1. Bulk Solids Sampling Applications II

2. Applications Review
Cement
Dairy
Chemical
Plastics

3. Cement Applications

4. Cement – Process flow

5. Process Flow Description
4 main ingredients:
Calcium (limestone) – 90%
Alumina (flyash) – 3%
Iron – 2%
Silica (sand) – 5%

6. Process Flow Description Raw Mill
Ball mill combines/mills proper proportion of limestone, flyash, iron and sand
Sent to rotary kiln after mixing in homogenizing silos

7. Process Flow Description Rotary Kiln
Mixture is heated to 2700°F temp to create “clinker” through a process known as calcination
Clinker is then stored until needed

8. Process Flow Description Finish Grinding
Combine clinker with gypsum
Limestone for mortar products
Mixture delivered to roller presses then ball mills for finish grinding
Discharge from the finish grinding mill is separated into finished product
Larger particles returned to mill
Cement is transported to silos prior to bulk shipping (rail, truck, barge)

9. Process Flow Description Barge Load Out Area

10. Process Flow Description ISOLOK® SAK Sampler on Load out Airslide

11. Why Sample in a Cement Plant?
Quality control of finished product
325 mesh/45 micron (94% passing)
Blaine – (determines total surface area in square cm per gram of cement)
Chemistry
Finished product is discharged from multiple silos into one shipment – needed to assure consistency
Provides data for report to terminal, tech reps / sales reps
Custody transfer
Provides sample for archival purposes

12. Challenges With Sampling in a Cement Plant
Direct sampling method is messy and dangerous
No good location for manual sample collection in load out area
Material particle size cannot be significantly degraded while collecting the sample
Minimize human variances
Dozens of sampling points result in high labor costs for manual collection of samples

13. Why Sentry Samplers?
Automatically takes sample of material taken at fixed time intervals
Simple, safe, and reliable
Uniformity and consistency of sample
(Elimination of human error)
Clean (eliminates material dusting / spillage)
VERY low labor costs
Eliminates time consuming manual sampling process
Compact design of ISOLOK allows for direct attachment on moving load out air slide
Model RX can penetrate the Airslide membrane to sample from the center

14. Dairy Applications

15. Dairy Process

16. Typical Sampling Points
Drying process
Models SAK, B1 and PR
Bag filling stations -custody transfer
Models SAK and B1

17. Milk Drying Process Milk drying is a three step process:
Multistage evaporator
Spray dryer
Fluid bed dryer
In multistage evaporator initially milk is concentrated up to about 48%
During drying in spray dryer, the excess water present in free form between the particles of the dry solids get evaporated easily
These last drops of water are removed in a fluid bed dryer

18. Milk Drying Process Produces powder with extremely good solubility
Instant powder
Drying:
Extends the shelf life of milk apart from
Reducing the weight and volume
Lowers the cost of transportation
Final moisture in the powder ranges between 2.5% and 4%

19. Bag Filling Process
ISOLOK® model SAK mounted in bag filling system

20. Bag Filling Process
Many sample systems incorporate an indexing system for lot archiving
Models SAK and B1 are often used
SAK seals have been supplied with springs that are impregnated within them
Can be detected in metal detectors

21. Foss Moisture Analysis
Dairy application analyzing whey powder
Model PR mounted in a pneumatic convey line
Extracted a fixed volume of sample and introduced to analyzer
After measurement sample was purged into the bottle for additional off-line analysis

22. Why Sample in Dairy Applications?
Butter fat content
Bacteria
Hormone levels (BGH)
Antibiotics
Moisture content

23. Challenges With Sampling in Dairy Applications
Equipment must be 3-A approved (section or 81-00)
Sample should be taken from various types of processes
Fluid bed dryers
Pneumatic conveying systems
Gravity chutes
Bag filling systems
Samplers need to be compact and easy to clean

24. Why Sentry Samplers? Model B1 and ISOLOK® SAK compact Model PR
Easy removal and cleaning
Reliable and consistent
Model PR
Installations in pneumatic convey lines
Integrate moisture analysis

25. Plastics Applications

26. Plastics Process Flow
Natural Gas is sent through a cracking unit which produces a feedstock
Feedstock is combined with hydrogen, catalysts into a reactor which precipitates a white powder known as “Fluff”
The Fluff is then passed through a catalyst deactivation unit
fluid bed vessel using nitrogen as the fluidizing medium

27. Plastics Process Flow
After deactivation, Fluff is pneumatically transported to silos
Fluff is fed into continuous blenders where blend additives are introduced
Blended material is heated, extruded through a die plate, chopped into pellet form and cooled
Finished pellet is screened an pneumatically conveyed to loading silos where it is bulk shipped by rail or truck

28. Typical Sample Points Inlet of catalyst deactivation unit
Outlet of catalyst deactivation unit
Discharge of continuous blender
Finished pellet

29. Why Sample Plastics? Monitor product composition and quality
Melt index tests
Check ethylene and rubber content
Catalyst residue (outlet of catalyst deactivation unit)
Provide feedback for process control
Check to ensure volatile organic compounds (VOC) levels are within acceptable limits
Custody transfer
Provides sample for archival purposes

30. Challenges of Sampling Plastics
Extraction of representative sample from pressurized line without allowing dust and gas to escape
Sampler must handle pressure surges well above process pressure
May need to have food grade wetted components if process line produces material that will go into FDA approved containers, bottle caps, or closures
Minimize labor cost, material waste, safety and cleanup concerns

31. Why Sentry Samplers?
Automatically takes fixed volume of material taken at fixed time intervals
Provides accurate verification for plant control
Closed sampling
Eliminates material spillage/waste
Extracts sample without releasing gas/dust to atmosphere
Built-in nitrogen purge port can connect to gas collection system to reclaim unreacted hydrocarbons
Keeps operator out of harms way
Food grade 316 SS and EPDM elastomers

32. Questions?

33. Applications/Pricing
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34. Questions?