Latest News

Petrochemicals are chemicals obtained from refining petroleum, crude oil and natural gas, the primary and raw material sources that enable numerous aspects of modern daily life.Several high-tech separation processes are undertaken in petrochemical plants to convert these raw materials into chemical products such as propylene, xylene, methanol and ethylene. The chemicals are then used to produce everyday products such as plastics, cosmetics, tyres, resins, rubbers, adhesives, and even embalming substances. 

During these high temperature and intensive processes of separation the exhaust streams produce potentially hazardous and corrosive chemical and gas residues. It is crucial that exhaust systems are of the highest corrosion proof quality to ensure safe operation. 

Industrial exhaust fans suitable for this industry are designed for corrosion protection, explosion protection and protection against other elements such as heat, moisture, and salty air. Explosion proof ATEX exhaust fans safely remove and transport the hazardous gases away from personnel and prevent these gases from mixing with other elements to avoid explosions.

What is ATEX 

ATEX stands for atmospheres explosible and refers to an area where there is a potential for an explosion if there is the presence of combustible dust or gases. The potential for the explosion is separated by what is known as gas and dust zones. The more likely an explosion the lower the number related to the zone. For example, zone 0 gas area classification means that an explosion potential is continuously present, zone 2 would mean the explosion potential may occur abnormally and with zone 1 it would occasionally be present. This dictates the type or equipment and the protection rating required to ensure continual safety. The same idea is in place for combustible dusts with zone 20, 21 and 22.

Choosing a Suitable Petrochemical Exhaust Fan

304 stainless steel ATEX fans are the ideal choice due to their ability to handle the extreme temperatures of the fracking process whilst also resisting any corrosive gases that may destroy internal or whole fan components.

304 stainless steel fans are available in two constructions. Either only the internal components are manufactured using stainless steel, if it is only these parts that will be present in the corrosive air, or alternatively, if the entire fan is situated in a corrosive environment and is at risk of rusting as a result, then the entire outer casing and internal components can be manufactured from corrosion resistant materials while still having explosion protection up to zone 1 gases.

ATEX Temperature Classes in Petrochemical

There’s a huge number of processes involved in petrochemical production. The distillation of crude oil which contains a mixture of hundreds of hydrocarbons involves heating in a furnace and the resulting mixture is fed as a vapour into a distillation tower. The chemicals produced have different temperatures that separate them during the fractional distillation stage creating a temperature gradient in the tower <350°C to 25°C. Following the distillation step, cracking is the main process that breaks these mixtures down into hydrocarbons by means of high temperatures and pressure. Hydrocarbons are generally flammable, so it’s compulsory that ATEX fans are used. Wherever air is contaminated with flammable substances then there is a need for protection.

Industrial fans are temperature rated to ensure that they’re not used in an environment that would exceed the highest acceptable surface temperature on the fan motors surface. If the temperature exceeds this level, ignition of either the gas or dust is possible. This is a required indication that the customer should communicate before any industrial fan selection for an explosive environment. Temperature charts are useful in determining the correct T class based on chemicals in the air stream. For example, Hydrogen is a IIC Gas group with a T temp class making it one of the hottest, most dangerous gases. 

Learn more at www.axair-fans.co.uk

The topic of “explosion safety” is omnipresent for plant operators and OEM´s when it comes to handling or transporting combustible dusts. Despite the widespread assumption that an increased risk of explosion only exists for gases, enormous forces can also be released by explosive dust- / air mixtures.

To help minimise the risk of explosions when handing combustible dusts, it is important to understand the requirements for an explosion and the respective dust safety characteristics, which are described below. The following picture shows the fire triangle and the explosion pentagon which must be taken into account.

The following conditions must exist for an explosion to occur within a production facility or machine:

Fig. 1: Explosion pentagon

If any one of the aforementioned prerequisites is eliminated, explosion prevention has intrinsically been practised. However, if this is not possible at all times and in all operating states, explosion hazards will still be present. In this case, it is necessary to divide any potentially explosive atmospheres into zones and systematically apply safety measures.

Drying processes in particular are used in many industries to produce material, for easier storage, more efficient transport and a longer shelf life. However, the combination of moisture extraction and high temperatures creates an increased risk of both, fires and explosions.

If fires and/or explosions occur in drying plants, which are usually very large, the situation is not only extremely dangerous for the machines and the business, but especially for the employees on site.

