Fuel Monitoring Matters

Today, cement manufacturing plants have to contend with a double-edged sword: How do they reduce production costs and still meet environmental regulations? How do they accomplish their goals and directives while maintaining their equipment in a manner that prevents unscheduled downtime and hazardous conditions? Reducing the cost of fuel is a common strategy employed within the industry; in turn, this has led to an increase in the substitution of coal with petcoke.

One area that has been impacted by the use of petcoke is the coal mill dust collector. Coal mill dust collectors have a substantial effect on productivity, yet have received relatively little attention as companies implement cost-saving programs, like the use of petcoke as a fuel reduction measure. Petcoke is typically ground finer than coal, and it has a particularly sticky nature that makes it more difficult to clean from filter bags. Its high sulfur content increases the likelihood of corrosion. All of these things bring into question whether the dust collector in use is properly designed for the conditions and if the operation and maintenance plan is effective in preventing system upsets and safety concerns. 

Here, we'll discuss effective design, operation and maintenance tips for this critical component of the coal grinding circuit and what you can do to evaluate the readiness of your coal mill dust collector.  

For complete recommendations on maintaining and operating coal mill dust collectors and how to reduce unscheduled maintenance, downtime and emissions, download the full article.

Dust collector operators must take into consideration these items as they evaluate their current equipment design:
 

An air-to-cloth ratio that does not exceed 3.5 ACFM per 1 square foot is recommended to prevent short filter life, high differential pressure, higher emissions and operating costs.
 

An undersized system can cause an excessive buildup of combustible material on the filter bags. The use of single diaphragm pulse valves or valves that are smaller than 1.5 inches often requires an upgrade.
 

Defined as the upward velocity of dust-laden gases between filter bags, excessive can velocity can result in higher pressure drop and excessive dust accumulation. For a coal mill dust collector, velocity should not exceed 240 fpm or 1.22 m/s.

Polyester, acrylic and aramid filter bag fabric materials require a dust cake for fine particle filtration. This can lead to an increased risk of combustion. Opting for an ePTFE membrane material, like the BHA Preveil filter from Parker Hannifin does not require a dust cake, reducing the combustion risk.  

BHA Preveil filters are made from PTFE resin, a substance with inherent non-stick properties that can be used to help your dust collector operate at maximum efficiency by providing:

• 99.99% efficiency
• Higher airflow
• Better cleaning
• Optimum emissions control

Proper inlet design distributes gas flow evenly and eliminates abrasion issues, which cause holes in the bags and increased emissions.
 

A steel, air-tight housing and hopper, free of shelves or other particle accumulation areas, equipped with level and temperature measurement devices is recommended to prevent hazardous conditions. To avoid buildup of combustible materials, hopper walls should be designed with a minimum angle of 70 degrees from horizontal.
 

A lack of insulation can result in moisture and accumulation of combustible dust. When petcoke is used this can also result in the increased formation of sulfuric acid and eventual corrosion of the dust collector.
 

It is essential that material handling equipment can withstand surges. A good practice is to size the equipment to the capacity of conveying equipment, even if the actual requirement is substantially less. Equipment should be equipped with motion sensors.

With a properly designed dust collector, good operational practices can result in a reduction of downtime, emissions and hazardous conditions. The following practices are recommended:

• Startup and shutdown procedures: Establish specific, written protocols.
• Regular dust collector inspection: Checking pressure drop, visible emissions, the cleaning system, material withdrawal equipment, damper settings and fan operation once per shift is a recommended practice.
• A staggered sequence of actuation of the cleaning system pulse valves: This will reduce dust recirculation and pressure drop across the filter bags.
• Continuous operation of the cleaning system and material removal equipment: This will help to prevent the excessive dust accumulation on the filter bags and in the hopper.

For complete recommendations on maintaining and operating coal mill dust collectors and how to reduce unscheduled maintenance, downtime and emissions, download the full article.

Contributed by the Filtration Team.

Related content

Choosing the Best Dust Collector for Air Quality Control in Manufacturing

Filter Upgrade Improves Baghouse Performance in Industrial Manufacturing

Reducing Dust Collector Maintenance and Energy Costs in the Cement Industry | Case Study

Lowering Emissions to Meet NESHAP PM Limits in Cement Manufacturing

In the biopharmaceutical industry, extractables and leachables have come under the spotlight as stainless steel manufacturing systems have given way to single-use assemblies in manufacturing operations. 

Yet, there is some confusion as to what the terms 'extractables' and 'leachables' actually mean. They are often talked about interchangeably, but there are actually distinct differences between the two. 

Extractables studies are an assessment performed on a material. They are performed to identify substances that a patient may be exposed to and are typically conducted using 'worst-case' conditions. 

Leachables studies are an assessment performed on the drug product to identify substances that patients are potentially exposed to and are typically conducted using 'true process' conditions. 

Learn about different approaches to extractables and leachables testing in our white paper: Demystifying Extractables Testing

Due to the nature of plastics and the potential release agents and plasticizers used in their manufacturing processes, there is potential for some of these to be released into the biopharmaceutical process stream. 

