Editorial

For a fast-growing company that makes machines for the post-harvest processing of vegetables, Hayley Group is set to provide two new Landia Chopper Pumps that have special external shredders.

Originally developed to deal with difficult wastewater solids in the fish processing industry, the Landia shredder-propeller design has now proved its capability in handling troublesome stringy material such as carrot tops, that typically cause problems for standard pumps.

Speaking for Hayley Group, the leading nationwide engineering component supplier (who also supply bearing and pneumatic products to the machinery manufacturer), Daniel Moulding, Assistant Manager, said:

“The Landia Chopper Pumps work extremely well for our customers in numerous applications. In this particular challenge, the specialist machinery company asked us for help, because their existing pumps struggled with the fibrous and gritty material that is an inevitable part of the wastewater process with vegetables.

“This latest purchase of two new Landia Chopper Pumps follows orders for five units that were successfully introduced at various locations during 2023.

“Landia have been very helpful indeed in working with us to understand our customer’s needs; adapting the shredder-propeller so that there is no longer any downtime on the processing lines, which is a huge benefit.”

Howard Burton, Technical Sales Engineer for Landia, added:

“For certain effluents with difficult solids, the pre-cutting shredder-propeller adds another important chopping stage; continuously reducing particle size and keeping the process running efficiently.”

Daniel Moulding from Hayley Group, continued: “In addition to providing such an effective, reliable solution, Landia also give us fast and efficient back-up whenever we need it.

“When our customer first used the Landia Chopper Pump, they said they’d never go back to the previous type of units. Another eight pumps later, we and they are very happy with the positive outcome, as are the end-users of the equipment.”

www.hayley-group.co.uk

www.landiaworld.com

Introduction

Non-Ferrous pyrometallurgical plants across the globe rely on smelting furnaces to extract copper, nickel, lead, and zinc which are subsequently used in a wide variety of manufacturing processes. Renowned for their efficiency and speed, these assets need to be carefully maintained to operate at maximum capacity. Waste Heat Boilers (WHB) play a crucial role in recovering and utilizing heat generated as a byproduct of these processes. However, these boilers are susceptible to high temperature sulfidation leading to waterwall degradation. This corrosive process has a detrimental impact on asset life and overall performance. This article will explore the causes of this type of corrosion and how it can be prevented.

What Causes Corrosion and Erosion?

The flue gas stream within a smelting furnace WHB has huge dust content, that may either slag on the surface depending on its melting point temperature or erode waterwalls. In general, metal oxides are present in the dust and are characterized as very erosive media.

Flue gas originating from sulphur containing fuel becomes corrosive below a temperature of approximately 150°C (acid dew point corrosion). Local cold spots in metal air preheaters lead to rapid breakdown and corrosion of tubes and plates. This type of corrosion is one of the key factors negatively affecting the energy efficiency of waste heat boilers.

Corrosion Often Leads to Depletion

The incredibly high temperatures (which may reach around 1,350 degrees Celsius) circulating within the waste heat boiler start to affect the waterwalls. If this process is allowed to continue, areas of the boiler wall can become completely depleted and require costly shutdowns and urgent repair to operate efficiently.

Prevention Methods: High Velocity Thermal Spray (HVTS)

High Velocity Thermal Spray (HVTS) by Integrated Global Services (IGS) offers a potential solution for extending the lifespan of existing smelting equipment by acting as an erosion barrier in critical apparatus.

Developed for safe on-site application, HVTS is a non-permeable thermal spray applied alloy cladding material specifically designed for corrosion and erosion resistance in high-temperature smelting and mineral refining environments.

Engineered for the mining and mineral processing industry, HVTS ensures better bond strength and excellent corrosion and wear resistance. The solution is designed for fast on-site application, facilitating a prompt return to service. Its capability to withstand challenging environments makes it a suitable choice where other coatings may not provide lasting performance.

HVTS Case Study: Waste Heat Boiler Corrosion no Longer a Problem at Copper Smelter

In a collaborative initiative with a leading global copper smelting operation, IGS recently completed a project focused on improving the reliability and lifespan of a waste heat boiler. This case study highlights the technical implementation and explores the substantial commercial advantages realized by the copper smelter.

