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Dispersion
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 CONTENTS APRIL 2023 | VOL. 36 | NO. 4

COLUMN: Plant Maintenance

12 Moving toward zero downtime

Predictive maintenance holds the key to maximizing uptime.

COVER SERIES: POWDER & BULK PROCESSING

16 An introduction to rotary dryers

Benefits, applications, limitations, operation and design
considerations for rotary drying systems.

20 Recordkeeping for effective dryer maintenance

16
What to include in an industrial dryer maintenance record and
how to use the information to better maintain and repair a dryer.

26 Inline moisture endpoint detection in wet

granulation using filtered NIR spectroscopy
Process development scientists study the efficacy of using
near-infrared spectroscopy for inline, real-time measurement of
product moisture during two different wet granulation methods.

FEATURES

30 Optimizing preventive maintenance drives

competitive advantage
At the intersection of data and industrial software, process
manufacturers are finding the strategies they need to improve
safety, performance and sustainability.

34 How CMMS connects workflows for preventive

maintenance and asset management
From pre-installation planning and engineering to
decommissioning, CMMS software helps organizations track
and manage their assets.

20 38 Advanced analytics enhance asset

performance management
Understanding organizational capabilities, infrastructure
and objectives are key to avoiding common pitfalls when it
comes to researching, selecting and implementing an asset
analytics solution.

42 Preserving critical plant knowledge is essential

for the digital transformation journey
Artificial intelligence can help support the capture and sharing
of institutional knowledge and why that is important as process
manufacturers move to Industry 5.0.

44 Case study: Sophisticated separation for a

fishmeal processing plant
Two Flottweg Tricanters take fish waste that would otherwise
be discarded at sea or shipped out of the country and turn
it into products that are used in aquaculture, livestock feed
and pet food.
34 38

www.ProcessingMagazine.com Facebook Twitter LinkedIn

facebook.com/ProcessingMagazine @ProcessingMag linkedin.com/showcase/27062974

2 Processing | APRIL 2023

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 CONTENTS
14
DEPARTMENTS
6 Editor’s Note
8 Industry News
14 Product Focus: New Products
24 Product Focus: Powder & Bulk Processing
46 Classifieds
47 Advertiser Index
48 ProcessingMagazine.com

Subscribe to our

DIGITAL EDITION
at www.processingmagazine.com

24
Cover image Courtesy of Heyl Patterson Thermal Processing

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 Publisher Jim Semple
jsemple@endeavorbusinessmedia.com

EDITOR ' S NOTE CONTENT

Chief Editor Jesse Osborne
josborne@endeavorb2b.com

Managing Editor Daniel Gaddy

dgaddy@endeavorb2b.com

T
Senior Editor Nate Todd
ntodd@endeavorb2b.com
he upcoming International Powder & Bulk
Solids Conference & Exhibition (April 25-27 Art Director Ryan Carlson
rcarlson@endeavorbusinessmedia.com
at the Donald E. Stephens Convention Center
in Rosemont, Illinois) serves as the unofficial Production Manager Josh Troutman
jtroutman@endeavorb2b.com
kickoff to the 2023 industry event circuit for
process manufacturers.
The “Powder Show” — which takes place every two
ADVERTISING
years — is a flagship event for process manufacturers, District Manager Jay Haas

Courtesy of PMMI
281-980-5831 | jhaas@endeavorbusinessmedia.com
and Processing has you covered with content before and
after the show. Visit www.processingmagazine.com to Account Manager Lisa Williman
518-322-6691 | lwilliman@endeavorbusinessmedia.com
check out our Powder Show preview and watch video
interviews with several of the subject matter experts
presenting educational sessions at the show, includ- Members of Processing’s editorial staff are scheduled
MARKETING
ing Jason Reason and Jack Osborn of Airdusco, Scott to attend the majority of these events, so be sure to Digital Product Director Nick Phillips
nphillips@endeavorb2b.com
Miller of Solids Handling Technologies, Jack Hilbert look for pre- and post-show coverage both in print and
of Pneumatic Conveying Consultants, Diane Cave of online closer to these event dates. Digital Operations Manager Mary Beth Romano
mbromano@endeavorbusinessmedia.com
Element6 Solutions, Jeramy Slaunwhite of Rembe and
Todd Smith and Kevin Solofra of the K-State Bulk Solids Coming soon: Breakthrough Products Awards Marketing Manager Lexi Richards
alexisr@endeavorbusinessmedia.com
Innovation Center. nomination period
Senior editor Nate Todd, who leads our powder and The nomination period will soon be open for Audience Development Manager Anna Hicks
ahicks@endeavorbusinessmedia.com
bulk processing coverage, will be on hand at the event Processing’s 2023 Breakthrough Products Awards. Our
visiting exhibit hall booths (make sure to check out annual awards program honors 10 innovative products Endeavor business media
our social media channels for images from the show or technology solutions that made significant contribu- CORPORATE
floor), attending educational sessions and networking tions to improvements in the process industries over
with industry experts in order to bring the Processing the course of the past year. CEO Chris Ferrell
audience more high-level content for our website and Last year’s winners included products from President June Griffin
monthly powder and bulk processing sections in print. Endress+Hauser, TrendMiner, Emerson, Trelleborg CFO Mark Zadell
In addition to The Powder Show, other important Sealing Solutions, Stratus Technologies and more. COO Patrick Rains
industry events on Processing’s 2023 schedule include: Nomination information, and previous winners, can be CRO Reggie Lawrence
• Measurement, Control & Automation Association found on the Breakthrough Products Awards section on
Chief Administrative and Legal Officer Tracy Kane
Industry Forum (April 24-26, Arlington, Texas). www.processingmagazine.com.
EVP/Industrial Group Mike C. Christian
• INTERPHEX (April 25-27, New York).
• Offshore Technology Conference (May 1-4, Sincerely,
Houston, Texas). Processing (ISSN 0896-8659, print; 2641-6581, digital) is published monthly by Endeavor
• EASA 2023 Convention ( June 25-27, National Business Media. Editorial and Executive Offices: 3918 Montclair Road, Suite 210,
Birmingham, AL 35213. Periodicals postage paid at Birmingham, AL 35243 and
Harbor, Maryland). additional mailing offices. POSTMASTER: Send address changes to Endeavor, PO Box 3257,
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Business Media, 2023. No portion of this publication may be reproduced in any form without
• WEFTEC (September 30-October 4, Chicago). josborne@endeavorb2b.com written permission of the publisher. Views expressed by the bylined contributors should not
be construed as reflecting the opinion of this publication. Publication of product/service
@ProcessingMag
• PROCESS EXPO (October 23-25, Chicago). information should not be deemed as a recommendation by the publisher.

Subscribe / Renew / Change of Address:

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Email: processing@omeda.com

EDITORIAL ADVISORY BOARD

Christine Banaszek, Sales Manager, ROSS Mixers | Frederic Baudart, CMRP, Senior Product Application Specialist, Fluke Accelix
Eric Maynard, Vice President, Jenike & Johanson | Jack Osborn, Senior Engineer, Airdusco | Colin Barbeau, Bulk Materials Handling Specialist, Hatch
Todd Smith, Manager, Kansas State University Bulk Solids Innovation Center | Bill Bremer, Principal, Food Safety, Kestrel Tellevate
Robert Rogers, Senior Advisor for Food Safety & Regulations, METTLER-TOLEDO | David Brewer, Mid-Atlantic Regional Manager, Sealing Equipment Products Co. (SEPCO)
David W. Sptizer, PE, Spitzer and Boyes LLC | Mike Klimes, Applications Engineer, Tsurumi (America) Inc.

6 Processing | APRIL 2023

Imagine. Design. Deliver.

It’s more than a bulk material handling system.

It’s a chance to help your team perform at the
highest level. By leveraging our experience across
thousands of applications, you gain a solution
that drives process improvement, increases
productivity, enhances safety and more.

Imagine how we can transform your operation!

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269.673.2125 | MaterialTransfer.com
 APRIL 2023 N E W S, N OT E S A N D I N S I G H T S F R O M A C R O S S T H E P R O C E S S I N D U S T R I E S
Survey examines food industry’s considerations
for updating conveying systems
T
he food processing industry continues
to experience significant growth, and
budgets are trending upward for con-
veying equipment and maintenance in
the year ahead.
To handle that growth, organiza-
tions are evaluating existing conveyor sys-
tems, determining the need for new systems
and selecting the best system for their require-
ments. A newly released report provides an
important overview of the state of the food pro-
cessing industry in 2023 as companies consider
updating their conveyor systems.
An independent study titled New Research
— Evaluating and Implementing New Conveyor
Systems has been released by Cablevey
Conveyors, a worldwide expert in cable and
disc conveying solutions.
Cablevey contracted with independent out-
side research firm Ascend2 to conduct the
study, in which the researchers surveyed 290
professionals in the food processing industry to
provide their insight on critical considerations
when evaluating a system.
8 Processing | APRIL 2023
processingmagazine.com
COMPANY NEWS
Emerson selected to automate Golden
Triangle Polymers facility
Emerson recently announced it will provide auto-
mation technologies, software and analytics from its
Plantweb digital ecosystem for the Golden Triangle
Polymers Project, a world-scale integrated polymers
facility on the Texas Gulf Coast. The project is a joint
venture between Chevron Phillips Chemical Company
Image courtesy of Cablevey Conveyors
LP and an indirect subsidiary of QatarEnergy.
Operations are expected to begin in 2026.
Designed using the latest greenhouse gas (GHG)
emissions reduction technology, the project aims
to have approximately 25 percent lower GHG emis-
sions than similar facilities in the U.S. and Europe.
“With its digital automation technologies,
industrial software portfolio, and deep energy
experience, we are relying on Emerson to help
ensure a project of this magnitude operates safely
and reliably, optimizes energy use and mitigates
emissions,” said David Godard, project director for
the Golden Triangle Polymers Project.
The Golden Triangle Polymers Project, located
in Orange, Texas, includes a 2,080 KTA ethane
cracker as well as two 1,000 KTA high-density poly-
ethylene units. Polyethylene is used to produce
The conveying systems considered were aero durable goods and essential packaging to protect
mechanical conveyors, bucket elevators, cable food and keep medical supplies sterile.
conveyors, pneumatic conveyors, round-link “The Golden Triangle Polymers Project and the
chain conveyors and screw augers. Respondents recently announced Ras Laffan Petrochemical
conveyed a wide range of product types such as Complex in Qatar are among the world’s largest
coffee, cereals, nuts, snacks and frozen foods. ethane crackers, both leveraging Emerson’s digital
According to the study, 67 percent of those automation technologies, software and expertise
surveyed plan to update or replace components to promote safer, smarter and more sustainable
of their conveying system. Of this group, 32 per- operations,” said Ron Martin, Emerson’s presi-
cent plan a conveyor update in the next year, dent, Americas. “We are proud to support Chevron
and another 42 percent expect to do so within Phillips Chemical’s and QatarEnergy’s track record
the next two years. of building world-class, optimized facilities.”
The study illuminates critical elements that Emerson will deliver integrated process control
respondents considered, such as how to pre- and safety systems that leverage advanced predic-
serve product integrity, cut waste, avoid cross- tive technologies to reduce operational complexity
contamination, conserve energy, simplify main- and minimize project risk through its DeltaV dis-
tenance and make efficient use of space. tributed control and safety instrumented systems
Respondents evaluated and ranked all seven and Rosemount gas analyzer and chromatograph
conveyor categories for product integrity, ener- solutions. The project also leverages Emerson’s
gy and efficiency, maintenance and downtime, Mimic and AspenTech HYSYS simulation software
and facility requirements. for operator training, energy management, safety
For more information, and to view the analysis and operational optimization. Emerson’s
complete study, visit www.cablevey.com. AgileOps operations management software and
alarm management services will help staff monitor
and maintain safety, alarms and the control system
to drive improved process and operational integrity.
PNEUMATIC
CONVEYING
COMPONENTS