Operators of spray dryers must combat a particular type of ignition source – namely smouldering nests that can lead to spontaneous combustion if the material undergoes excessive caking. Caking occurs due to sub-optimal drying of the material and its initially high moisture content. The caked material is then insulated against the surrounding air by a build-up of moist material. The high temperatures ensure that the caked material is continuously heated until a biological reaction takes place involving protein, carbohydrate and water – known as the Maillard reaction. The Maillard reaction generates additional heat that cannot be dissipated due to the insulating layer of caked material. This process continues to accelerate until spontaneous combustion finally occurs.

Caking of this kind can build up both on the nozzles and the inner wall of the spray dryers. If the nozzle malfunctions, droplets may fall down into the fluid bed and cause further clumping. If a smouldering nest is able to form, this can ignite the explosive atmosphere inside the dryer or the downstream machinery.

How can such conditions, which are frequently encountered in practice, be prevented?

Everything starts with the human factor, i.e. properly trained personnel for the respective processes. Optimal process control is also required to avoid caking. But without precise and reliable information/measurements, this is virtually impossible, even for specialists. Nowadays, humidity and one of the by-products of spontaneous combustion at early stages – carbon monoxide (CO) – are used as indicators to ensure a smooth and thus safe process. However, the fact that combined measurement systems cannot clearly distinguish between these two indicators is problematic and can result in inaccurate measurements.

The REMBE CO.Pilot makes exactly this symbiosis possible!

Via a permanent comparison of recorded data with a database of stored reference gases that serve as "fingerprints" of the selected gases, it is possible to perform a one-time check in real time and thus permanently verify the measurement accuracy. At the same time, the real-time fingerprint analysis eliminates the cross-sensitivity to other gases in the measurement spectrum that is common in commercial gas analysers.

To ensure a reliable measurement of the operating status, samples are sucked in from all of the dryer's relevant supply and exhaust air ducts under very high vacuum. REMBE calculates the delta CO value on the basis of the absolute values measured at the individual measuring points. This value is the mathematical difference between the CO content of the extract air and the CO content of the supply air. Thus, only events that actually occur in the respective process are detected. External factors that may disturb the process can thus be ignored.

A proprietary evaluation algorithm (RFA REMBE Flow Algorithm) enables the measured supply and exhaust air values to be compared in real time. As a result, the REMBE CO.Pilot is the first system on the market that makes it possible to adjust the individual alarm limits and gas run times for the individual measuring points in the dryer's various air throughputs without any delays. The ratios of the different supply air channels and the flexible operating hours are balanced via the software and calculated accordingly in the PLC.

Thus, if an increased carbon monoxide concentration is detected due to spontaneous combustion during the process, countermeasures can be initiated immediately.

But what does this mean in detail?

This special sampling process eliminates the need for costly and error-prone gas treatment, thus ensuring that the CO.Pilot is less susceptible to faults and requires less maintenance. Furthermore, this measurement method can make recurring calibrations unnecessary. Due to the precise measurement technology and the reproducible results, false alarms and downtimes can also be avoided. And in combination with moisture measurements, the entire drying process can be optimally controlled, significantly increasing the energy efficiency of the system.

Fig. 2: REMBE CO.Pilot

About REMBE – the REMBE Alliance introduces itself

Most people associate REMBE with REMBE GmbH Safety+Control, the specialist for explosion safety and explosion venting worldwide. The company offers customers cross-industry safety concepts for plants and equipment. All products are manufactured in Germany and meet the requirements of national and international regulations. REMBE customers include market leaders in various industries, including the food, timber, chemical and pharmaceutical industries.

The company’s engineering expertise is based on almost 50 years of application and project experience. As an independent, owner-managed family business, REMBE combines expertise with the highest quality standards and is involved in various specialist committees worldwide. Short coordination paths allow for quick reactions and customer-specific solutions for all applications, from standard products to high-tech special designs.

In addition to REMBE GmbH Safety+Control (www.rembe.de) with approx. 300 employees worldwide, headquartered in Brilon (Hochsauerland, Germany), and numerous subsidiaries worldwide (Italy, Finland, Brazil, USA, China, Dubai, Singapore, South Africa, Japan), four other companies operate under the REMBE umbrella brand:

• REMBE Research+Technology Center GmbH (rembe-rtc.de)
• REMBE Advanced Services+Solutions GmbH (rembe-services.de)
• REMBE Kersting GmbH (rembe-kersting.de)
• REMBE FibreForce GmbH (argusline.de)

Explosion safety concerns almost everyone. The following article explains the available protective systems as well as a cost-effective way to protect spray dryers.