Commercial Benefit Analysis

Avoided Downtime and Replacement Costs

Traditionally, the copper smelter plant encountered significant challenges related to the waste heat boiler, with a service life of critical panels limited to only 11 to 18 months. This recurrent issue resulted in prolonged downtime, elevated replacement expenses, and logistical complications, further exacerbated by disruptions in the supply chain owing to the prevailing COVID-19 situation.

IGS addressed these challenges by introducing a high velocity thermal spray (HVTS) alloy cladding solution, aimed at extending the intervals between turnarounds. The successful implementation of this solution remarkably mitigated downtime and replacement costs.

Identification of Issues and Initial Contact

The copper smelter plant in Chile, grappling with corrosion and erosion problems in their waste heat boiler, traditionally relied on panel replacements, single tube replacements, and weld build-up strategies. A pivotal moment arose when a representative of the plant discovered a waste heat boiler reliability project executed by IGS and approached the company in search of alternative solutions. Subsequently, a comprehensive technical presentation was made to the plant's maintenance and commercial teams.

Contract Award and Application

Following successful presentations and in-depth discussions, IGS secured a contract for the application of its proprietary HVTS high-nobility alloy cladding over a 70-square-meter area. The application took place in a laydown yard in October 2022, strategically targeting critical areas of the waste heat boiler.

Post-Application Inspection

The waste heat boiler operated continuously until the end of September 2023. In August, anticipating an outage, IGS mobilized an inspection crew, including local representatives from Chile. Despite a tight five-hour window, the team conducted a thorough inspection using magnetic lift-off (MLO) gauge testing. The results were overwhelmingly positive, with the cladding exhibiting no degradation after 11.5 months of service.

Kevin Phillips, overseeing both the project and inspection, described the cladding as being in an applied condition. "In all my years as a technical solutions partner, I have never had a client hug me. They were so pleased with the outcome!" remarked Kevin.

Future Collaborations and Market Expansion

The success of the waste heat boiler project has opened avenues for potential collaborations on other critical components within the copper smelter. Converter hoods, copper cooling plates, and other identified assets are currently under consideration for IGS solutions. The client's satisfaction has solidified IGS as a trusted partner.

Conclusion

The project addressing the waste heat boiler challenges demonstrates the company's commitment to finding effective solutions. It has shown that a proactive approach and proven methods can contribute to overcoming operational challenges, potentially extending asset life and enhancing productivity. As the collaboration advances, the lessons learned from this project may inform future ventures, highlighting the potential for industry-wide advancements through strategic partnerships and innovative engineering approaches.

The examination of waste heat boiler challenges in copper smelters underscores the critical role these boilers play in the efficient extraction of metals. The corrosive effects of high temperature sulfidation pose significant threats to the operational longevity and overall performance of these crucial assets.

The collaborative efforts and successful outcomes detailed in the case study serve as a valuable reference for industries seeking reliable solutions to enhance the performance and reliability of waste heat boilers and other critical components in similar environments.

 

 

The British Compressed Air Society (BCAS) has appointed Steven Rohan as its new president.

Steven is the division engineering manager for Parker Gas Separation and Filtration Division - Europe, Middle East and Africa and takes over the role from immediate past president, Mark Ranger from Atlas CopCo.

Having held the role of vice president for the past two years, Steven is keen to build upon the excellent foundations set by the Society's predecessors and to ensure that BCAS continues to play its crucial role in driving progress in the compressed air industry.

Said Steven:

"It is an honour to be appointed as the 59th president of BCAS, a society that has been at the forefront of promoting safety and best practice in the compressed air industry for more than 90 years.

"The world is changing rapidly. We are facing new challenges from the increasing demand for energy efficiency and more cleaner and sustainable technologies. With this comes changing legislation and standards in a post-Brexit regulatory landscape and, BCAS has a key part to play in representing its broad membership and as an independent voice of the compressed air industry.

