egorically conclude that the U.S. chemical

industry is “back.” Read more on page 12.

The natural gas being exported from Australia is of the conventional, and not the shale, sort. But transported as liquefied natural gas (LNG), its use is set to transform the regional economy and is already resulting in on-going mega-projects, including the Gorgon project and LNG plants expected to produce 15.6 million metric tons of LNG per year. It’s all about meeting energy demand in Southeast Asia, and for flow-

meter makers the question is, “Who’s gonna measure all that?” To read flowmeter expert Dr. Jesse Yoder’s column, turn to page 28.

www.ProcessingMagazine.com

Weighing Systems Standardize Batching and Filling OperationsIn 2009, Rice Lake Weighing Systems acquired the Santa Rosa,

Calif-based FlexWeigh Div. of Enduro Systems. Since then, Rice

Lake has been busy supporting the brand’s existing product lines

and engineering a new generation of the popular FlexWeigh

DWM-IV. As FlexWeigh’s replacement for the DWM-IV Series,

Rice Lake’s 920i FlexWeigh Systems are pre-engineered and pre-

programmed for many of manufacturing’s most common weighing

tasks. For more information on weighing & feeders, turn to page 40.

Rice Lake Weighing Systemswww.ricelake.com/920iFlexWeigh Write In 501

Featured Article

Featured ColumnistValves & Actuators

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In This Issue2

12 US chemicals industry again globally competitive Natural gas as fuel and feedstock; demand growth from emerging economies.

18 Plastic connectors: Many factors weigh in when choosing the right ones Metal connectors continue to be supplanted in many industrial and laboratory applications.

22 Larger Coriolis mass flowmeters take center stage A brief discussion of measurement needs and practices in North America’s oil and gas industry.

28 LNG: key to supplying Asia Pacific energy needs Australia uses about half the natural gas it produces and exports the rest in the form of liquefied natural gas.

38 Industrial-grade computer peripherals: more than just a NEMA enclosure Rugged internals and components keep joysticks, mouse pointers

and keyboards from breakdown in harsh, messy environments.

4 Productivity Perspectives

6 Industry Briefs

32 Valves

40 Weighing & Feeders

42 Filtration/Separation

44 Powder & Bulk Solids

46 Info Center

47 Classifieds

48 Index

January2013 • volume26,number1

January 2013•www.ProcessingMagazine.com

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“R&D today isn’t about white coats. It’s about working with customers,” Ashish Kulkarni, Dallas-based Celanese Corp.’s recently appointed chief technology and innovation officer, says. But, Kulkarni adds, you need to go beyond the bro-mide of “listening to your customer.”

“Customers focus on their most immediate challenges,” Kulkarni says. “We need deeper engagement than that.”

Kulkarni will continue leading Celanese R&D efforts for advanced engineered materials and emulsions, but he’ll take on additional duties to accelerate collaboration across four busi-ness segments to enhance “dual capabilities in technology-enabled chemistry and customer-oriented solutions. Capabilities… address global macro trends including environmental concerns, resource scarcity, the growing middle class and safety, health and wellness.” Mark Rohr, chairman and CEO, says. In 2011, the company’s revenues were around $6.8 billion.

An example of “technology-enabled chemis-try and customer-oriented solutions” is found in a Celanese study that won best paper at the recent Society of Plastic Engineers Automotive Composites Conference and Exhibition.

Interest in use of polymer composites by trans-portation OEMs is growing, the paper notes, so “suppliers of polymer composite materials are working to improve thermo-mechanical perfor-mance, increase processing speeds, reduce part mass and costs, enhance surface aesthetics with fewer post-mold operations and generally make

it easier to position composites against high strength steel and aluminum.”

While carbon fiber-reinforced plastics (CFRP) regularly receive auto industry attention for their “high-tech glamour,” lightweight stiffness and strength, cycle-time constraints and fiber availability make these materials pricey. One alternative is to increase stiffness and strength in workhorse composites like glass-reinforced poly-propylene.

Here, with the switch from customer solution to chemistry, it starts to get sticky. But a typical means for improving composite performance would be by “an increase in retained fiber length and fiber-volume fraction as well as by using fibers in a more intelligent manner.”

The tailored D-LFT process for compression molding composites was developed for the auto-motive industry in Europe. The study details how a tailored D-LFT process might be used to boost the mechanical properties of D-LFT composites.

Asked to name several larger trends impacting Celanese materials science, Kulkarni first alludes to the 20th century’s most significant technology development, the computer. He says it’s the abil-ity to “model complex processes, combinatory chemistry and the amount of information avail-able from customers today, which really makes a difference.”

4

Dual capabilities, four business segments and many global macro trends

Reader Advisory Board

• RobertJ.Bockserman,President, Conatech

• PeterS.Cartwright,President,

Cartwright Consulting Co.

• BarryCharnay,President & CEO, Whisper

Ingredients Inc.

• KenDelafrange,President, Jadee Inc.

• DonGraham,President, Graham Sanitary

Design Consulting, Ltd.

• StanleyHerzog,President, Princeton

Process Technology Consultants

• B.GeorgeKniazewyz,President, Renovare

• EricLanger,President, BioPlan Associates

• EdMarshall,President, Maintenance

Management Technologies

• JohnStansield,Plant Manager,

Accelerated Curing Inc.

• Dr.JesseYoder,President, Flow Research

• RobertM.Donnelly,Vice President of

Marketing, Flo-Tite Valves & Controls

—KevinParker,[email protected]

Group Publisher, MikeWassonPh: 973-539-7715, Email: [email protected]

Editorial Director, KevinParker Email: [email protected]

Managing Editor, NickPhillips Email: [email protected]

Associate/Web Editor, ChristyUnderwoodEmail: [email protected]

Art Director, JamesArmstrongEmail: [email protected]

Marketing Manager, MaryBethTimmermanEmail: [email protected]

Advertising Sales Assistant, CookieRayfordEmail: [email protected] AdministrativeTeam:General Manager, BarryLovetteVice President of Operations, BrentKizzireVice President of Marketing, HankBrownVice President of Finance, BradYoungbloodGroup Director of Circulation & Fulfillment, Delicia Poole

Circulation Manager, AnnaHicks

PROCESSING (Pub.#ISSN 0896-8659)

PROCESSING Magazine is published monthly by Grand View Media Group. Editorial and Executive Offices: 200 Croft Street, Ste 1, Birmingham, AL 35242. Periodicals post-age paid at Birmingham, AL & additional mailing offices. Canada Post: Publications Mail Agreement #40612608. Canadian Returns to be sent to: Bleuchip International, P.O. Box 25542, London, ON N6C 6B2. POSTMASTER: Send address changes to PROCESSING Magazine, PO BOX 2174, Skokie, IL 60076-7874. SUBSCRIPTIONS: Non-qualified domestic subscriptions: one year, $57; two year, $99; single issue, $10. Canadian and foreign surface subscriptions: one year, $93; two year, $162. Air mail subscription: one year, $203; two year, $355. © Grand View Media Group, 2013. PROCESSING Magazine assumes no responsibility for validity of claims in items reports.

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S O L U T I O N S F O R T H E P R O C E S S I N D U S T R I E S

Productivity Perspectives

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6 Industry BriefsLAKE CHARLES, La. — South African-based energy and chemicals com-

pany, Sasol, says it will proceed with front-end engineering and design (FEED) phase for an integrated, 96,000 bbl/d gas-to-liquids (GTL) facility and a world-scale ethane cracker with downstream derivatives, at its Lake Charles site in southwest Louisiana.

At a media conference with Louisiana Governor Bobby Jindal, Sasol CEO David Constable said there is significant opportunity to benefit from abun-dant gas reserves in the U.S. by leveraging Sasol’s GTL experience and technology. Sasol’s GTL process diversifies the use of natural gas through the production of liquid fuels and chemicals.

“By incorporating GTL technology into the USA’s energy mix, states such as Louisiana will be able to advance the country’s energy independence, through a diversification of supply,” said Constable.

“This project will be the largest single manufacturing investment in the history of Louisiana and it also represents one of the largest foreign direct investment manufacturing projects in the history of the entire United States,” said Governor Jindal.

The GTL facility, said to be the first of its kind in the U.S, will produce four million tons per annum (mtpa), or 96,000 bbl/d of high quality transporta-tion fuel, including GTL diesel and other value-adding chemical products.

Current project costs for the GTL facility are estimated between $11 bil-lion and $14 billion. The GTL project will be delivered in two phases, with each phase comprising 48,000 bbl/d. The first phase is planned to come into operation in the 2018 calendar year and the second phase the follow-ing calendar year.

The world-scale ethane cracker, Sasol says, will allow it to expand its eth-ylene derivatives business in the U.S. The cracker will also benefit from the current low U.S. natural gas prices and the abundance of ethane.

Current cracker project costs are estimated between $5 billion and $7 billion. Sasol expects beneficial operation to be achieved during the 2017 calendar year. It will produce an estimated 1.5 mtpa of ethylene with downstream derivative plants.

The integrated GTL and ethane cracker projects will, Sasol estimates, together, create a minimum of 1,200 permanent positions, 7,000 construc-tion jobs at peak and thousands of indirect jobs both in Louisiana and in the rest of the U.S.