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COUPLINGS • INSTALLATION ACCESSORIES

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Endress+Hauser opens new regional
logistics hub
Endress+Hauser recently announced the opening
of a new 48,000-square-foot Indianapolis, Indiana,
regional logistics hub.
“This new regional logistics hub will allow us to
move products through a global network regardless
of where they’re produced and where they need to
be shipped,” said Steve Demaree, North America
regional supply chain manager at Endress+Hauser.
“Additionally, our logistics systems are now as auto-
mated and standardized as possible.”
In partnership with Hellmann Worldwide
Logistics, Endress+Hauser will strengthen logis-
tics capabilities for the United States, Canada
and Mexico as well as internationally in terms of
response time, throughput time and on-time deliv-
ery, all of which are pivotal for modern distribu-
tion centers. Endress+Hauser already operates
two regional logistics hubs in Germany for all of
Europe and in China. An additional regional hub is
currently being built in India.
“Our regional logistics hub in Indianapolis will
continue in serving our mission of reliably supply-
ing customers with measurement and automation
technology,” said Oliver Blum, corporate director
of supply chain at Endress+Hauser.
WECO and Multiscan Technologies form
strategic partnership in North America
WECO and Multiscan Technologies, both mem-
bers of the Duravant family of operating compa-
nies, recently announced that they have entered
into a strategic partnership to support nut, fruit
and vegetable packers and processors across
the United States, Canada and Mexico. In these
regions, the WECO sales and service organization
is now selling, leasing and supporting Multiscan’s
optical sorters and other inspection equipment.
“Bringing two leading suppliers together in this
way provides enormous value to both WECO and
Multiscan customers,” said Don Douglas, president
of WECO. “With the addition of Multiscan’s technol-
ogy to WECO’s portfolio, we’re able to deliver even
more sorting and pre-sorting solutions that address
a broader range of turnkey line layouts and capac-
ity requirements. And with WECO’s industry-lead-
ing sales and service network, Multiscan’s North
American customers can receive the highest level of
support to maximize uptime and improve efficien-
cy of their operations.”
Integrated Water Services acquires
Hyperion International Technologies
Integrated Water Services, Inc. (IWS), a leading
provider of water and wastewater treatment solu-
tions, recently acquired Hyperion International
Technologies, a developer of industrial control
systems for the water sector. IWS, in partnership
with Sciens Water Opportunities Management,
has acquired 100 percent of the equity of Hyperion.
The acquisition of Hyperion expands IWS's
product and service solutions, advances its digital
services strategy and places the company at the
forefront of water treatment equipment and ser-
vice providers in North America.
Hyperion, headquartered in Austin, Texas, pro-
vides control systems and engineering services for
industrial and municipal clients in the water and
wastewater treatment markets. The company spe-
cializes in designing and supplying equipment for
process and control projects, as well as commis-
sioning and supporting industrial and municipal
plant owners.
Scott Johnson, general manager of Hyperion,
said, "We are thrilled to join forces with IWS. We
see this as an excellent opportunity to build some-
thing special while protecting the environment
and conserving water as a precious resource."
Send news and events for consideration to
josborne@endeavorb2b.com

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Processing | APRIL
1 2023 3/16/23 11:20 AM
RIBBON/PADDLE/PLOW VEE-CONE BLENDERS FLUIDIZED BED MIXERS
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 COLUMN: PLANT MAINTENANCE
By JORGE
IZQUIERDO
VP, MARKET Development
PMMI
Jorge Izquierdo is vice president
of market development for PMMI,
The Association for Packaging
and Processing Technologies. He
oversees PMMI’s market devel-
opment plans, research and pro-
grams for strengthening the com-
petitiveness of North American
suppliers of packaging and pro-
cessing equipment.
Moving toward
zero downtime
Predictive maintenance holds the key to maximizing uptime.
D
owntime, and especially
unplanned downtime, is
expensive, with some cost
estimates exceeding $1 mil-
lion per hour. When a line
is down, overhead expenses
continue but no product is being pro-
duced and no profit is being generated.
If the downtime delays deliveries, cus-
tomer satisfaction plummets.
Common causes of downtim e
include general wear and tear, operator
error, product changeover, unexpect-
ed component failure, maintenance
schedule mismanagement, machine
programming issues and machine
consumables problems, according to
Packaging and Predictive Maintenance,
a recent report published by PMMI
Business Intelligence, a division of
PMMI, The Association for Packaging
and Processing Technologies.
To maximize uptime, machines and
systems must run reliably, consistently
and at required speeds. Proper main-
tenance is crucial. Preventive mainte-
nance forestalls breakdowns through
actions such as lubrication, tightening
components and replacing worn parts.
Such tasks are performed according to
a regular schedule in an effort to mini-
mize unexpected failures and avoid
unplanned downtime.
Predictive maintenance takes this
concept a step further by using digi-
tal tools to monitor and analyze asset
behavior, predict asset behavior and
perform repairs proactively to prevent
unplanned downtime. This requires
equipment that can monitor its sta-
tus by collecting data about its per-
formance such as run time, voltage
(especially for motors), speed, pressure,
temperature and vibration and provide
a warning if attention is needed.
Predictive maintenance is one of
four key priorities identified in anoth-
er recent PMMI report, Challenges
and Opportunities for Packaging and
Processing Operations. Avoiding down-
time and preventing product loss are
the major drivers pushing process
manufacturers toward implement-
ing predictive maintenance. Other
benefits include longer machine life
and a reduction in parts requirements
because replacements are installed
as needed rather than on an arbitrary
schedule.
As a result, there is a huge demand
for technology that increases machine
reliability, and interest in predic-
tive maintenance continues to grow.
According to the report, 43% of con-
sumer packaged goods (CPG) compa-
nies currently use predictive mainte-
nance and 45% are planning to imple-
ment it in the next three years. Of those
using the technology, many firms are
still working on installing it throughout
their operations.
CPG firms using predictive main-
tenance rely primarily on three tools:
thermography, full equipment monitor-
ing and CMMS (computerized mainte-
nance management system) software.
Other areas of interest include vibra-
tion analysis, machine health monitor-
ing sensors, parts room setup and orga-
nization, oil monitoring analysis, risk
and reliability software, machine-level
fault codes, tracking hours of use until
downtime, outage planning and sched-
uled TPM (total productive mainte-
nance), risk minimization, best practice
and mean time between failures data.
The most successful applications
of predictive maintenance depend on
receptive management and carry the
most impact when deployed in asso-
ciation with critical assets and expen-
sive components with long lead times.
Predictive maintenance practices are
ID 51962026 © Arne9001 | Dreamstime.com
particularly useful on 24/7 lines and
help eliminate bottlenecks. Key drivers
include delivery of actionable informa-
tion, ease of application to new and
legacy equipment, good ROI, scalability
and the ability to collect the right data.
However, collecting the right data
often depends on remote access to the
machine. Historically, this has been a
tough sell to CPG companies due to
cybersecurity concerns. However, the
COVID-19 pandemic, which limited,
or even eliminated, in-person service
calls, forced many CPG companies to
reconsider remote access and shift-
ed attitudes. “Remote access is more
acceptable now,” Adrian Lloyd, CEO &
research director of Interact Analysis,
told the audience during The Future of
Automation, a webinar, sponsored by
PMMI in December 2022. “CPG com-
panies have realized remote access is
doable, and there are benefits associ-
ated with it.”
Implementing predictive mainte-
nance depends on two categories of
technology: hardware, typically smart
sensors, and software/analytics (often
hosted in the cloud). PMMI’s Packaging
and Predictive Maintenance report
notes new business models are needed
to ensure that predictive maintenance
delivers on its promise of optimiz-
ing equipment performance for CPG
companies while ensuring that origi-
nal equipment manufacturers (OEMs)
generate the revenue they need to stay
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model, Machines as a Service, or MaaS,
replaces the outright sale of a machine
with payments based on output. With
maintenance as an integral facet of
this business model, there is potential
to minimize downtime and maximize
machine lifetime and deliver advantag-
es to both end user and OEMs.
Another tool to help processors
establish a maintenance program
is the Asset Reliability Roadmap for
the Consumer Products Industry.
Developed by PMMI’s OpX Leadership
Network, it helps CPG companies and
OEMs understand common defini-
tions; outlines key performance indi-
cators (KPIs) related to people, opera-
tions and finances; provides useful
calculations; and delivers the leader-
ship guidance needed to develop an
asset reliability initiative. Both CPGs
and OEMs gain an understanding
of the necessity of providing a solid
business case for calculating main-
tenance program costs. This coop-
erative effort can yield significant
improvements in overall equipment
effectiveness by focusing on opportu-
nities to reduce the impact of planned
and unplanned downtime.
“When developing this tool, our team
of CPG and OEM maintenance experts
shared their individual and varied expe-
riences, insights and leadership guid-
ance to identify and define a number of
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Bryan Griffen, director, industry ser-
vices, PMMI. “As a result of this collabo-
ration, the OpX Leadership Network
is excited to provide the industry with
a unique, effective tool that will help
businesses quantify the total value of
asset reliability to the organization.”
What’s next?
What comes after predictive main-
tenance? Prescriptive maintenance.
This concept, which relies on machine
learning, is in its infancy but represents
the next level in the maintenance hier-
“uptime,
To maximize
archy.
Instead of monitoring machine sta- machines and
tus and recommending when to per-
form maintenance, prescriptive main-
systems must
tenance uses machine learning to not run reliably,
only determine when an asset will fail,
but also how to fix it. After the work has consistently
been completed, monitoring continues
to ensure that the action taken fixed
and at required
the problem, and the tool works out
possibilities for the next improvement.
Opx Leadership Network tools,
speeds.
”
including the Asset Reliability Roadmap,
are at www.opxleadershipnetwork.org.
Another resource, PACK EXPO Las
Vegas (Sept. 11-13, 2023), will show-
case many machines equipped with
downtime-mitigating technologies.
PMMI
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APRIL 2023 | www.processingmagazine.com 13
1/30/23 2:19 PM
 NEW PRODUCTS
P R O D U C T

FOCUS
Send products for consideration in this section to
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EXPANSION JOINTS
When choosing the correct equipment for mud pumps,
shale shakers or frac tanks, Proco Products’ Series
240/242 molded spherical expansion joints are an
excellent choice. Available elastomers for the Series
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saltwater systems, neoprene tube and cover for HVAC
The new Alfa Laval ThinkTop V20 hygienic valve indication unit is driving digital transformation within chiller systems, nitrile tube and neoprene cover for hot
the process industries. With automation, digitalization and real-time communication, the ThinkTop V20 water systems where glycols are present, nitrile tube
raises the bar on process control, making it more reliable and accurate while saving time and money on and neoprene cover for diesel-based mud operations
installation, commissioning, operation and maintenance. The ThinkTop V20 is the first pure valve-sensing and PTFE tube and neoprene cover for operations where
unit that is maintenance-free and does not require manual adjustment or programming. It enables 360° zinc bromides may be present. Proco’s products are
LED visual status indication from all directions. It also provides convenient control-room monitoring of the manufactured in accordance with ASTM F1123-87 and
real-time status of Alfa Laval hygienic valves used across the dairy, food, beverage, pharmaceutical and are Coast Guard-approved. Products can also be offered
many other industries. Purpose-designed to digitalize essential on-off valve monitoring, the ThinkTop V20 that meet ABS requirements.
sensing unit provides a pragmatic approach to enhancing the reliability of valve status and position. This
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TRANSMITTERS
Honeywell recently introduced its Versatilis transmitters for condition-based monitoring of rotating
equipment such as pumps, motors, compressors, fans, blowers and gearboxes. The transmitters provide
relevant measurements of rotating equipment, delivering intelligence that can improve safety, availability
and reliability across industries. The transmitters measure vibration, surface temperature, and acoustics
to anticipate rotary equipment anomalies. These measurements have additional applications such as
heat exchange reliability and substation reliability. Versatilis Transmitters can seamlessly integrate with
Honeywell’s Experion HS and other SCADA or asset management platforms. When used with Honeywell’s
analytics software, this technology can predict equipment failures such as asset imbalance, misalignment
and bearing-related issues before they happen, helping to reduce unplanned downtime.