"To add further value for our membership, during my tenure I will also focus on talent acquisition and development. Our training and development portfolio and qualification programs will be broadened and strengthened, forming closer partnerships with the education sector. This will support the aim to attract more talent to our industry and our members' businesses."

As part of the Society's ongoing plans to boost growth, the BCAS team will be strengthened further too.  Vanda Jones will continue in post, providing governance and stability while a new executive director is appointed, before continuing in the new role as company secretary. 

Tim Preece, as technical officer continues to expand the Society's remit in the areas of EU and global standards and legislation, and a new training and development officer will be announced shortly.  Frances Marsh also continues in her vital role as society administrator, providing membership support to manufacturer, distributor and end-user members.

Commenting on Steven’s appointment, Vanda Jones, BCAS Executive Director added:

“At board level we now have a wealth of experience across the team, with a balance of manufacturer and distribution directors to better represent our membership.  This ensures we continue to support all our stakeholders on the issues that matter most to their businesses - whether it's lobbying for changes in legislation to deliver a better outcome for customers, providing guidance on energy reduction or delivering technical training. 

“It is an exciting time for Steven to be leading the BCAS board and I look forward to working with him to support all our members and compressed air end users.”

For further information about the British Compressed Air Society, please visit www.bcas.org.uk

 

 

When faced with metal wastage, asset owners and operators can address the corrosion mechanisms with a corrosion-resistant alloy (CRA) barrier. The technique used to apply this CRA will mainly be determined by the shutdown time available to carry out the application.

While weld metal overlay remains a reliable option, laboratory testing and performance validation, field application, and subsequent site inspections of High Velocity Thermal Spray (HVTS) alloy cladding projects have confirmed this solution to perform “in the same league” with several added benefits.

The Evolution of High Velocity Thermal Spray

Thermal spray technology has been utilized for the application of CRA since the 1980s, spraying metals widely used for corrosion protection. However, it was quickly noted that the thermal spray process itself can negatively affect the condition of the material being sprayed. The resulting cladding, when using traditional metal alloys and commercially available thermal spray equipment has not been able to create a sufficient barrier to corrosive media.

Permeability coupled with internal stress and lower bond strength with the base metal creates a path for corrosion and premature failure. These early failures resulted in an understandable and rather universal distrust of early iterations of commercially available thermal spray technology.

Engineering a Solution

Engineers and material scientists have successfully developed a solution to this problem by redesigning both the equipment used to apply the metal cladding, the process technology, and the alloy of the feedstock material.

True High Velocity

The atomization velocity is a critical success factor in thermal spray cladding for critical equipment liquid and gas corrosion environments. For thermal spray cladding applied with a wire feed stock, a high velocity process is defined where the material atomization occurs in a super-sonic gas stream (gas stream velocity equal to or greater than Mach 1) which results in specific particle characteristics critical to achieving an impermeable barrier.

Creating an Impermeable Barrier

As particles are ejected from the thermal spray torch at high temperature and velocity, they are exposed to air with a high nitrogen and oxygen content. The molten particles are inclined to rapidly oxidize in flight. On deposition, oxide bands are formed in layers along with the metal splats.

These oxide structures constitute permeable pathways through the applied thermal spray and are to be avoided in any application, especially where corrosion is present. Chemical and process controls are employed to significantly inhibit in-flight oxide formation.

Bond Strength

The problem of bond strength, both between the applied metal particles and the substrate, was solved by increasing velocity and improving the quality of the substrate surface preparation. When the molten metal particles hit the substrate with a suitable profile at speeds close to supersonic, they splat and embed metal into the substrate, forming tight bonds. The particles themselves do not have a perfectly smooth microstructure; this feature promotes good intersplat adhesion. Multiple additional overlapping passes of the thermal spray torch then create a 500-micron thick cladding with excellent adhesion throughout. ASTM adhesion pull-off tests measure bond strengths of 30 - 60MPa.

Case Study 1: Fixing Failed Low Velocity Thermal Spray Coatings

The Problem

A US refinery identified a problem with its second stage desalter and overhead accumulator vessels during a routine inspection.

