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Triple offset design
Process valve with butt weld ends

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Chemicals, Food & Beverage, Valves, Pipes & Fittings

It’s absolutely tight, durable and versatile – for isolation and control even in harsh industrial environments. Ari-Armaturen’s metallic sealing, triple offset Zetrix process valve is a premium product for the international market that outlasts and outperforms the competition. New: A version with butt weld ends is now also available from Ari as an alternative to the double flanged and fully lugged designs.

Zetrix unites all the benefits of a metallic sealing process valve with the advantages of a butterfly design. With its small footprint and reduced weight, this cutting-edge butterfly valve is very easy to handle. The triple offset principle guarantees a permanently tight seal conforming to leakage rate A as per DIN EN 12266-1, because the valve fits precisely and closes without friction. Available in cast or stainless steel, it can optionally be used as an isolation and control valve – yet another example of its great versatility.

Zetrix is suitable for liquids, gases and vapours in a wide range of applications, for example in oil and gas processing, refineries, petrochemicals, chemicals, solar thermal power stations, power plants, district heating, pulp and paper, steelworks, sugar processing and industrial and plant manufacturing in general.

The Zetrix design was developed and optimised using the very latest generation of tools, including the finite element method, contact angle calculations, flow simulations and characteristic measurements. Field tests (e.g. fire safe) and endurance trials were carried out at an accredited testing laboratory as well as in our own experimental lab. The new Zetrix process valve has been tested and approved as fire safe according to ISO 15848 / German clean air regulations (TA-Luft) and SIL.

The finite element method (FEM) is a numerical calculation technique that was used to simulate the stresses and their distribution occurring over the valve disc. The aim was to achieve the required strength at pressure load levels in combination with a slim and flow friendly shape.

The media flow through the piping system was additionally determined with the help of flow simulations which enabled the flow velocity, flow direction and pressure distribution to be visualised.
Due to the optimised disc geometry, turbulences have been minimised and pressure loss prevented. The result: uniform flow plus a high flow capacity.

The flow values in different valve positions were measured on a special test section in our in-house laboratory. The curves obtained in this way were used to fine-tune the control characteristic of the process valve.

The rotation of the lamellar sealing ring into the body seat was optimised by ensuring that all sealing geometry parameters are precisely coordinated. The ideal plug shape that is critical for frictionless opening and closing of the Zetrix valve was then computed.

Last but not least, the new valve was subjected to the acid test. In many applications there is an increased fire hazard. In the event of a fire, the valve must continue to meet internal and external leak-tightness requirements for a defined period of time if exposed to direct flame impingement. This ability was impressively demonstrated in a fire safe test according to ISO 10497 / API 607 6th Edition.

Key features at a glance
The metallic sealing Zetrix has a triple offset design; in addition to a “smart”, self-aligning sealing ring, it also provides isolating and control functions. It is tight closing according to DIN EN 12266 (leakage rate A), has a stellited seat, hardened shaft bearings and a blow-out proof stem as standard and can be used as a pipe-end valve on both sides. The valve can be insulated in line with industrial standards and has ISO 15848 / TA-Luft, ISO 10497 / API 607 6th Edition fire safe and SIL approvals.

The Zetrix design complies with DIN, ANSI and API specifications, and the valve can be made from either cast carbon steel (1.0619 +N; SA216WCB) or stainless steel (1.4408; SA351CF8M). Its face-to-face length corresponds to DIN EN 558-1 Series 13 (double flanged), Series 16 (fully lugged) or Series 14 (new version with butt weld ends). The valve is rated for operation at temperatures from -29°C to +427°C.

Zetrix process valves are available in several different nominal diameters from DN 80 to DN 1200, for nominal pressures from PN 10 to PN 40 and conforming to Class 150 or Class 300, depending on the type of connection. Apart from the double flanged design, the valves can also be ordered as a fully lugged version or – in future – with butt weld ends. Zetrix valves are used with a manual gearbox or with a pneumatic, electric or hydraulic actuator. The manufacturer emphasises that other configurations, e.g. customer-specified connection types, nominal diameters, pressure classes, face-to-face lengths, materials and temperature ranges can also be implemented on request.

