Product Focus: Materials
Enzyme Boosts Profits for Ethanol Plants
Avantec Amp is an enzyme that improves yield and throughput in corn ethanol production, while increasing corn oil extraction and significantly reducing the need for some of the harsh chemicals often used in ethanol production. The manufacturer reports that this product could earn a 110-million gal/yr ethanol plant up to $2.5 million per year of additional profits. Because it frees oil bound in the corn germ, the enzyme may help to boost corn oil output, which has become an increasingly important revenue stream for corn ethanol producers. The enzyme also reduces or eliminates the need for chemicals used to control and accelerate production processes, including urea, surfactants, and ammonia, which enhances safety and reduces costs.
Novozymes
Elastomer Boasts Strength and Flexibility
This high-strength silicone has a tensile strength up to 50% higher than other silicone elastomers on the market and material properties that combine to make it strong but also soft and pliable. The elastomer’s strength, elongation potential, and low durometer are particularly attractive for the design of medical devices such as balloon catheters. The material also bridges the strength gap that prevents manufacturers from upgrading from latex to silicone in some demanding applications, such as mechanical pumps. These high-strength silicones give design engineers the ability to innovate beyond the conventional performance limitations of silicone elastomers, and improve devices by making them thinner, stronger, and more resilient.
NuSil Technology
Topical Ingredients Answer Consumer Demands
As consumers focus more on health and wellness, they are demanding more solutions to address minor ailments and appearance issues that they may have previously ignored or overlooked. This topical ingredient portfolio helps manufacturers drive innovations in topical over-the-counter (OTC) products that treat scars, stretch marks, acne, and other skin conditions. The broad range of 19 products includes formulations for creating a variety of product forms and textures, including gels, sprays, lotions, and creams. The ingredients are produced at manufacturing sites with healthcare oversight, audits, and testing to assure quality. Raw material tests are performed on each batch and an elemental impurities test is performed biannually.
Dow Corning
Material Improves Fire Resistance of Insulation
TEROL 649 aromatic polyester polyol is suitable for manufacturing rigid foam insulations, particularly spray polyurethane foam (SPF). It features enhanced solubility, improved performance in the event of a fire, and compatibility with new blowing agents. The material reduces the need for polyether polyols and flame retardants, and may eliminate the use of brominated flame retardants (BFRs). With this product, users can design insulation products that enable customers to realize energy savings.
Huntsman
Coatings and Linings Resist Corrosion
Process plant areas that undergo frequent and severe chemical exposure, thermal shock, or mechanical stress can benefit from surface coatings that protect against the corrosive effects of aggressive substances. Flowchem is a family of seamless, elastomer-modified vinyl ester resin coatings and linings designed for harsh industrial environments, including those found in the power, oil and gas, and petrochemical sectors. Vinyl ester resin — a hybrid of polyester resin strengthened by the addition of epoxy resin — protects against concentrated and aggressive acids, alkalis, and solvents, including sulfuric, nitric, and hydrochloric acid, as well as ethanol, butane, and methanol. These durable coatings resist abrasion and temperatures up to 350°F. Fast curing minimizes downtime and production loss.
Flowcrete
Thermoplastics Enable Lightweight Designs
100 eXtra Performance (XP) thermoplastic compounds are formulated with higher strength, modulus, and impact properties than standard chopped-fiberglass-reinforced polypropylene (PP) compounds. They have strength, stiffness, and impact resistance similar to the manufacturer’s very long fiber (VLF) compounds, but have the lighter weight and chemical resistance of standard polypropylene. They have up to 20% higher modulus values and twice the impact resistance of common glass-fiber-reinforced polypropylene at similar loadings. Their inherent chemical resistance and nonhygroscopic nature make 100 XP thermoplastics suitable alternatives to nylon or other compounds in applications where moisture can reduce load-bearing capabilities. Additives may be incorporated to create robust compounds that meet demands such as resistance to long-term heat aging, cold-weather impact resistance, flame retardance, or ultraviolet protection. The products are supplied as standard pellets that can be easily injection molded into large or small complex geometries.