Dow delineates long-term strategyMIDLAND, Mich. — At its 2012 Investor Forum, The Dow Chemical

Co. shared with investors “strategic interventions and key catalysts that will enable Dow to achieve near-term targets and drive sustainable earn-ings growth.”

“We have built a more simplified organization – concentrating only on those things that increase cash flow, improve return on capital and drive earnings growth,” said Dow Chairman and CEO Andrew N. Liveris.

During the event, Liveris presented several key drivers that will fuel Dow’s near-term earnings growth:

Dow says it has deployed $2.5 billion of “aggressive” measures in 2012. These actions are expected to deliver $1 billion in cost and cash “interven-tions” in 2013, of which $500 million will impact EBITDA. With nearly 40 project cancellation and plant shutdowns announced this year, the com-pany is taking swift steps to improve asset utilization, drive down structural costs — particularly in Europe — and enhance return on capital.

The company says it remains on schedule to restart its St. Charles Operations ethylene cracker, which is expected to deliver a $150 million increase in EBITDA in 2013. Taken on the whole, Dow’s U.S. Gulf Coast investments in ethylene and propylene integration, coupled with favorable shale gas dynamics, are expected to deliver $2 billion in additional EBITDA in 2017. The company also reaffirmed that its Sadara joint venture remains on track, with an anticipated construction workforce peak of about 60,000 people next year, and operations slated for start-up in 2015.

CEOs see emerging nations surge as U.S., Germany and Japan face

changing gameWASHINGTON — Over the next five years, 20th-century manufactur-

ing stalwarts like the United States, Germany and Japan will be chal-lenged to maintain their competitive edge against emerging nations such as China, India and Brazil, according to the “2013 Global Manufacturing Competitiveness Index” from Deloitte Touche Tohmatsu Limited’s Global Manufacturing Industry group and the U.S. Council on Competitiveness.

The Index confirms that the landscape for competitive manufacturing is in the midst of a “massive power shift” — based on an in-depth analy-sis of survey responses from more than 550 CEOs and senior leaders at

Sasol commences FEED phase for $21 billion Louisiana gas-to-liquids facility



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manufacturing companies around the world.The Index lists the United States as the world’s third most currently com-

petitive manufacturing nation, but ranks it fifth just five years from now, only slightly ahead of the Republic of Korea. The three other developed nations currently in the top 10 also fall in five years: Germany drops from second to fourth place, Canada slides from seventh to eighth place and Japan drops out of the top 10 entirely, falling to 12th place.

“America and Europe have continued to watch emerging markets mature and become formidable competitors over the past decade,” said Craig Giffi, vice chairman, Deloitte LLP and consumer and industrial products industry leader, who co-authored the report and lead the research team.

Giffi points out that in five years key emerging nations are expected to “vault forward” in the Index: Brazil jumps from its current eighth place slot to third place and India jumps from fourth to second place. China remains firmly in first place.

Brazil’s processed plastics industry losing ground to importsSAO PAULO, Brazil — Brazil is seeing growing domestic demand

for plastics, but the industry there is finding it impossible to meet the increase. The country is therefore relying on imports to provide feed-stock for the required plastic products, with China emerging as a leading supplier, the PlastEurope website reports.

In 2011, the Brazilian plastic processing industry reported a modest 1 percent growth to 6.5 million tons output. This proved insufficient to match the 2.3 percent rate at which demand increased, reaching 6.89 million tons of processed plastics. While presenting the annual industry

report for last year, José Ricardo Roriz Coelho, president of Brazil’s plas-tics industry association Abiplast, warned that domestic producers risk being pushed out of the market by foreign manufacturers.

Other figures that Roriz Coelho cited from the report for 2011 con-firm his concerns. Brazil’s exports of plastics feedstock went down 13.5 percent to 268,000 tons, compared to a 7.1 percent growth in imports, which came in at 660,000 tons. In addition, the total value of foreign-made plastics reached $3.39 billion, a 20 percent rise on the previous year, compared to a 2.7 percent increase in export value, which came in at $1.51 billion. As a result of this market development, Brazil’s trade deficit for processed plastics soared by 37 percent to $1.88 billion.

The outlook for 2012 does not foresee more optimistic results for the domestic industry, PlastEurope says. Between March and September 2012, exports of processed plastics shrank 13 percent to 137,000 tons, whereas imports rose by 8.2 percent and reached 392,000 tons. Similarly, the total value of imports continued to grow over the period and reached $2.03 billion, a 7.6 percent increase, while the export value fell by 9.3 percent to $792 million.

The processing industry in Brazil depends on feedstock coming from China and Asia in general, which accounted for a third of the total imports up to September. The second most important supplier of plastics was the European Union, accounting for 23 percent of the imports, fol-lowed by Latin American countries and the United States, which provided 19 percent and 16 percent of the imported plastics, respectively.

Roriz Coelho singled out several factors that contributed to the poor performance of the local plastics industry. One of the reasons is the

Industry Briefs8

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slowdown in Brazil’s GDP growth, with readings dropping sharply from 7.53 percent in 2010 to 2.73 percent in 2011. The International Monetary Fund expects this to fall further to 1.47 percent this year. Other purely internal factors, such as high operating costs, poor infrastructure, bureau-cracy and corruption also have a negative impact on the industry, the Abiplast president noted.

US to surpass Saudi Arabia as global oil production leaderLONDON — The United States is likely to emerge as the world’s big-

gest oil producer by 2020, following a shale oil production surge that will allow it to surpass Saudi Arabia, the International Energy Agency (IEA) said in its just released annual World Energy Outlook publication.

The IEA said that the global oil market is going through significant changes in terms of energy supplies and geopolitics. The U.S. is set to lead the way in oil and gas production over the coming years, the IEA added, contrasting with its own prediction from last year, which saw Saudi Arabia and Russia as the top contestants for the trophy.

The U.S. has reduced the volume of oil imported over recent years and it now accounts for about one-fifth of the nation’s needs. Over the next 10 years imports will drop by more than half, from the current 10 million bpd to about 4 million bpd. At the same time U.S. oil exports are expected to increase, as domestic production booms, the IEA claims.

The main factor that has contributed to the recent boost in oil produc-tion is the unexpected rapid development of hydrocarbon resources from tight rock formations like shale, which are currently being extracted through a combination of hydraulic fracturing and horizontal drilling.

The IEA prediction chimes in with the recent acknowledgement from the Organization of the Petroleum Exporting Countries (OPEC) that its exports to the United States are likely to decline due to the develop-ment in shale oil production. By 2035 OPEC’s exports to the U.S. are predicted to drop by nearly two-thirds, to less than 2 million bpd, the organization has estimated.

Furthermore, the IEA says that the U.S. will effectively need no oil imports from the Middle East and this might have an impact on military alliances. As Asia is expected to account for 90% of the Middle East oil exports, OPEC will increase its global share from 42% to 50% by 2035 and Asian countries will have the primary interest in maintaining politi-cal and economic stability in the region, explains Richard Jones, deputy executive director at the IEA.

Nevertheless, the IEA notes that the U.S. is not likely to remain the world’s largest oil producer in the long run. According to Fatih Birol, the IEA’s chief economist, Saudi Arabia is likely to return to the top if no new U.S. resources are found over the next few years and global oil prices fall from their current levels.

Correction: In Processing’s December 2012 coverage of the Breakthrough Products award winners, we wrongly identified the head-quarters of Camfil Farr APC. The company is actually headquartered in Jonesboro, Ark., and it is the team there that was responsible for devel-opment of the Integrated Safety Monitor Filter (iSMF).

Industry Briefs10


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It’s all a matter of vocabulary. First the word “shale” entered the daily water-cooler discourse, along with “horizontal drilling” and “fracturing.” It wasn’t long before large swaths of the American public realized the natural-gas energy revolution was on.

In the next phase, growing numbers will become aware that shale gas,

used as both feedstock and fuel, gives the North American petrochemi-cal industry a big advantage. Cable news and business sections will point out that new found quantities of ethane, which comes out of the ground along with the natural gas, are causing corporations and local govern-ments to engage together in groundbreaking and ribbon-cutting cer-

emonies. “Large volumes of ethane obtained as a by-product in

shale gas production have changed the cost position of North American cracker operators from an inferior rank to the second best, topped only by operators in the Middle East,” says Prof. Rainer Dierks, president of the petrochemicals divi-sion of industry giant BASF, in an online interview conducted at ACHEMA 2012.

Energy has always been a volatile commodity. Put in motion by this dramatic shift in natural gas supply, idled plants are being restarted in North America, and units are being converted from naphtha to ethane use as cracker feed-stock. Expanded capacity for production of ethylene, based on ethane and a core petrochemical feedstock, has been announced, as well as considerable expansion in downstream capacity for products like polyethylene and ethylene glycol.