A nickel-copper thermal spray coating had been applied in both vessels approximately 20 years ago. Initially, the coating performed as expected. However, after some time, localized damage was evident on the bottom third of both vessels, leading to deep pitting and metal wastage beyond the existing corrosion allowance.

Thermal Spray Coating and Weld Failures

Typical thermal spray coatings are not suitable for internal protection of mission critical process equipment due to their permeability, weaker bond strength and propensity to cracking. These “low velocity” thermal spray systems cannot produce flat and tightly packed particle sizes or nano-scale grain structures, leading to the coating’s failure due to corrosion and/ or permeation.

Furthermore, weld repairs were also attempted, adjacent to the failing thermal spray, and a crack had formed on its heat affected zone (HAZ). In 2017, refinery engineers decided they needed a more permanent solution.

The Solution

An HVTS alloy cladding solution was chosen to stop corrosion for the expected life of the asset without any further maintenance anticipated for at least the next 15+ years.

HVTS technology utilizes alloy materials, which offer erosion-corrosion protection, even in high-temperature and high-pressure service up to 1371°C/2500°F.

The cladding option also offered significant time savings compared with weld overlay. As a result, the refinery project manager welcomed the solution, and HVTS was applied in the Spring of 2019.

The bottom third of the overhead accumulator, including the stem pipe with a vortex breaker and a flange, were protected with HVTS. Regular inspections have shown no deterioration of the cladding since application.

Key Benefits of HVTS

• More Robust than Organic Coatings

HVTS is considered more robust than organic coatings for several reasons. Firstly, HVTS relies on mechanical bonding to the substrate; molten particles are propelled at high velocities creating a bond that is inherently stronger than the adhesive bond typical with organic coatings.

Furthermore, HVTS has a higher immersion temperature resistance which makes it often chosen for applications involving immersion in aggressive substances. Its resistance to immersion at elevated temperatures surpasses that of organic coatings, which may experience degradation or chemical breakdown when exposed to corrosive liquids or gases.

For example, TCO in Kazakhstan holds 26 billion barrels of oil and gas and has a high sour gas (hydrogen sulfide or H2S) content of about 6%. The plant identified major corrosion and process vessel integrity issues due to earlier applications of organic coatings. These coatings are often solvent-based, and in these instances, apart from other limitations, problems are experienced due to solvent retention within the film. This retained solvent will then increase in volume as it is exposed to higher temperatures, which in turn leads to blistering.

In contrast, the robustness of HVTS compared to organic coatings can also be attributed to its hardness, temperature resistance, flexibility in thickness and resilience to mechanical and chemical stresses.

• More Cost-effective than Weld Overlay

HVTS offers several cost-effective advantages over traditional weld overlay methods, such as:

• Reduced Downtime and Faster Application

HVTS has a faster application process compared to weld overlay. Traditional weld overlay involves time-consuming welding procedures, which may require the shutdown of equipment or entire facilities. In contrast, HVTS can be applied more rapidly, minimizing downtime, and allowing for quicker return to service. The efficiency of the application process contributes to overall cost savings by reducing the impact on production schedules and operational continuity.

 

• No Heat-Affected Zones (HAZ)

Weld overlay introduces heat-affected zones (HAZ) in the substrate material due to the welding process. These zones can experience changes in metallurgical properties, potentially leading to issues such as reduced material strength or increased susceptibility to corrosion. HVTS, being a thermal spray process, does not generate HAZ. This eliminates the need for post-weld heat treatment and reduces the risk of material degradation, simplifying the overall process and reducing associated costs.

Other factors that make HVTS a more cost-effective option include lower equipment and labor costs, material savings, and the elimination of post-weld inspections.

Case Study 2: ½ The Cost and ⅓ The Application Time in LP Separator Renewables Conversion

Introduction

A multinational oil and gas company has been focusing on meeting the world’s growing energy needs while reducing its carbon emissions intensity. As a result, it converted one of its refineries to a renewable fuels manufacturing and terminal facility to be able to produce approximately 730 million gallons of renewable fuels per year.

