Improved Batch Control Technology for Specialist Fluids Production
Creating a Polished Performance in Liquid Batch Control
Improving a fluid control process requires expertise and process knowledge to achieve an efficient integration with the existing infrastructure. For Kemet International, the aim was to improve efficiency and productivity while also minimising waste and reducing energy costs. Teaming up with experts from Bürkert ensured that all the new fl ow control components were correctly matched to the application and installed in the most effective way.
Improving process efficiency Kemet International is at the forefront of precision lapping and polishing technology, creating diamond polishing compounds, slurries and machinery for a wide range of industrial processes. A need for additional batch controls brought about a meeting with experts from Bürkert, who assessed the application and made a number of recommendations.
The first objective was to reduce the time taken to fill a storage tank and to add a control circuit that would automatically stop the pump precisely when the tank was full. By installing a larger capacity pump and new pipework, the filling time was reduced by 75%. The addition of a Type 8110 tuning fork level switch gave the necessary signal to the pump to prevent overfilling.
A new batch control system was designed and manufactured allowing several pre-set batch sizes from 450 ml to 25 litres to be produced automatically. The system used a paddlewheel flowmeter and an angle seat control valve directly connected to the Type 8025 batch control module to provide a simple and effective installation that can accommodate seven batch sizes and has a built-in automated calibration process.
The new solution offers an improved delivery capacity and throughput has increased by 70%
The final part of the project was installed for the production of de-ionised water and involved the supply of a new 1200 litre tank, along with a pump and the installation of all the pipework to allow several batching points to be supplied at once via a manual ball valve. The installation is designed to provide a pressurised supply to four outlets. When demand is low the water is returned to the storage tank via a bypass valve. The installation includes a digital flowmeter, located downstream of the pump, that also acts as a totalizer to record the amount of de-ionised water produced each day.
Teamwork delivers the solution The final installation has delivered exactly the improvements that were specified, with a significant improvement in productivity, the elimination of virtually all waste whilst also minimising energy usage. The project was carefully managed throughout and Bürkert will continue to provide on-going field support.
“This project has been developed using Bürkert’s expertise with the aim of improving productivity and efficiency. The final installation has achieved this and also helped us with our company goals of r educing waste and minimising energy usage.”
Richard Bolton, Operations Manager at Kemet International