The 2015 Paris Agreement has forced many counties to present long-term strategies and nationally determined contributions (NDCs) to reduce emissions. One strategy is to transform waste into usable fuels and Raven SR is a clean fuels company dedicated to achieving this. However, the company uses a process that requires high temperatures and precise control to maintain efficiency and cost-effectiveness. To streamline Raven SR’s energy transformation process, industrial heating technologycompany Watlowprovided extensive expertise in thermal system design, as well as Industry 4.0 control. 

Raven SR is a clean fuels company that transforms municipal solid waste, organic waste and methane into high-quality, clean hydrogen and synthetic fuels. These synthetic fuels are Fischer-Tropsch synthetic fuels, meaning that they are produced from a gas-to-liquid polymerization technique that converts carbon monoxide and hydrogen into liquid hydrocarbon fuels that can act as substitutes for petroleum products.

At the heart of Raven SR’s processes is a CO2 reforming process that changes mixed feedstock and organic waste into products in an environmentally friendly way, without the need for combustion. As a result, no emissions are produced — only clean hydrogen and fuels as output.

The work done by Raven SR is a crucial step in achieving clean energy and greater energy independence. Not only does their process create fuel from waste that would otherwise end up in a landfill, but its products can also be created locally and delivered directly to gas stations in the region without the need for long-distance transportation or pipelines. 

The challenge

Although combustion is not used as part of Raven SR’s technology, precise thermal control plays a huge part in driving an efficient and safe process. There is already a clear connection between the operational targets that Raven SR is putting forward and the thermal content of the system. At higher temperatures, it’s possible to achieve 99.9 per cent target output, a level of efficiency that also makes the process more cost effective. Achieving the high temperature requires running heaters at their maximum capacity for extended periods of time.

However, those heaters are difficult to replace if something fails. As a result, not only is precise control of temperature needed, but the entire system also needs to be monitored for any signs of a problem, or for indications of degraded performance.

The power of a complete thermal system

Watlow, which has manufactured electric thermal systems for 100 years, provides a breadth of expertise that helped Raven SR to solve its challenge, by designing a comprehensive thermal system from start to finish.

The full thermal system provides an extraordinary range of temperature control through different components. This includes the high-temperature MULTICELL™ heater, which offers three major advantages over other insertion heaters. These are extreme process temperature capability, independent zone control for precise temperature uniformity and loose fit design for easy insertion and removal. The proprietary design of MULTICELL™ heaters with integrated thermocouple sensors, provides a “thoughtful” zoning and control approach, delivering precise control within the three dimensions of the reactor. 

Watlow also connected the system to other sensors for gas composition, flow and pressure. Using the WATCONNECT® control panels, comprising temperature and process controllers, it could monitor all thermal and electrical characteristics to ensure proper process stability for the application. Lastly, it’s the connected architecture that makes this system whole.

The Internet of Thing (IoT) “box” is at the heart of the system and includes hardware for connectivity, syncing data from eight F4T® controllers with control loops across four WATCONNECT® panels.

Connectivity to the cloud via a cellular router allows further routing of data to other applications and devices, while a human machine interface (HMI) screen displays the total state of the system at any time using a custom-designed dashboard. These features allow for near real-time data logging and monitoring of system output.

Applying Industry 4.0

This particular project is a great demonstration of Industry 4.0 at work. At a minimum, Industry 4.0 involves a physical layer of interconnected devices, but advanced cases also usea simulation layer that models and predicts the behavior of a system as it unfolds over time. 

The sensors, controllers and connectors lay the groundwork for such a system, an important function of which provides a foundation for predictive and diagnostic analytics. One of the chief principles of Industry 4.0 systems is to gather granular data for better system operation while avoiding unnecessary maintenance cycles. For example, if a system can be monitored and studied in real time, it is possible to look for the indications of a potential part failure, allowing engineers to proactively fix or replace the part.

Over time, this data can also be used to understand system wear and part longevity, allowing engineers to have better insight into maintenance cycles and system inefficiencies — prolonging system lifespan. 

Watlow’s sensors, control architecture and dashboard all work together to allow Raven SR’s engineers to capture data and use it proactively to keep system efficiency and uptime as high as possible.

Transforming waste into fuel is one of the most significant ways to become resource efficient and contribute to the Paris Agreement’s targets. Companies like Raven SR are key in driving this, but without thermal systems that encompass Industry 4.0 technology, the efficiency of these crucial processes becomes limited.