The Problem

A low-pressure separator with minimum corrosion allowance remaining was being prepared for renewable diesel conversion to mitigate the risk of carbonic acid attack in the new operating environment. The plant considered welding internal cladding, but that option carried significant costs and would require 30 shifts to apply.

The Solution

The plant selected HVTS to upgrade the metallurgy of the separator to a higher nobility alloy able to prevent carbonic acid corrosion. References, operational excellence, and the ability to inspect the separator in between turnarounds without shutting it down were the key drivers for the plant’s decision. The application cost 50% less than weld metal overlay would have cost and was applied in one-third of the time.

Solving Complex Challenges with HVTS

Case Study 3: Chloride Stress Corrosion Cracking in Critical Process Assets

Chloride-induced Stress Corrosion Cracking (CSCC) poses a significant threat to the structural integrity of critical process vessels and hence the process safety of the plant.

This form of corrosion cracking can be challenging to effectively monitor with inspection and once initiated can lead to catastrophic failures if not addressed effectively.

Why does CSCC Occur?

This phenomenon occurs due to a combination of three key factors: the presence of chlorides in the process fluids, tensile stress in the substrate material, and elevated operational temperatures. When these three factors combine, they create a corrosive environment that initiates micro-cracks or micro-pits in the stainless-steel surface. These cracks become the focal points for localized corrosion and can propagate rapidly under the influence of the applied tensile stresses, particularly in Heat Affected Zones or areas of higher material hardness. Austenitic stainless steels, which are commonly used in process vessels due to their excellent corrosion resistance and mechanical properties, are particularly susceptible to CSCC.

The Problem

In this case, IGS was contracted to combat CSCC in six critical process vessels offshore in the Arabian Sea operated by an LNG corporation: four discharge drums, and two condensate strippers.

The Solution

To mitigate CSCC in its process vessels, the HVTS cladding was applied. It delivered an effective corrosion barrier against chloride penetration, isolating the asset substrate from the chlorides in the process fluid, thus preserving the integrity and safety of critical process vessels in the high chloride environment.

After ten years in service and three outages/ inspections, all the applied cladding was found to be in its original condition, devoid of any cracks, blistering, or delamination.

ESG Considerations

HVTS is considered advantageous for Environmental, Social, and Governance (ESG) objectives due to its specific characteristics and performance attributes, such as:

 

 Reduced Environmental Impact:

The application of HVTS often involves fewer environmental concerns compared to alternative methods like traditional weld overlay. HVTS typically generates fewer emissions and requires less energy during the application process, contributing to a lower overall environmental footprint.

ESG Reporting and Compliance:

Utilizing HVTS for corrosion protection aligns with ESG reporting and compliance requirements. Organisations that adopt technologies with environmental benefits, such as HVTS, can demonstrate a commitment to sustainability in their reporting and contribute to a positive ESG score.

Long-Term Sustainability:

HVTS coatings are designed for durability, providing long-term protection against corrosion. This longevity aligns with sustainability goals by reducing the frequency of coating applications and associated resource consumption over the asset's lifecycle.

Case Study 4: HVTS and ESG

A recent ESG case study conducted by Integrated Global Services (IGS) shows a breakdown of the O&G projects that IGS has completed since 2012. Looking at the statistics of 1354 projects, with an average scope of 680 sqft. each, for only the past 11 years the following calculation can be done to determine the amount of carbon dioxide that would potentially have been released into the atmosphere if those vessels had to be replaced.

 304,090 tonCO2 is equivalent to 703,340 barrels of oil consumed or 340,627,459 pounds of coal burned.

Conclusion: Advancing Corrosion Mitigation for Sustainable Industrial Practices

In the ever-evolving landscape of corrosion mitigation technologies, the journey from conventional methods to cutting-edge solutions like HVTS has been transformative. As we navigate the lessons learned from thermal spray applications in process vessels and columns, a clear narrative emerges—a narrative of innovation, quality standards, and sustainable practices.