Honeywell
www.honeywell.com

14 Processing | APRIL 2023

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 POWDER & BULK PROCESSING
An introduction to
rotary dryers
This article describes the benefits of rotary drying systems as well as their
applications, limitations, operation and design considerations.
R
otary dryers are a cornerstone of modern industrial processing,
offering efficient, high-capacity drying for a wide range of materials.
From traditional techniques to novel processes, rotary dryers are a
diverse and reliable option for any facility looking to dry bulk solids.
The following covers the many benefits these industrial drying
systems can offer as well as applications and limitations. The article
also explains how these dryers work and discusses considerations in design.
Why choose a rotary dryer?
While a number of industrial dryer types are available, rotary dryers have
remained a preferred choice for decades thanks to several key advantages:
16 Processing | APRIL 2023
 FEECO rotary dryer.
All images courtesy of FEECO International.
| By Shane Le Capitaine, FEECO International
Customization. Rotary dryers are extremely customizable, allowing pro-
ducers to tailor a system to their precise material and process goals.
Reliability and longevity. Thanks to a robust build and simple mechani-
cal operation, rotary dryers are recognized for their reliability and longevity.
When properly maintained, a rotary dryer can operate for decades without
issue.
Tolerance to feedstock variation. One key advantage particularly suit-
ed to many bulk solids processing operations is the rotary dryer’s tolerance
to variation in feedstock and processing conditions. Unlike with some other
dryer types, slight changes in particle size distribution, moisture content,
and even throughput do not cause process upsets.
 Added polishing of granules. Producers
looking to dry a granular product also favor the
rotary dryer for the “polishing” it can offer. The
dryer’s rolling action helps to break off particle
edges and further round granules, creating a pre-
mium product.
High throughput. Rotary dryers are also
favored for their high-capacity processing, which
ranges from 1 tph to over 200 tph. This makes
them an ideal fit for working with bulk solids.

Rotary dryer operation

Rotary dryers consist of a large rotating cylinder
(called the “drum”) set horizontally but at a slight
angle. Material passes through the drum and is
heated by a heating medium according to a pre-
determined temperature profile and retention
(or residence) time to achieve a target moisture
content.
A burner is mounted at one end of the drum,
and exhaust gas handling equipment is mounted
at the other end. Flexible seals connect the rotat-
ing drum to stationary inlet and outlet breechings.
Riding rings, or tires, support the drum and
facilitate smooth rotation of the unit on trunnion
roller assemblies. A drive assembly, most com-
monly a gear and pinion type, provides the power
to rotate the drum.

 Rotary dryer flights.

Material is fed into the drum at one end and

discharged at the other end, with gravity and the
rotation of the drum shell helping to convey mate-
rial along the slight downward slope through the
unit.

Direct versus indirect drying

Drying can occur either directly, through material
contact with the airflow, or indirectly, through
material contact with the externally heated drum
shell. For direct drying, a combustion chamber is
recommended to prevent direct contact between
the material and the burner flame. Direct drying
is by far the most common, as it is significantly
more efficient, but indirect drying offers an effec-
tive approach in niche applications.

Direct rotary dryers

 3D model of a rotary dryer.
Direct rotary dryers are used in a variety of
industries working with bulk solids, processing
everything from minerals and ores to chemical
compounds and fertilizer products. In the direct
configuration, hot air and combustion gasses are
passed through the rotating drum, in direct con-
tact with the material being processed, heating
the material via convection.
Flights (also called material lifters) pick up
the material and carry it up the drum wall as it
rotates, then drop it through the air stream in a
cascading effect, creating a curtain of material

APRIL 2023 | www.processingmagazine.com 17

in the drum’s cross section that maximizes heat
transfer.
The material and products of combustion may
be fed into the same end of the unit (parallel or
co-current flow) or into opposing ends (counter-
current flow). The choice between co-current or
counter-current flow depends on the characteris-
tics of the material to be dried.
Co-current dryers are often chosen for materi-
als that carry the bulk of their moisture as sur-
face moisture, as this configuration puts the hot-
test air in contact with the material at its wettest
point. The co-current configuration is also ideal
for controlling material temperature, minimizing
the potential for overheating the material, dimin-
ishing the potential for discoloring the material,
and reducing the generation of fines (attrition).
In contrast, a counter-current dryer puts the
material in contact with the hottest air at its dri-
est point. This provides increased thermal effi-
ciency for materials that must be heated to higher
temperatures. The counter-current configuration
is also beneficial when drying materials that have
internal moisture and therefore require higher
heat and an extended drying cycle to draw out the
moisture.
Indirect rotary dryers
With the indirect configuration, the rotating
drum is enclosed in a furnace or heat shroud,
which is externally heated to prevent contact
between the material and any process gasses,
and the material is heated via conduction. While
f lights on the drum interior are ineffective in
this configuration, bed disturbers are typically
employed to ensure that the material bed is in
constant rotation.
 Co-current airflow (top) versus counter-current airflow (bottom) in a direct rotary dryer.
18 Processing | APRIL 2023
Indirect rotary dryers are used in settings  FEECO rotary dryers in
where the material must not come into contact use at a sand drying plant.
with process gasses or when the particle size dis-
tribution is very small, such that direct drying
would risk the material becoming entrained in
the airflow. As such, indirect dryers are typically
employed in processing specialty products such
as catalysts and adsorbents.
Rotary dryer applications and limitations
Few applications exist that are not a fit for rotary
dryers. Their extreme versatility has them in use
in nearly every industry. They are widely used to
process:
• Aggregates, minerals, and ores
• Fertilizers and soil amendments
• Limestone and gypsum
• Organic and inorganic chemicals
• Paper pulp and sludge
• Potash
• Recycled manure solids (RMS) bedding
• Roofing granules
• Salts and sugars
• Sand
While rotary dryers are extremely universal in
application, there are a few cases in which anoth-
er dryer type, such as a fluid bed, may provide a
better option. Design considerations
Since rotary dryers pick up and drop the material While standardized designs are available on the
during processing, some particle degradation can market, rotary dryers offer the greatest efficien-
occur if the material is fragile. When fragility is a cy, performance and reliability when designed
concern, a fluid bed dryer may be more suitable. according to the characteristics of the material to
Some sludge-like materials can also be chal- be dried, facility considerations and process goals.
lenging for rotary dryers, though several options The following points are essential aspects of rota-
are available for managing a non-flowable mate- ry dryer design.
rial in the dryer, including the incorporation of a
back-mix circuit. Material
Rotary dryer manufacturers must consider a
number of material characteristics when design-
ing a rotary dryer. Characteristics such as particle
size distribution, bulk density, raw material mois-
ture content, specific heat, heat transfer proper-
ties, fragility, chemical composition and addition-
al physical qualities, all influence how a material
will respond to the drying process. A rotary dryer
must be designed around these characteristics to
optimize dryer performance and longevity.
For this reason, many producers can benefit
from testing their material in a facility such as the
FEECO Innovation Center. In this setting, a pilot-
scale dryer is used for testing trials to gather criti-
cal process data and aid in the design of a com-
mercial-scale unit.
It is important to recognize that material use
can have ramifications on dryer design as well,
particularly on whether the dryer must be direct
or indirect depending on whether or not the mate-
rial can be exposed to combustion gasses.
Facility
Operating facility factors can also influence dryer
performance and must be considered during the
design process. This includes elevation, whether
 the dryer will be operating indoors or out-
DEEPLY IMMERSED IN
doors, and climate, particularly humidity CHOOSING THE RIGHT CHILLER?
and ambient air temperature.

Exhaust gas handling

To meet regulatory emissions requirements,
direct rotary dryers must be equipped with
exhaust gas handling equipment. While
indirect dryers must also meet local, state
and federal regulations, their exhaust gas
management requirements are minimal
since the material does not come into con-
tact with the products of combustion. For
this reason, indirect dryers also hold greater
potential for capturing and reusing waste
heat in other applications in the plant.
The level of exhaust gas handling required
in a given setting can vary significantly,
depending on the specific emissions pro-
duced by the system and where the facility
is located.
The most common configuration con-
sists of an induced draft (ID) fan paired
with a baghouse. This combination is ideal
in settings where excessive carryover is not
an issue and there is no need to treat the
exhaust gas for chemical pollutants such as
VOCs or fluorine. Other options include cyclones and scrubbers.

Automation and controls

Automation and control systems are powerful tools in optimizing dryer effi-
ciency, minimizing maintenance requirements and avoiding process upsets.
Not long ago, these systems were considered a luxury, but as technology has
advanced, they have quickly become a necessity in efforts to improve efficien-
cy and maintenance planning.
Systems range in complexity, from those that simply assist in startup and
shutdown, to more advanced systems that can allow control from a remote
location, alert operators when key parameters fall out of spec, and even pro-
vide trends and reporting around performance and operating data. This type
of information is extremely powerful in predictive maintenance planning, as
well as in optimizing overall efficiency.
As technology continues to evolve,
Conclusion you might have more questions than
Due to their versatility and benefits such as high throughput and long-term
reliability, rotary dryers have become the preferred option for drying a range answers when it comes to choosing
of bulk solids, from ores to chemicals and everything in between.
For optimal performance and longevity, rotary dryers should be designed the best process cooling equipment.
around the unique characteristics of the material to be processed, as well as Let Thermal Care help keep your
the process goals. This makes testing a significant advantage in developing a
commercial-scale unit. head above water.
Facility considerations also influence the design process, while local, state,
and federal regulatory requirements, along with the dryer’s unique emissions,
dictate exhaust gas handling needs. Automation and control systems can
help to maximize performance and longevity.
For these reasons, it is important to work with an expert supplier for the
design and fabrication of a commercial-scale system.
COMPLIMENTARY
SIZING CARD

Shane Le Capitaine is process sales engineer at FEECO International. 888-387-9725

sales@thermalcare.com
FEECO International www.thermalcare.com
www.feeco.com

APRIL 2023 | www.processingmagazine.com 19

 POWDER & BULK PROCESSING

All images courtesy of Heyl Patterson

Recordkeeping for
T
he increasing sophistication and cost
of dryers used for bulk solids handling
operations make dryer maintenance

effective dryer
very complex, which can affect an opera-
tion’s profits. Much of a maintenance
program’s effectiveness stems from keep-
ing an accurate maintenance record and using
that record for planning.