For more information about Watlow, Industry 4.0 or environmental applications of thermal systems, visit www.watlow.com. Or, to find out more about Raven SR and its projects, visit www.ravensr.com/

This article can also be found in the issue below.

Adhesives and sealants specialist Henkel is extending its support to manufacturers and MRO teams through a comprehensive range of survey and training services, with the aim of helping them reduce costs and improve quality through the use of Henkel products, including the world-famous LOCTITE® brand.

Rising energy costs, raw material shortages and fluctuating currency markets have posed significant challenges for manufacturers, impacting their bottom lines. To address this, manufacturers are seeking ways to maintain and improve the performance of products and machinery, while contending with changing consumer demands, supply chain disruptions and increased competition.

Innovation and agility are essential for keeping a competitive edge. Henkel’s line of LOCTITE® adhesives, sealants and equipment offer cost-effective solutions to improve quality and increase efficiency, helping manufacturers meet these challenges.

To help businesses make informed choices, Henkel provides detailed surveys of manufacturing plants and processes to identify potential cost-savings and improvements. This involves a tour of production lines and sub-assembly areas to document cost reduction opportunities, as well as potential challenges in maintenance, repair and overhaul (MRO).

Using the findings from these surveys, Henkel can then deliver tailored seminars at manufacturers’ sites, covering topics such as bonding, sealing, dispensing and curing equipment. Attendees are encouraged to bring parts and specific design challenges to the workshop.

Henkel’s industry specific application training helps manufacturers in selecting the proper adhesive and equipment for their assembly challenges. The training incorporates technical guides, application information and case histories. Upon completion of a survey, manufacturers receive a detailed audit of their operations, recommendations for process improvements, a report of cost-saving opportunities, as well as a cost analysis.

Gavin Jackson, Applications Engineering Manager at Henkel, said:

“We’re dedicated to providing solutions that help our customers save costs and improve quality. We understand that manufacturers face a multitude of challenges, and our team is committed to working closely with them to address their specific needs and give tailored solutions.

“Our LOCTITE line of products, the surveys and the training are designed to assist our clients, increase efficiency, reduce waste, save time and costs; and ultimately achieve manufacturing goals in the long run, too.”

For more information on Henkel, visit www.henkel-adhesives.co.uk, or to schedule a LOCTITE Cost Reduction Line Survey, click here.

This article can also be found in this issue below.

The manufacturing industry is in the midst of a major transformation - the largest since the Industrial Revolution - driven primarily by a confluence of increased automation and a labour shortage.

Manufacturers of all kinds are still finding their way in this new digitized landscape; for those that don’t just want to survive, but thrive, digital transformation will be essential.

RealWear provided a remote assistance solution for its manufacturing operations to help PepsiCo safely improve its production line efficiency through its wearable technology. In a recent episode of BBC's Inside the Factory, PepsiCo’s Walkers Crisps factory, in Leicester, UK, showcased how they have integrated RealWear's solution to streamline the factory’s maintenance and service processes.

When a machine breaks down, it can cause a significant loss in production time and ultimately revenue. Traditionally, the process of getting a specialist engineer on-site to repair the machine would involve significant travel time and expenses. However, with RealWear's wearable technology, the engineer can be called in from anywhere in the world, reducing downtime and increasing efficiency and productivity.

RealWear's solution allows a subject matter expert to see what the on-site technician sees through a head-mounted wearable system. The engineer can then provide real-time instructions and guidance, even when the issue is in a high-noise zone, allowing for safe and efficient repairs. Additionally, the device is designed to be hands-free, allowing the technician to have both hands available to work, while receiving the guidance from the remote engineer.

PepsiCo’s implementation of RealWear's solution has resulted in significant improvements in its production line efficiency. The ability to repair machines quickly and efficiently has resulted in less downtime, increasing the production capacity, and reducing revenue loss. The technology has also eliminated the need for travel, saving on expenses and reducing their carbon footprint.

In conclusion, RealWear's technology has enabled PepsiCo to improve maintenance and service processes, resulting in increased production line efficiency and cost savings.

Click the link for more info.

https://bit.ly/40aaAa1

SOCOTEC UK has been shortlisted in four categories at the prestigious 2023 Ground Engineering (GE) Awards. The winners of the awards will be announced at a gala dinner ceremony, taking place on Wednesday 12 July 2023, at the JW Marriott Grosvenor House Hotel in London. 