Further, “this shift to lighter feedstocks causes a differ-ent product output pattern in steam crackers,” Dierks says. “Using a large portion of ethane as cracker feedstock allows production of nearly exclusively ethylene. Typical by-products of naphtha crackers, like propylene or butadiene, are

US chemicals industry again globally competitiveNatural gas as fuel and feedstock; demand growth from emerging economies



By Kevin Parker

Shale gas, used as both feedstock and fuel, gives the North Ameri-can petrochemical industry a big advantage.

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produced in only small amounts in these ethane-based crackers.” The result, Dierks goes on to say, is a significant increase in propylene

and butadiene prices, leading to investments in “on-purpose” propylene production.

Unfolding implicationsBut why is natural gas proving such a big advantage for North

America? After all, there are huge shale deposits outside the U.S. While global companies and overseas governments are eager to drill, a Dec. 3 article in The Wall Street Journal suggests, significant delays are being caused by “governmental ownership of mineral rights, environmental concerns and a lack of infrastructure to drill and transport gas and oil.”

It’s also the case that less is known about the geology in most foreign countries than in the U.S. North America’s infrastructure includes a trans-portation pipeline network already in place and the ready availability of drilling rigs. What it all means, experts say, is that significant overseas shale energy production could be a decade away.

Other reasons why a more general U.S. manufacturing renaissance, encompassing both process and discrete manufacturing industries, may be imminent, are evoked in a June report by Accenture consultants Paul Bjachek and Larry Oglesby, which notes, “The U.S. has a top-notch sup-ply base, one well accustomed to delivering world-class quality levels on time and at agreed-upon prices.”

The consultants say U.S. ethylene production could increase by as much as 30% by 2017, and categorically state, “Based on the current trajectory of low and stable gas prices, the U.S. chemical industry is once again globally competitive.”

Widening ramifications

Natural gas accounts for between 24% and 30% of total energy con-sumption in North America. In India and China it is only 7% and 3% respectively.

Of course, besides being a feedstock, natural gas is also a fuel and it

14 Chemical Industry

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“The U.S. has a top-notch supply base, one well accus-tomed to delivering world-class quality levels on time and at agreed-upon prices.”

Marcellus Shale gas well site in northern Pennsylvania.

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makes up about three-quarters of the energy used by the chemical indus-try in the U.S., excluding pharmaceuticals, Accenture says. Overall, aside from the energy industry itself, chemical production has by far the highest energy intensity of all other industries.

Natural gas prices used to rise and fall with those for oil and naphtha, but the last several years their prices have diverged. One reason is dif-ficulties in transporting natural gas, making it less expensive the closer to the source the buyer is. A similar split is occurring downstream as chemi-cal companies that make greatest use of natural gas find a competitive

advantage, while other chemical industries still dependent on high-priced oil struggle with high energy costs and lumpy demand.

Still further downstream, the chemical industry is said to “touch” 90% of manufactured goods, making goods makers the largest consumers

of chemical products. The result, say Accenture’s Bjacek and Oglesby, is that “executives in a number of high-value-added industries, such as chemicals and automobile production, are seeing compelling reasons to make products in [North America] again that trump trying to capture low labor costs.”

Coin’s other sideThe chemical industry has been grow-

ing for the last five decades, according to Zacks Equity Research, most especially production of synthetic polymers used as plastics, fibers and elastomers. The indus-try also had a strong recovery from the 2008 recession.

As this issue of Processing magazine goes to press, the Dow Chemical Co., which has announced its own $4 billion investment plan in petrochemical plants in Texas and Louisiana, has calculated the total value of announcements in shale related investments at $90-billion plus, says the Financial Times.

Reports indicate that the price of eth-ane has fallen in the U.S. from about 80 cents per gallon at the start of the year to less than 23 cents a day.

Further, since the start of 2010, industri-al production is up 12% in the U.S., while it has fallen 2% in China.

Yet apart from the high hopes and significant investment engendered by the natural gas boom, and the potential for North America to take market share away from other global regions, the U.S. chemicals industry is projected to expe-rience only moderate growth the next several years, according to the American Chemistry Council (ACC).

It is a $720 billion industry that contrib-utes 26% of U.S. gross domestic product, with output expected to rise about 2% in 2013. Earlier this year, the ACC said the immediate prospect is for slow growth with improvements in investment spend-ing and residential investment as bright spots. Capital spending in the business of chemistry will reach $35.5 billion in 2012, rising to $51.5 billion in 2017, while longer term the industry will continue to grow faster than U.S. GDP, based on increasing exports.


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Chemical IndustryOverall, aside from the energy industry itself, chemical production has by far the highest energy intensity of all other industries.

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Diverse challenges confront industrial and laboratory original equip-ment manufacturers (OEMs) in developing versatile, user-friendly, light-weight and cost-effective equipment and instrument solutions. One important, but not always fully appreciated, task is selecting tubing con-nectors for transfer and management of fluids and gases, particularly for mission-critical applications.

For many applications, plastic tubing connectors continue to supplant those made of metal, not only for design flexibility, improved ergonomics, reduced weight and lower cost, but also for their ability to meet stringent industry standards in diverse and harsh environments. Many plastic con-nector features, long proven in critical medical equipment applications, are being integrated into a broad spectrum of industrial equipment and laboratory instruments.

Choosing the right plastic connector can be a challenge, with more options for material selection, user interface and custom design than metal connectors. A basic understanding of the options available can

support specification of the most optimized features, leading to peak equipment or instru-ment performance.

Application drivenWhile plastic connectors fill many roles,

they aren’t suitable for all laboratory and industrial uses. Brass, aluminum, die-cast zinc and stainless steel connectors are right for

extreme durability and high-performance fluid handling, particularly when influenced by high pressures and temperatures. Choosing the ideal con-nector calls for a careful application assessment. Prime factors to consider include the following:

Temperature range – minimum and maximum temperature tolerances within which the connectors need to function. Depending on connec-tor material, temperature tolerances can range from -40 F to 200 F and above;

Pressure range – determining minimum, maximum and working pres-sures the connectors are expected to tolerate;

Flow rate – required volume per minute, and the effect of fluid pulsa-tion and modulations from connect and disconnect forces;

Media – the viscosity, sensitivity and corrosiveness of the fluid or gas moving through the connection;

Exposure – degree of impact from external or internal conditions, such as UV, wind, dust, vibration, radiation, gases, water submersion, chemicals, cleaning agents or mechanical stress;

Specialized environments – for food and pharmaceutical grade manufacturing, including wash-down, clean room, aseptic environments and vacuums;

User interface – level of human contact expected with the system and connectors; and

Cycle life – anticipated maintenance and

Plastic connectors: Many factors weigh in when choosing the right ones Metal connectors continue to be supplanted in many industrial and laboratory applications



By Riley Phipps

Plastic conical or taper seal connectors, called luers, can link various industrial and laboratory system components.

The MQC Series plastic quick connect from Value Plastics provides a wide selection of color-coding options for ease of maintenance and to prevent misconnections.

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changeability required for the system, and expected operational longevity.

Once identified, the application requirements then determine what materials are best suited for the connectors.

Plastic connector materialsPlastic connector material is chosen based on

mechanical requirements and the media type moving through the system. Significant pros and cons need to be weighed. Properties such as toughness, ductility, impact strength, trans-parency, lubricity, temperature capability, ozone resistance and UV compatibility may all come into play.

The media is critically important, given that fluid or gas flowing through a connection can affect its strength, surface appearance, color and performance. And, conversely, the wrong connector material can adversely impact the media. Chemical compatibility need be con-sidered and the most appropriate plastic resin chosen.

When made from high-purity resin materials for use with aggressive chemicals, plastic connectors offer broad compatibil-

ity. Many are manu-factured from virgin resins, with accom-panying certification of lot traceability. Plastic resins across

a broad spectrum are used for connectors, each with characteristics to match specific application needs. Some thermoplastic resins commonly used for connectors include:

Polyethylene – chemically resistant, translu-cent or opaque, with low-temperature impact, to withstand a variety of application environ-ments;

Polycarbonate – hard, transparent and with moderate chemical resistance, provides good impact resistance and superior dimensional stability;

Polypropylene – soft, highly resistant to chemical attack from solvents and chemicals in harsh environments;

Polyamide (Nylon) – versatile, with good wear and chemical resistance, low permeability to gases and performs well at elevated tem-peratures;

ABS – tough, with good stiffness and impact resistance even at lower temperatures, as well as good dimensional stability and high tem-perature resistance;

Acetal – strong, lightweight and provides high strength and rigidity over a wide range of temperatures; and

PVDF – strong, with good ductility over a broad temperature range, as well as excellent chemical resistance.

In addition, PTFE is fluoropolymer-resistant to most chemicals and solvents, with stability at high temperatures. Once the connector mate-rial is determined, the type of connection best suited to the need can be picked.

Connection optionsConnectors are meant to accommodate tub-

ing of varying hardness, as would be measured by a durometer, from soft and flexible like PVC, silicone and C-flex, to semi-rigid types like poly-propylene, polyethylene, polyurethane and eth-ylene vinyl acetate (EVA).

To facilitate these varying styles of tub-ing, different con-nector types include barbed connectors, check valves, luer connectors, quick connects, threaded luers and tube-to-tube connectors. Of these, the most commonly used tubing connectors are tube-to-tube, luers and quick connects. These basic styles cover a wide range of liquid and air appli-cations in laboratories and plants.