CRA technologies signify a commitment to a future where corrosion mitigation goes hand in hand with environmental responsibility and operational efficiency. With each use case, HVTS reinforces its role as a cornerstone in the pursuit of a corrosion-free, sustainable industrial landscape.

 

www.integratedglobal.com

 

 

 

 

Not content with being a global leader and manufacturer of lower carbon, energy efficient heat transfer solutions, Fulton Limited has gone a step further with its own Net Zero plans by embracing green technology initiatives at its UK headquarters.

Commenting for Fulton, managing director Carl Knight says: “With solutions like our award-winning VSRT and electric steam boilers, we are committed to working with customers to ensure their processes are as efficient as possible. What’s more, by adopting heat transfer solutions and decarbonisation strategies that are designed to reduce lifecycle costs, we are helping our customers on their Road to Net Zero.

“But Net Zero isn’t just the goal of our customers. Realising the potential energy and carbon savings we could achieve by utilising otherwise redundant roof space, we invited Heatsource Direct to run some figures on the savings achieved by installing roof-mounted photovoltaic panels, and we were impressed.”.

Installed and commissioned in 2022, the roof-mounted solar panel installation has already proved a valuable investment for Fulton and is on track to save the company over 40 tonnes of CO₂ and nearly 90,000 kWh of energy in just the first year.

Commenting for Heatsource Direct, managing director Tom Thurling says: “This is a great example of what a SME can achieve from a relatively simple installation. With a feed-in tariff agreed and in place, Fulton is set to recover over 33% of the total cost of installation in just 12 months, with a total ROI of less than three years. But what is perhaps more impressive are the lifetime savings, with the figures estimating a total production of over two million kWh, and nearly one million tonnes of CO₂ and approximately £1.25 million saved!”.

Spurred on by these savings, Fulton has gone further in bolstering its green credentials by installing six EV charging points at its Bristol facility and rolled out a fleet of electric vehicles, including six EVs and one Hybrid vehicle, for its sales and service managers. Additionally, the company is looking at the option of a battery installation to store the energy from the PV installation, rather than simply feeding the small amount of excess energy generated back into the grid.

For further information contact Carl Knight

Fulton Limited, Fernhurst Road, Bristol, BS5 7FG

Tel: 0117 972 3322 Fax: 0117 972 3358

E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it. Web: www.fulton.co.uk

Northern Ireland’s Agri-Food and Biosciences Institute (AFBI) has made a significant breakthrough with its research into on-farm biogas production by introducing a new digester mixing system.

At Hillsborough, one of seven AFBI sites that provide scientific research and services to government, non-governmental and commercial organisations, the retrofit of the AD plant’s main digester has improved biogas yields by 15-25%.

At what was the first biogas plant of its type in Northern Ireland, the cow slurry from the site’s 300-strong dairy herd is co-digested with grass silage produced on the research farm, to produce biogas which is combusted in a CHP engine providing heat and electricity for the site.

The new mixing system ensured that fresh feedstock was being better mixed in the main digestion tank and was not discharged too early, as witnessed by higher discharge temperature than that observed from the old mixing system.

Dr Gary Lyons from the Agri-Environment Branch at AFBI, said: “The original mixing system, installed when the plant was built, worked well for a number of years, but eventually a build-up of sludge in the bottom of the primary and secondary digestion tanks meant that we were getting poor digestate mixing. This impacted biogas production and the level of methane in the biogas. We decided that we needed to shut the system down, clear the sludge from the tanks, and retrofit a new mixing system on to the main digestion tank, which would not give us issues with sludge build-up in the future.”

 

 

‘A robust mixing system is critical’

He added: “At AFBI, we understand that busy farmers have more than enough to do, without having to constantly repair and maintain their biogas plant, so we’ve been able to see first-hand that a robust mixing system is critical. One that doesn’t have any wear parts on the inside of the tank will prevent the big headache of downtime.”

The new mixing system in question is a simple, but highly effective one. Externally-mounted, a Chopper Pump (invented by Landia in 1950) with venturi nozzles. No working at height. No working in the gas zone. And no costly downtime for servicing.