Explosion safety measures

The obvious steps include organisational measures such as regular maintenance of the plant components, comprehensive, thorough cleaning of all parts as well as the production facilities themselves, and training of the responsible personnel. Nevertheless, there is plenty of potential for improvement in many areas.

Explosion prevention concepts are designed to prevent a build-up of explosive dust or gas/air mixtures and/or ignition sources. The goal here is to reduce the probability of explosions occurring. Various options are available: dedusting and cleaning, inerting, earthing, vibration monitoring, camera systems for nozzle monitoring and the use of CO detection systems.

But even if all these precautions have been taken, reliable or complete explosion safety is often not guaranteed.

Explosion protection, by contrast, involves reducing the effects of an (inevitable) explosion and is the central, most frequently applied explosion safety concept.

Certified protective systems are used to safeguard employees, affected plant components and the entire environment. All available options for explosion protection are briefly described below.

Conventional venting via explosion vents

Explosion vents are often used in systems located outside buildings or for plant components mounted on an exterior wall. For example, dryers, silos, filters and elevators located outdoors are protected in this way. In the event of an explosion, the explosion vent protects the corresponding system by opening, thus dissipating the overpressure in the vessel and releasing the explosion outside to a safe area. Since virtually no two industrial processes are the same, various types of explosion vents are available, which differ in terms of their shape, material, temperature and pressure/vacuum resistance. Nowadays, even processes that are subject to strict hygiene requirements can be protected using explosion vents. For example, the EGV HYP hygienic explosion vent instantaneously protects critical systems such as spray dryers with or without wet cleaning, fluid bed dryers, filters and mixers, thus providing a cost-effective protection solution that ensures compliance with the requirements of hygienic design.

Fig. 1: Explosion vents differ in shape and structure depending on the application.

Flameless explosion venting for plants inside buildings

For plants located inside buildings, explosion vents are not suitable due to the lack of a sufficiently large safety area into which the escaping dust and flames can be directed. Since this represents an enormous safety risk for personnel and plant components alike, this problem is often solved by means of vent ducts, also called relief ducts. However, the latter often preclude a process-optimised plant design and are usually very expensive, since the pressure that the duct and the system must withstand increases in proportion to the distance from the explosion source. This cost increase is due to the fact that the vessels to be protected require increased compressive strength.

Flameless venting is an economical and effective solution. Different manufacturers use various technologies to ensure flameless venting.

REMBE, the inventor of flameless venting, offers three different products: Q-Rohr, Q-Box and Q-Ball. The special stainless steel mesh filter inlet used in the products cools down flames efficiently so that no flames or pressure escape. The typical pressure increases and noise during an indoor explosion are reduced to a barely perceptible minimum, ensuring the protection of both man and machine. In addition to the special stainless steel mesh filter, Q-Ball, Q-Rohr and Q-Box consist of an explosion vent with integrated signalling, which informs the process control system about the burst of the explosion vent.

Fig. 2: Flameless venting Q-Rohr

Explosion isolation

In every production facility, individual plant components are interconnected by means of pipelines. The purpose of explosion isolation systems is to seal these pipelines in the event of an explosion to prevent the propagation of pressure and flames, thereby protecting the adjacent plant components. A distinction is made here between active and passive isolation systems.

Active systems use sensors or detectors to detect an explosion as it occurs. They register the rising pressure or flames as they form and activate the associated isolation device, e.g. a quench valve. Due to their structural design, passive isolation systems, which are ideal for dust applications, react purely mechanically to a build-up or loss of pressure. Explosion isolation flap valves are a popular example of such a solution. They are kept open during normal operation by means of the currents present in the pipeline. In the event of an explosion, the valve closes due to the expanding pressure front, effectively preventing the propagation of pressure and flames.

Explosion suppression

In addition to the methods already mentioned, explosion suppression is another aspect of explosion protection. In this case, the idea is to eliminate the explosion before it can fully form. This is made possible by detectors that use sensors to detect pressure or flames and immediately trigger the extinguishing agent canisters that are also installed in the system. The latter disperse a highly effective extinguishing agent within milliseconds and thus nip the explosion in the bud. If required, an explosion suppression system can also be used for explosion isolation.