maintenance
Maintenance planning entails recording a dryer’s
performance and normal operating conditions and
scheduling dryer inspections and regular preven-
tive maintenance. As long as a maintenance record
is organized, complete and up to date, its physical
form is not critical. Hard copies of information can be
organized in a filing system or bound into record or

This article discusses elements that should be part of logbooks, or the information can be consolidated and
transferred to a computer database. A maintenance
an industrial dryer’s maintenance record, how to use record should include the following information:
• Legal documentation
each element when maintaining the dryer and how to • Operations and maintenance manuals
• Drawings
use the record when deciding whether to repair, • Parts lists
• Daily maintenance procedures
rebuild or replace an older dryer. • Special and emergency maintenance procedures
• Safety procedures
• Baseline operation record
• Operations log
By Heyl Patterson Thermal Processing • Maintenance log

20 Processing | APRIL 2023

 • Lubrication record
• Annual turnaround procedure
Legal documentation
Legal documentation includes copies of all legal
documents related to a dryer and its operation,
including such items as licenses; permits; appli-
cations to the Corps of Engineers, Environmental
Protection Agency (EPA) and Occupational Safety
and Health Administration (OSHA); inspection
reports; test reports; and the American Society
of Mechanical Engineers boiler and pressure ves-
sel code certifications, including original, repair
and modification records of design, materials and
welding procedures and tests.
Keeping this material organized can help ensure
that the entire plant complies with pertinent regu-
lations. Maintaining such material demonstrates
that a genuine effort has been made to comply
with these regulations, which can help with any
legal and regulatory issues in the future.
Operations and maintenance manuals
Manuals for the dryer and related equipment can
help train and provide further reference for super-
visors, operators and maintenance workers. To help
workers quickly and easily access the information
they need, systematically update the manuals with
supplementary information, manufacturer corre-
spondence, operation and maintenance notes and
copies of related technical articles and data.
If a dryer’s installation differed from the design
specifications, insert corrected “as-built” drawings
and specifications into the manuals. This informa-
tion can simplify dryer startup, training and main-
tenance and is essential for managing process
upsets and mechanical emergencies.
Drawings
Save copies of all arrangement and installation
drawings of the dryer and related equipment.
Catalog them to simplify identifying and locating
 Safety procedures typically
include specific information for
maintenance workers, such as
using the buddy system, using
proper tools and ventilation,
using equipment lockouts
to ensure that the dryer's
power supply is cut off during
maintenance, and blocking or
locking out the dryer to prevent
unexpected shifting or rotation
of a rotary dryer's shell when
maintenance workers enter it.
a particular drawing. To save storage space and
preserve the drawings, keep them in stick files,
in which up to 50 drawings can be clamped onto
metal bars and stored in a hanging file. Reduced
copies of the drawings can be bound for quick
access or converted to microfilm. If drawings are
MOBILE
not already in a digital format, they can be scanned
and stored for safekeeping. No matter which cata-
PAIL FILLER
loging system is used, establish controls to prevent
loss or unauthorized removal of any drawings.
The drawings can help workers understand cer-
tain dryer components, such as the drive assembly,
and thus facilitate dryer inspections and repairs.
The drawings can also help establish or confirm
repair parts information. Although a dryer manu-
facturer may not release proprietary detail draw-
ings, which specify individual parts, the detail
drawings may be referenced on the arrangement
and installation drawings, so the manufacturer
can be asked for the information if necessary.
Parts lists
Parts lists for the dryer and related equipment
include details such as material specifications, sizes
and grades of bolts and other fasteners, tolerances,
hardnesses, finishes and lubricants. If these details
aren’t included on the lists, be sure to add them.
Also add information about which parts should
be ordered from the supplier so the parts meet all
original specifications and incorporate all design,
material and manufacturing improvements. For TM
instance, if the manufacturer of a rotary dryer Ready to Ship
states that the dryer’s thrust roll assembly has been
redesigned, increasing the part’s design capacity
by 40% but increasing its cost by only 15%, add the BUILT TO FILL. BUILT FOR LIFE.
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APRIL 2023 | www.processingmagazine.com 21
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22 Processing | APRIL 2023
surprises during emergencies and ensure that the
correct parts are ordered.
Daily maintenance procedures
Daily maintenance procedures include instruc-
tions for the shift supervisor’s simple walk-through
inspection, performed once during each shift, and
the maintenance worker’s more thorough daily
inspection. These procedures can be used for train-
ing supervisors and maintenance workers, as well
as for periodically training new workers.
Special and emergency
maintenance procedures
Special and emergency maintenance procedures
specify the steps required in an emergency condi-
tion, which may require a scheduled or unscheduled
shutdown. The steps can include stopping feed to the
dryer, partially or completely emptying the dryer, and
cooling it down. For instance, if a dryer is severely
overheating and vibrating, and likely to fail, repair-
ing it during operation would be unsafe. Instead, it
is best to immediately reduce the plant’s production
rate if possible or stop production upstream from
the dryer. The latter permits the dryer to be partially
or completely emptied and cooled prior to its shut-
down. Keeping a record of special and emergency
maintenance procedures can help companies plan
for emergencies and train workers in advance, ensur-
ing a much safer and more orderly procedure if an
emergency occurs.
 Table1: Sample
page from a dryer
operations log.
Safety procedures
Safe practices for workers who operate and maintain
the dryer are always a top priority throughout plan-
ning, training and operation. For instance, safety pro-
cedures typically list information about proper lighting
for all workers near the dryer and specific information
for maintenance workers, such as using the buddy sys-
tem, using proper tools and ventilation, using equip-
ment lockouts to ensure that the dryer’s power supply
is cut off during maintenance, scheduling frequent
supervisor checks and blocking or locking out the
dryer to prevent unexpected shifting or rotation of a
rotary dryer’s shell when maintenance workers enter
it. Post-repair safety procedures that are typically listed
include replacing equipment guards, discarding any
debris and removing any hoses, cables or tools used.
Baseline operation record
The baseline operation record lists a dryer’s nor-
mal operating conditions. The conditions should
be recorded at dryer startup and then updated at
regular intervals. The record lists normal operating
speeds, temperatures, flows, feed rates, amperage
readings, vibration readings ( frequency graphs of
the vibration levels) and other data. Any changes in
how the dryer is operated can also be listed, such
as increasing the feed rate, along with the date a
change is instituted. The record can serve as a sta-
tistical quality control for future reference, in that
the information about the dryer’s normal operating
conditions can help workers quickly evaluate prob-
lems and choose solutions when the dryer oper-
ates abnormally. For instance, checking the dryer’s
normal vibration readings after spotting wear on a
dryer part can help workers determine when the
wear started and how serious the vibration is.
Operations log
The operations log, as shown in Table 1, records the
dryer’s operating variables, such as inlet and outlet
material and gas temperatures, dryer drive motor
and exhaust fan amperage readings, and production
rate on an hourly basis. The log can show deviations
from standard norms, excursions above posted safe
limits and operating behaviors that vary from the
baseline operation record (represented in Table 1 as
the Normal Setting column). A worker responsible
for both operations and maintenance should regu-
larly review the log to look for such abnormalities
so they can be investigated and corrected. A good
log can also help the worker spot the problems that
most frequently cause downtime so those problems
can be resolved first.
Maintenance log
The maintenance log tracks all dryer adjustments,
repairs and inspection data. Recording internal
clearances of a rotary dryer’s roller bearing assem-
blies during regular inspections is a useful pre-
ventive maintenance tool that enables workers
to check bearing wear. The regular recording of
vibration readings, which should be stored in the
maintenance log, for bearing housings and drive
components when the equipment is well adjusted
and in good condition provides a good baseline for
measuring vibration severity later. For instance,
a new vibration reading that shows higher vibra-
tion amplitude than an older reading may indicate
the first symptom of a problem, such as a lack of
lubrication, that if left unchecked could suddenly
require repair and cause unscheduled downtime.
Regularly recording temperatures at specific loca-
tions throughout the dryer by using an optical
or infrared pyrometer can help workers locate
abnormal hot spots later. A hot spot can indicate
tooth wear from abnormally heavy contact areas
on large gear teeth, which is easily corrected by
adjusting the gears or adding lubrication.
Reviewing the log to see what type of mainte-
nance an older dryer has required can be the first
AUTOMATIC BOTTLE
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repaired, rebuilt or replaced.
Lubrication record
The lubrication record includes the supplier’s pro-
cedures for lubricating the dryer. It specifies the
correct oil or grease types and grades, where they
should be used and at what intervals, as well as
the procedure checklists and a log for recording
completed lubrication. Lubrication is typically per-
formed by a maintenance worker as part of the
daily inspection. If the worker notices and reports
any smoke or heavy oil or grease leakage during
lubrication, which may indicate that a seal or other
component has failed, the failure can be promptly
investigated. Recording the smoke or leakage in the
lubrication log can also provide helpful information
for investigating subsequent component failures.
Annual turnaround procedure
The annual turnaround procedure lists the steps Simply Efficient. Simply Rugged.
for performing major dryer repairs or rebuilding SM
a dryer during the off-season or other scheduled
downtime. The procedure can help workers plan
SimplyFILL
and coordinate the required work, so it is success- Specialty Equipment has a full line of bottle filling
fully completed in the allotted time. Coordination and capping machines ideal for the lubricants,
with production schedules in a large plant is espe- oils, chemicals, cleaning and personal care/
cially important because the turnaround proce- beauty industries. Up to 14 filling heads; fills
dure often involves diverting dryer feed to stor- up to 100 2oz to 2.5 gallon bottles or 5-gallon
age tanks or other production lines in the plant. F-style jugs a minute; servo-driven, inline, rotary
Coordination with outside staff, such as manu- filling; both flowmeter and piston-based fillers
available. For more information, contact us at
facturer-supplied technicians and outside con-
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tractors, ensures that their work is completed as
quickly as possible to minimize production losses.
The annual turnaround procedure can mini- Benefits
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replaced. Record any repairs made at the annual
turnaround in the maintenance log.
Types of Bottles We Fill
Conclusion
Establishing and maintaining a complete mainte-
nance record that includes the elements described
in this article can make any dryer maintenance
program more effective. The maintenance record
can help workers quickly spot abnormal dryer
operation, identify the problem’s cause and correct
it. Referring to the maintenance record can also
help determine whether an older dryer should be
repaired, rebuilt or replaced.
We also provide installation, parts and field service.
Heyl Patterson Thermal Processing
www.hpprocess.com Learn more by calling 833-467-3432
www.specialtyequipment.com
 The maintenance log tracks all dryer adjustments, repairs and inspection
data, and reviewing the log can be the first step in determining whether a
dryer should be repaired, rebuilt or replaced.
APRIL 2023 | www.processingmagazine.com 23
 POWDER & BULK PROCESSING
P R O D U C T

FOCUS
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 POWDER & BULK PROCESSING

All images courtesy of Freund-Vector.

