PC-SEP24-PG30.1_Layout 1 16/09/2024 13:15 Page 30
CHEMICALS & PHARMACEUTICALS
FULL STEAM AHEAD FOR ACCURATE MEASUREMENT
The non-intrusive flow measurement of steam, using Flexim technology, is enhancing chemical park operations at a site in Germany
he efficient and cost-effective supply of energy is crucial for the chemical industry. At the chemical park of a leading industrial service provider in Knapsack, Germany, being able to ensure a reliable supply of steam, alongside other resources like electricity, natural gas, and compressed air, is paramount. The steam required for various chemical processes at the site is sourced from local generation plants, including a refuse-derived fuel (RDF) power plant, which converts up to 300,000 tons of alternative fuels into steam and electricity annually. Additionally, a nearby RWE power plant supplements this steam supply. Accurate volume measurements are essential for managing the steam network efficiently. These measurements help balance the quantities of steam generated and fed into the grid with the quantities consumed.
T
n the laboratory, researchers and biopharmaceutical manufacturers need a bioreactor that is simple to use and with the capacity to switch between producing different batches without contamination. That is why Cellexus International is using Watson-Marlow 323Du/D and 323Du/RL peristaltic pumps with Pumpsil tubing in its popular CellMaker bioreactor range, due to the ease of use and flexibility of being able to switch between pumpheads.
I
Cellexus provides single-use CellMaker bioreactor systems for cell culture and fermentation applications. In April 2024, Watson-Marlow suggested the 323Du/RL pump as an additional option with the CellMaker, providing increased flow rates (up to 2200mL/min) to cater for customers which need quicker bioreactor fills. Since 2020, the Watson-Marlow 323Du/D
30 SEPTEMBER 2024 | PROCESS & CONTROL
However, natural measurement uncertainties and unrecorded purchases can lead to discrepancies. To address this, creating smaller balancing sub-networks is an effective strategy.
The chemical park is divided into two sections, with these sections being connected by an internal road and a pipe bridge that also carries steam from Knapsack to a second plant. Measuring the steam quantity on this connecting line forms two balancing sub- networks - crucial for identifying discrepancies, but halting production at the second plant to install measurement devices would be highly disruptive.
Innovative clamp-on ultrasonic flow measurement technology offered a solution. The experts at the chemical park already had significant experience of the benefits of this non-intrusive technology, which was further
has been an optional purchase for a dispensing pump with the CellMaker, for filling and emptying the CellMaker bags, dosing and feeding the bioreactor, fed- batch and continuous fermentation. The 323Du/D peristaltic pump can be integrated with CellMaker’s systems and software and features a pumphead for 1.6 – 8.0mm ID tubing. It is controlled manually or via the CellMaker Controller software to automate pumping for semi-batch applications.
The single-use CellMaker uses Cellexus’ patented air lift technology for aerating and mixing cells and can produce a range of cell types in working volumes from 1.5 to 50L. The 323Du/D also fulfils Cellexus' requirement for a space-efficient solution, as, like the CellMaker, it has a relatively small laboratory footprint. The 323Du/RL offers increased capacity, with the same
enhanced by recent advancements made by Flexim’s developers. These developments expanded the use of non-intrusive flow measurement to superheated steam, generating considerable interest. Traditional ultrasonic flow measurement relies on the transit time difference principle, but for high temperature steam, Flexim’s meters use the cross-correlation method. This involves mounting two pairs of ultrasonic transducers on the pipe at a defined distance, creating two acoustic measurement barriers. The ultrasonic signals interact with the vortices of the flowing steam, and as these vortices travel through the barriers, they modulate the signals, which are then cross-correlated over time to determine the flow velocity. The mass flow is calculated based on the pipe geometry and the physical parameters of the steam. To validate this new measurement technology’s reliability and accuracy, a long- term test was conducted. The measurement point was installed at the RDF plant exit, and its readings were compared with those of an inline ultrasonic measurement system, showing good agreement. This success led to the decision to purchase and install the system on the pipe bridge between the two plants. For precise mass flow calculation, temperature and pressure are also recorded directly at the measuring point.
This innovative approach ensures a reliable
and efficient steam supply for the chemical park, highlighting the importance of adopting advanced technology to help maintain operational excellence in the chemical industry.
Flexim
www.emerson.com
PERISTALTIC PUMPS ENABLE EASE OF USE AND FLEXIBLE PUMPHEAD SWITCHOVER IN BIOREACTOR SYSTEMS
connectivity and benefits as the 323Du/D. Adam Ostrowski, Technical Application Specialist at Cellexus, said: ““The pump saves time because it’s quick to use, easy to connect and it doesn’t require a specialist to run the pump. There are very few things that can go wrong with it, which minimises downtime.
“With the pumphead being adjustable and changeable, it is an advantage for our customers. We had a customer that had quite specific requirements and I worked with the Watson-Marlow sales engineer and technical team to choose the combination of pump to pumpheads to match the needs of the customer. We closed the deal on that accessory.”
A video introduction showing the pump’s role in the bioreactor system can be found by visiting
cellexus.com/blog/introduction- to-the-cellmaker/
www.wmfts.com
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