The Q-Bic extinguishing barrier from REMBE was developed in strict compliance with the hygiene requirements for spray-drying plants. Thanks to the convex dirt protection cap, neither water nor dust deposits can accumulate on the Q-Bic. The blue-green QXP extinguishing powder prevents cross-contamination and the patented SJX nozzle ensures optimum application of the extinguishing powder. The Q-Bic is particularly suitable for large pipes attached to dryers and filters or complex shaft geometries such as conveyors and elevators.

Fig. 3: REMBE extinguishing barrier Q-Bic

Protection of spray dryers and cyclones – a case study

The task is to protect a spray dryer and a connected cyclone; the product is discharged via the cyclone.

The technical data at a glance:

• Drying temperature: 90˚C
• Dust specifications:
  • organic dust St1
  • K_St value: 150 bar*m/s
  • P_max: 8 bar
  • lower explosion limit: 255g/m3
  • strength of all system elements: tested P_design of min. 0.3 bar

A safety concept is required that incorporates as few explosion safety products as possible. This is a common requirement; however, it can only be met by considering the plant as a whole and taking all technical specifications, as well as the latest research findings, into account.

In the present case, explosion isolation of the spray dryer from the cyclone is not necessary. At first glance, this contradicts the statement made earlier that isolation is absolutely necessary to prevent an explosion from propagating. However, scientific evidence shows that decoupling can be dispensed with if a Pred of max. 0.3 bar is determined for the entire plant, since any hazardous pre-compression in the neighbouring equipment can then be ruled out.

Protection for the spray dryer

VDI guideline 2263, or more precisely Sheet 7.1, states that under the following circumstances a reduced volume can be assumed when calculating the necessary vent areas / protective systems:

1.         No integrated fluid bed

2.         No recirculation of fine dust into the head of the spray dryer

3.         The average dust concentration inside the spray dryer is lower than the lower explosion limit of the dust.

If these three conditions are met, as in the present case, either a reduced volume of 1/3 of the total volume or the volume of the cone can be assumed. The larger volume must be selected in each case.

For the spray dryer in question, 1/3 of the total volume, i.e. 19.85 m3, was selected.

Observance of VDI guideline 2263, Sheet 7.1. allows an additional reduction in addition to the volume, resulting in smaller required vent areas. If it can be assumed that, due to the process, the optimum dust concentration for an explosion will never be present, the protective systems can be designed with a reduced K_St value. Due to the nature of the process – the product is to be dried after all – it has been scientifically proven that a maximum concentration of 250 g/m³ cannot occur in the spray drying system.

The inclusion of the latest research results and current guidelines in the design thus leads to a reduction in the volume to be considered and the K_St value. This in turn allows the creation of a safety concept that is not only safe but also cost-effective. By comparison, without taking these reductions into account, the vent areas for the spray dryer to be protected would have been up to 340% larger. From the operator's point of view, this is over-engineering, because larger relief areas always mean greater effort to modify the respective plant components and, last but not least, higher acquisition costs.

The following table shows how the protection system for the spray dryer under consideration might look with and without the described design requirements:

* Rather unusual in the industry, as the plants are typically located inside buildings and "free" explosion venting is therefore not possible.

For round vessels such as spray dryers, selected flameless explosion venting systems, e.g. the Q-Box, can be installed by means of an adapter flange. Since the entire plant is located inside a building and the operator wanted an explosion protection system with the lowest possible maintenance requirements, flameless venting was chosen in this example.

Protection for the cyclone

For the associated cyclone, the original safety characteristics of the dust in question must be taken into account. Cyclones are usually vented via the vortex finder, which must be included in the design as a vent duct. Therefore, it is also crucial to know the exact dimensions of this plant component. In this particular case, the cyclone is protected by a DN 800 Q-Rohr equipped with an ERO hygienic explosion vent. By ensuring that the smooth surface of the explosion vent faces the processing area, all hygiene requirements from production are met.

The product discharge area below the cyclone is equipped with an explosion-proof and flame-proof rotary valve.

Risk of tampering with safety systems

Even the highest quality protective systems can only do their job if they are installed correctly and protected against tampering. The risk of tampering is an important issue, and also one that is sometimes ignored.

