Thermal Mass Flowmeters: Advancing Efficiency in Industrial Applications

Thermal mass flowmeters have become indispensable tools in various industries. They provide accurate and reliable measurements of gas flow rates. Their unique operating principles and performance characteristics make them suitable for applications ranging from boilers to wastewater aeration, oxidizers, and flares.

Understanding Thermal Mass Flowmeters

At the core of thermal mass flowmeter technology lies the principle of thermal dispersion. These devices measure the mass flow rate of gases by detecting temperature changes. Two temperature sensors are used: one heated and one unheated (reference). As gas flows over the heated sensor, it carries heat away, causing a temperature drop proportional to the mass flow rate. The flowmeter measures the energy required to maintain the temperature difference between the sensors, thereby calculating the mass flow directly without needing pressure or temperature compensation.

Performance and Advantages

Thermal mass flowmeters offer several advantages over other flow measurement technologies. They provide direct mass flow measurements, eliminating the errors associated with density fluctuations. Their wide turndown ratio allows for accurate readings over a vast range of flow rates, making them ideal for processes with variable demand. Additionally, they exhibit low-pressure drop and minimal intrusion into the flow, preserving system efficiency and reducing energy costs.

Common Applications

In boiler systems, thermal mass flowmeters monitor fuel gas and combustion air to optimize combustion efficiency, reduce emissions, and ensure safe operation. Accurate gas flow measurement enables precise control of the air-to-fuel ratio, leading to energy savings and compliance with environmental regulations.

Wastewater treatment facilities rely on thermal mass flowmeters for aeration control. By measuring the flow of air or oxygen injected into aeration basins, operators can maintain optimal dissolved oxygen levels, promoting efficient microbial activity for waste breakdown. This control reduces energy consumption and enhances treatment performance.

Oxidizers, used to destroy volatile organic compounds (VOCs) and hazardous air pollutants (HAPs), benefit from thermal mass flowmeters in monitoring and controlling the flow of process gases. Precise flow measurement ensures that oxidizers operate within design parameters, maximizing destruction efficiency and minimizing operational costs.

In flare gas systems, thermal mass flowmeters provide critical data for compliance and reporting. Accurate measurement of flare gas helps monitor emissions, detect leaks, and optimize flare performance. The ability to handle low flow rates and variable gas compositions makes thermal mass flowmeters particularly suitable for flare applications.

EPI Thermal Flowmeters: The FAT Probe Advantage

EPI offers advanced thermal flowmeter solutions that address common challenges in industrial applications. Their FAT probe stands out with its ability to perform accurately with as little as 5-7 pipe diameters of straight-run, about half the length required by typical thermal mass flowmeters with flow conditioners. This feature proves invaluable in retrofit projects or installations with limited straight-run piping, where space constraints often hinder the placement of conventional flowmeters.

The FAT probe's design provides engineers with greater flexibility in system layout and reduces installation costs. Its accuracy and reliability remain strong despite the reduced straight-run requirement, ensuring consistent performance in demanding environments. By choosing EPI's thermal flowmeters, engineers can enhance process control, improve efficiency, and achieve compliance with industry standards.

Thermal mass flowmeters are crucial in optimizing industrial processes by providing precise gas flow measurements. Their application in boilers, wastewater aeration, oxidizers, and flares demonstrates their versatility and effectiveness. EPI's innovative thermal flowmeters, notably the FAT probe, offer significant advantages in installations with space limitations. Engineers seeking efficient, reliable, and flexible flow measurement solutions will find EPI's products valuable to their systems.

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Enhancing Safety and Hydrogen Purity in Water Electrolysis with Advanced Gas and Moisture Analyzers

Download Panametrics' white paper titled "Ensuring Process Safety and Product Quality in Water Electrolysis Using Oxygen, Hydrogen, and Moisture Analyzers" to learn how advanced analyzers enhance safety and ensure hydrogen purity in water electrolysis processes.