26 Processing | APRIL 2023

Inline moisture
endpoint detection
in wet granulation using filtered NIR spectroscopy
Process development scientists study the efficacy of using near-infrared
spectroscopy for inline, real-time measurement of product moisture during two
different wet granulation methods. | By Garrett Alfred and Mitch Crawford, Freund-Vector

G
ranulation technologies play a central role in industries from phar- Top spray granulation
maceutical to food and beverage to animal nutrition, among others. Top spray granulation is a one-pot, wet granulation method where a dry blend
Wet granulation involves the infusion of solvents, either aqueous or consisting of only raw material is loaded into a fluid bed and fluidized using
organic, along with the aid of wet or dry binders to agglomerate fine conditioned process air, while a binding solution (water or a multi-component
particles into larger, more free-flowing powder. The most common solution) is sprayed downward and atomized from a spray gun seated approxi-
methods are extrusion, high shear mixing, and fluid bed granulation. mately halfway up the fluid bed.
Moisture content during wetting and drying cycles is a critical factor that Top spray granulation trials were conducted using the Freund-Vector VFC-
influences agglomeration rates and overall particle growth. Typically, moisture 15M FLO-COATER with a 20-liter product container and the Freund-Vector
content is measured according to the standard Loss-on-Drying (LOD) meth- VFC-60M FLO-COATER with a 220-liter product container. An NIR filter pho-
od. Instruments manufactured for this purpose heat a known mass of sample tometer was used for measuring inline moisture content (Figure 1), while the
and evaporate any moisture present. The instrument then calculates the mass Mark-3 LTE moisture analyzer was used for offline moisture measurements.
lost as a percentage, typically in as little as 5 to 15 minutes. For both units, a placebo formulation consisting of 70% lactose monohy-
However, due to the dynamic nature of wet granulation, the material’s drate (312), and 30% microcrystalline cellulose (Emcocel 50M) was used as
current moisture content may be different than the sample being tested.
Depending on the sampling method used, the process upset could range from
a minimum of a slight disruption by offline destructive samples, to a major
process upset by pausing or stopping a process to pull multiple samples. This
could be detrimental to the process if the material is on the verge of being
oversaturated and may crash the batch.
To reduce stoppage and sampling times, an efficient moisture sampling
technique is needed. Inline near-infrared (NIR) spectroscopy can provide
instantaneous feedback on moisture content. The rapid measurements may
eliminate stoppages, decrease process errors such as over-wetting, and may
even help predict when the material is dry enough to discharge. This tech-
nique speeds up process times and reduces the need for a redundant LOD
instrument.
To obtain meaningful information from the NIR sensor, a relationship
between signal (absorbance value) and concentration (product moisture) must
be established. To verify the correlation and associated least squares regres-
sion line, two wet granulation methods were evaluated using NIR spectros-
copy to determine an ending moisture infusion and drying point, without pro-
cess interruption. The data strongly correlated with offline data. These studies
narrow in on multiple fluid bed granulation methods and incorporating NIR
spectroscopic measurements in-process. Additionally, the effects of moisture  Figure 1: Filter photometer placement in the product container of the VFC-15M with 20-liter top spray
content on particle size and morphology were examined post granulation. container (left) and VFC-60M with 220-liter top spray container (right).

APRIL 2023 | www.processingmagazine.com 27


a starting point for development batches. After the feasibility work with the
placebo was completed, semi-fine acetaminophen (APAP) was granulated to
demonstrate NIR capabilities with an active formulation. Active and placebo
blends were granulated using a 10% polyvinylpyrrolidone (PVP) K30 solution
to theoretical weight gains of 7% and 5% weight by weight (w/w), respective-
ly. The process was considered finished when the final moisture content was
below 2%.
Best-fit curves were created for both blends, as shown in Table 1. Hausner
ratio and Carr’s index were calculated, as shown in Table 2. Angle of repose
was calculated for granulated product and raw material but does not pro-
vide meaningful comparisons due to the poor flowability of the raw mate-
rial. Particle size distributions were measured using the QICPIC particle size
analyzer.
 Table 1: Top
spray granulation
absorbance
best-fit curves
and associated R 2
values.
“pot,Rotary spherical granulation is another one-
wet granulation process that allows for
targeted particle sizes with a narrow particle
size distribution. ”
The particle sizes of both the raw and granulated materials were also mea-
sured to show repeatability between trials using identical process param-
eters. Table 3 shows the values obtained for the D10, D50 and D90 of each
granulation.
The placebo trials yielded a percent difference of only 3.81% when run on
the VFC-15M small-scale FLO-COATER versus the VFC-60M large-scale FLO-
COATER. When using APAP, the percent difference between small- and large-
scale trials shrinks to 1.79%, which demonstrates a very high level of repeat-
ability between individual trials as well as the scaled-up processes.
GXR rotor spherical granulation
Rotary spherical granulation is another one-pot, wet granulation process that
allows for targeted particle sizes with a narrow particle size distribution. The
particles are much more spherical, which also helps create a dense, free flow-
ing powder. Although done in the same fluid bed as a top spray process, the
tangential movement of the product allows for a “snowball” type effect, while
the high velocity of the conical rotor allows for vigorous mixing to ensure even
particle size growth throughout the batch. As with any other wet granulation

 Table 2: Bulk and tapped densities of all raw material blends and final granulations, along with the
associated Hausner ratios and Carr’s indices.

After running calibration batches, the moisture content measured by the

NIR filter photometer averaged over 30 seconds was within 1% of the con-
firmed moisture content measured by the Mark-3 LTE moisture analyzer at
each interval that a sample was taken. Physical characteristics of each batch
matched closely when similar moisture profiles were used during the granula-
tion process (Table 2).
All granulated products have a calculated Hausner ratio below 1.34 and are
considered passable. Both raw materials have Hausner ratios over 1.4 (high-
lighted in Table 2), indicating poor flowability. Supporting these calculations,
the Carr’s indices for the granulated materials are all below 23, which is within
passable or better ranges, whereas the raw materials are both over 30 and in
the poor to extremely poor flowability range.

 Figure 2: Filter photometer placement in the expansion chamber of the GXR-35 rotor.

 Table 3: Particle size distribution for each of the trials conducted with both placebo and APAP blends.
method, peak moisture and final moisture content are both critical factors in
determining the physical characteristics of the final granulation.
Granulations were performed using a Freund-Vector VFC-Lab 3 FLO-
COATER with a GXR-35 rotor insert. Three granulation formulations were
used: a placebo blend of lactose monohydrate (312), partially pregelatinized
starch (B815), and microcrystalline cellulose (Emcocel 50M); a singular blend
of acetaminophen semi-fine powder; and ibuprofen 25. For each granulation
process, 5% PVP K-30 aqueous solution was used as a binder.
Absorbance values of the moving product bed were recorded using an NIR
fiber optic photometer located approximately four inches above the product
surface, and values were captured using Putty software (Figure 2). Granulation
samples were withdrawn from the sample port throughout the granulation

28 Processing | APRIL 2023

  Table 4: Rotary
spherical granulation
absorbance
best-fit curves
and associated R 2
values.
process and Loss-On-Drying (LOD) measurements were determined using a
Mark-3 LTE moisture analyzer. Absorbance values and LOD measurements
were correlated to make corresponding calibration curves.
Best-fit curve equations for each of the granulations are shown in Table 4.
All equations had an R2 value in the range of 0.97 to 0.99. These equations were
programmed into the photometer so that it would directly display moisture
during the validation trials. During the validation trials, the difference between
the % moisture measured by the photometer and the LOD machine was not
more than 1%.
Conclusions
This study accomplished two goals. The first goal was to develop repeatable
moisture curves for a placebo product and active products, which can be pro-
grammed into an NIR filter photometer and can read out real time product
moisture data without the need for invasive or disruptive sampling. The sec-
ond goal was to take this small-scale calibration data and implement it on a
production-scale fluid bed and evaluate the final product characteristics to
determine the scalability of the NIR moisture prediction models.
NIR spectroscopy provided significant advantages over offline moisture
measurement in terms of time for sample analysis without a drop off in
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accuracy. In this study, repeatable moisture curves for a placebo product and
an APAP product were produced and validated. The calibration data can be
programmed into an NIR filter photometer, which in turn can read out real
time moisture data from the product without the need for invasive or disrup-
tive sampling.
Additionally, the calibration curves generated on the small scale were
implemented on a production scale fluid bed and evaluated to determine
scalability of the NIR moisture prediction models. Having the capability to
measure moisture in line and in real time also allows for greater control over
the final product’s physical characteristics, which minimizes batch-to-batch
variation and could greatly reduce reject batches or catastrophic failures.
Garrett Alfred is a process development scientist at Freund-Vector and has been with
the company since 2018. He has been involved in numerous customer development
trials and field startups and has also conducted research using PAT control methods
and instrumentation for both wet and dry granulation methods. He graduated from the
University of Iowa with a BS in chemical engineering.
Mitch Crawford is a process development scientist at Freund-Vector and has been with
the company for 10 years. He has been involved in numerous customer development
trials and has conducted research using PAT control methods and instrumentation
for both wet and dry granulation methods. Prior to joining the lab, Mitch worked as
a service engineer for 4 years. He graduated from Iowa State University with a BS in
mechanical engineering.
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APRIL 2023 | www.processingmagazine.com 29
2/15/23 3:10 PM
 PLANT MAINTENANCE & SAFETY

 Figure 1: Modern
condition monitoring tech-
nologies, such as Emerson's
AMS Machine Works, can
be accessed via an array of
communication technolo-
gies, untethering personnel
from the control room.

All images courtesy of

Emerson

Optimizing P
rocess manufacturers are operating differ-
ently than they did even five short years
ago. A global pandemic, supply chain cri-
ses and a stronger public focus on sustain-
ability have increased the need for plants

preventive
across an organization to all operate at
peak performance. Every link in the chain is essen-
tial, so in most cases every plant across the enter-
prise needs to step up to meet new goals.
Accomplishing these goals requires changes
in the way plants operate in terms of equipment,

maintenance
processes and personnel. But these changes often
seem at odds with the needs of maintenance staff
who, as part of their preventive maintenance strat-
egies, require consistency so they can trust equip-
ment to run as expected for a certain length of
time. Change cascades across the organization,

drives competitive advantage
At the intersection of data and industrial software,
process manufacturers are finding the strategies they
need to improve safety, performance and sustainability.
By Monil Malhotra, Emerson
and if initiatives do not take the needs of the reli-
ability team into account, it can cause frustration,
lost revenue and even safety incidents.
Fortunately, predictive technologies are now avail-
able that can help ease the transition to new and
more efficient equipment operation. By improving
collection of data from process and balance-of-plant
assets, and by connecting that data to modern indus-
trial software solutions, process manufacturers can
empower operators to innovate, helping meet sus-
tainability and efficiency goals, while simultaneously
improving the entire preventive maintenance process.