Recently, REMBE engineers have found indications of such deficiencies increasingly frequent during plant inspections:

For example, safety devices are disabled, electronic signalling and warning devices are bridged, mechanical elements are secured with too few fasteners and bolts. The reasons for this are complex and certainly not easy to understand.

The protective systems from renowned manufacturers such as REMBE are therefore designed from the ground up to ensure a high degree of in-built safety that is immune to tampering. For example, screw connections are replaced by non-detachable riveted connections; bolts are designed to be self-locking and captive.

This is particular essential for more complex components such as devices for flameless venting. These systems are typically installed indoors, but always in locations where free venting, e.g. via explosion vents, is not possible. However, if the part responsible for flameless venting fails or has any weak points, this could have devastating consequences for the surrounding area, which would be left defenceless against the flames and pressure of an explosion.

Fig. 4: REMBE Flameless venting on a fluidbed

www.rembe.de

Combustible waste is a deadly hazard that impacts businesses across a wide range of verticals from bakeries to paper plants. Left unchecked; this waste material can cause combustible dust explosions, which can be devastating to both life and property. As such; the removal of this waste material is a must for building owners and cleaning teams.

Cleaning in these designated combustible zones - designated ATEX in the UK and Europe and Div.2 in the USA - requires specially certified cleaning equipment that has been approved for use in these areas.

SpaceVacs award winning ATEX high-level cleaning systems allow for the safe and cost-efficient removal of this waste material from the safety of the ground floor - removing all of the risks associated with cleaning at height. The systems utilise an interlocking pole system; accessorised with a range of cleaning accessories and brushes providing operators with options to easily remove dust and combustible waste across a range of areas - from walls and ceilings to vents, ducting and pipework.

By moving cleaning to the ground floor, these ‘high reach’ systems allow operators to clean up to 20m high without the need of additional access equipment; reducing the costs associated with these specialist cleans - as well as minimising the impact on the kind of high-volume production environments such as bakeries and woodsheds where this waste can often be found.

Manufactured in the UK, the ATEX cleaning system is made from 100% Carbon, making it completely conductive, and it was the first system of its kind anywhere in the world to be certified as safe for use in these specialist combustible environments.

In addition to these high-level cleaning systems, SpaceVac also offer a range of powerful industrial vacuums for the removal of combustible dusts - including the TITAN range of ATEX vacuums, the MERCURY line of ACD models (for removing combustible dust from non-combustible areas) and even specialist options for the removal of metal, pharmaceutical waste and other specialist materials. This family of new machines offer market leading filtration and suction as well as durable construction, to stand up to the rigours of cleaning in the industrial space.

In addition, the ATEX line can be further accessorised with a range of add-ons, including an ATEX certified wireless camera and monitoring system (the Explorer Extreme) which allows for real time monitoring of cleaning work, and even a set of brushes and tools specifically designed for use removing organic, combustible waste material from Food & Drink production environments.

After a decade at the forefront of cleaning innovation, SpaceVacs range of cleaning systems are trusted by some of the biggest companies in the world including Tesla, Nike, Facebook, Coca Cola, Harley Davidson and more…

To find out why, and to see the impact SpaceVac could have on your cleaning and facilities management regime - be sure to reach out to the team to book a free consultation today at spacevacinternational.com or call the team to discuss your requirements on +44 1604 968668

Dust explosions from combustible dust can occur in any industrial process where materials are processed. This combustible dust could exist in the form of a cloud or by build-up, which when circulated can cause an explosive atmosphere. This occasion is rare in normal operation and often temporary. Zone 22 specifically relates to the presence of an explosive dust atmosphere that occurs only by accident, but not in normal duty, category 3D and equipment level Dc is required at a minimum.

In ATEX coding, G represents gas and D for dust, while the second letter refers to the protection level required. Dc equipment protection levels offer enhanced protection; the equipment remains safe in normal operation and may have extra protection to minimise ignition risk in fault situations. A single fault may cause the equipment to shut down on Gc or Dc labelled equipment.

ATEX fans certified for zone 22 use are designed to exacting standards and are suitable for dust group IIIB non-conductive dusts such as milk powder, sugar, or flour, and IIIC conductive dusts such as graphite powder and toner. Some of these materials are not normally combustible, but they can burn or explode if the particles are the right size or concentration.