The GE Awards celebrate exceptional individuals, projects, and organisations in the ground engineering sector. This year’s event is expected to bring together some of the biggest names in the industry to recognise outstanding achievements in various categories. 

SOCOTEC has been shortlisted for six submissions in the following four categories:

1. Ground Investigation Specialist of the Year 
2. International Project of the Year (SOCOTEC Italia)
3. Ground Investigation Project of the Year
   • Hurst Castle Ground Investigation
   • Hampshire Water Transfer and Water Recycling Project
   • Lyneham Banks
4. Health and Safety Award 

The recognition of SOCOTEC in these categories is a testament to the company's commitment to excellence, innovation, and client satisfaction. SOCOTEC’s expertise and experience have been critical in delivering high-quality services and solutions in the ground engineering sector.

SOCOTEC UK’s Ground Investigation Engineering Manager, Peter Hepton, expressed his delight at the nominations, saying, "We are thrilled to be recognised for our hard work, dedication, and expertise in the ground engineering sector. These nominations highlight our commitment to providing outstanding services and solutions to our clients, and we are proud to be shortlisted alongside other esteemed organisations."

The entire SOCOTEC team looks forward to the awards ceremony and wishes all the other nominees the best of luck.

To view the full shortlist, click here.

From May 24-25, 2023, the leading trade show and branch meeting for industrial maintenance will take place in Dortmund: the maintenance Dortmund. Around 200 exhibitors will present tools and equipment for the maintenance of machines and plants as well as services and software solutions for "smart" maintenance. The industry is already looking forward to a live meeting at a high level - and to a fully booked trade show which, thanks to numerous well-known new exhibitors, is more diverse than ever before. So this year, a visit will be particularly worthwhile.

https://www.maintenance-dortmund.de/en/

This article can also be found in this issue below.

Enerpac announces the ML40 Mini Lift Gantry with 40-ton lifting capacity. Designed to be portable, simple to set up, and easy to use, it is the ideal solution for machinery movers, plant relocation services and medical equipment installers who need to move machines and equipment in compact spaces.

Machinery Relocation

When moving machines or parts of machines either within the same building or to another building, space is always limited. The ML40 Mini Lift Gantry has a compact size ideal for moving equipment around old installations. Its short, collapsed height (1.97m) and narrow width (750mm) means the ML40 Mini Lift Gantry can get into spaces that other equipment cannot. The gantry can also rotate the load (up-end or down-turn) to move through the building. 

Machinery Installation or Replacement

When performing a new equipment installation or the removal and installation of equipment for maintenance or repair, industrial movers are often faced with minimal headroom and many obstacles. The ML40 Mini Lift Gantry makes it easy to offload the equipment from the delivery vehicle and re-position it for use in the facility. Additionally, it makes it easy to assemble the equipment in sections and then move it as a complete unit into final position. When replacing old equipment, disassembly in sections may be easiest method of removal. The small size of the ML40 Mini Lift Gantry makes it easier to mobilise and set up. 

Medical Equipment Installation

Installing medical equipment typically involves difficult access within the hospital. Medical equipment is often delicate and needs smooth, even lifting. Standard synchronised lifting on the ML40 prevents damage to equipment. The compact size of the ML40 Mini Lift Gantry is also a critical feature. It is easy to transport and fits into most freight elevators. Single phase voltage 115 or 230 VAC operation eliminates need for long, high voltage power connections or noisy generators.

ML40 Mini Lift Gantry – powerful lifting capability

When it comes to safety, the ML40 Mini Lift Gantry features standard synchronised lifting and control and load readout to ensure safe and level lifting. A wireless pendant keeps the operator away from equipment during operation. The ML40 is also versatile. Its high capacity and simple set up mean even jobs with challenging or uncertain information can be managed without issue. It is also easy to use. A simple set up means even relatively new rigging operators can operate the equipment.

ML40 Mini Lift Gantry has 40 ton capacity (4 legs) in all three lifting stages. It is 750 mm wide, 1.97 m collapsed height and 5.5 m extended height. Each leg weighs 1350 kg with oil. The ML40 uses an industry standard 610mm (24-inch) track gauge, and can be operated without support track with considerations for load and ground conditions. It uses the same accessories as the Enerpac SL100 gantry such as track, header beam and side shifts. For ease of deployment, the ML40 Mini Gantry features freewheel operation for transportation and set up, and a roll cage for overhead lifting and/or towing and pushing for installation.