As the global demand for clean energy intensifies, hydrogen emerges as a promising solution to reduce carbon emissions and transition toward a sustainable future. Water electrolysis, a critical method for producing green hydrogen, requires the highest levels of hydrogen purity. Contaminants can compromise the efficiency of hydrogen as a fuel and the safety of its production and utilization. Gas and moisture analyzers play an indispensable role in maintaining the integrity of water electrolysis processes, ensuring the highest levels of hydrogen purity, and enhancing safety.

Hydrogen's effectiveness as an energy carrier hinges on its purity. Impurities such as oxygen, nitrogen, and moisture can harm hydrogen fuel cells, industrial applications, and storage systems. For instance, oxygen contamination can lead to explosive mixtures, posing significant safety hazards. Moisture can cause corrosion in pipelines and storage tanks, while nitrogen can reduce the calorific value of hydrogen, affecting its performance. Therefore, monitoring and controlling these contaminants become essential for any hydrogen production facility aiming for excellence.

Several factors can introduce impurities into the hydrogen stream in water electrolysis. The water and electrolytes might contain dissolved gases or minerals that transfer into the hydrogen produced. Gas crossover, especially in proton exchange membrane (PEM) electrolyzers, can occur when hydrogen and oxygen permeate through the membrane, leading to cross-contamination. Also, system leaks can allow atmospheric gases to infiltrate the hydrogen stream. Addressing these challenges requires precise and continuous monitoring, where gas and moisture analyzers come into play.

Gas analyzers serve as the first line of defense by detecting and quantifying unwanted gases within the hydrogen stream. They provide real-time data on contaminants like oxygen and nitrogen, enabling operators to make immediate adjustments to the process. For example, if oxygen levels rise beyond acceptable limits, operators can investigate potential membrane failures or system leaks promptly. This proactive approach not only maintains hydrogen purity but also prevents hazardous situations that could arise from combustible gas mixtures, underscoring the preventive role of gas analyzers.

Moisture analyzers, on the other hand, focus on measuring the water vapor content in the hydrogen gas. They play a crucial role in preventing several operational issues. In fuel cells, high moisture levels can degrade the proton exchange membranes, reducing their efficiency and lifespan. Moisture can also freeze in cryogenic systems, causing blockages and equipment damage. By keeping moisture levels within specified parameters, moisture analyzers help prevent corrosion, maintain the performance of fuel cells, and ensure the smooth operation of storage and transportation systems, underscoring their role in preventing operational issues.

Integrating gas and moisture analyzers into water electrolysis setups enhances safety and efficiency. These instruments provide the data necessary to optimize the electrolysis process, such as adjusting the operating conditions to minimize gas crossover or improving the purity of input water and electrolytes. They also help facilities comply with industry standards and regulations regarding hydrogen purity, crucial for applications in sensitive sectors like aerospace, medical, and energy generation.

Moreover, the use of these analyzers contributes to long-term cost savings. Facilities can avoid costly repairs, downtime, and equipment replacements by preventing contamination-related issues. High-purity hydrogen also commands a premium in the market, offering a competitive advantage to producers who consistently deliver superior quality.

The commitment to producing pure hydrogen aligns with the broader environmental sustainability goals and technological advancement. As industries adopt hydrogen as a clean energy source, safety, reliability, and performance expectations continue to rise. Gas and moisture analyzers represent the technological advancements that make it possible to meet these expectations. They embody the precision and control required in modern industrial processes, ensuring the push toward a hydrogen economy is effective and safe.

Gas and moisture analyzers are critical components in the water electrolysis process for hydrogen production. They enable detecting and controlling impurities that can compromise hydrogen purity, safety, and efficiency. These instruments provide real-time monitoring and data analysis, allowing operators to maintain optimal conditions within the electrolysis system. As the world moves toward greater reliance on hydrogen as a clean energy source, the role of gas and moisture analyzers will become even more significant. Investing in high-quality analyzers is a technical necessity and a strategic move supporting achieving a sustainable and carbon-neutral future.