The above-mentioned product series is further enhanced with an array of useful options: a flushing port for the shaft bearings and a buffer port for protecting the stuffing box, a flushing port for the bottom flange, a welded bottom flange, a double packing with a drainage line (e.g. for thermal oil services), a test port, a “clean air” bushing according to TA-Luft, a solid sealing ring for special applications, a heating jacket for high viscosity fluids and blow-out protection to API 609.

Zetrix is typically used in the oil and gas industry, chemicals and petrochemicals, district heating, energy and power plants, iron and steel, food and beverages, sugar making, shipbuilding, the gas sector and pulp and paper.

Chemicals Food & Beverage Pumps & Compressors

Leybold offers a dry claw pump for robust rough vacuum applications

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Especially for rough industrial processes Leybold introduces the uncomplicated, dry rough vacuum CLAWVAC pump. Besides food processing, packaging and environmental technology applications, it is suitable for drying and sterilization processes. The pump, which is offered in three pumping speed classes, is specially designed for continuous operation at every working pressures. Additionally the special pump design avoids that oil comes into contact with pumped gases, what allows higher Oxygen applications. At the same moment, Leybold also offers with the CLAWVAC System series a new multiple pump system. These systems are based on CLAWVAC and offer a redundant plug-and-play solution.

Uncomplicated handling

The daily use is uncomplicated: Thanks to the self-supporting construction, the vacuum generator is easily accessible. What allows to directly clean the pump on-site. The simple handling of the robust pump can also be attributed to its operating principle: A pair of claw rotors rotating in the pump stator completely free of contact and wear. It also distinguishes itself from standard claw pumps on the market by the choice of materials. Rotors made of stainless steel and a corrosion-resistant coated vacuum chamber, it proves its worth even under harsh process conditions. This makes an important contribution to reliable operation.

 

Disassembly in a few minutes

The modular pump design allows a quickly dismantling, opening and cleaning of the pump essentials as the pumping chamber and the silencer. For a mechanic these steps can be done in a few minutes and the frequency is purely depending on the hardness of the process. Except the 20 000 hr oil & lipseal replacement, no further regular maintenance is required and additionally it is independent of the application. “Thanks to this pump characteristic, we have reduced the amount of servicing required and improved the environmental balance,” explains Niels Gorrebeeck, Product Manager Rough Vacuum, Leybold, Cologne.

Minimal downtimes

The design allows the user to disassemble and clean the claws quickly and easily as the rotors can be removed without having to readjust the synchronization. This primarily relieves customers with rough & dirty processes, whose pumps previously needed a synchronization at the manufacturer side. The set-up is based on a quick component replacement, which has to ensure a minimal downtime and low service costs.

Wide range of applications

On the basis of CLAWVAC, Leybold also has a new multiple pump system in its program, a powerful plug-and-play solution. Especially for packaging plants, pneumatic conveying lines or clamping devices of CNC machines the multi claw pumps are a reliable solution. This also applies to plastics processing machines, drying processes and central vacuum supplies.

Low energy consumption, low CO2 output

Depending on the required flow rate, the systems contain two to four CLAWVAC pumps in one housing. “The robust, long-life pumps operate in an intelligent controlled dry and air-cooled solution” summarizes Niels Gorrebeeck. “On top of that, CLAWVAC System only delivers the required vacuum.” One pump is speed-controlled, that allows the exact adjustment of the generated vacuum. The intelligent control activates or disactivate the other fixed speed pumps based on the vacuum need. This speed control reduces the necessary energy consumption and CO2   emissions.

A constant & redundant vacuum supply

“During the design we strongly focused on the customer needs as a high redundancy level, minimal maintenance needs and stable vacuum supple even in harsh environments” explains Niels Gorrebeeck. The earlier mentioned constant vacuum level guarantees the customer product quality in all conditions, the same intelligent control equalizes the running hours of the fix speed pumps. The control principle is even as such developed that your CLAWVAC System keeps on running, even with half of it pumps active. CLAWVAC Systems clearly meets all its targets.

Housing reduces noise and heat

With this multiple pump system, Leybold brings all necessary components under one acoustic enclosure and offers at the same way a compact, intelligent system solution. The robust housing protects the pumps, reduces noise and heat and combines all the technology necessary for operation in one box.

Choose with CLAWVAC System for an innovative and effective vacuum solution, which has a positive effect on your overall performance. Leybold offers these space-saving systems with pumping speeds between 604 and 1144 m3/h. As with the individual claw pumps, the system also allows a ultimate pressure up to 140 mbar absolute.