Tube-to-tube connectors are popular for applications that don’t require equipment or parts disconnection at any point during use. Tubing connectors are available in many different configurations, sizes and material options to adapt to different tube sizes or styles, reroute the flow direction without kinking and act as a manifold.

Delivery systems can employ conical or taper seal connectors, called luers, to link various sys-

tem components. The male and female compo-nents of luer connectors join together to create secure, yet detachable, leak-proof connections with no O-ring or gasket required.

Luer connectors come in a variety of configurations, includ-ing for tube con-nections, threaded connections (UNF, NPT and metric) and other luer or quick connect termina-tions. Some of those incorporate a tapered UNF thread, similar to a pipe thread, which can also seal on the thread due to interference on the pitch diameter, facilitating directional align-ment with tees and elbows.

So-called “quick connects” allow flexible tubing and equipment to be quickly and safely connected and disconnected. This may be pre-ferred over general connectors for fluid control because they can incorporate built-in shut-off valves that prevent spillage, allow multiple dis-connections and faster servicing.

One of the newest and most versatile plastic quick-connect solutions available for laboratory and industrial applications, the MQC Series manufactured by Value Plastics, a Nordson Company, provides an intuitive push-to-connect design. With its large, ergonomic buttons pro-viding an audible click on connection and grips for easy handling with gloves, combined with a wide selection of color-coding options, the MQC is unique for ease of handling and the prevention of misconnections.

Many of the latest quick connect designs focus on the user interface and are equipped

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www.ProcessingMagazine.com•January 2013

Plastic tube to tube connec-tors are a popular choice for applications that do not require the disconnection of equipment or parts at any point during production or use.

Plastic connector technology affords designers and manu-facturers a wide latitude of flexibility, such as with this latest generation of check valves.

The selection of the barb style on both plastic and metal connectors is very important to the connector’s tube holding capability.

with simple thumb-latch and side-latch mechanisms to make for easy han-dling in laboratory and industrial fluid management applications. Quick connects mitigate the prospect of accidental misconnections and create quicker and safer device connections.

One barb, or two?Plastic barb-style connectors accom-

modate the widest possible range of tubing properties and application con-ditions, including a multitude of con-figurations such as tees, Ys, elbows and manifolds. Barb designs are available for handling assembly forces, tensile resis-tance and blow-off resistance, without the need for clamps.

Barbs derive their holding capability by expanding tubing above its nomi-nal inside diameter (ID), creating some

amount of interference for a secure seal and good mechanical retention. The tube expansion can vary dramatically, from lower profile, easier con-nections to much more aggressive interferences, depending on the pres-sure and tensile pull requirements.

The selection of the barb style is very important to the connector’s tube-holding capability. The cylindrical surface behind the barb should allow the tubing to relax against the connector. In choosing a barb style, users should be sure the barb has a sharp peak, allowing it to “bite” into the tubing for optimal retention.

Many plastic connectors and almost all metal connectors use a multi-barb, making for an inferior tube connection and seal. Multi-barbs cannot create a sharp bite on the tube, inhibiting retention, and do not allow the tube a chance to relax behind the barb, also resulting in poor tensile pull strength.

The multi-barb manufacturing process leaves a parting line on the seal-ing surface, creating a potential leak path. This is an inherent design flaw, yet all multi-barb connector designs, including metal connectors, display this liability. In fact, many inferiorly crafted single-barb plastic connectors are also afflicted with a parting line, reducing connector efficacy. A good injection-molded connector has a singular barb with no parting line, a sharp bite and a clean sealing surface.

Design optimizationMany factors reduce tubing’s ability to perform under pressure —

including temperature, chemical degradation, mechanical stress, fluid pul-sation, selection of connector type and barb design. The latest generation of plastic connector technology affords designers and manufacturers wide flexibility to design and set-up applications to fit their specific needs.

Compared to metal, plastic connectors offer a considerable reduction in weight and much improved flexibility with regard to the equipment they serve. Plastic quick connects allow rapid and easy servicing and maintenance of assembly-line equipment, filling systems and packaging systems. The cost difference between metal and plastic connectors is a major motivating fac-tor in the embrace of plants and laboratories of plastic connectors.

Given demanding project requirements and timelines, precision fluid management solutions are critical to achieve a high efficiency ROI. Plastic connectors, particularly when custom designed for the application, are becoming the preferred solution in industrial and laboratory settings.

Value Plastics Inc., a Nordson Co., manufactures and markets fluid man-agement components designed specifically for flexible tubing and instru-mentation. Riley Phipps is technical and design services manager there.

Value Plasticswww.valueplastics.com

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20

The latest plastic quick connect designs can be equipped with in-tuitively simplistic thumb latch and side latch mechanisms to make for easy handling in laboratory and industrial fluid management applications.

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Accurate liquids measurement is important for the oil and gas industry. But it’s essential for bulk-transfer devices where large product volumes are moved and monitored, including crude oil depots, gasoline and jet fuel tank farms, refineries and even cruise line terminals.

Mass transfer has been measured in batches with weigh scales or load cells. But their use is not suitable for continuous flow measurement.

For continuous processes, orifice plate and magnetic flow tubes can measure volumetric flow, but other instruments are needed to measure temperature and pressure to compensate for fluid density changes. Additional instruments also introduce errors, resulting in an overall mea-surement error rate as high as 3.0%.

Several measurement standards are moving toward use of Coriolis mass flowmeters, which can measure mass flow directly and at the same time measure temperature and density. What’s more, mass transfer mea-

surement is independent of, and unaffected by, changing process fluid characteristics, including pressure, temperature, viscosity, conductivity and gravity.

Among Coriolis devices available, the straight-tube design is the most accurate and easiest to install and maintain. Especially for measurement skids, widely used in the oil and gas industry, the straight-tube Coriolis meter can be a factor in minimizing skid size.

From mechanical to Coriolis Petroleum fluid flow has been measured fairly reliably using a wide

range of mechanical meters. One significant drawback is that mechanical meters experience serious wear and tear, which leads to high mainte-nance costs and need for frequent replacement parts.

Also, mechanical meters must be calibrated on a single grade, making recalibration, also known as meter proving, necessary each time a differ-ent product is measured. Custody system operators often need to use a prover for measuring one batch to another, reproving for every different fluid transaction.

Advances in manufacturing technology have led to larger Coriolis meter sizes, making them viable for oil and gas applications that have heretofore been the domain of mechanical meters. Coriolis meters have no moving parts. Unlike mechanical meter measurements used for custo-dy transfer, Coriolis meters measure product mass directly, independent of pressure and temperature.

Direct mass flow measurement with Coriolis flowmeters means that one flowmeter with a single point of measurement can obtain multiple measured values, including mass flow and mass total, density and con-centration, volume flow, volume total and temperature. It also reduces

Larger Coriolis mass flowmeters takecenterstageA brief discussion of measurement needs and practices in North America’s oil

and gas industry



By Andre Verdone

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overall costs, because only a single instrument is bought and main-tained. Cable laying and power consumption are reduced, and controls simplified.

Reducing pressure drop

Pushing fluids past a mechanical meter always creates a pressure drop, which is not recoverable. Every time pressure drop is imposed, it must be overcome with pump use, which adds equipment, cabling and energy costs.

No extra pressure drop is experienced across a Coriolis mass flowme-ter. Most meters have twin tubes, and the

only pressure drop is caused by splitting the flow into the two pipes. A straight-pipe Coriolis meter creates less perma-nent pressure drop than the bent-tube variety.

Almost all operators using mechani-cal flowmeters also run separate pressure and tem-perature meters.

Say the mechanical flowmeter exhibits a 0.5% accuracy error; the pres-sure meter also poses a 0.5% accuracy error; and the temperature meter a further 1.0%. Combined in a flow corrector or computer, the overall calculated error rate could be 2.0% or higher. Plus, since each instrument independently drifts over time, accuracy is further degraded, perhaps to as high as 3.0%.

The Coriolis meter’s error rate is only 0.1% to 0.2% of rate, making it nominally five to 10 times more accurate than mechanical measurement. Its long-term drift is minimal compared to devices with moving parts.

The straight-tube Coriolis meter takes up little space with simple pro-cess piping. The straight-tube design is easier to clean than the bent-tube version, which tends to get deposit buildup on the tube, and much simpler than equivalent mechanical meters, which also require strainers and upstream filters.

With a typical Coriolis mass flowmeter, operators view all fluid-related parameters, including volumetric flow, mass flow, density and tempera-ture. Most have options for multiple outputs, including digital convert-ers that allow for direct MODBUS to all parameters. Available controls ensure the correct product is going through the meter; verify product is drawn from the right tank; and tell operators if product is hotter or cooler than expected.

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Ontario refinery experience

At one Ontario petroleum refinery site that produces refined gasoline, jet fuel and other petroleum products, operators ship and meter product through a 5-kilometer long, 8-inch diameter pipeline that connects to a major pipeline delivering product to the greater Toronto area. Product is measured leaving the plant site and going to the shipping pipeline, and a density reading was wanted at the same time. Different products are shipped through one line and the site needs to confirm correct product shipment.

