Bulk Solids Sampling Applications II

Applications Review Cement Dairy Chemical Plastics

Cement Applications

Cement – Process flow

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

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

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

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)

Process Flow Description Barge Load Out Area

Process Flow Description ISOLOK® SAK Sampler on Load out Airslide

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

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

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

Dairy Applications

Dairy Process

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

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

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%

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

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

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

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

Challenges With Sampling in Dairy Applications Equipment must be 3-A approved (section 59-00 or 81-00) Sample should be taken from various types of processes Fluid bed dryers Pneumatic conveying systems Gravity chutes Bag filling systems Samplers need to be compact and easy to clean

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

Plastics Applications

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

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

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

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

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

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

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