Motors characterised as “Increased Safety” Ex ec or ex eb, are used on industrial zone 22 explosion proof fans. Ex ec is the lowest and most normal level of Ex protection, known as reduced risk protection. The design of ex ec motors prevents an internal malfunction from creating sparks in normal operation and therefore is not capable of causing an explosive atmosphere to ignite. The construction ensures reliable prevention of unacceptably high temperatures and sparks or electrical arcs that could act as ignition sources in hazardous areas. It also aims to prevent excessive heating and offers a safer design against the risks of sparks during starting.

If a dust cloud enters in contact with a hot surface, it may auto ignite and explode. The MIT, or minimum ignition temperature is the minimum temperature for which a surface will ignite a dust cloud. MIT values are generally between 150-700 degrees Celsius depending on the material. During design phase, a dust explosion risk analysis is carried out on test material to determine the ignition point. This is then used to ensure the system is designed so that the ignition temperature cannot be reached by any component in the process.

Unlike gas zones, where maximum surface temperatures fit into a class that is dependent on the carried gas ignition properties, for dust, the maximum surface temperature should be used as an absolute figure. Industrial fans suitable will advise the absolute figure on their ATEX label; for example, 120° and 135°. Maximum admissible temperatures should be equal or lower than the lowest value of the temperature limit. This is given as 2/3 of the maximum ignition temperature of the dust.

Axair are an award winning team of industrial fan integration experts but cannot by law assess an area to determine its hazardous area classification. We encourage anyone working with hazardous areas to contact an independent body for a zone assessment before requesting information about ATEX certified components for gas or dust extraction. For industrial fan assistance contact our team who will be happy to discuss key ATEX concepts and the suitability of explosion proof or material handling components for dust rich environments.

Axair Fans UK Limited

This article can also be found in the issue below.

With 12,000 workplace-related respiratory deaths every year, a further 14,000 lung conditions reported, and 400,000* working days lost annually through breathing problems, effective fume and dust extraction technology is seen as central to safeguarding employee health and safety.

Regardless of whether the business is an automotive workshop, a small-to-medium sized manufacturing company or indeed any type of operation that simply needs dry and clean compressed air, the new G-TEC Air Compressor from FPS provides a complete compressed air workstation with ‘game-changing’ capabilities. This 6-in-1 offer comprises a high-performance compressor, refrigerated dryer, dual filtration, 270/500 litre air receiver, oil-water separator and controller, making the G-TEC Air Compressor the optimal and most convenient choice, for a whole host of applications.

Avoiding the need for many individual components that typically form part of a complex compressed air system, the G-TEC workstation features an integrated and modular design that saves space, reduces installation and improves efficiency. It delivers outstanding performance, producing a consistent supply of compressed air to power a wide range of pneumatic tools and machinery. With its high-efficiency motor and innovative design, this complete workstation also meets the growing demand for more sustainable and cost-effective compressed air solutions.

G-TEC workstations from FPS are available with a range of 7.5 to 22kW with pressure from 8 to13 bar. The high-efficiency screw compressors ensure optimal productivity and reliability. Importantly, the workstation comes with a 270 or 500 litre receiver and an integrated dryer and filters. The result? Clean, dry air for quality-assured pneumatic operations that lead to reduced downtime and maintenance costs and Indeed, reduced corrosion within pipes that also means fewer product rejects, and fewer costly air leaks, delivering yet more savings.

Another integral component of the G-TEC Air Compressor workstation is the condensate oil-water separator, supplied as standard by FPS to reduce environmental pollution. Furthermore, the intuitive built-in control panel makes using the G-TEC workstation easy to use for operators of all skill levels.

Among the business that can take advantage are automotive workshops. From tyre centres to body repair shops, the task of paint spraying and when using general garage equipment can benefit from the fixed and variable-speed models of G-TEC Air Compressor line-up. As a particular point of note, noise output is exceptionally low.

Further applications include pneumatic tools on production/assembly lines, woodworking tools such as sanders and staplers, and plasma/laser cutting. In all cases the outcome is the same: high-quality, professional compressed air delivery with economy and sustainability in mind. When operating variable-speed models, the remarkable energy-saving capabilities of the G-TEC Air Compressor workstation render it an environmentally responsible choice that also reduces operational costs by as much as 30%.