Management did not want to do a large-scale modification to install additional structural supports for meters. Pressure drop through the meter needed to be minimal to avoid increasing the cost of running the pipeline.

The facility looked at ultrasonic, vortex shedding and orifice plate meters, but ultimately chose a Coriolis mass flowmeter.

The straight-tube design offered lower pressure drop and was less sub-ject to plugging. Most importantly, it was simpler to install and took up less space than other available options.

Managers initially had reservations about using a straight-tube design. Bent tube is the more traditional choice and has a larger installed base. However, they chose a straight-tube OPTIMASS 2000 Coriolis meter from KROHNE, based on lower installation costs, combined with high accuracy and linearity.

The refinery can monitor the meter remotely from a laptop. The meter sensor has its own smart-sensor interface and on-board memory, so the electronic convert-er/transmitter “talks” digitally and directly to the sensor.

While sharing device configuration data, the two installed devices are remote and segregated, so if there is a prob-lem with either sensor or transmitter, technicians can replace one or the other independently. Sensor calibration files or converter parameters can be uploaded from either device, adding to the meter’s reliability.

Custody transfer has a significant impact on the bottom line, so preci-sion and reliability are key requirements. Today’s Coriolis mass flowmeters can compete with traditional mechanical meters. For the bulk measurement of any fluid with a significant value, large diam-eter Coriolis mass flowmeters offer more accurate and repeatable bulk fluid trans-fer measurement. Further, straight-tube Coriolis meters offer the lowest pressure drop and highest accuracy.

Andre Verdone is a vice president and technical expert with Krohne, Inc., a glob-al technology leader in the development, manufacture and distribution of accurate, reliable and cost-effective measuring instruments for the process industries. He has spent the last 35 years working in the water industry and has written and pre-sented several papers around the world on key issues related to improving the operation, conservation and management of water systems.

Krohne, Inc.www.krohne.com

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Flowmeters

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(Editor’s note: Dr. Yoder is just returned from an 11-day research trip to Australia, where he delivered the keynote speech at the November Flow Measurement & Control Forum held in Perth.)

China and India tend to grab the head-lines when it comes to economic growth in Asia. But when it comes to energy, the entire Asia-Pacific region is of extreme interest and encompasses much more than can be con-tained within those two countries’ borders. In fact, given the distinct cultures and diverse political systems of the countries involved, the region’s characteristics aren’t easy to classify. One way to do it is as follows:•China,theKoreas,andthecountriesofSoutheast Asia mainland; •Japanstandsbyitself;•TheislandsofthePhilippines,MalaysiaandIndonesia;•AustraliaandNewZealand;and•Othersmallerislandsintheregion.Theprimaryenergysourcesintheregionare

coal, nuclear, oil, natural gas and renewables. It will take 20 to 30 years before renewables

count as a substantial energy source for most ofthesecountries.Thetechnologyisnotyetsufficiently developed for it to be price com-

petitivewithcoal,oilandnaturalgas.Nuclearenergy has its dangers and coal is a significant source of pollution, so many countries are turning to oil and natural gas as their primary energy sources. Between the two, natural gas iscleanerandmoreplentiful.Thus,naturalgasis increasingly seen as a long-term bridge to renewables.

Energy challengesManyofthecountriesintheregionarechal-

lenged when it comes to energy resources. Theymusteitherproduceenoughenergytobe self-sufficient or import what they cannot produce. China is rich in coal, and still relies heavilyonitasanenergysource.Japanhaslittle in the way of oil or natural gas, and has reliedonnuclearpowerandcoal.Nearlyallofthe natural gas and oil it uses must be import-ed.Naturalgasisimportedintheformofliqueiednaturalgas(LNG).ChinaalsoimportssigniicantamountsofLNG.

Other countries in the region, including Australia, are rich in natural gas. Yet transport-ing natural gas can be challenging. Over long distances, natural gas is transported either by pipelinesoraboardshipsasLNG.Pipelineswork within a country or regionally, but

LNG: key to supplying Asia Pacific energyneedsAustralia uses about half the natural gas it produces, and exports the rest

in the form of LNG


January2013•www.ProcessingMagazine.com

By Jesse Yoder, PhD

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typically not across the ocean’s expanses. Of course, natural gas pipe-lines can be buried under the water, as demonstrated by the natural gas pipeline that runs under the Persian Gulf from Qatar to Abu Dhabi in the United Arab Emirates (UAE). This pipeline supplies much of the natural gas used by both the UAE and Oman.

Australia, both a country and a continent, sees an opportunity to be a major natural gas supplier to the region. It has proved natural gas reserves roughly equal to those of China.

Australia already has undertaken a large number of natural gas proj-ects. The largest by far is the Gorgon Project, located off the west coast

of Australia. Construction of the Gorgon Project began in 2010. It is on schedule to produce its first natural gas late in 2014. Once the project is operational, it is expected that about three LNG shipments a week will be loaded for export to Asian markets via a 1.3 mile jetty.

The primary participants in the Gorgon Project are Chevron Australia, Shell Development Australia, and Mobil Australia Resources. Its current estimated cost is $54 billion. The Gorgon and Jansz fields are located about 130 kilometers, or roughly 80 miles, off the coast of Western Australia. An LNG plant is being built on Barrow Island, conveniently located between the natural gas fields and the mainland. This plant is

expected to produce 15.6 million metric tons of LNG per year.

Conventional and not so muchWhile the Gorgon project is devoted to

producing what is usually called conven-tional gas, Australia also has a significant amount of technically recoverable shale gas — about the same amount as Canada. Because Australia is so rich in conventional gas, developing shale gas has not been a priority. However, in October 2012, the first shale gas in Australia was pumped from a well in outback South Australia.

Now that Australia has begun produc-ing shale gas, it will undoubtedly become a growing resource for this vast continent. Australia uses about half the natural gas it produces, and exports the rest in the form of LNG.

Australia has many other natural gas projects besides the Gorgon Project, though none larger. And there are many other natural gas fields throughout the region. What is common to many of these projects is that they involve shipping natu-ral gas in the form of LNG. While there are some pipelines in the Indonesian-Malaysian region, sheer distance dictates that much of the natural gas shipped in this region will be in the form of LNG. In the Asia Pacific it is one of the most prom-ising growth opportunities that has ever existed in the field of energy.

Natural gas has to be measured, espe-cially for custody-transfer applications, whether it is in the form of LNG or goes by pipeline. This presents a major oppor-tunity for flowmeter manufacturers. Both McCrometer and GE Measurement have brought out flowmeters designed specifi-cally for LNG measurement. Look for other flowmeter manufacturers to take advan-tage of this unprecedented opportunity.

Jesse Yoder, Ph.D., is president of Flow Research, Inc. (www.flowresearch.com), a company he founded in 1998. He has 24 years of experience as an analyst and writ-er in process control. Dr. Yoder special-izes in flowmeters and other field devices, including pressure, level and temperature products. He has written over 100 market research studies in industrial automation and process control and has published numerous journal articles.

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As an alternative to one-piece ball valve body designs, a new split-body valve series with a two-piece bolted-body design meets ANSI take-out dimensions for either a long full port or short reduced port pattern.

Engineers typically discard larger, one-piece body valves when seat failures occur. In many cases the equipment

required to repair a one-piece body design is not available. One-piece body designs can have very finely threaded seat retainers, which tend to cause galling, a problem only amplified when it comes to stainless steel valves. Upgrading and converting a valve to have a metal seat, when it has a one-piece body design, is expensive and time-consuming.

On the other hand, the two-piece body design can accommodate a variety of hard-seat materials, including Peek, UHMPFE and other exotic materials.

A two-piece design offers:•Easeofmaintenanceandseatchangeout;

•Lowercostandlighterweightthanfullport;•Improvedlowcontrol;and•CustomV-Portoptions.

Given the ease of ball valve change-out in the two-piece body design, full-portvalvesareeasilyconvertedtoV-Portcontrol.Areduced-portcon-trolvalveoffersbetterperformancewithmoreoptions,tocustomizelowat lower prices and torques.

It is now possible for a reduced port valve body to be provided with the same ease of assembly and disassembly as a full-port version. Flo-Tite’sEZseries,two-piecereduced-borelanged-endballvalves,are

availablein6-through14-inchANSIClass150.

Robert M. Donnelly is vice president of marketing with Flo-Tite Valves & Controls.


January2013•www.ProcessingMagazine.com

32 Valves & ActuatorsEasy maintenance characteristic of two-piece, reduced-bore split-body ball valve

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34 Valves & Actuators


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Integrated Multi-port Valve SystemsFor 20 years, GEMÜ has manufactured stain-less steel, sterile multi-port valve blocks for the pharmaceutical and biotechnology industry.

For customized block designs, GEMÜ integrates a

wide range of functions: blend-

ing, splitting, diverting, drain-

ing, feeding or cleaning. Double

shutoffs, cross connections, safety and control func-

tions as well as the integration of sensors, filters and check valves are also possible. GEMÜ can even inte-grate tanks, process containers and plant hous-ing walls as well as mounting points.