Discover how to enhance process safety and product quality in water electrolysis by utilizing advanced oxygen, hydrogen, and moisture analyzers. Panametrics in-depth white paper explores these analyzers' vital role in maintaining hydrogen purity and optimizing electrolysis processes. Unlock valuable insights and practical solutions to ensure your hydrogen production meets the highest standards. Download the white paper now at https://www.h2-view.com/white-paper/ensuring-process-safety-and-product-quality-in-water-electrolysis-using-oxygen-hydrogen-and-moisture-analyzers/2108903.article/#whitepaperform.

Red Lion Rolls Out High-Performance RTUs for Demanding Industrial Applications

Industrial Remote Terminal Units (RTUs) are critical components in industrial automation and control systems. These devices interface with field equipment, gather data, and transmit it to a central control system. RTUs typically operate in harsh industrial environments, monitoring and controlling machinery, processes, and other systems. They are often used in manufacturing plants to provide real-time data on system performance, enabling operators to make informed decisions that enhance efficiency, reduce downtime, and improve safety.

RTUs have input/output (I/O) interfaces to connect with sensors, actuators, and other devices. They collect data from these sources and communicate it to a supervisory control and data acquisition (SCADA) system or other central controllers via wired or wireless networks. In addition to data acquisition, RTUs can execute control commands, automate processes, and provide remote monitoring capabilities, making them essential for maintaining the smooth operation of industrial processes and ensuring that plants can operate continuously and efficiently, even in remote or hazardous environments.

Red Lion Controls introduced two new programmable Remote Terminal Units (RTUs), the VT-MIPM-138-D and VT-MIPM-248-D, specifically designed to excel in extreme industrial environments. These rugged industrial controllers come with onboard I/O and handle demanding process-oriented applications such as water and wastewater treatment, oil and gas production, and other advanced automation systems.

These RTUs offer robust, standalone control for even the most challenging industrial processes. They feature automatic datalogging, timestamping, and logging capabilities for trends, alarms, and event sequences, providing operators with comprehensive visibility into their operations. Red Lion Workbench’s IEC 61131 programming environment allows extensive programming and troubleshooting, while ISaGRAF support ensures backward compatibility. The units also boast an open system design, supporting Ethernet TCP, Modbus, and Linux.

Ideal for use in water, wastewater, and oil and gas processing facilities, the VT RTUs are pre-certified and allow operators to scale from 1 to over 1000 stations quickly. They feature multi-user connectivity through 10/100 Ethernet ports, RS232 and RS485 interfaces, and up to four communication ports. The onboard I/O includes a mix of digital inputs, digital outputs, analog inputs, and analog outputs. Advanced communication capabilities, such as reporting on exceptions, store and forward, and peer-to-peer networking, further enhance their utility.

Designed for hazardous environments, these controllers are rated for operating temperatures ranging from -40°C to 70°C and carry UL Class I, Division 2, CE, and ABS Type certifications.

For more information about these Red Lion Controls RTUs in Utah, Western Wyoming, Idaho, Northern Nevada, Arizona, New Mexico, Colorado, Eastern Wyoming, and Montana contact Process Technology, Inc.

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801-264-1114

Precision and Purity: The Advanced Fluid Process Pumps from SMC

High-purity fluid process pumps are specialized devices engineered to handle fluids without contamination, ensuring the highest levels of cleanliness and purity. They are constructed from corrosion-resistant materials like stainless steel or high-grade polymers, designed to prevent particle generation and fluid interaction with pump components.

Industries that rely on high-purity fluid process pumps include pharmaceuticals, biotechnology, food and beverage, semiconductor manufacturing, and cosmetics. Maintaining the integrity and purity of fluids is critical in these sectors, as contamination can compromise product quality, lead to financial losses, or pose health risks.

Typical applications for high-purity fluid process pumps vary. In pharmaceuticals and biotechnology, these pumps transfer sterile liquids such as injectable drugs, vaccines, and cell culture media. In the food and beverage sector, they handle ingredients like dairy products and flavorings, which require contamination-free processing. Semiconductor manufacturing uses these pumps to transport ultra-pure water and chemicals for microchip production. In cosmetics, high-purity pumps are essential for precisely handling lotions, creams, and other skincare products.