30 Processing | APRIL 2023


Rescuing stranded data
At the heart of improving plant performance is
good data. A reliability team that cannot see the
health of its assets is often surprised when they
fail. Surprise is the antithesis of a successful reli-
ability program. These unexpected equipment
failures can lead to unplanned outages, which are
expensive and time consuming to remedy, and
repair and maintenance is much more expensive
than planned work.
Many teams do not collect all the data they need
due to a number of factors. First, process manufac-
turing plants can be large and contain numerous
hazardous areas. These physical barriers increase
the time and planning it takes to collect data. If
it takes an hour or more to drive out to an asset
to inspect it with a handheld analyzer, the asset
is likely to be checked infrequently, if at all. Or if
it takes an hour to get the gear and safety checks
done to enter a hazardous area to check an asset,
inspections are also unlikely to happen regularly.
But even in the rare case a plant has the time
and resources to regularly drive to remote assets
and perform the critical safety steps required for
accessing hazardous areas, in today’s plant envi-
ronment teams rarely have the spare personnel
to do so. Retirements have claimed many of the
plant’s most experienced personnel, and process
manufacturers frequently run with skeleton crews
who work extra hours just to get all the basic tasks
done. Rarely will they have the free personnel to
perform manual rounds, especially for equipment
located remotely or in hazardous areas.
The solution is improving preventive mainte-
nance by implementing predictive technologies
across the entire facility. Today’s most success-
ful process manufacturers are moving away from
traditional route-based maintenance and instead
 Figure 2: SIF tracking software monitors safety functions and alerts users when those functions are not operating as expected.
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The most modern SCADA implementations
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get data directly from assets via nodes and easily
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Once critical asset health data is in the cloud,
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maintenance through advanced analytics and Battery-Grade LiOH Drying
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Improving safety with predictive
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Every plant values production, but even more impor- COLLECTORSS
tant is safety. An organization’s personnel are its most
critical assets, so the reliability of safety systems and
related equipment must always come first. However,
one thing many teams do not realize is that properly
functioning safety systems also improve performance.
Consider a facility’s safety showers. If the show-
ers are operating every two hours, something is
clearly wrong. Perhaps a pump is pumping too Recapture Li2CO3 & LiOH
much or not enough, or maybe the pressure is too
high or too low. Whatever the root cause, some-
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risk. In addition, some systems, such as high tem-
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MIXERSS
that might not refresh fast enough, risking them & BLENDERS
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APRIL 2023 | www.processingmagazine.com 31
tion while they are dealing with the problem, or
may be ineffectively using their limited personnel
trying to clean up and troubleshoot in response to
each incident.
To avoid these problems, today’s innovators are
using modern sensing technologies coupled with
industrial software to track the integrity of safety
systems in their facilities, and then instantly report
aberrations through the SCADA system. Safety
instrumented function (SIF) tracking software can
automatically identify safety systems in a degraded
state, helping plant personnel resolve issues before
the operation becomes unsafe (Figure 2).
Operators can use the software to verify the
integrity of the safety systems they are responsi-
ble for, and, if issues are identified, help prioritize
work orders to restore the integrity of that system.
Operators can also use SIF tracking software to
verify that bypasses are cleared, ensuring safety
systems can perform effectively when called upon.
Data-driven maintenance
When safety systems are securely monitored, plant
personnel can turn their attention to the many
pieces of rotating equipment across the facility —
its pumps, compressors, motors, fans and more.
Historically, plants relied on technicians with
decades of experience to examine these assets
and identify when something was beginning to
degrade. Often, those technicians could even haz-
ard a reasonable guess as to how long it would
take the asset to fail.
Today, few plants have a deep bench of experi-
enced personnel. But what they do have is months,
years or even decades of data stored in process his-
torians. Often, teams have baselines and metrics
from peak performance of rotating assets when
they were brand new. This data is the ideal founda-
tion for an analytics program using artificial intel-
ligence (AI) and machine learning (ML)-driven
asset monitoring software.
AI and ML-driven software takes all the data
from a process historian and creates a baseline of
functionality and a set of metrics for how the asset
should perform. In real time, the software can take
newly collected asset health data and monitor it
for deviations from the baseline. When a deviation
is detected, plant personnel receive early, accurate
and intuitive warning of when equipment failure
will occur, how the failure will occur and what to
do about it.
Armed with accurate data about when and how
failures will occur and how to address each issue,
even inexperienced personnel can create mainte-
nance schedules based on planned outages. And
in the plants lucky enough to still have technicians
with decades of experience, analytics software will
identify problems long before human senses can
detect them, providing far more lead time to per-
form repairs. In addition, analytics software can
also help with scheduling maintenance. Using its
AI and ML engines, the software can examine mul-
tiple assets with identified problems and then cre-
32 Processing | APRIL 2023
ate a schedule combining repair events in the ideal
order to result in minimum loss of revenue.
Streamlining maintenance via simulation
Today’s most effective maintenance teams are also
harnessing the power of simulation to stay ahead
of problems in the plant. Process manufacturers
around the globe are implementing new projects
to refine and expand operations to meet changing
market needs, and to improve efficiency and sus-
tainability to meet corporate and societal goals.
Whether greenfield or brownfield, project costs
spiral quickly when problems arise during startup.
Proper maintenance is essential to ensure that
those problems do not cause startup delays or
damage to expensive plant equipment.
Using simulation software, teams can avoid
those risks altogether. Digital twin simulations are
extremely accurate replicas of plant equipment and
processes that exist only in the digital world. Rather
than learning by trial and error on live equipment
— starting up and shutting down as problems
arise — teams can instead tune controls and train
operators ahead of commissioning to help ensure
that all equipment will operate safely and without
failure, even before the equipment arrives on site.
Once bugs have been worked out of the system and
operators are trained, the team can safely start and
operate its assets, without worry of creating main-
tenance issues on brand new equipment.
The same benefits translate to making process
and equipment changes to existing operations.
Squeezing every last bit of efficiency out of opera-
tions often means tweaking process parameters or
even bringing in new equipment that is untested
in the plant’s proprietary processes. While the
rewards of such changes can be great, the risks of
testing them — unscheduled outages, newly cre-
ated issues downstream in the process, etc. — can
be prohibitive, making teams hesitant to make
changes. Simulation software addresses this and
other issues (Figure 3).
Today’s powerful simulation technologies can
practically predict the future. Teams can make
changes to processes and run the simulation faster
 Figure 3: Mimic
simulation software
empowers personnel
to test and train on
new systems, equip-
ment, and processes
without the need to
use live equipment.
than real time, allowing them to see results of any
changes in only a fraction of the time as compared
to a live plant.
If the team wants to swap an old heat exchanger
for a new, higher-efficiency model, they can run a
test on the simulator using the new model’s speci-
fications to identify if it creates issues somewhere
in the process. Or the team might use the simula-
tor to test filling a drum or soaking a turbine — in
a matter of minutes rather than 10 hours. Armed
with this information, teams can add or change
equipment without creating increased mainte-
nance stress and spend.
Software will drive the future
Capturing competitive advantage in an increas-
ingly global marketplace will require operating at
peak efficiency 24/7. But achieving that efficiency
means more than tweaking processes and adding
new equipment. If efficiency changes come at the
expense of reliable operations, process manufac-
turers could see losses rather than gains.
For that reason, it is essential that plants hoping
to compete in the coming years focus on improv-
ing preventive maintenance. This can best be per-
formed through a process of improving data col-
lection and then connecting that data to the key
industrial software solutions that will help teams
move from reactive to proactive maintenance.
These enablers are available today and can integrate
directly with the SCADA and maintenance systems
teams already rely upon, empowering plant person-
nel to improve operations safely and quickly.
Monil Malhotra is the vice president of industrial
software for Emerson’s systems and software
business. He has worked for Emerson for over
15 years. Monil is responsible for managing
Emerson’s strategic partnership with AspenTech
and the standalone industrial software business-
es including Bio-G, Performance Services, Plantweb Optics and Zedi.
Emerson
www.emerson.com
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 PLANT MAINTENANCE & SAFETY

by JOHN BERNET
MECHANICAL APPLICATION
& PRODUCT SPECALIST
FLUKE RELIABILITY
As a mechanical application and
product specialist with Fluke
Reliability, John Bernet works with
customers from all industries to
successfully implement their reli-
ability programs. He has more
than 30 years of experience in
the maintenance and operation of
commercial machinery and as a
nuclear power plant electrician in
the U.S. Navy. He holds a Category
II Vibration Analyst certification
and is a Certified Maintenance
Reliability Professional (CMRP).

“management
Asset

is about
maintaining
an optimal
level of
performance
from assets,
at the lowest
possible cost
spanning each
asset’s life
cycle... ”
 Using a CMMS streamlines and
bolsters asset management so you
can extend the useful life of your
assets and focus your time where it
is needed most.
All images courtesy of Fluke

34 Processing | APRIL 2023

How CMMS connects workflows for
preventive maintenance
and asset management
From pre-installation planning and engineering to decommissioning,
CMMS software helps organizations track and manage their assets.

T
here is a saying in mainte-
nance: “If it wasn’t docu-
mented, it didn’t happen.”
Manually tracking process-
es and documenting work
takes a lot of time and has
many points where errors, miscommu-
nication and lost paperwork can hap-
pen. Digitizing and centralizing those
efforts brings teams onto the same
page. And the best way to do that is
with computerized maintenance man-
agement system (CMMS) software. The
benefits of CMMS include greater con-
sistency, improved recordkeeping and
seamless, more robust reporting.
A CMMS can be used to manage
many types of assets across an organi-
zation. An asset can be anything from
production equipment to vehicles to
buildings. No matter how many assets
an organization has, asset management
can be time-consuming. But using a
CMMS streamlines and bolsters asset
management to extend the useful life
of each asset and focus time where it is the most. Whether it is condition moni- their assets by getting the most out of  Tracking the maintenance history
needed most. toring sensors on critical assets or soft- the tools the team is already using. on your assets gives you the ability to
make data-driven decisions that use your
Asset management is about main- ware tools such as Power BI for data And with the reporting features in a resources most effectively.
taining an optimal level of perfor- visualization, a CMMS can bring exist- CMMS, sharing meaningful insights
mance from assets, at the lowest pos- ing tools together. And through integra- across teams or throughout the orga-
sible cost spanning each asset’s life tions with vibration sensors or other nization is simpler and more effective.
cycle, so an organization can offer condition monitoring devices, a CMMS For example, teams can analyze histori-
the production or services customers can help teams with around-the-clock cal costs and trends to identify priori-
expect. With this goal in mind, organi- awareness of asset health — even vibra- ties or showcase KPI tracking.
zations can weigh when to repair and tion analysis. A CMMS can also help manage and
when to replace assets. Tools that work together can do more streamline resources, including parts
From pre-installation planning and and offer a fuller picture of operations. and labor, while also making neces-
engineering to decommissioning, CMMS By combining software with hardware, sary tasks easier. Audits and regulatory
software helps track and manage assets. such as condition monitoring sen- compliance are simpler to manage with
And with real-time insights into the sors, teams can gain a more complete a centralized, digitized trail of docu-
health of assets, organizations can better picture of maintenance activities and mentation and work done. Think of it
plan, schedule and perform maintenance. real-time asset health in one place. as a digital paper trail — easily find and
Equipped with a holistic view, organi- compile all the information that regula-
Integrating CMMS software zations can make better decisions, save tory agencies need to demonstrate that
and tools time and money, and more effectively all necessary standards have been met.
The right CMMS software can also pair and efficiently manage assets. Again, Even warranty claims are easier with
with the tools maintenance teams use organizations can get the most out of robust recordkeeping.