With its fully integrated components, the compact design of the G-TEC Air Compressor makes it ideal for any customer where space is at a premium. This, when combined with straightforward installation and maintenance, allows the G-TEC workstation user the benefit of a hassle-free and highly cost-effective solution for businesses of all sizes.

“Users of the G-TEC Air Compressor can achieve the perfect balance between power and efficiency, ensuring that your compressed air needs are met without excessive energy wastage,” states Moiz Palaci, Director of FPS Air Compressors. “At FPS, we are committed to providing innovative solutions that meet the evolving needs of customers. Our G-TEC Air Compressor is no exception, boasting a range of features that make it the ideal choice whenever low noise, energy efficiency, convenience and reliability are primary demands.”

Purchase, lease and rental options are available.

For detailed information on the G-TEC range of air compressors please visit:

www.fps-compressors.co.uk/gtec.html

With energy bills likely to remain high for some time, users of compressed air must consider every potential energy-reducing measure. In tandem with growing demands to reduce carbon footprint as the UK transitions to a net-zero future, many companies are looking at compressed air technologies for the solution. Air dryers, which are essential to improve the quality of compressed air and protect valuable assets, are no exception. With this thought in mind, Hi-line’s latest Tundra range of refrigeration air dryers is its most energy-efficient to date, helping companies reduce costs, remain competitive and boost their green credentials.

Tundra refrigeration air dryers outperform rival technologies in energy efficiency by minimising pressure drop and lowering absorbed power. The principle of operation is direct expansion, which offers a notable advantage over thermal expansion dryers, namely a far more stable dew point of +1°C at all load levels. This stability contrasts greatly to thermal expansion dryers, where dew points can range from +3°C to +20°C. Importantly, this impressive stability in no way compromises performance: Tundra refrigeration dryers deliver continuous dry air that satisfies ISO 7183 industry standards.

One of the secrets behind the energy-efficient Tundra series is the improved and patented single-cell heat exchanger, which delivers highly efficient heat transfer at low energy costs. In essence, pre-cooled air enters the all-aluminium heat exchanger module while post-heated air departs, supporting a reduction in the energy consumed by the chiller circuit.

Another energy-saving attribute of the Hi-line’s Tundra range of refrigeration air dryers involves condensate removal. A link between the microprocessor controller and the condensate removal valve ensures minimum loss of compressed air during condensate discharge, again saving energy. This function is fully programmable in line with climatic and seasonal conditions.

A variable-speed fan is among further energy-reducing technologies that help to drive down bills. Fan speed is adjustable via the multifunction control panel, providing users of Tundra refrigeration air dryers with improved process control, increased power factor and significant energy savings.

Controlling the fan speed on the refrigerant circuit also presents the opportunity to eliminate components such as fan pressure switches which, over time, can sometimes become defective in compressed air dryers. The less moving parts, the more reliable the product.

Providing a robust and highly reliable build quality is a priority at Hi-line. For instance, following significant company investment, all Hi-line Tundra dryers now feature Scroll Freon refrigerant compressors, which offer the lowest possible power consumption and deliver cost-effective, long-life performance. The refrigerant system also takes advantage of liquid receivers, line dryers, thermostatic expansion valves and a series of safety features to protect the Freon compressor and its parts. In short, the design of Hi-line’s Tundra range centres on engineering specification, rather than budget.

As a point of note, Tundra dryers take advantage of R513a refrigerant in models up to and including Tundra 115 (115 cfm, 195 m3/hr capacity). A HFC/HFO blend, R513a refrigerant has no ODP (Ozone Depletion Potential) and a much reduced CO2 impact in comparison with the previous R134a refrigerant.

Tundra refrigeration air dryers with capacities up to 1530 cfm are available ex-stock from Hi-line’s centrally located headquarters and manufacturing facility in Burton upon Trent. The company also offers larger and higher pressure dryers (up to 40 bar) on short lead times.

www.hilineindustries.com

The Si124 range of acoustic cameras now detects air leaks from 2 - 65 kHz - and the small change means big operational improvements for industrial applications across sectors.

The Teledyne FLIR range of acoustic imaging cameras, the Si124, Si124-PD and Si124-LD, now offers an improved bandwidth range for detecting compressed air leaks in industrial settings. The change means that the industry-leading range can now detect leaks from anywhere between 2 to 65 kHz and adds crucial functionality to the previous peak bandwidth of 35 kHz.
While it may seem like a minor change, the operational impact of the improvements cannot be overstated: it means marked savings for industrial applications globally, reducing costs and improving reliability.