SMC designs and manufactures process pumps that meet stringent industrial requirements. These advanced pumps are not just engineered for precision, but they redefine it, setting a new standard for efficiency in operations demanding high standards of fluid control. Constructed from high-quality materials such as stainless steel and advanced polymers, SMC's pumps offer durability and resistance to harsh conditions, ensuring long-term, reliable performance.

Industries, including pharmaceuticals, biotechnology, food and beverage, semiconductor manufacturing, and cosmetics, trust SMC's process pumps for their critical applications. SMC pumps support the sterile transfer of sensitive products in pharmaceuticals and biotechnology. In the food and beverage industry, they handle consumables with high purity standards. Semiconductor manufacturing relies on these pumps to transport ultra-pure water and chemicals precisely. Cosmetics facilitate the clean handling of skincare products, ensuring contamination-free processing.

SMC incorporates advanced technology into its process pumps to enhance performance and efficiency, significantly reducing downtime and increasing productivity. These pumps are designed to optimize fluid transfer and control, featuring robust construction and innovative engineering to meet the specific needs of each application. Engineers can rely on SMC for consistent, reliable performance in demanding environments.

Choosing SMC and PTI means accessing a team of experts who provide support throughout the selection, installation, and maintenance phases. The unwavering commitment to quality and relentless pursuit of innovation ensures that SMC process pumps not only meet but exceed the highest standards, making them a reliable and future-proof choice for critical industrial processes. For precision, purity, and performance in fluid control, consider SMC process pumps. Contact PTI today to learn more about SMC products and how they can meet your operational requirements.

Process Technology, Inc.
https://process-tech.com
801-264-1114

Mining Slurry Valve Application: Optimizing Efficiency, Reliability, and Service Life

Abrasion is one of the most challenging issues for valves when used in mining industry slurries. Slurries often contain abrasive particles, such as sand, gravel, and rock fragments, which can cause significant wear and tear on valve components. Over time, this abrasion can lead to valve failures, leaks, and reduced performance, resulting in costly downtime and maintenance.

To manage the challenge of abrasion, valve manufacturers employ several strategies:

Material selection: Valve components exposed to abrasive slurries are constructed from highly wear-resistant materials, such as hardened alloys, ceramics, or elastomers. These materials can withstand the constant bombardment of abrasive particles and maintain their integrity over extended periods.

Coating and surface treatments: Valve surfaces can be coated with hard-wearing materials, such as tungsten carbide or chrome, to increase their resistance to abrasion. These coatings provide an extra layer of protection and can significantly extend the valve's service life.

Design modifications: Valve designs can be optimized to minimize the impact of abrasive slurries. For example, some valves feature streamlined flow paths that reduce turbulence and minimize the contact between the slurry and valve components. Other designs incorporate replaceable wear parts, such as sleeves or liners, which can be easily replaced when worn without replacing the entire valve.

Proper sizing and selection: It is crucial to select the right valve size and type for the specific slurry application. Oversized valves can increase turbulence and accelerate wear, while undersized valves can cause high-pressure drops and reduced performance. Valve experts can help mining companies select the most suitable valve for their specific slurry application, considering particle size, concentration, and flow rate.

Regular maintenance and monitoring: Implementing a regular maintenance and monitoring program can help detect and address abrasion issues before they lead to valve failures. Regular maintenance may include periodic inspections, cleaning, and replacement of worn components and monitoring of valve performance indicators, such as pressure drop or leakage rates.

Elastomer pinch valves, like those manufactured by Red Valve, are an excellent choice for mining slurry applications due to several key advantages they offer:

Abrasion resistance: Pinch valves feature a resilient elastomer sleeve that can withstand the abrasive nature of slurries. The elastomer material, such as natural rubber or neoprene, can absorb the impact of abrasive particles and resist wear, ensuring a long service life even in challenging mining conditions.

Full-bore design: Pinch valves have a full-bore design, meaning that when fully open, the valve's internal diameter matches the pipeline's diameter. This design minimizes flow restrictions, reduces turbulence, and lowers the risk of clogging or material buildup, which is particularly important in slurry applications.