GEMÜwww.gemu.com

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Emergency Gas ShutoffHalogen’s Terminator emergency shutoff system sequentially closes 150 lb. cylinder valves con-taining toxic gas in less than three seconds when activated from remote sensors and switches. The

operator would then be required to correct the condition, check the facility and manually reset the valve before restarting the gas sys-tem. The Gemini con-troller has a self-con-tained battery system that guarantees the operation of the motor-ized closing mechanism

even during a power failure. This dual-torque microprocessor controlled system applies 40 foot-pounds of torque for emergency closures of the cylinder valve.

Halogen Valve Systemswww.halogenvalve.com

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Gate Valve Modern sustainability demands require plants to increase efficiency and reduce carbon diox-ide emissions. KSB’s ZTS Gate Valve has the performance and reliability to provide this efficiency, helping plants meet zero-emission goals. With its hammer-forged steel body, the

valve can handle water, steam, gas, oil, and other non-aggressive fluids, even at temperatures in excess of 1000 F. The valve’s

efficiency and durability make it ideal for industrial settings, power stations and

process-engineering systems.

KSB, Inc. www.ksbusa.com

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36 Valves & ActuatorsSolenoid Valves with Two Coil TypesParker Fluid Control Division, manufacturer of the Skinner and Gold Ring lines of solenoid valves and the Sinclair Collins line of process

control valves, offers the choice of a tab or integrated coil as part of its Series 204 and 304 solenoid valve lines. The options feature flexible production possibilities for long-lasting valves that can operate under maximized pressure ratings. The 204 and 304 Series is a family of direct-acting sole-

noid valves for air and liquid (including light oil) applications. These small yet powerful valves meet virtually all of today’s commercial, industrial, mobile, instrumentation and medical market needs.

Parker Fluid Control Divisionwww.parker.com

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Control SystemsVal-Matic Control Systems provide low maintenance and reliable con-trol of butterfly, plug and ball valves equipped with cylinder actuators. Hydraulic and electric panels operate pump control valves with air, oil or water power and include solenoid and flow control valves for slow open/close and emergency shutdown. Oil Accumulator Systems provide a clean

and reliable oil supply to operate pump control valves even after power outages. Hand control valves are also available to provide open-close and manual position of a cylinder operated valve without electrical power.

Val-Matic Valve & Mfg. Corp.www.valmatic.com

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Slide Gate Valve for Heavy Duty and Abrasive Material HandlingThe Vortex Titan Series TSG Valve is designed to meet the most demand-ing applications when handling heavy-duty abrasive materials such as sand,

gravel, coal, whole grains, metal powders or minerals. The TSG Valve handles dry material in gravity flow applications where positive material shut-off and dust tight sealing are required. This slide gate is available in a wide variety of configurations with rectangular sizes and customer specific hole pat-terns. The TSG Valve has “live loaded” nylon seals that extend service life by compensating for wear

and provide an exceptional material seal across the gate and to atmo-sphere. The TSG Valve has replaceable liners that can be swapped while the valve is still in-service vastly reducing downtime.

Vortex Valveswww.vortexvalves.com

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Rotary Airlock ValvesIdeal for sanitary applications such as food processing, pharmaceutical processing and chemical or plastics appli-cations, the Run-Clean™ Series of rotary airlock valves are

designed with multiple features that reduce the material buildup inside the valve housing that can occur during operation. These features include: angled surfaces and rounded edges inside the housing to eliminate dead zones and ensure optimal material flow; factory-applied internal surface coatings, such as tungsten, to prevent

surface wear imperfections where material can buildup; gland-less, sleeve-style shaft seals that prevent contaminant migration into the housing; and stainless steel housings cast in North America to ensure superior strength in the composition and solidification of the housing’s metallurgy.

ACS Valveswww.acsvalves.com

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Industrial peripherals — the joysticks, mouse pointers and keyboards that act as the interface between humans and processing equipment — are under constant assault in harsh, messy industrial environments.

In processing plants, mines and mills across the country, these peripherals are exposed to extremely high and low temperatures, moisture, high-pres-sure wash downs, dirt, grime and operator abuse — often around the clock.

Unfortunately, many industrial peripherals built to last in these envi-ronments often fail or malfunction within months and are replaced or repaired at considerable ongoing cost.

The problem isn’t always the harsh, abusive environment. Instead, many industrial peripheral manufacturers rely too heavily on ruggedized enclo-sures, while using commercial-grade components and internal designs

adopted from the PC market.

One technician’s take on itFor Robert Johnson, a ser-

vice technician for Bethlehem, Pa.-based Minteq, a supplier

of refractory systems, the steel foundry environment is, “among

the harshest imaginable” and the choice of peripherals used in any

control system is critical to care-free daily operation.Minteq’s LaCam laser profile measur-

ing system for non-contact measurement of refractory linings in metallurgical reac-

tion and transport vessels operates in an environment where tempera-tures can vary from -10 F to more than 2,000 F at the furnace.

“We were using an industrial keyboard/mouse combination unit,” Johnson says. “But it wasn’t reliable. It wasn’t very industrial. It didn’t react to the temperature extremes like we needed. It would lock up from time to time. We were constantly replacing them.”

The keyboard/mouse combination came with a guide rail and roller system, to pull the keyboard out during use. It wasn’t designed to handle dirt or extreme high and low temperatures. The mouse didn’t respond well when operators wore gloves, which in the steel industry is most of the time. Finally, once the membrane that covered the mouse got dirty or roughed up it didn’t work at all. When the mouse began failing the entire unit had to be replaced. Johnson estimates this occurred every couple of months over the span of 10 years.

NEMA designationsBuilt strictly to meet established industry standards, many industrial

peripherals are protected by a NEMA 4X (IP66) enclosure. This desig-nation indicates the enclosure protects internals from dust, dirt, water (including pressure washing) and even external ice formation.

In addition to enclosures, the industry uses several other common tech-niques to keep peripherals sealed and watertight. Industrial keyboards, for example, are commonly covered with a monolithic elastomer cover.

But like the old saying goes, “you can’t judge a peripheral by its cover or enclosure.” A deeper look into the internal components and design separates the “industrial” peripheral from those truly ruggedized devices that survive — and thrive — for many years.

Industrial-grade computer peripherals: more than just a NEMA enclosureRugged internals and components keep joysticks, mouse pointers and keyboards

from breakdown in harsh, messy environments

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A true industrial-grade peripheral entails ruggedized components that can stand a temperature range from -40 C to 80 C, are hardened against wear caused by heavy or rough use and have few moving parts or poten-tial failure points.

Johnson says he spent a considerable amount of time searching for an alternative and tried six or seven different products before discovering the Industrial Mouse from Stratford, Conn.-based CTI Electronics, which designs and manufactures industrial-grade trackballs, joysticks, keyboards and intel-ligent switches for OEMs, system integrators and commercial end-users.

The ‘joy’ of itThe Industrial Mouse is a rugged joystick used as a mouse pointing-

device, with an inductive effect patented by CTI Electronics to deliver the desired control. Unlike most joystick-style devices, there are no physi-cal contacts and only three moving parts, so there is little internal wear despite potentially millions of operations.

“It’s the easiest thing to install, you basically plug it in and it works,” explains Johnson. “There’s no fooling around with it — no drivers, no set-tings, no nothing.”

Today, the devices Johnson installed 18 months ago are still in service.“The most impressive thing is that it’s almost indestructible,” says

Johnson. “It handles everything we throw at it from the extreme heat down south to extreme cold up at the top of Lake Superior. Sometimes, you’ve got to go from the furnace at 2,400 F back to -10 F in about a min-ute. It handles all that without skipping a beat.”

The operators love it, adds Johnson. “It’s a joystick and they can use it while wearing gloves. It’s got a little button on top. Basically, it’s like a video game to them. It’s easy and fast. They can just move, click, move, click, move, click.”

The Industrial Mouse allowed Minteq to eliminate the keyboard compo-nent altogether. Now operators use the joystick along with touch screens.

Eliminating the keyboard also put an end to the difficulties with the guide rail and roller mechanism. That delivered about 1.25 inches of addi-tional room inside the machine for future design elements, says Johnson. “It’s a complete win. We’ve upgraded every keyboard/mouse unit that failed or that we simply wanted to upgrade.”

CTI Electronics Corp.www.ctielectronics.com

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Screw-style FeederHapman’s new screw-style U-Trough feeder is designed to efficiently measure ingredients and consistently deliver material to the

process. This versatile feeder is available with either volumetric or gravimetric controls. The range of measurement options makes this feeder optimal for dry product integration for use in food, chemical or water treatment processing. Featuring an optional integral agitator, the U-Trough Feeder is engineered to effectively operate as a dry material mixer.

Hapmanwww.hapman.com

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40 Weighing & Feeders

Versatile Vibratory FeederEquipped with a drive that vibrates a specially designed feed tray, the SolidsFlow 2000 provides versatility for a number of process applications. A key feature of the SolidsFlow 2000 is its uniquely designed feed tray.