To learn more about the latest Enerpac tools, visit the Enerpac Innovations page on www.enerpac.com. 

This issue can also be found in the issue below.

Track assets and manage inventories more efficiently in complex industrial environments with (fully customisable) RFID labels that can fit any surface. Scan and identify, or locate multiple items at once from a distance, or 1 by 1 in close proximity.

Brady’s UHF RFID LED Label for general application is designed with the intention to locate a tagged item or a group of items from the field by means of LED light. The label is suitable for use outdoor and indoor, good read ranges, and UV exposed environment.

The label contains a small green LED-light that illuminates when triggered by the radio waves of the Brady handheld & fixed RFID readers (within 3.5 m), when the label is selected on-screen. This speeds up picking & locating items in warehouses, data centers and in distribution. Especially in contexts where many items are stored very close to each other, the UHF RFID LED label helps picking the right item, server, or package much faster.

Using an RFID reader, metadata & information can easily be added to the label, which is equipped with 1312 bits of memory, sufficient to store up to 164 characters. The label is designed for applications on non-metal surfaces.

Find out more about LED RFID labels from Brady>>

Brady Corporation

www.brady.co.uk

Most companies are familiar with the manual T Card Board for planning and coordinating tasks and T Cards Direct have been at the forefront of providing bespoke systems for clients. Having a “Go to Board” at your fingertips can help staff get on with the day-to-day business and assist with customer service.

Over the past 12 years T Cards Direct have developed a simple Online system designed to be used like the tried and tested manual system. Clients often need a clear and precise status of work, and this does exactly that but with all the benefits and analysis tools available digitally. The latest release for T Cards Online is being showcased and will include some exciting new features.

Simple to customize to your application it can seriously help improve the efficiency of your operation. Benefits are seen immediately as you can start using the software as soon as you have registered for the NO-Obligation 21-day trial. This includes our UK based support team providing personal assistance to get you up and running with the minimum of fuss.

We have been a regular exhibitor for the past 20 years, initially promoting the manual systems and now demonstrating the power of the Online System. We have always found it a busy and productive show with a broad range of companies interested in T Cards Online. It is a great opportunity to explore the benefits of the system. The venue has certainly improved over the years and access is fantastic compared to other venues in the UK.

 The new release being showcased is an exciting development for planning and the control of workflow. It includes a new “What IF” engine that can generate automated workflows.

Think of it as an “If This Then That”. Action then consequence. For example, if a card or job is moved to a pre-defined position a consequence or alert is automatically triggered. That consequence could be a clear visual change in colour or an email alert or just a flashing card on the screen. You decide.

One application already being used is to highlight delays when a due date is passed. Showing automatically on the screen rather than waiting for a report or trawling through pages of data.

Come and see how T Cards are the proven management tool to help keep track, allocate and improve efficiency.

www.tcardsdirect.com

This article can also be found in the issue below.

 SOCOTEC UK’s Monitoring team were approached to provide a temporary/rental system to monitor the railway assets adjacent to the temporary works on a railway bridge, located on River Way, Harlow, Essex. The client, Essex Highways, and Network Rail required assurance that any structural movements were in-line with predicted ground movements and that any significant movement trends could be identified at an early stage.

SOCOTEC UK’s Monitoring team proposed a monitoring system that included 75m of track tilts installed at 3m c/c spacing on each line, critical rail thermometers, both tilt and vibration monitoring on the bridge piers, and tilt monitoring on the surrounding OHLE supports. SOCOTEC’s scope also included baseline and close-out track geometry surveys, with additional surveys as required if any significant movement had been detected by the automated system. This provided further assurance to the client and Network Rail that all movements were being accurately reported.

The installation works and initial track geometry survey were completed over a single possession lasting 5.5 hours. The data was hosted online, giving the client and Network Rail live access to the data and direct email alerts if any trigger values were exceeded throughout the duration of works.

SOCOTEC UK’s temporary monitoring system provided assurance to the client and Network Rail that any structural movements were in-line with predicted ground movements and that any significant movement trends could be identified at an early stage. This allowed for quick response times and corrective action if needed, minimising potential downtime or disruptions to train services.

SOCOTEC UK’s monitoring system provided effective and reliable monitoring of railway assets adjacent to a temporary worksite. The automated system allowed for a quick and accurate reporting of any significant movement trends, providing assurance to the client and Network Rail that their assets were being monitored and protected. 

If you have a monitoring project to discuss, please get in touch.
Contact us.