RTP Co.
Plastic Allows Thinner Wire and Cable Insulation
Fluon C88AXMP-HT is an ultra heat-resistant grade of ethylene tetrafluoroethylene (ETFE) that maintains its performance characteristics at temperatures up to 200°C. It is 20% less dense than fluorinated ethylene propylene (FEP), so less product is required and cables and wires can have a much thinner insulation layer. A high melt flowrate enables fast processing line speeds. Other benefits include improved crack and abrasion resistance and enhanced mechanical strength. One product grade is suitable for wire cross-sections from 0.3 mm 2 to 10 mm 2 .
AGC Chemicals Americas, Inc.
Basic Emulsifiers Are an Economic Option
In some drilling conditions, high-performance emulsifiers are unnecessary and present an opportunity to reduce operating costs. The XPLOR basic emulsifiers are an economic alternative to the high-performance emulsifiers used in some oilfield applications. These products meet basic performance requirements for drilling mud without sacrificing quality. They can be used with mineral-oil- and diesel-based solvents, and can be effective at converting or treating drilling fluid.
Georgia-Pacific
Fluids and Solids Handling
Container Is Strong But Lightweight
The Dura-Lite family of liquid containers addresses customer demands for stronger and lighter gallon and half-gallon square bottles. The design features radii, ribs, and angles that achieve weight reduction without sacrificing performance. Reduced weight helps achieve environmental sustainability goals by minimizing the amount of plastic needed per container. The container has been vetted through multiple rounds of fill-line and consumer testing, and is suitable for most dairy or water supply chains.
Consolidated Container Co.
Pipeline Connectors Avoid Process Shutdown
Traditional steam trapping assemblies often require plant shutdown for new trap installation, which takes significant time and reduces plant output. The PC3000 and PC4000 pipeline connectors, with single or double isolation, allow steam traps to be installed without the need for process shutdown. Benefits include an ASME 600-rated forged body that is compatible with line temperatures up to 800°F, a fully shrouded piston valve stem that resists corrosion, and a strainer that protects the trap from debris entrained in the condensate. The connectors are suitable for applications where steam traps are used on tracing and mainline drainage systems in the oil, petrochemical, and chemical industries.
Spirax Sarco, Inc.
Handle Aids Manual Valve Actuation
The Speed Handle is available as an option for the manufacturer’s manual butterfly valve that enables smoother and faster single-handed revolution of the handwheel for quicker valve actuation. The glass-reinforced polypropylene glycol (PPG) handwheel is available in red or blue, and the handle grip is made of nylon with a stainless steel 400 chromate-treated bolt and stainless steel hex nut. The Speed Handle can be installed on an in-service butterfly valve or ordered on a new valve. Compatible valves include the manufacturer’s Type-57, Type-57IL, Type-57LIS, Type-56, and Pool-Pro butterfly valves in sizes of 1.5 in. to 16 in.
Asahi/America
Air Knives Cut Out Static
Static can attract dust and contaminants, and static discharge can damage electronic equipment and shock personnel. These ionizing air knives neutralize the static that can occur during the handling of various materials and objects, which makes material handling simpler and safer. A static-neutralizing bar generates positively and negatively charged ions that are carried by a uniform sheet of amplified air to the item being handled. Interchangeable shims allow the airflow to be adjusted to meet specific application requirements. The air knives are suitable for moving webs, films, sheets, strips, and other large assemblies and objects. The system requires compressed air and a power supply, and the knives are available in lengths from 6 in. to 24 in.
Vortec
Instrumentation
Analyzer Performs Inline Orthophosphate Measurements
The Liquiline system CA80PH analyzes and monitors orthophosphate in water treatment applications. The analyzer automatically obtains a water sample from the process, filters it, adds the reagent, measures the concentration, and then cleans the sampling system with compressed air or water in preparation for the next test. Analyses can be scheduled as often as desired, and a typical sample analysis takes between eight and eleven min, depending on the method used. It is available in four measuring ranges — two low ranges use the standard molybdenum method, and two high ranges use the molybdate vanadate method. A unique chemical manager reduces chemical consumption, and an energy-efficient cooling module maintains reagent shelf life for up to 12 weeks.