APRIL 2023 | www.processingmagazine.com 35

The importance of tracking and trending
If there is a required level of service or output, tracking and trending assets
and performance over time will help determine what needs to be done to
maintain that level.
Reactive maintenance, which is what happens when something fails or
shuts down, tends to increase maintenance costs because of the prices of
labor overtime and expedited parts. Even preventive maintenance, which is
maintenance work done based on usage or time elapsed rather than on asset
condition, can lead to unnecessary spending. Any maintenance that is done
when it does not actually need to be done uses time and parts and introduces
risk that something could go wrong.
Tracking and trending asset condition over time and getting insights from
a CMMS can alert teams to asset decline. With an early warning of potential
problems, organizations can identify the actions that need to be taken, sched-
ule them as needed and even have extra time to order parts. Planned mainte-
nance is less expensive — and safer. Real-time data from a CMMS paired with
condition monitoring devices leads organizations to more informed decisions.
With a CMMS, it is easier than ever to achieve asset management best prac-
tices. Tracking the maintenance history on assets gives organizations the abil-
ity to make data-driven decisions that use resources most effectively. Labor
hours, parts and budgets are not infinite, so it is important to use them all
effectively. With a CMMS, teams can use the data to determine what needs to
be done and when, reducing both failures and unnecessary work.
Documentation ensures consistency
Work orders are a crucial part of any maintenance program. A CMMS offers
work order capabilities that keep teams up to date on projects, problems,
requests and more. Mobile capabilities allow team to receive, track and com-
plete work orders on the go.
Prioritizing work, from backlogs to urgent repairs, is easier when work
orders are digitized and centralized. A CMMS helps ensure that the work gets
done, and that it gets done on time. And again, such documentation helps
organizations when it comes to compliance.
With a CMMS, teams can effectively manage workflows and minimize
downtime while keeping tabs on asset health to know what needs attention
and when. Using a CMMS software means teams can level up their asset man-
agement programs and improve tracking and analysis of maintenance KPIs.
Transparency is another benefit. Sharing data and documentation across
teams and sites can eliminate data silos and provide one single source of truth.
Over time, teams learn what works — and what does not — to implement best
practices across the organization.
Real-world examples of the benefits of CMMS
Here are a few ways CMMS users have taken advantage of the features and
capabilities to improve their asset management:
A manufacturing company has standardized maintenance across 33 plant
locations. Using a single CMMS across the sites made reporting and oversight
possible at the enterprise level. A consistent asset hierarchy and consistent
naming conventions have brought everyone onto the same page. The compa-
ny is now able to track and trend KPIs consistently across the organization,
making continuous improvement possible.
A warehousing company has streamlined and improved its inventory man-
agement. It has 17 sites and used to hold spare parts at every single site.
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Now, using a CMMS, the company can manage its overall inventory much
more effectively. The company can ensure it has enough spare parts for all of
its assets and communicate in one centralized place. The right parts get to the
right sites when they are needed, and the company does not need to buy, store
and track duplicate parts across 17 sites.
A cooperage producing barrels for a distillery has to maintain its produc-
tion equipment while also running a dust mitigation system. Using the work
order feature of a CMMS, plus machine-mounted vibration sensors, helps one
cooperage plan and prioritize the work that it does. The cooperage is able to
separate the project-based, longer-term tasks from the more urgent, real-time
response needs.

Why asset management matters

Effective asset management is important for a number of reasons. Done right,
it prolongs equipment life, makes effective use of maintenance resources and
helps ensure consistent, quality production or services. Organizations can
make sound budgets and plan for replacements or critical repairs when they
know how long assets will last.
With a CMMS, organizations can take asset management to the next level.
By decreasing maintenance costs and increasing asset reliability and availabil-
ity, asset management becomes a way of adding value to a business and pro-
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APRIL 2023 | www.processingmagazine.com 37

 ASSET MANAGEMENT
Advanced analytics
enhance asset performance management
Understanding organizational capabilities, infrastructure and objectives
are key to avoiding common pitfalls when it comes to researching,
selecting and implementing an asset analytics solution.
E
very vendor, analyst and end-user company
in the process industries describes asset per-
formance management (APM) differently,
with definitions ranging from data manage-
ment strategy, to software and workflows,
to decision-making processes. The Gartner
definition — one of the more comprehensive —
states that APM encompasses the capabilities of data
capture, integration, visualization and analytics tied
together for the explicit purpose of improving the
reliability and availability of physical assets.1
In a vendor-heavy market, one of the greatest
challenges to implementing a successful APM strat-
egy is often identifying which building blocks are
38 Processing | APRIL 2023
| By Allison Buenemann, Seeq Corporation
best for an organization. One of the most common
misconceptions in this journey is that it must occur
linearly, beginning with a data capture and man-
agement strategy, but some of the most successful
implementations begin by envisioning the result.
Imagine first identifying the required outputs
of the APM strategy and working backwards. This
can be a great way to ensure that the foundation of
data storage, access and analytics capabilities sup-
port the desired outcomes.
Moving from insight to action…
One of the primary considerations for analytics solu-
tions being used in APM is how the output is pre-
ID 32247126 ©Alexxxey | Dreamstime.com
sented and shared with others in the organization.
Flexibility is a critical component — flexibility in visu-
alization options, in displaying focused versus roll-up
views, in the amount of information shared and in
the way it is shared — and it is key when it comes to
enterprise-wide solution adoption.
Managers are frequently most interested in
high-level OEE metrics, summarized in tables and
pareto graphs of bad actors when making business
plans. Meanwhile, operators and process engi-
neers desire simple interfaces for comparing all
assets under their responsibility to identify which
are most likely to cause problems in the near term.
Furthermore, reliability and maintenance engi-
neers desire methods to dig into the data around They overlap in need for easy-to-implement time- The technical details
bad actor assets to understand root causes. A series analytics involving unique data sources, and This use case starts with live data connectivity and
chosen analytics solution must contain various can be organized into asset hierarchies built for Chevron Oronite’s ability to simultaneously view
interactive and static visualization options for live use cases deployed at scale. and analyze process data from its plant historian,
dashboarding and reporting and be easily naviga- Chevron Oronite — a manufacturer of lubri- along with forecasted and actual weather data
ble between one and many assets. cants, fuel additives and chemicals — has a goal from a web API. Its advanced analytics solution,
of minimizing Co-Gen turbine runtime while con- Seeq, provides this multi-datasource environment
….And from data to insight tinuing to provide reliable power for site opera- with the asset hierarchy construction, flexible
Applying time series data analytics effectively is tions. The company uses an advanced analytics time-series calculations and collaboration capa-
difficult due to high volumes of information (which solution to combine flexible calculation methodol- bilities required for efficient APM.
compound over time), high frequency required for ogies with ad hoc and repeatable asset hierarchies Using a regression algorithm built into the solu-
logging and disparate systems of record. This type to predict and roll up the total available power tion, the company can correlate past temperature
of analysis historically took place using spread- generated by turbines in its Co-Gen unit. Subject forecast data with actual values to predict tem-
sheets, but these are incredibly cumbersome when matter experts (SMEs) then use these predictions perature values that account for the uncertainty of
filled with large quantities of data, require manual to inform operational decisions, aiming to reduce forecast data. SMEs then use predicted tempera-
manipulation and quickly reach row and file size the number of Co-Gen turbines online to save the ture to plot the available power of each turbine
limitations. These constraints — paired with the company maintenance expenses and reduce sites’ based on a well-established correlation between
fact that data is no longer live the moment it is carbon footprints. ambient temperature and power generated. To
copied into a spreadsheet — solidifies the need for
a better approach.
Solutions must possess unique time series ana-
lytics capabilities, and be able to complete calcu-
lations performantly across any number of assets
required by a given manufacturing company.
Analysis of time series data is underpinned by
the ability to encapsulate specific time periods
of interest to focus and bound calculations. Once
identified, these focus periods can translate into
performance metrics, golden profiles, regression
model training data sets and more, and these out-
puts help inform operations decisions that drive
business value.

Data storage and structure considerations

APM solutions are typically piecemeal, with dif-
ferent software tools for achieving different objec-
tives. This approach promotes collaboration
among vendors at various points along the solu-  Figure 1: Seeq describes the
critical link asset hierarchies play
tion spectrum, and innovation-driving competi- in turning data into action.
tions among those with similar offerings. Seeq Courtesy of Seeq
(Figure 1), an advanced analytics solution, feder-
ates process manufacturing companies’ mixed  Figure 2: An Organizer Topic
report in Seeq is used by opera-
bags of process historians and databases, whether tions staff to quickly determine
hosted in the cloud or on-premises. whether the spinning reserve
In addition to performant storage systems is more than 2,000 kW, which
indicates they can take a turbine
for process and contextual data, a structure to offline with confidence it will not
organize the data is also required. Many com- need to be restarted in the next
panies implement asset hierarchies to help one to two days.
organize tag data, tying it to useful metadata, Courtesy of Seeq
such as physical equipment and location. These
structures help data users locate the neces-
sary tags, and if configured appropriately, scale
their analytics calculations. Solutions that offer
flexible asset hierarchy capabilities — such as
building new hierarchies specific to particular
analyses or modifying existing hierarchies for
the subset of assets of interest — provide even
greater advantages.

Recipes for success

Real-world case studies in this area are plentiful,
comprised of assets ranging in size from single
control loops to entire oil field production systems.