In a single-use assembly, numerous components have the potential to contribute to extractables and leachables. These include tubing, connectors, bags, bottles and filters. Therefore, the whole assembly should be assessed collectively. 

Every plastic will have some degree of compound leaching or release, but each compound may not be given equal importance with regard to what is allowed or is applicable to the process stream. 

As there is no 'one size fits all' with regard to what is and isn't allowed for many compounds, end-users need to assess the risk based on a number of factors. 

Risks and assessment can be categorised into:

• Those which impact on patient safety, for example toxicological effects
• Those which relate to technical factors, such as process control and regulatory approval
• Those which relate to social factors and perceived negativities, such as social media trending of compound 'buzz words'.
   

Vendors usually take on the responsibility of performing extractables studies, while end-users taken the leachables part - as these studies should be conducted using 'true process' conditions. However, there remains some confusion over what a vendor should provide. 

In our Demystifying Extractables Testing webinar, we asked participants what their expectation was of a single-use vendor's role in extractables and leachables studies. 

While more than 70 percent of respondents believed that the vendor could only offer extractables data, more than 20 percent responded that both extractables and leachables data should be supplied by the vendor. However, leachables data needs to come from a true process stream that only the end-user would have access to. 
 

The vendor would take the following steps:

• Selection of component parts - selection and materials of construction would be scrutinized, ensuring that as much as possible, industry-standard components or materials are used
• The material of construction - product contact materials and additives would be considered
• Assessment of stability to irradiation
• Assessment of stability to common biopharmaceutical process solutions and chemicals
• Assessment of further manufacturing process steps which would have the ability to change or add compounds which could be released

The vendor would then either perform their own extractables study, or obtain the extractable data set from their supply chain in order to identify 'worst-case' released compounds under extreme conditions. 

The outcome from the vendor's point of view would be to:

• Ensure that products have patient safety at the forefront
• Instill confidence with their customers that they are supplying good quality characterized consumables
• Ensure that, throughout the supply chain, there is control over the individual component parts
• Understand any interactions which may occur that could have the ability to negatively affect customer processes
   

The customer would take the following steps:

• Selection of component parts - customers may have experienced negative effects on their own processes with specific components used within singe-use assemblies. This may inform their choices

• The material of construction - product contact areas and any additional additives would be key considerations
• Stability to irradiation, process streams, solvents and chemicals would be assessed

The process would then be mapped out to ensure that all components are compatible for their intended use. The next step would be to take the 'worst-case' extractables data from the vendor and risk assess this based upon knowledge of their process.

This helps the customer understand how componentry will behave, but to satisfy regulatory bodies, further 'leachable' studies may need to be performed using the actual process stream intended for use with the assembly. There is generally more process risk from extractables and leachables as the process progresses. Released compounds early in the process may be removed through processing steps, but as the process reaches its final formulation, the risk attached to any released compounds present exponentially increases. 

The outcome of this data generation from the customer's point of view would again be to:

• Ensure that the products they supply always have patient safety at the forefront
• Ensure that their manufacturing process and drug product is consistent and 'in-control', in order to receive regulatory approval
• Ensure that there is control over the individual component parts throughout the supply chain, and to understand any interactions which may occur and could negatively affect processes
   

It is vital that there is clarity across the biopharmaceutical manufacturing industry on the importance of extractables and leachables studies and who should carry out the studies. And, while both vendors and customers may have different reasons for carrying out testing, the end goal for both parties is the same. 

Learn more about extractables and leachables testing in our white paper: Demystifying Extractables Testing

This post was contributed by Graeme Proctor, product manager (single-use technologies), Parker Bioscience Filtration, United Kingdom.

Parker Bioscience Filtration specializes in automating and controlling single-use bioprocesses. By integrating sensory and automation technology into a process, a manufacturer can control the fluid more effectively, ensuring the quality of the final product. Visit www.parker.com/bioscience to find out more. 

5 Benefits of Single-Use Technology vs Stainless Steel

Five Critical Challenges in Single-Use Bioprocessing

Filtration and Biopharmaceutical Process Protection

Eliminating Leaks and Faults: Single-Use vs Stainless Steel Systems

Design Space and its Use in Single-use Bioprocessing

Has Single-use Customization Gone too Far?

Battlegrounds Coffee is a small, community-oriented coffee shop in Haverhill, MA. The owners were challenged to find a more efficient and consistent way to deliver Nitro Coffee to their customers.

According to Battlegrounds Coffee, Nitro coffee is the new trend.

It has a soft smooth mouthfeel. It’s like sipping on a Guinness. It gives the sensation that you’ve added cream to it but you haven’t. It looks fantastic poured and cascading in a glass. Nitrogen gas enhances some of the complex coffee flavors that you find in our blends and roasts at Battlegrounds Coffee. Prior to using the generator, we were using pre-charged food-grade nitrogen tanks.

"Tanks were the most difficult aspect of making and maintaining nitro coffee. The pressure gauges on the regulator were faulty indicating you had more nitrogen that was really left. As owners, we would get calls in the middle of the day saying 'Hey, we are out of nitrogen!'