Endress+Hauser
Analyzer Monitors Product Quality Continously
The LiquiSonic inline analyzer measures concentrations of ingredients in liquid products directly in vessels or pipes of any size. The ability to monitor product quality continuously in real time allows resources to be used more efficiently and helps to prevent off-specification batches. The instrument employs sonic velocity measurement to provide precise, reliable concentration values that are updated every second. This meter is more robust and requires less maintenance than meters that use other measurement techniques, and it can be integrated into a process without a bypass. Measurement data are transferred online to PCs or process control systems. A trend view on the control display shows a comprehensive view of the process, and if a value is out of range, a signal is sent immediately to the operator.
SensoTech
Controller Manages Data Remotely
A pressing challenge for industrial operations is converting data from complex automation systems into relevant, actionable information. This challenge is even more difficult when the assets and data that must be managed are remote, for example at oil or gas exploration and production sites. The RTU2020 process controller gives users the ability to manage complex automation and control systems in remote locations. The unit withstands harsh environments, and, because it consumes little energy, it is ideal for use with solar power. Maintenance can be performed remotely, and monitoring and diagnostics can be done in minutes. The controller also reduces travel and increases safety because personnel do not need to travel to the field to address device issues.
Honeywell
Pressure Measurement Innovations Solve Tough Installation Challenges
Process control engineers are often challenged by the fact that existing technologies do not meet the measurement needs of harsh operating environments. The Rosemount 3051S thermal range expander with UltraTherm 805 oil fill fluid and the Rosemount 3051S high static differential pressure transmitter can handle the extended temperature and pressure ranges that are encountered in challenging operating environments. The thermal range expander enables pressure measurements in processes operating at temperatures up to 410°C (770°F) and in variable ambient conditions, and it does not require impulse piping or heat tracing, which can be costly, maintenance-intensive, and difficult to install. The high static differential pressure transmitter provides reliable flow measurements in high-pressure applications up to 15,000 psi (1,034 bar).
Emerson
Cement Analyzer Predicts Gas and Liquid Migration
The Model 5265MG gel-strength analyzer directly measures the development of a well cement slurry’s gel strength under downhole conditions, which helps users optimize cement slurries and accurately determine the potential for annular gas and liquid migration. A precision motor coupled with a reaction force transducer enables the instrument to precisely measure phase changes. A magnetically coupled shaft keeps the motor and measurement electronics outside the high-pressure and high-temperature environment. The motor is capable of speed control as low as 0.2 degrees per minute in the gel phase and up to 150 rpm under slurry conditions. The analyzer can operate in environments with a maximum temperature of 400°F (204°C) and a maximum pressure of 20,000 psi. The system can fit into a standard single-cell ultrasonic cement analyzer (UCA) or static gel-strength analyzer (SGSA) cylinder.
Chandler Engineering
Operations and Maintenance
Stretch-Wrapping Machine Simplifies Packaging
The Wrapper Tornado orbital stretch-wrapping packaging machine secures loads to pallets as a single unit for improved protection, safety, stability, and transportation. The machine wraps the plastic film around a horizontal axis, which allows the load to be wrapped and attached to the pallet while raised on a forklift or fed by conveyor. This ability renders turntable stretch-wrapping machines obsolete and eliminates the need for banding and strapping. The apparatus is suitable for securing loose or packaged items, including metal and plastic components and filled drums, containers, and bags, as well as oversized irregularly shaped loads. The manufacturer offers three standard models, but will also fill custom orders to accommodate virtually any size requirement.