The improved Si124 range promises easier, more impactful inspections

The range of three cutting-edge Si124 models are now equipped to measure virtually all compressed air leaks in manufacturing settings - regardless of how small and seemingly insignificant. This unique range covering 63 kHz is scientifically the optimal sound spectrum range for detecting leaks, which occur on this measurable threshold. Detecting ranges outside of this spectrum actually detracts from long-term functionality as detecting background noise beyond 65 kHz can interfere with baseline readings and negatively impact leak detection.

Failure to detect air leaks can cost companies thousands of pounds in replacement costs for units that are not operating optimally, and can have a knock-on effect on production when parts are replaced and production lines forced into downtime.
Federico De Lucia, Team Lead of Condition Monitoring Specialists (EMEA Solutions) at Teledyne FLIR explains why this seemingly small change cements the Si124 range as operating across the optimum bandwidth for detecting compressed air leaks in industrial applications.

“Let’s look at, for example, a compressed air leak from a small hole of just 1.5 millimetres and on a network of compressed air at seven bars of pressure. Two years ago, with a price of €0.07 per kilowatt hour, that would have cost a company roughly €1500 (£1300) per year, if we assume an average operating time of 6000 hours.

“Now that the energy situation is more challenging, it means that costs may be three, four, even five times higher in some cases, which could be a cost of up to £7500 a year - which is a shocking amount simply for failing to identify a single small hole in a vital production component. This is staggering when you consider the scale of industrial manufacturing and the scope for leaks to crop up unnoticed.”

Tightness testing is an outdated model

“The EV industry is a particularly timely example of how acoustic imaging can be used to replace outdated inspection models, given the rising cost of energy on all fronts.

“This is because the batteries for electric vehicles must be hermetically sealed to ensure they hit operational guidelines and safety standards. They must be both airtight and watertight to keep dirt, dust and other external contaminants from penetrating the core components, which could cause the device to short-circuit and become a fire risk.

“Traditionally, these units were probed by mass spectrometers to identify foreign compounds within the casing or through the more rudimentary method of immersing the units in water to identify leaks by looking for air bubbles - which we call tightness testing - but this was incredibly impractical, as well as wasteful.

“Teledyne FLIR’s improved range of acoustic imaging can detect leaks quicker than this outdated model as well as identify much smaller leaks that are not visible to the naked eye, able to be heard by the ear, or even detected on traditional thermography. The improved bandwidth range of the Si124 ensures that operators are only focusing on the exact and specific frequencies that compressed air leaks can be detected on - and not wasting valuable battery power or AI functionality struggling to filter out avoidable background noise on higher frequencies.”

Lighter and more ergonomic than any other acoustic imaging camera for industrial inspections
As well as benefiting from the optimum range of bandwidth for compressed air leak detection, the Si124 range also offers clear advantages for inspectors in industrial applications.

The Si124 range is incredibly lightweight. In fact, it is almost 60% lighter than rival models on the market at just 1.25kg including the battery. This makes sure that they can be used with a single hand, freeing up the operator to carry out harder-to-reach inspections in challenging environments. The lightweight range can be used for up to two hours and can even be operated in a range of challenging industrial settings from between –10°C to 50°C (14°F to 122°F), making it one of the most robust models available.

The acoustic imaging camera range is able to detect problems up to 10 times faster than traditional methods, including detecting air leaks, minimising excess utility costs and making avoidable equipment failures in pneumatic machinery a thing of the past.

The range also has an agile AI which uses projective algorithms to estimate how much a detected compressed air leak will cost by evaluating the air lost in real-time, calculating the spend per kWh and displaying an expected saving per year. Critically, this ensures that inspectors have valuable evidence needed to justify any incurred repair costs across the production line.

The Si124 range also benefits from Thermal Studio: a FLIR-exclusive plug-in which is able to build reports with more than 100 images quickly with fully customizable templates, overlays, and formulas. It streamlines thermal imaging analysis and ensures that inspectors are able to analyse, edit, segment and edit thermal video.

The improved FLIR Si124-PD, Si124-LD, and the original Si124 Industrial Acoustic Imaging Camera models are available for purchase globally from Teledyne FLIR and its authorised dealers. To learn more or to

purchase, visit https://www.flir.com/products/si124.