Each tray con-tains a number of slats with a gap and overlap across the entire width of the dis-charge opening. All slat dimen-sions and angles are designed to suit the particu-

lar physical characteristics of each material being fed. Therefore, when the vibrations cease, material flow stops instantaneously due to chang-es in the vibrated and static angle of repose of the product.

Schenck AccuRate www.accuratefeeders.com

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Wireless Scale SystemCardinal’s SnapStream allows a scale to send weight data wirelessly to an indicator and the indicator in turn to send that data wirelessly to a host of peripheral equipment such as remote displays, printers, PCs and networks. The digitally controlled weighing and diagnostic system was designed utiliz-ing 802.15.4 Zigbee protocol for reli-able and accurate weight and data transmission. SnapStream may be used with Cardinal’s model 205, 210 and 225 digital weight indicators, where scale diagnostics can be viewed directly on the indicator without having to go to the scale itself. SnapStream may be configured using one to 16 load cells.

Cardinal Scalewww.cardinalscale.com

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Crane Scale with Wireless RemoteThe Alliance/CAS IE Series Crane Scale is suitable for a wide range of mate-rial handling applications. It includes a wireless remote control with a 32-foot range and fea-tures a sturdy aluminum die cast case, an easy-to-read 1.1-inch LED or LCD display and func-tion keys for power, zero, tare and hold. The portable crane scale will operate for up to 50 hours on a fully charged battery and includes a rugged hook and shackle for hanging.

Alliance Scale, Inc.www.alliancescale.com

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Bulk Bag Discharging and Feeding SystemPatented MATERIAL MASTER™ BULK BAG DISCHARGING SYSTEM lifts, loads, seals and discharges flexible intermediate bulk contain-ers of dried bulk materials. Unit features an electric chain hoist with motorized trolley, monorail system and energy chain package. Unit features a custom product discharge transition with integral Sure-Seal™ system for dust-tight discharge into a vibratory feeder with vari-able speed controls. Equipment includes a Flo-Lock™ discharge gate for partial bag discharging, allowing bag to be retied, removed and reused.

Material Transfer & Storage, Inc.www.materialtransfer.com

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Multiple Screw Feeder UnloaderThe Unloader from Sodimate, Inc. fea-tures a vertical spindle fitted with flex-ible blades to ensure the mechanical discharge of dry powders from silos, rigid bins and hoppers. The unloader rotates within the container bottom to prevent non-flowing materials from jamming, bridg-ing, compacting or rat holing as often seen with vibration and fluidization sys-tems. The system can also integrate up to four precise volu-metric screw feeders. Each feeder is totally independent and can feed up to 15,000 lb/hr with different lengths and through-put variations. Sodimate’s discharger was specifically designed for difficult dry powders and chemicals such as lime and soda ash.

Sodimate, Inc.www.sodimate-inc.com

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Eddy Current SeparatorThe RevX-E™ Eccentric Eddy Current Separator is the newest offering in Eriez’ extensive line up of state-of-the-art Eddy Current Separators. Designed for separation of nonferrous metals, the RevX-E is ideally suited for purifying cullet and plastics, and recovered valuable metal from sec-ondary metals and incineration ash, especially the separation of small par-ticles. The RevX-E features an eccentrically mounted magnetic rotor within a non-conductive larger diameter shell. This eccentric rotor concentrates its eddy current forces into a zone of separation at the end of the belt.

Eriez www.eriez.com

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42 Filtration/Separation‘Universal’ Filter FrameCamfil Farr has introduced a time-saving, universal filter frame for built-up bank HVAC systems. The FastFrame air filter holding frame uses exclusive new Camfil Farr compression tab technology. This innovation allows rapid filter change-out without the hassle of clips and fasten-

ers, or the very common problem of finger cuts caused by the sharp edges on conventional framing systems. FastFrame is constructed of 16-gauge all-welded galvanized steel for long-term corrosion protection. Its unique design allows for convenient, simple filter replacement while preserving the integrity of the filter seal.

Camfil Farrwww.camfilfarr.us

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Downdraft TableAirflow Systems’ DT-3000V2 downdraft table is designed to provide high-efficiency, source-point collection and filtration of powder, dust, fumes, smoke and other contaminants produced during industrial pro-

cessing and production operations. The DT-3000V2 generates 195 FPM of downdraft air velocity across the 19.25 sq. ft., grate-style work surface to quickly draw contaminants down and away from the worker’s breathing zone. Contaminants are then collected and filtered from the airflow path using high-efficiency filtration (MERV 17 after-filter). The Airflow Systems DT-3000V2 prevents contaminants

from becoming airborne, migrating throughout the facility and present-ing possible environmental health and safety concerns.

Airflow Systems, Inc.www.airflowsystems.com

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43


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Filtration System with Real-time Process MonitoringThe lack of specialized equipment for manufac-turing-scale bioprocesses can increase the labor and time required for normal flow filtration operations. PendoTECH’s recently launched Virus-Depth Filtration System enables complete pro-cess control with pre-programmed functions for differ-ent steps during the critical flow filtration process. Equipped with a real-time monitor and built-in alarms that provide regu-lation, the system’s use of PendoTECH’s Single Use Pressure Sensors, tubing pinch valves, sin-gle-use flow meter and non-invasive air detec-tor permit a single use fluid path to increase the process efficiency.

PendoTECHwww.pendotech.com

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Multi-bag Filter Housing System for High Volume ApplicationsEaton Corporation’s PROLINE 100™ Series filter housings are 100 PSI rated, non-coded vessels for use with standard #2 size filter bags. The new HE Series vessel design offers a spring-assisted lifting mechanism that balances the cover perfectly. The SE Series vessel offers the revolutionary QIC-LOCK® opening mechanism for fast and easy access to the filter chamber with minimal downtime. Eaton’s develop-ment of the PROLINE 100 Series multi-bag vessel took into consideration the total life cycle costs as well as their commitment to sustainability. As a result, the housings are only available in 304 stainless steel, which is 100 per-cent recyclable when service life is complete.

Eaton Corp.www.eaton.com/filtration

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Low-maintenance Air Filtration Solution The patented “Never Miss” cleaning mecha-nism from Mac Process pulses the bags only when the nozzles are in direct position. Exceptionally uniform media cleaning is achieved, which opti-mizes bag life and pressure drop. The result is better bag cleaning, less energy consumption, lower emissions and longer bag life. The MCF PowerSaver requires no integrated plant compressed air to function, which generates energy cost-savings of up to 50 percent over conventional high pressure pulse jet or reverse air cleaning systems.

Mac Process www.macprocessinc.com/air-filtration

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44 Powder & Bulk Solids

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Vacuum Conveying SystemVolkmann’s ATEX-approved INEX vacuum conveying system takes vacuum transfer of dry or wet powder

and granules into potentially hazard-ous conditions to a new level. By using a sophisticated, patent-pending nitrogen purging function, INEX reduces oxygen content within the unloaded batch to

below 7% (or lower when required), maintaining the material’s inert safety while providing dust-free transport. The INEX features a closed station that can be flushed from within by sucking in the washing liquid or through WIP/CIP. Standard lightweight and pres-sure-rated systems are available with INEX functionality.

Volkmann, Inc.www.volkmannUSA.com

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Precision Feed SystemsAdding the PosiPortion feeder to any Hapman conveyor or bulk bag unloader instantly transforms equipment into a precision deliv-

ery system that automatically supplies material to your process in premeasured batches, or continuously on a rate-controlled basis. PosiPortion’s engineered design maintains the quality of your bulk material without degradation, segregation or agglomeration. Plus,

it easily starts under heavy loads, making the unit ideal for installing beneath silos and large surge hoppers. Hapman has extensive experience in custom tailoring systems to meet unique application requirements, including necessary controls and process instrumentation.

Hapmanwww.hapman.com

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Powder Induction, Wetting, Dispersion in One ProcessThe Ystral Conti-TDS, now certified by 3-A Sanitary Standards, brings major efficiencies to the production process by offering powder induction, wetting and then dispersing of an agglomerate-free liquid — all with one machine. Powder Technologies, Inc., (PTI), exclusive distrib-utor of Ystral powder and liquid process-ing systems throughout North America, offers the Conti-TDS as one of its solu-tions for processing applications in the food, cosmetics, pharmaceutical, chemi-cal and coatings industries.

Powder Technologies, Inc. www.powdertechusa.com

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46 Info Center

New Rotork CMA Actuators New Rotork CMA, continuous modulation actuators, are avail-able in several sizes and are suitable for linear, quarter-turn, and rotary control valve and pump applications. They offer precise position control, easy set-up, and can be powered by single-phase or DC supplies.

ROTORK, Inc.675 Mile Crossing Blvd., Rochester, NY 14624585-247-2304•Fax:585-247-2308www.rotork.com•Email:[email protected]

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Heavy Duty Butterfly ValveThe Posi-flate Series 585/586 inflatable seated butterfly valves are designed for the most the most severe applica-tions. The new heavy duty seat has been designed for higher operating pressures and tem-peratures.

Posi-flateSt. Paul, MN 651-484-5800Email:[email protected]•www.posilate.com

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Automated Tank Cleaning MachinesGamajet manufactures cost-effective, time-efficient rotary impingement machines for all types of tanks and vessels. Gamajet machines provide the best clean by preventing cross-contamination and eliminating the need for confined space entry.