TAB Industries
Labeler Has Multiple Operating Modes
The LW-PX900 is a thermal transfer printer for labels, heat-shrink tubes, and bar-codes that is portable, rugged, and PC-compatible. It is designed for use in safety, compliance, and quality improvement activities, as well as other labeling applications. The pick-and-print operating mode automatically pauses after printing and cutting the first label in a series and resumes after the label has been removed, so the user does not need to type and print labels one at a time. The mixed-length mode lets the user create a strip of variable-length labels with a half-cut for easy removal and application, as well as reduced tape waste. The drop-strop, which works with a single label or a series of labels, holds a label after it is cut so it does not drop out of the printer. Removable magnetic feet allow the printer to be mounted on a metal surface. The manufacturer offers a lifetime warranty.
K-Sun
Beam-Mounted Light Fixture Resists Corrosion
The HALP-48-2L-LED-SIBAB-SS stainless steel hazardous area light-emitting diode (LED) light fixture can be easily mounted to an I-beam. It is designed to handle the rigors of wet and corrosive environments. A polyester housing reinforced with glass fiber, a poured-in gasket that provides reliable sealing, and an impact-resistant acrylic diffuser contribute to the corrosion-resistant design. Eight corrosion-resistant stainless steel latches secure the lamp cover to the housing and provide a firm lock against the seal to prevent drips and water intrusion. The 28-W LED lamp produces 30% more illumination than standard fluorescent lighting, and is more reliable, stable, and energy efficient. The mounting mechanism allows the light to be attached to an I-beam without penetrating the beam, and it can be oriented to offer upward or downward lighting.
Larson Electronics
Software & Information Technology
Bundle Streamlines Data Access and Reporting
The Wonderware Office Bundle streamlines access to and interpretation of operations data, which helps plant managers and executives identify process improvement opportunities and make more-informed business decisions. Plant management can evaluate key performance indicators (KPIs) by analyzing data in near-real-time from a variety of devices and sources, and the software’s native connectivity to plant floor and business applications simplifies these activities. The foundation of the bundle is Wonderware Historian, which can collect information from any industrial data source. By combining this data trove with a reporting interface, Wonderware Office Bundle delivers valuable business information to all stakeholders. The software package is tightly integrated with Microsoft Office and features the Wonderware SmartGlance app that provides fast access to KPI reports from any mobile device.
Schneider Electric
Software Recognizes Piping System Deficiencies
With several improvements to existing features, including new functionality, additional device operating modes, 15 new calculations, enhanced reporting, and automatic solutions for over-controlled scenarios, PIPE-FLO Professional v15 helps users recognize and troubleshoot piping system inefficiencies. Heat transfer functionality is augmented with thermal analysis calculations and devices to model heat sources, heat sinks, and heat exchangers. New devices and device operating modes account for temperature control, suction pressure, and discharge pressure. The update also boasts improved identification of over-controlled scenarios and automatic solutions for over-controlled scenarios involving pumps. Those designing, commissioning, operating, or modifying fluid piping systems may find this software helpful.
Engineered Software, Inc.
Simulation Platform Is Now More Robust
COMSOL Multiphysics Version 5.2 and the updated COMSOL Server include new features, improved stability and robustness, and faster execution. Major upgrades to the Application Builder available in COMSOL Multiphysics include the new editor tools for easy creation of user interface components, commands for dynamic updates of graphics, and more control over the deployment of simulation apps. The Application Builder also includes more than 50 new and updated example apps in the Application Library. Simulation specialists can now bring any model parameter, physics setting, or result, such as numerical data and plots, into the user interface of an app with a few mouse clicks. The updated COMSOL Server allows simulation apps on a corporate network or cloud to run five times faster than previously.
COMSOL
Search Engine Provides Visual Data
Engineers preparing reports, presentations, website content, or other materials may find Graphiq Visualization useful. The tool draws from a deep knowledge base and delivers pre-designed visualizations that are live-updating, embeddable, and responsive. Over 10 billion pre-designed graphs, plots, maps, and other representations provide the necessary information to support a range of corporate-research or enterprise projects. A new feature called Freeze allows users to take a snapshot of any visualization so only the information relevant to a user’s project is displayed. The tool is free to use on the company’s website.
Graphiq
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