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Chemicals News Processing Technologies Water & Waste Water

New belt press range for the environment industry

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International technology group ANDRITZ presents the SME-Q and the SMX-Q, the new belt presses for the environment industry reflecting the very latest state of the art. Due to their low-profile components, they are extremely operator-friendly and feature high quality design with low maintenance needs, thus ensuring maximum performance in terms of dryness and throughput.

Different Models for a wide range of requirements

The medium-pressure belt filter presses in the new SME-Q range are suitable primarily for standard and medium duty performance levels, while the high-pressure belt presses in the SMX-Q series were developed for medium to heavy-duty performance levels where each individual machine must achieve high throughputs. The two machines include the same features in terms of design and have an extra-long thickening zone, a camber wedge for a steady, optimized pressure increase, a low profile, and an open, stainless steel frame structure for easy access. Both models will provide excellent operating availability and reliability in operation.

Investement versus throughput and perfomance

Compared to the SMX-Q, the medium-pressure belt press SME-Q provides a smaller footprint at lower investment cost and has been specifically developed for small to medium-sized sewage treatment plants and for industrial applications. The investment costs are low due to its optimized structural weight. In addition, the innovative design of the belt press makes it possible to dismantle parts of the machine quickly and easily so that it can be transported in conventional containers or on standard-size trucks.

The high-pressure belt press SMX-Q delivers highest throughputs thanks to its large filtration and pressing area. Its robust frame structure generates high belt tension and high pressure on the sludge to provide the best dewatering performance for a belt press. The specific features of the SMX-Q enable this machine to be adapted to almost any application – even with the most challenging dewatering requirements.

Among the advantages of the new ANDRITZ belt presses are the lower investment costs (SME-Q) compared to other products currently available on the market, perfect dewatering results, highest throughputs, and lowest residual moisture. They offer the right technical solution for municipal and industrial sludge treatment plants, for thickening and dewatering in a single stage (thanks to the efficient thickening zone or combination with a gravity table) and for achieving high efficiency in specific applications such as pulp and paper, manure, biogas, slaughterhouse and chemical sludges.

ANDRITZ SEPARATION

Provides mechanical and thermal technologies and services for solid/liquid separation, serving the chemical, environmental, food, mining and minerals industries. The customized, innovative solutions focus on minimizing the use of resources and achieving highest process efficiency, thus making a substantial contribution towards sustainable environmental protection. In addition, the business area offers technologies and services for the production of animal feed and biomass pellets.

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Chemicals

Energy Leader
Merck’s DOZN Green Chemistry Tool Named Top Product of the Year

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Merck announced that it won a Top Product of the Year award from Environment + Energy Leader for its DOZN system, a quantitative tool that evaluates the relative greenness of chemicals and chemical processes against the 12 Principles of Green Chemistry.

“Our DOZN™ system is enabling the global scientific community to make data-driven decisions to increase the environmental sustainability of the sector,” said Jeffrey Whitford,  head of sustainability and social business innovation and branding at the Life Science business of Merck. “This recognition further confirms the importance of quantitative tools that make data actionable.”

The Environment + Energy Leader Awards celebrates excellence in environmental, sustainability and energy management. The win is an indication that the program’s judges consider Merck’s DOZN™ tool a top example of the exemplary work being done in the environmental management field.

Merck’s DOZN™ system has more than 300 active, registered users representing some of the most prestigious names in the academic world, government institutions and business-to-consumer companies. The tool has been cited in 17 papers since its May 2019 launch.

Chemists and scientists look for sustainable options in the lab, such as recycling gloves and using greener packaging. However, they may not think about the impact of green chemistry and often face the challenge of evaluating the sustainability of a chemical or process. Merck’s DOZN™ tool provides a consistent and reliable framework for measuring the greenness of chemicals and processes. It also raises awareness for scientists and communicates the environmental improvements for products labelled as greener alternatives. Products receive an aggregate score based on a scale of zero to 100, with zero being the most desired.

The DOZN™ system instructs customers how to calculate scores for products that the company does not offer and allows customers to  carry out meaningful research while positively contributing to their own environmental impact goals.

Merck plans to expand the applications of the tool, including the implementation into curricula at academic institutions to further increase the adoption of quantitative metrics in green chemistry.

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