“There’s more to it than that of course,” continued Gary. The Landia GasMix provides the dual benefit of both hydraulic and biogas mixing in one system, which was appealing to the AFBI team. We’re not a commercial plant, but our role is to explore all of the possible benefits for farmers. This means not only maximising the amount of clean energy that can be produced, but how to achieve that with the minimum amount of energy that goes in.

‘More gas and also better quality gas’

“When we were just using slurry as a feedstock, the Landia mixers increased our output from 300 cubic metres of biogas per day of dry solids to typically 360, and as high as 400. I’m a sceptic by nature, but the results were there right in front of us with our readings; more gas and also better quality gas, with the Landia GasMix system working away without any problems, continuously reducing the particle size of the feedstock.

“Over time, only two of the 18 lines on the old mixing system hadn’t blocked. We knew we had to look for a lower maintenance alternative.”

Gary and his team’s search saw them consult with the first biogas plant of its type in the Republic of Ireland, where in County Limerick, impressive performance numbers were being reported at the site owned and operated by Greengas.

I spoke with David McDonnell at Greengas,” said Gary. “He told me that his plant was benefiting from having Landia mixers. I also looked hard at the Danish Biogas Association’s advice on the use of venturi nozzles for digester mixing at AD plants. This led to us working with DPS (part of the EPS Group) of Bangor (who supply Landia equipment in Northern Ireland and the Republic of Ireland) to help with their knowledge and experience

“In this situation, throwing more power at the process isn’t the answer. We’ve also understood that dwell times are very important, which takes convincing for some, but through careful fine-tuning, we don’t have to run the Landia mixers flat out to optimise biogas yields; just in 10-minute cycles, so only 30 minutes each hour. We need to experiment more with dwell times to hit the sweet spot of minimal mixing for maximum plant performance.

“We have had no problems with digestate mixing whatsoever since installing the Landia digester mixing system. By increasing the surface area of the feed with truly comprehensive mixing of the tank, the bacteria get to work much quicker. I do like the fact that the system incorporates biogas recirculation, and we do not appear to have solids settlement issues.

“As a scientific research centre, we’ve experienced the good, the bad and the ugly of AD, which should help farmers avoid the downside of those mixing systems that can only be retrieved by having to laboriously drain down the tank and then have to start the whole process from scratch. We won’t be doing that again.

“Following the increase in biogas production and methane content that we saw with mono-digestion of slurry as the feedstock, it will be very interesting in time to collate the data from the co-digestion of slurry and grass silage.”

www.landiaworld.com

 

Rules of Thumb for Maintenance and Relibility Engineers by Rick Smith and and Keith Mobley.  to read this great article click on the link below. 

Leading_and_Lagging_Key_Performance_Indicators_2.pdf

Interested in Maintenance and Reliability Best Practices Articles? If so go to: www.worldclassmaintenance.org

 

The demand is constantly increasing. SONOTEC has just handed over another laboratory system for non-contact ultrasonic testing to its customer CETIM.

 CETIM is a French Technical Center for Mechanical Industries and has been created in 1965 to support innovation and competitiveness of companies thanks to its multidisciplinary expertise and unique R&D capacity.

SONOTEC’s SONOAIR system enables CETIM to perform measurements on materials that are difficult or impossible to inspect using conventional ultrasonic testing. This applies, for example, to state-of-the-art fiber composites or honeycomb structures. This system is coming to complete the broad spectrum of NDT equipment at CETIM’s facilities.

In June 2023 the Factory Acceptance Test (FAT) took place at SONOTEC GmbH in Halle, Germany, where sample scans of the customer were carried out directly, which were brought along by Mr. Guillaume Pors on behalf of the customer. Last week, the Site Acceptance Test occured in Nantes, France, during which Andreas Bodi, Director of Electronics Development at SONOTEC GmbH, installed, commissioned, and provided on-site training for the SONOAIR system.

SONOTEC’s ultrasonic transducers have outstanding acoustic properties thanks to their highly flexible SONOTEC piezo-composite technology.

www.sonotec.eu