Gentle handling of materials: The elastomer sleeve in pinch valves gently compresses the slurry, minimizing the shear forces and particle degradation that can occur with other valve types. This gentle handling helps maintain the slurry's consistency and reduces the risk of valve damage caused by sharp or oversized particles.

Simple design and easy maintenance: Pinch valves have a simple yet effective design with few moving parts. This simplicity makes them easy to install, operate, and maintain. The elastomer sleeve is the only component that comes in contact with the slurry, and it is easy to replace when worn without removing the valve body from the pipeline.

Tight sealing: When closed, the elastomer sleeve provides a tight, 360-degree seal, preventing leaks and ensuring reliable shut-off. This tight sealing is crucial in mining applications, where leaks can lead to material loss, environmental concerns, and safety hazards.

Versatility: Pinch valves can handle various slurry consistencies, from thin, watery mixtures to thick, paste-like materials. They can also operate in multiple flow control modes, including on/off, throttling, and even non-slam check valves, providing flexibility in mining process control.

Corrosion resistance: The elastomer sleeve in pinch valves resists abrasion and provides excellent corrosion resistance. This is particularly important in mining applications, where slurries may contain corrosive chemicals or have extreme pH levels that can damage other valve types.

Red Valve, a leading manufacturer of pinch valves, offers a range of valves designed explicitly for mining slurry applications. Their valves withstand the most challenging mining conditions, providing reliable performance and long service life. By choosing elastomer pinch valves from reputable manufacturers like Red Valve, mining operations can benefit from improved process efficiency, reduced maintenance costs, and increased overall system reliability.

And as always, collaboration between mining companies and local valve experts is essential to develop and implement the most effective solutions for each application.

Process Technology, Inc.
https://process-tech.com
801-264-1114

Enhancing Craft Beer Quality with High-Quality Measurement Solutions

Craft brewing has experienced a significant surge in popularity over the past decade, with consumers increasingly seeking unique and high-quality beer experiences. Craft breweries must closely monitor and control various parameters throughout the brewing process to ensure consistent product quality and flavor profiles. The most critical measurements are pH, dissolved oxygen, dissolved CO2, gaseous oxygen, conductivity, and turbidity. By investing in high-quality instruments for these measurements, craft breweries can positively impact their product quality and maintain a competitive edge in the market.

1. pH Measurement:

pH plays a crucial role in the brewing process, as it affects enzyme activity, yeast health, and the overall flavor and stability of the final product. Accurate pH measurement is essential during mashing, as the optimal pH range (5.2-5.6) ensures efficient starch conversion and extraction of fermentable sugars. During fermentation, yeast activity can cause pH shifts, which need monitoring to prevent off-flavors and ensure consistent fermentation. High-quality pH meters with automatic temperature compensation and calibration capabilities help brewers maintain tight control over pH levels, resulting in better product consistency and quality.

2. Dissolved Oxygen (DO) Measurement:

Oxygen plays a vital role in yeast health and fermentation, but excessive oxygen exposure can lead to oxidation and the development of stale, cardboard-like flavors in the finished beer. Measuring dissolved oxygen levels at various stages of the brewing process, particularly before and after fermentation, helps brewers ensure that their beer is not over-exposed to oxygen. High-quality DO meters with fast response times and minimal drift provide accurate and reliable measurements, allowing brewers to make informed decisions about oxygen management and prevent oxidation-related quality issues.

3. Dissolved CO2 Measurement:

Dissolved carbon dioxide (CO2) is responsible for beer's carbonation and mouthfeel. Accurate measurement of dissolved CO2 helps brewers achieve the desired level of carbonation for each beer style and maintain consistency across batches. High-quality dissolved CO2 meters with automatic pressure and temperature compensation provide precise measurements, enabling brewers to fine-tune their carbonation levels and ensure that their beers balance bubbles and creaminess.

4. Gaseous Oxygen Measurement:

In addition to dissolved oxygen, monitoring gaseous oxygen levels in the headspace of fermentation tanks and packaging lines is critical for preventing oxidation and ensuring beer quality. High-quality gaseous oxygen analyzers with low detection limits and fast response times allow brewers to quickly identify and address any oxygen ingress issues, minimizing the risk of oxidation and preserving their beers' freshness and flavor stability.

