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Instant coffee in Vietnam
Freeze-dried coffee production plant for Tata Coffee

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Gea
Picture: Gea

Gea has completed a new freeze-dried instant coffee plant on a green field site in Vietnam for Tata Coffee Vietnam Company Limited, a 100% subsidiary of Tata Coffee Limited, India.

According to the timetable for the contract project which was signed two years ago, the new plant was inaugurated on March 6, 2019 – just 19 months after the groundbreaking ceremony.

Vietnam is the world’s second largest producer of green coffee, after Brazil. The plant in the Binh Duong Province produces 5,000 metric tons/annum of freeze-dried coffee. Gea supplied the entire production line from roast bean treatment right through to the packing of the freeze-dried powder using its proven technology. This included: Carine extraction which operates at optimal conditions, using precisely developed extraction times to obtain the highest possible yields while respecting the final product quality; aroma recovery; mechanical vapor recovery (MVR) evaporation; and a Conrad 600 XL Eco freeze dryer for highly efficient continuous operation with minimal energy consumption. The company also supplied a complete pilot plant, providing Tata with facilities where it can develop exclusive blends for customers.

Previous work carried out for Tata Coffee includes a coffee extraction and evaporation plant that Gea built for the company in India in 2013. Gea also has extensive experience of building coffee plants in Vietnam and this local experience was extremely useful as Gea project managers were able to provide Tata with support in sourcing experienced and reliable local partners for managing, utilities, installation and workshop facilities. The factory required nearly one million man hours to build and maintain an exemplary safety record. The site has been certified for LEED (Leadership in Energy and Environmental Design) and is expecting BRC (British Retail Consortium) certification shortly.

Kim Knudsen, Head of Sales, Coffee and Freeze Drying at Gea said that the Tata factory in Vietnam had been a model project for the company. “This type of project is ideal for us at Gea because our expertise and scope of supply allows us to build the entire coffee line using our own resources,” he said. “This means we can maintain control and take responsibility for the entire project from start to finish.”

Chemicals News

Marl Chemical Park
Siemens build industrial power plant

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Siemens to build industrial power plant at the Marl Chemical Park in Germany
Picture: Siemens

Siemens will build a highly efficient combined cycle power plant as a turnkey project at the Marl Chemical Park in North Rhine-Westphalia, Germany. The order was placed by the specialty chemical group Evonik Industries. The new industrial power plant will consist of two units, each with an electrical capacity of 90 megawatts, and produce both electricity and process steam for the chemical park. The site’s integrated steam network will also supply district heat for about 2,000 homes in the future. The plant’s fuel efficiency will thus exceed 90 percent. With this combined cycle power plant, Evonik will replace its last coal-fired plant at the Marl Chemical Park. Because the plant will produce environmentally friendly electricity, process steam, and district heat from natural gas, the company will be able to cut CO2 emissions by one million metric tons per year. The plant thus makes an important contribution to decarbonization. Construction is scheduled to begin later in 2019, and the power plant is expected to go into operation in 2022. Siemens Financial Services (SFS), Siemens’ financing arm, developed a leasing financing solution specifically for Evonik in collaboration with Siemens Gas and Power. Together with the KfW IPEX Bank and LBBW, SFS will handle refinancing of the leasing agreement. The project volume is in the lower triple-digit million euro range.

“In building this power plant, whose technical and commercial concept was worked out jointly between Siemens and Evonik, we’re helping Evonik significantly cut its CO2 emissions,” said Michael Becker, CFO of Siemens Gas and Power. “In addition, the state-of-the-art plant will ensure a reliable supply of electricity and process steam for the chemical park. The ability to use various gases as fuel is another benefit and further increases the plant’s economic feasibility.”

“In deciding to build the new power plant, we’re ending our coal-based production of electricity and steam in Marl after more than 80 years, and cutting the direct annual greenhouse gas emissions of our plants by nearly one fifth worldwide,” said Thomas Wessel, Chief Human Resources Officer at Evonik. “We are pleased to have Siemens at our side, a reliable partner who is helping us to achieve our ambitious climate goals.”

“Siemens Financial Services’ structuring expertise and experience in the energy sector for years enabled us to offer a financing solution tailored to the customer’s needs,” said Veronika Bienert, CFO of Siemens Financial Services. “This made it possible to implement the project in close cooperation with Siemens Gas and Power, which is providing the technology and service activities.”

Siemens’ scope of supply includes the turnkey construction of two identical power plant units as well as one industrial gas turbine, and one industrial steam turbine for each unit. It also includes generators, auxiliary systems, and the control system.