Gamajet, part of the Alfa Laval Group604JeffersCircle,Exton,PA193411-877-GAMAJET•610-408-9940•Fax610-408-9945Email:[email protected]•www.gamajet.com

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High Accuracy Digital Pressure GaugesOmega’snewDPG409seriesofhigh accuracy digital pressure gages features a large backlit display that makes it possible for users to read digits from over 10.7m (35 ft). The Stainless Steel enclosure is designed spe-cifically for wash-down, sanitary and marine applications.

OMEGA ENGINEERING, INCOneOmegaDrive,Stamford,CT06907203-359-1660•Fax:203-359-7700www.omega.com

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Dry Run ProtectionNew PMP-25 Pump Load Control guards against dry run-ning, cavitation and overload. It monitors true pump power formaximumsensitivitywhiledisplaying power, trip points and delays. The 4X-enclosure is small enough to fit on size 1 starters and can be door-, panel- or wall-mounted.Free30-daytrial!

Load Controls, Inc.www.loadcontrols.com888-600-3247

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Automated Bulk Bag ConditionerBLOCK-BUSTER®BulkBagConditioner loosens bulk materials that have solidified during storage and ship-ment. Hydraulically actuated, variable-height turntable allows automated bag rotation and conditioning at varying heights.

Flexicon Corporation1-888-353-9426Email:[email protected]•www.lexicon.com

Write In 404

Rota-Cone™ Vacuum DryersRota-Cone™ Vacuum Dryers provide an efficient and eco-nomical method of drying sol-ids. The slow tumbling action of the double-cone is gentle on friable solids. Vacuum dry-ing lowers the evaporation temperature of liquids, which improves heat.

Paul O. AbbeBensenville, IL800-524-2188•Email:[email protected]

Write In 406

Metal Detectors for Severe DutyTheEriezMetalarmMA3600Eagle/HawkSeriesdetectsmetal as small as ½”, using pulseinductionversuscoils.Forharsh conditions in quarries and mines, and highly-conductive products like iron ore and steel corded belts. Download a free Metalarm brochure.

ERIEZ888-300-ERIEZwww.eriez.com

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Stainless Steel Hose Reel Offers Maximum ProtectionHannay Reels SS1500 Series stainless steel hose reel is engineered to withstand con-taminates and corrosion in industrial, chemical and food processing settings or any harsh environment.

Hannay Reels877-467-3357www.hannay.com

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Krytox® Fluorinated LubricantsDuPont™Krytox®GreasesandOilsare:Chemicallyinert.Nonflammable. Thermally stable-103to800F.OxygenCompatible. No migration. Low outgassing.OffersExtremePressure, Anticorrosion, Antiwear properties. Mil-spec, Aerospace,FoodGrades!

MILLER-STEPHENSON CHEMICAL CO., INC.California – Illinois – Connecticut – Canada 203-743-4447email: [email protected]

•www.miller-stephenson.com Write In 409

Efficient Plastic Diaphragm Valve SolutionThenewR677andR690DiaphragmvalvesfromGEMUhave been designed to be a highly efficient plastic dia-phragm valve solution. The optimized internal geom-etry provides higher Cv’s and improved flow characteristics.

Gemü Valveswww.gemu.com

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Loss-in-Weight FeedersTheMECHATRON®Loss-in-WeightFeedersprovideprocessing industries precise material feeding accuracies of ±1/4 to 1 percent of feed rate setpoint at 2 sigma. Complete disassembly from the non-pro-cesssideofthefeeder.Feedrates from .002 to 1,100 ft³ per hour are achievable.

Schenck AccuRate746E.MilwaukeeStreet,Whitewater,WI53190800-558-0184www.accuratefeeders.com/mechatronfeeders.html Email:[email protected]

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Jefferson Stocks Stainless Steel ValvesSame day shipping on all valves we have in stock includ-ing stainless steel and brass solenoid valves. Jefferson stocks ALL seat materials such as EPMD, FKM, PTFE AND BUNA N. Cost-effective cross-over done on all valves.

Jefferson Valves 20225 NE 15th Ct., Miami, Fl 33179www.jeffersonvalves.com305-249-8120

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Wobble Pump Shop! Wobble Pumps are very easy to handle and economical. Only one joint saves costs and reduces downtime when replacing spare parts. The wobble-stator pump saves space because the lantern has been dispensed with – the drive flanged onto the pump directly.

seepexshop.seepex.com

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Size Reduction EquipmentAtlantic Coast Crushers manufactures and sells innovative size reduction machinery for use in the chemical process industries. Company specializes in design-ing machinery that uses impact to shatter chunks, lumps and agglomerations formed from friable materials.

Atlantic Coast Crusherswww.gocrushers.com Email: [email protected]•Fax:908-259-9280

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47

Classifieds

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The Processing Blog features commentary

and insights from some of the top minds in

the process industries.

Visit www.ProcessingMagazine.com/Blogs

to ask questions and interact with

Processing’s expert bloggers.

We can picture your ad here!For more information, contact Liz Zane at [email protected]


48 IndexA d v e r t i s e r I n d e x

Filtration/Separation

Airflow Systems, Inc. ………………………………………… 42

Camfil Farr ……………………………………………………… 42

Eaton Corp. …………………………………………………… 43

Eriez …………………………………………………………… 42

Mac Process …………………………………………………… 43

PendoTECH …………………………………………………… 43

Powder & Bulk Solids

Hapman ………………………………………………………… 44

Material Transfer & Storage ……………………… Front Cover

Powder Technologies, Inc. …………………………………… 44

Volkmann ……………………………………………………… 44

Valves & Actuators

ACS Valves ……………………………………………………… 36

GEMÜ …………………………………………………………… 34

Halogen Valve Systems ……………………………………… 34

KSB, Inc. ………………………………………………………… 34

Parker Fluid Control Division ………………………………… 36

Rotork Controls, Inc. ………………………………… Front Cover

Val-Matic Valve & Mfg. Corp. ………………………………… 36

Vortex Valves …………………………………………………… 36

Weighing & Feeders

Alliance Scale, Inc. …………………………………………… 41

Cardinal Scale ………………………………………………… 40

Hapman ………………………………………………………… 40

Material Transfer & Storage, Inc. …………………………… 41

Rice Lake Weighing Systems ……………………… Front Cover

Schenck AccuRate …………………………………………… 40

Sodimate, Inc. ………………………………………………… 41

Argonide ....................................................... 38

Assured Automation ..................................... 40

A-T Controls, Inc. .......................................... 35

Automatic Filters, Inc. ..................................... 6

Benko Products ............................................. 28

Blue-White Industries .................................... 39

Cashco ............................................................. 4

CheckAll Valve .............................................. 18

CME............................................................... 12

Collins Instrument Co. ................................ 43

CPV Manufacturing ....................................... 28

Dynamic Air ..................................................... 1

Eldridge Products ......................................... 22

Eriez Manufacturing Co. ................................. 8

Federal Equipment ....................................... 40

Flexicon ........................................................... 5

FLEXIM Americas Corp. ............................... 44

Flo-Tite Valves & Controls ............................ 32

Fox Thermal Instruments, Inc. ...................... 24

GEA Process Engineering ............................. 30

GEMCO Valve Co. ........................................ 37

Greyline Instruments ..................................... 38

GEMÜ ............................................................ 24

Halogen Valve Systems ................................. 18

Hannay Reels ................................................. 20

Hapman Conveyors ........................................ 7

H-P Products ................................................. 15

Inline Industries ............................................. 32

Jefferson Solenoid Valves USA .................... 34

K-Tron America, Inc. ..................................... 14

Kuriyama of America, Inc. ............................. 39

Load Controls Inc. ........................................... 6

Lutz Pumps .................................................... 22

Magnatrol ...................................................... 28

Material Transfer & Storage, Inc. ................. 11

Micro Motion ................................................ 31

Midwestern Industries................................... 27

Morris Coupling Co. ..................................... 21

Nanmac Corp. ............................................... 19

New Age Industries ...................................... 42

Omega Engineering ...........Inside Front Cover

Paul O. Abbe ................................................ 36

Plast-O-Matic Valves, Inc. .............. Back Cover

Posi-flate........................................................ 36

Process Flow Direct ...................................... 45

Rice Lake Weighing Systems ........................ 17

Rosemount Analytical, Inc. ........................... 13

Rotork Controls, Inc. ..................................... 23

Schenck AccuRate ......................................... 26

seepex, Inc. ................................................... 12

Sierra Instruments, Inc. ................................. 29

SmootCo, Div. of Magnum Systems ............ 10

Specialty Equipment ....................................... 3

SPX Flow Technology ..........Inside Back Cover

Triple S Dynamics ......................................... 41

Tuf-Lock International ................................... 38

Vac-U-Max ..................................................... 16

VEGA Americas, Inc. ....................................... 9

Viega, LLC ..................................................... 33

Vortex Valves ................................................ 25

Water/Waste Processing .............................. 42

P r o d u c t I n d e x

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