5. Conductivity Measurement:

Conductivity measures the total dissolved solids in water, which can impact beer's flavor, mouthfeel, and stability. Monitoring conductivity during brewing helps brewers ensure that their water chemistry is consistent and appropriate for each beer style. High-quality conductivity meters with automatic temperature compensation and wide measurement ranges provide accurate and reliable measurements, enabling brewers to decide about water treatment and ingredient additions.

6. Turbidity Measurement:

Turbidity, or beer's cloudiness, is an essential quality parameter that affects the final product's appearance and perceived quality. While some beer styles, such as hefeweizens, are intentionally cloudy, most beers are clear and haze-free. High-quality turbidity meters with low detection limits and good repeatability allow brewers to monitor the clarity of their beers throughout the brewing process and make necessary adjustments to ensure that their beers meet customer expectations for appearance and quality.

Investing in high-quality instruments for pH, dissolved oxygen, dissolved CO2, gaseous oxygen, conductivity, and turbidity measurements is crucial for craft breweries seeking to produce consistently high-quality beers. By accurately monitoring and controlling these critical parameters, brewers can optimize their processes, prevent quality issues, and deliver exceptional beer experiences to their customers. As the craft brewing industry continues to grow and evolve, those breweries that prioritize quality and invest in reliable measurement solutions will be well-positioned to succeed in an increasingly competitive market.

Process Technology, Inc.
https://process-tech.com
801-264-1114

Duckbill Check Valves

Duckbill check valves allow flow in only one direction through a pipe or tube while preventing any backflow in the opposite direction. When fluid pressure is applied from the upstream side, the duckbill flexes open to allow flow. But if pressure comes from the downstream side, the duckbill flaps seal shut to block reverse flow.

Typical applications for duckbill check valves include:

• Preventing sewer and septic tank backflow
• Inline pump protection
• Sprinkler and irrigation systems
• Drainage and flood control

Duckbill valves' simple, passive operation offers reliable backflow prevention without needing manual intervention, a power source, or maintenance. The elastomeric duckbill is the only moving part. Its flexing action allows it to seal around solids, making it resistant to clogging compared to other check valve designs with hinge mechanisms that can jam.

Duckbill valves find wide use across industrial, municipal, and commercial sectors due to their simple and reliable operation, compact size, and low cost compared to mechanical check valves. Some of the most common applications include:

• Wastewater and stormwater management: Duckbill valves are extensively used in sewer lines, septic systems, and stormwater outfalls to prevent backflow of contaminated water during heavy rains or floods. They are less prone to clogging than flap valves.
• Irrigation and agriculture: In sprinkler systems and agricultural pipelines, duckbill valves maintain consistent flow direction and prevent pump prime loss. They also inhibit dirt, rodents, or other foreign materials from entering pipes.
• Marine and aquatic systems: Duckbill valves are used in boat bilge pump discharge lines, live fish holding tanks, and pond aeration systems. Their unobtrusive profile minimizes flow restrictions.
• Industrial processes: In chemical processing, printing, and manufacturing operations, duckbill valves control gases and liquids, vent tanks and pipelines, and isolate pressure gauges and instruments.

Compared to traditional swing check valves or spring-loaded poppet valves, duckbill valves offer several advantages:

1. No mechanical hinge or spring to fail or wear out, giving them superior reliability and service life.
2. Low cracking pressure and high flow rate due to streamlined design.
3. Tight sealing even around suspended solids and minimal leakage.
4. A simple one-piece elastomer duckbill is inexpensive to manufacture and easy to replace.
5. Various elastomer choices to suit corrosive chemicals, high temperatures, or food grade needs.

Duckbill check valves' versatility, dependability, and low maintenance requirements make them a popular choice across diverse industries for providing economical, trouble-free backflow prevention and fluid control. While not suited for every application, they offer an elegant solution in many common fluid handling scenarios. 

Process Technology, Inc.
https://process-tech.com
801-264-1114