Siemens will carry out preventive maintenance work on both gas turbines for a period of 15 years under a long-term service agreement. This agreement also covers remote diagnostic services for daily plant monitoring and monthly analyses of the operating data. These digital services will ensure high plant availability.

Thanks to the use of special heat recovery steam generators and catalysts, the system can operate on natural gas as well as re-gasified liquefied natural gas (LNG), and various other gases, such as residual gas from production processes. Each power plant unit can produce not only electricity but also up to 220 metric tons of process steam per hour. Thanks to the plant’s high flexibility that enables it to compensate for the fluctuating infeed of renewable energy into the power grid and its ability to produce district heat, it is also supporting the energy transition in Germany.

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Measurement, Instrumentation, Control & Automation News Plant Construction, Engineering & Components

Industry digitization with 5G campus networks
Partnership for smart production

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Endress + Hauser is one of the first manufacturers to equip its field devices with mobile communication modules and to connect existing systems to 5G networks via newly developed Hart gateways. (Picture: Endress + Hauser)
Endress + Hauser is one of the first manufacturers to equip its field devices with mobile communication modules and to connect existing systems to 5G networks via newly developed Hart gateways. (Picture: Endress + Hauser)

With its campus networks, Deutsche Telekom offers an infrastructure for the smart factory of tomorrow. Together with partners from industry, Europe’s largest telecommunications company wants to further expand its 5G ecosystem for industry. In process automation, Deutsche Telekom is now cooperating with Endress + Hauser.

The aim of the cooperation is to develop joint offers in the field of measurement and automation technology for the process industry. This involves the integration of measuring instruments and accessories into the next generation of mobile communication networks as well as digital services based on them. Both companies have signed a corresponding memorandum of understanding and are now working on a coordinated timetable.

Measuring instruments with mobile communication module

Endress + Hauser is one of the first manufacturers to equip its field devices with mobile communication modules and to connect existing installations to 5G networks via newly developed Hart gateways. This enables a large number of instruments to transmit a wealth of process and device data in parallel and in real time. These can, for example, be used in cloud applications for predictive maintenance of process plants.

Campus networks open second signal path

“In addition to the actual measured values, our instruments record a wealth of information from the process and about the sensor. 5G campus networks open up a second signal path that is independent of the plant’s control system and thus make it possible to tap this potential. This will enable us to link value chains more closely across company boundaries and make industrial processes more efficient.”

Matthias Altendorf, CEO of Endress + Hauser

Strong partners for smart production

“Building a complete 5G ecosystem for industry will accelerate the pace of digitalization in industry,” explains Claudia Nemat, member of the Deutsche Telekom Board of Management, Technology and Innovation. “We look forward to working with renowned and experienced partners.” In addition to the partnership with network supplier Ericsson, the telecommunications company now also cooperates with E&K Automation, a manufacturer of driverless transport systems, and Konica Minolta, which offers augmented reality glasses, among other products.

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Hima partners with ECT
Expanded rotating machinery business

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Hima Paul Hildebrandt, independent provider of smart safety solutions for industrial applications, has entered into a partnership with Energy Control Technologies (ECT), a US company focused on the rotating machinery market.

The partnership will combine the strength of Hima’s SIL rated products and worldwide sales presence with the strength of ECT’s capabilities and experience. The US-based company would as well be a supplier to Hima, supplying rotating machinery control technology and commissioning support. Together, both companies will offer safety customers SIL-rated hardware for rotating machinery applications. The efforts would utilize ECT’s algorithms for surge control, performance control, load sharing and master control, steam turbine speed and extraction control, and expander control.

“The partnership with ECT will help us to drive our business in a very attractive market”, said Stefan Basenach, Group Vice President Business Segment Process at Hima. “We know about our customer’s needs and our high performance SIL-rated products have the ability to excel in rotating machinery applications. We have proven success on several rotating machinery projects and see this new partnership combining the experience of two specialized companies as the perfect means to address a growing market.”

Paul Fisher, President of ECT, commented: “The partnership with Hima is opening new markets for us. Our expertise is in controlling compressors, turbines and expanders and the algorithms that are necessary to maximize a plant’s production and efficiency while providing superior machine protection. Partnering with Hima, we bring together the best of two worlds for the benefit of the client.”

Primary target group of the partnership will be end users, typically brown-field projects, where modernization of existing machines is necessary. The partnership’s offering is useful to refining applications like fluid catalytic cracker air blowers and wet gas compressors, power recovery systems, hydrogen recycle applications and refrigeration. Chemical applications like ethylene and ammonia plants can take advantage of the SIL rated hardware and rotating machinery control technology.

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