For us, it was a hassle getting those tanks refilled. We had to drive to the local welding shop. We change out the tank 3-4 times per week so you had to assure that was done right and that there were no leaks. It wasn’t an efficient system and was becoming a hassle. The supplier was charging more than $50 per tank for food-grade nitrogen so my payback was very quick."

— Sal DiFranco, Battlegrounds Coffee

Nitrogen Generators with on-board compressors for low flow applications provide safety, savings, and convenience.

Parker nitrogen generators completely eradicate the danger, inconvenience, and high costs of truck delivered nitrogen. The hassles of changing high-pressure tanks and the routine interruption of nitrogen supply are eliminated. They offer long-term cost stability by eliminating vendor price increases, contract negotiations, long term commitments, transportation issues and hazmat charges.

Once installed, a continuous supply of high purity nitrogen is available within a few minutes of startup. Nitrogen, unlike CO2, imparts a small bubble that creates an attractive cascade down the side of a glass. More importantly, the small size of the nitrogen bubble creates a smooth, creamy finish on your palate. Consumers report that it is even sweeter than conventional iced coffee.

Watch the video interview with Battlegrounds:

Building on Parker’s history of over 35 years of producing Nitrogen Generators for beverage dispense, we are pleased to offer a nitrogen gas generator specifically designed to meet the needs of retail coffee establishments. Parker Nitrogen Generators eliminate the danger, inconvenience and high costs of truck delivered nitrogen. There is no need to rely on an outside supplier. The hassles of changing high-pressure tanks and the routine interruption of nitrogen supply is completely eliminated. 

Parker Nitrogen Generators are also good for the environment because delivered nitrogen is manufactured using an energy-intensive process and then distributed in smog generating trucks. Parker generators offer long term cost stability by eliminated vendor price increases, contract negotiations, long term commitments, tank rental fees, delivery fees and hazmat charges. Once the generator is installed, a continuous supply of high purity nitrogen is available within a few minutes of startup.

Cold brewed coffee may be enhanced with nitrogenation. Nitrogen becomes infused into the coffee, much like a nitro beer. Nitrogen, unlike CO2, imparts a small bubble that creates an attractive cascade down the side of a glass. More importantly, the small size of the nitrogen bubble creates a smooth, creamy finish in your mouth. Consumers even report that it is sweeter than conventional iced coffee. Imagine the reaction of your customers to a creamy slightly sweet coffee without the need for added cream or sugar! Parker nitrogen generators are ready to operate as delivered with carefully matched components engineered for easy installation, operation and long term reliability. The generators are free-standing and housed in an attractive cabinet with casters.

The Parker DN-6NA Nitrogen Generator is designed to provide a constant supply of nitrogen gas, at a pre-selected purity, flow, and pressure. The system uses proven Pressure Swing Adsorption (PSA) technology with a Carbon Molecular Sieve (CMS) to separate N2 from the atmosphere and deliver it at high purity. The installation consists of simply connecting the plug to a standard outlet and connecting the nitrogen outlet to your coffee dispenser.

The onboard compressor means that there is no need to connect to a source of compressed air. Simply turn it on, and the air is then prefiltered, compressed, and passed through a 0.01 micron filter rated at 99.99%. The air is then passed through the CMS separation bed which captures the oxygen, creating a stream of high purity nitrogen. Lastly, the stream of nitrogen is passed through a sterile grade filter rated at 99.99999+% at 0.01 micron and then sent to the coffee dispenser. The CMS bed is regenerated to remove the captured oxygen and the cycle repeats.

• Nitrogen generator, filters, controls, and an on-board compressor
• Floor mount on casters
• Automatically shuts down if there is no demand
• Stays in standby mode until more nitrogen is needed
• Environmentally friendly
• Compact - frees up floor space
• Eliminates unexpected shutdowns
• Hassle-free operation
•  Safe and reliable
• UL, NSF, & CE listed
• CB Scheme, CSA, EMC and IEC certified

"The Parker DN-6 provides nitrogen without any interruption. It’s always ready. Saved us at least four man-hours per week. It is awesome! We use nitrogen to push Kombucha too. Plug and play. It’s always working and saves us a lot of time. We also pour wine and we keep the wine bottle purged with nitrogen to keep it fresh. We are also looking at using it to pour our beer too.”

— Sal DiFranco, Battlegrounds Coffee

"We were always fighting with the tanks to work properly to pour the perfect pour for a nitro cold brew. Since we’ve had the nitrogen generator it has been easy breezy. With a generator, you don’t have to worry about it. You set and forget. We never have to tell customers 'Sorry we aren’t pouring today.' The pour looks great, tastes even better.”

— Dana, Battlegrounds Coffee

To learn more about self-contained nitrogen generators for nitro iced coffee, download a copy of the case study and call Parker today at 1-800-343-4048. 

Article contributed by the Gas Generation Team.

Nitrogen Gas Generators Save Winemakers Time and Money

Consumers and Roasters Benefit from Coffee Packaging with Nitrogen

Top Frequently Asked Questions About Nitrogen Generators