APRIL 2023 | www.processingmagazine.com 39

“solutions
One of the primary considerations for analytics
being used in APM is how the output is
presented and shared with others in the organization.
account for drift between modeled and actual val-
ues over time, the model undergoes continuous
retraining using the most recent two days of data.
Chevron Oronite uses asset templating to scale
the model-building exercise rapidly across all five
of its Co-Gen turbines, three or four of which are
operating at any given time. Building out this use-
case-specific asset hierarchy also provides the
capability to perform roll-up calculations on key
metrics, such as the total available power at any
time. Comparing this roll-up of total available
power with the previous 24-hour power demand
equips operations staff with data to make deci-
sions on when to take turbines offline, for example
when the predicted power generated is greater
than 2,000 kW over the previous day’s demand.
Chevron Oronite lead process engineer,
Christopher Harp, notes the browser-based
advanced analytics solution’s sustainability and
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”
support for employee succession. “I can share
[each Data Lab Notebook] with the next process
engineer, and they can run the script and output
the exact same structure, resulting in consistency,”
Harp says.
This consistency is critical to ensure that analyt-
ics and their acceptance among operations teams
continue in the future.
Back to the basics
Getting the most out of an APM strategy begins
with the data. Data must be available and acces-
sible to those who need it, in environments that
are source-agnostic, along with flexible calculation
capabilities that support both ad hoc and struc-
tured time-series analytics. Finally, insights derived
from analyses must be shareable and actionable
within an organization and externally throughout
supply chains so value can be added.
Batch & Continuous Mixing That
Delivers More
• Easy to clean and
maintain
• Excellent heat
transfer
References
1. https://www.gartner.com/en/information-
technology/glossary/asset-performance-
management-apm
Allison Buenemann is the Chemicals Industry
Principal at Seeq Corporation. She has a process
engineering background with a BS in chemi-
cal engineering from Purdue University and an
MBA from Louisiana State University. Allison has
nearly a decade of experience working for and with bulk and specialty
chemical manufacturers like ExxonMobil Chemical and Eastman to
solve high-value business problems leveraging time series data.
Seeq Corporation
www.seeq.com
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 Q&A: OPERATIONS
by Andreas Eschbach
FOUNDER/CEO
ESCHBACH
Andreas Eschbach is the founder
and CEO of the software company
eschbach, which helps production
teams stay safe and work smarter
through better information shar-
ing and collaboration. Holding a
degree in computer science, he
draws his practical experience
from leading a variety of inter-
national software consulting and
implementation projects for lead-
ing chemical manufacturing com-
panies, focusing on production,
continuous improvement, EHS
and maintenance. His company
is a provider of manufacturing
solutions and headquartered in
southern Germany with offices in
Boston, Massachusetts.
42 Processing | APRIL 2023
Preserving critical
plant knowledge
is essential for the digital
transformation journey
Andreas Eschbach discusses how artificial intelligence can help
support the capture and sharing of institutional knowledge and
why that is important as process manufacturers move to Industry 5.0.
I
nformation on plant operations
between teams is exchanged during
daily activities, much of which can be
essential to managing ongoing plant
processes. If this tacit knowledge,
particularly between operational
teams and shifts, is captured in a digital
“knowledge bank” with intuitive access,
process manufacturers can be more effi-
cient, safer and more competitive. Andreas
Eschbach, CEO and founder of eschbach’s
Shiftconnector platform, discusses how
artificial intelligence (AI) can help support
the capture and sharing of this knowledge
and why it is important as process manu-
facturers move to Industry 5.0.
Qthink: knowledge
What challenges related to
management do you
process manufacturers will be
facing over the next five years?
A :
Over the next few years, about 25%
of chemical industry workers will
be eligible to retire. For many process
manufacturers, this could translate to a
significant loss of skill, experience and
critical plant knowledge — all of which
could negatively impact productivity,
safety and overall profitability.
Process manufacturers rely on knowl-
edge management, which is the process
of creating and maintaining information
related to a manufacturer’s operations,
shift-to-shift or team communications as
well as sharing vital operational process
information enterprise-wide. Often, the
most difficult knowledge to capture is
tacit knowledge where a long-time work-
er has gained extensive knowledge about
plant operations throughout the years.
Qpreserve
: With this in mind, how do
companies capture and
critical plant knowl-
edge that exists only in the
minds of these workers?
A
For starters, it is vital to establish
:
knowledge-creation processes
and techniques to preserve and build
upon institutional knowledge. There is
know-how among teams and individu-
als, which needs to be preserved in a
structured way so that it can easily be
shared across the enterprise, including
multiple and geographically dispersed
plants.
Kn o w l e d ge m a n a ge m e n t i s a
domain-specific discipline. There is for-
mal (explicit) vs. informal (tacit) knowl-
edge. Digitalization is critical to cap-
ture both types of knowledge, so it can
be shared across teams, new employ-
ees and the entire organization. Tacit
knowledge is trickier to capture, so dig-
italization can help an organization not
only capture the information but use it
where and when it is needed most.
Qtechnologies
: Can tacit knowledge be
combined with any new
to help solve this
potential loss of skills, which is
a major challenge for process
manufacturers?
A : Yes. Tacit knowledge, otherwise
known as “people experience”
within processing plants, integrated
with the power of AI, can drive inno-
vations that will help manufacturing
teams solve complex problems and
expand ingenuity in the process. For
instance, AI-enabled systems can keep
track of operational teams’ activities,
thus increasing efficiencies and asset
performance. An AI system enables the
retrieval of collected data enterprise-
wide, enabling real-time access to per-
tinent data to address specific produc-
tivity issues when they arise. The use of
machine learning, for instance, allows
for continuous input by workers to
teach a smart search to retrieve more
relevant information faster.
Q: Can you give a
real-world example?
A: For example, one area that is note-
worthy is the essential knowledge
transfer that occurs between shifts. It
is important to take a people-centered
approach that looks beyond digitaliza-
tion and considers the needs of people
using these tools. What do they need to
know and when? What kinds of deci-
sions do they need to make and who
else needs to be involved to facilitate
critical decisions?
Consider a day-shift technician in
a chemical processing plant. At the
start of their day, they need to quickly
come up to speed with the status of
the processes inherited from the night
shift and what, if any, next steps are
required. They also need to know if
there are any problems to troubleshoot,
new directives from management or
safety or maintenance issues that need
attention. While some information can
be conveyed during a shift handover
meeting, other data tends to be scat-
tered among logs and documents, often
maintained in siloed areas of the plants
— unshared and not transparent.
In all user cases, visual management
is used as an efficient management
approach to engage people on the shop
floor to improve production capacity.
Visual management empowers frontline
personnel with data and engages them
to make data-driven decisions. It allows
for the visualization of batch cycle times,
process variations and overall equip-
ment effectiveness (OEE) losses.
Executing continuous improvement
initiatives requires a 24/7 commitment
by every shift team.
To accomplish this, everybody needs
to be on the same page to support plant
objectives. The key is to make sure
improvements are owned by the people
involved and supported by digital appli-
cations that deliver data from every-
where in the plant and can be accessed
whenever and wherever it is needed.
For instance, when operations person-
nel such as engineers are working from
home, the KPIs with their targets and
actual results must be made available
onsite or remotely.
2304Pro_ProcoProducts.indd 1
Q: What KPIs should
be considered?
A: Certain KPIs can measure the
asset utilization of a single plant
and deliver insight into an enterprise’s
network of manufacturing plants
around the globe.
One of those KPIs is OEE, which con-
siders the effects of the many different
work processes influencing output,
from demand generation and planning
to operations and asset maintenance.
OEE strategies have become instru-
mental in monitoring these processes.
For instance, for a single plant or pro-
cess cell, OEE has been proven to yield
improvements in production rates.
Qtransformation
: As process manufacturers
continue their digital
journey and
embrace Industry 5.0, what do
you think will be some of the
positive outcomes?
A Industry 5.0 ushers in the smart
:
factory and people and machines
working together. It is the promise of
moving beyond focusing on just the
machines and empowering people. With
the power of AI, people and machines
can work together to improve operation-
al performance, quickly solve problems
and accelerate the pace of improvement.
New systems that are part of a plant pro-
“technologies,
cess management approach have the
power to capture the full organizational Like all
knowledge of the workforce across mul-
tiple systems and sites and can make
that knowledge easily available to all AI tools will
team members in a way that will benefit
their contributions to the company. continue to evolve,
Like all technologies, AI tools will
continue to evolve, creating exciting
creating exciting
new prospects for process manufactur- new prospects
ers, their team members and custom-
ers. In an era of increasing competition, for process
customers are demanding excellence
and speedier times to market. Agile
and forward-looking organizations
manufacturers... ”
will greatly benefit from embracing
Industry 5.0 with an AI assist that will
improve safety, productivity and com-
petitive advantage.
eschbach
www.shiftconnector.com
APRIL 2023 | www.processingmagazine.com 43
3/13/23 1:51 PM
 FILTRATION & SEPARATION
Case study:
Sophisticated separation
for a fishmeal processing plant
Ocean Protein transforms “trash to treasure” by using two Flottweg Tricanters to take
fish waste that would otherwise be discarded at sea or shipped out of the country
and turn it into products that are used in aquaculture, livestock feed and pet food.
By Daniel Lakovic, Flottweg Separation Technology
E
fficiently separating water, solids and
oils has been a smooth process for nearly
two decades at Ocean Protein, the only
fishmeal processing plant in the state of
Washington. The company transforms
“trash to treasure” by using two easy-to-
use Tricanters to take fish waste that would oth-
erwise be discarded at sea or shipped out of the
country and turn it into products that are used in
aquaculture, livestock feed and pet food.
“One of the reasons we chose the Flottweg Z4E
Tricanters over traditional decanters was because
our product does not process well with a high-
speed separator,” said Rick Crume, Ocean Protein’s
plant manager. “We could accomplish everything
we needed with less equipment this way. That was
a big issue for us.”
44 Processing | APRIL 2023
A Tricanter separates three phases simultane-
ously, which traditionally requires a two-step pro-
cess, using a decanter to separate water and oil
from solids, then a separator to separate the water
and oil.
The Tricanters were first installed in 2005, the
year the facility was built in Hoquiam, Washington.
The plant averages 4,000 MT of meal, 670 MT of oil
and 80 MT of bone meal annually. A sister compa-
ny to Ocean Gold Seafoods — which has the high-
est volume capacity for processing fish on the west
coast — Ocean Protein pursues both technological
and sustainable industry innovations.
The company recognizes that its efforts to
achieve its goals of enhanced environmental sus-
tainability, community development and local jobs
has its challenges — chief among them being the
challenge of containing and limiting odor, which
is a natural byproduct of fishmeal processing. In
its early days, the company struggled to make the
industry’s then-current odor control standards fit
the unique needs of a community where industrial
and residential lines are so closely drawn. But in
cooperation with regulatory agencies such as the
Olympic Region Clean Air Agency (ORCAA) and
the Department of Ecology (DOE), Ocean Protein
has committed more than $5 million in advancing
new odor control technologies.
That dedication led the DOE to state in a 2007
report that Ocean Protein was utilizing “the best
available” technology for odor control. And the
company continues to add more enhancements to
its processes to ensure that the benefits it brings to
the community are not outweighed by any nega-
tive repercussions of its processes.
The fishmeal separation process
Crume explained that fish remnants are essen-
tially cooked — similar to how one might cook a
roast. Just as a roast leaves “juices” in the pan, so
too does fish in the cooking process. This “juice”
is then processed to remove the oil from the liq-
uid. The liquid is then processed to recover all the
remaining proteins to produce the fish meal and
fish soluble products.
“First, we cook the fish, then press it to get rid
of some of the liquid and moisture,” Crume said.
“The solid product goes to a dryer to be dried.
Everything that is pressed off goes to the Flottweg
Tricanter. That is the slurry with all the oil, water
and solids. We use the Tricanter to separate the
water, solids and oil. The solids go back to the
dryer with rest of the solids. The water goes to
 In the classic separation process, solids are separated from a liquid,
or two liquids of different densities are separated. But often both come
together. The Tricanter allows the continuous separation of three phases
(solid-liquid-liquid) in a single process.
Courtesy of Flottweg Separation Technology
an evaporator and the oil goes to a fish oil tank.
We don’t have to polish anything. Right from that
machine, the product goes directly to bulk sale.”
Ocean Protein installed the two Z4E Tricanters
when the plant was built in 2005. The same
machines continue to run efficiently with relative-
ly low maintenance.
“We can only run at a certain gpm, so once we
figured out our best configuration, we have now
perfected the process and not had any problems,”
Crume said. “The Tricanters are very low mainte-
nance. We can do minor maintenance here at the
plant, but when we need balancing or something
more complicated, which is not very often, we ship
the machines back to Flottweg and they send them
back with a full inspection report, recommenda-
tions and pictures. It’s a very smooth process.”
How the technology works
In the classic separation process, solids are sepa-
rated from a liquid, or two liquids of different den-
sities are separated. But often both come together.
The Tricanter allows the continuous separation
of three phases (solid-liquid-liquid) in a single
process. This is efficient in the treatment of oily
sludges, in starch production and in fat recovery.
More than 40 years ago, Flottweg developed
the Tricanter to separate three phases in a single
simultaneous process. The prerequisites for this
are that the liquids are not soluble in each other,
that they have different densities and that the sol-
ids phase has the highest specific weight. On this
basis, the specially designed impeller system pro-
duces optimal separation results.
Three-phase separation offers users several
advantages. The combination of the processing
steps eliminates the need for additional separation
stages, which results in cost savings. In addition to
its high selectivity, the Tricanter is particularly use-
ful because of its versatility. It can adapt to chang-
ing feed conditions at any time.
The design and function of the Flottweg three-
phase centrifuge is similar to that of a decanter
(two-phase separation). Solids settle on the inner
wall of the bowl when subjected to centrifugal
force. The scroll constitutes the conveying tool.
The difference in the decanter lies in the dis-
charge of two distinct liquid phases. With the
Tricanter, the heavy liquid phase is discharged
under pressure via an adjustable impeller and the
light liquid phase via gravity. The impeller allows
precise adjustment of the pond depth during
operation and permits fast, precise adaptation to
changing feed conditions — without interrupting
operation.
The Tricanter is easy to operate and maintain
due to its application-optimized, compact design.
A motorized process is possible with impeller
adjustment via an actuator controlled by the HMI.
Results
Crume was aware of the efficiency and advantages
of using a Tricanter from working with a differ-
ent company before joining Ocean Protein at its
inception.
“For me, choosing the Tricanter was a no-brainer,”
he said. “We installed them at Ocean Protein and
have never regretted it.”
Daniel Lakovic is the business development man-
ager at Flottweg. He holds a BS in International
Business and an MBA in Finance. He can be
reached at dlakovic@flottweg.net.

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APRIL 2023 | www.processingmagazine.com 45

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