DISCHARGE VALVES – A CRITICAL ELEMENT

Discharge is always a critical phase of each batch process machine. Depending on the design of this element, performances can vary drastically.

Delta, thanks to its extensive experience in chemical processes, developed many specific solutions to this issue. A custom design has been specifically developed for:

  • Solids discharge from vacuum dryers and Nutsche filter dryers
  • Solids sampling
  • Slurry discharge from reactors
DISCHARGE VALVES – A CRITICAL ELEMENT

SOLID DISCHARGE VALVES

Solids discharge valves are installed at the discharge nozzles of process machines that handle powders. Because of their function, they need to be designed for:

  • Managing dry and wet product, even in the worst conditions
  • Providing needed tightness both for pressure and vacuum
  • Being totally washable (especially when applied in the pharma or API industry)
  • Being easily maintainable

The Delta Zero Dead Area Plug Valve meets all the above listed features because of:

  • simplicity: it is composed of only three main parts (body, plug, and driving system)
  • the ability to be completely opened and inspected
  • Its CIP/SIP system composed of sprayers and rotating balls that can reach all surfaces.

The plug perfectly contours the shape of the machine body. Tightness between the plug and seat is provided by the conical plug profile where an o-ring or a metal on metal seal is installed.

A screw/drive screw system provides the plug movement. The final driving system can be hydraulic or pneumatic, as well as manual in small machines.

Depending on process needs, the Delta Zero Dead Area Plug Valve can also be equipped with high-containment devices like a:

  • Double sealing system for segregating the process area from the driving system
  • RTP (rapid transfer port) or continuous liner system at the discharge nozzle
SOLID DISCHARGE VALVES

SOLID SAMPLING – SPOON VALVE

Product sampling is an easy way to check the process status, but in many cases sampling is not a simple task. In particular, when a product is a solid/powder, the sampling device needs to have high-level features.

Depending on product and process needs, Delta can equip its machines handling solids with different sampling systems like blind ball valves or plug valves. For meeting the highest requirements, however, a totally different design has been developed.

The Delta Spoon Sampling Valve design is based on a piston that is inserted inside the machine body through a screw, driven by a hand wheel. Once inside the machine body, a lever tilts the piston and product falls inside the spoon. The sample is then recovered by removing the piston with the hand wheel and rotating it again.

Tightness is provided by a packing composed of PTFE rings and o-rings, which are located around the piston inside the valve body.

In order to avoid any damage, once the piston enters inside the machine body, a safety switch turns on and stops the agitator rotation, placing it in the parking position.

The valve can also be equipped with an RTP for highly potent products, and can be completely dismounted for washing (and sterilizing).

Compared to other sampling systems for solid products, the Delta Spoon Sampling Valve obtains samples from inside the product cake, thus avoiding product located near the machine body that might not be a representative sample.

SOLID SAMPLING – SPOON VALVE

MUSHROOM VALVES FOR SLURRIES AND LIQUID PRODUCTS

Discharge valves for fine chemical or pharmaceutical reactor plants are required to meet the following criteria:

  • sealed tight at process conditions (from vacuum to 20 barg or more)
  • allow a complete and total discharge of the vessel
  • create no dead areas
  • be completely dismountable and cleanable
  • integratable process instruments

In order to meet customer needs, Delta developed a Mushroom Zero Dead Area Valve. The body and plug design allows for easy product flow, avoiding any dead areas.

The tightness is provided by the compression between the plug and the valve seat. The actuation is provided by a stem, driven by a double acting pneumatic actuator. If there is a lack of instrument air, the valve can be opened using the side hand lever.

The valve, depending on process needs, can be equipped with:

  • limit switches, for valve status reporting
  • a temperature probe or other process instruments located on the valve plug
  • a CIP/SIP system, for cleaning and sterilizing
MUSHROOM VALVES FOR SLURRIES AND LIQUID PRODUCTS

SIDE BLOWERS FOR PRODUCT RECOVERY

Recovery of the heel cake from the filtering sheet is one of the most important features that a Nutsche filter dryer must have.

Being able to discharge even the last few particles remaining on the machine bottom means improving plant profitability, not only because of increased production, but also because of fewer -washing and cleaning procedures.

The DNFD Delta Nutsche filter dryer was developed with this issue in mind. The agitator is based on a simple design that minimizes the number of components. The body is oversized, in order to minimize elastic bending. The construction and the final assembly are constantly checked for reducing tolerances.

Any remaining heel cake (since the distance between the agitator blades and the filtering sheet cannot go lower than a few millimeters for safety reasons) can be recovered using the Side Blowers System developed by Delta.

A series of sprayers (numbers and position depend on the machine size) are located on the machine body side, at the filtering sheet level. Once the agitator discharge phase has been completed, sprayers start blowing nitrogen towards the discharge nozzle, lifting the heel cake and pushing it to the outlet.

In order to avoid dust production inside the machine and outside the discharge nozzle, the discharge valve is equipped with a connection to the plant vacuum system, generating a slight ambient pressure inside the body.

The system is also complete with a nitrogen feeding system that includes a small buffer tank and fast-acting valves.

SIDE BLOWERS FOR PRODUCT RECOVERY

HIGH CONTAINMENT AND DELTA

High-potency products are increasingly becoming more important in the chemical world. The ability to manage these molecules is a result of the combination of the design of the production plant and specific operating procedures.

Delta, with the help of leading high-containment device suppliers, offers its customers a global approach, providing integrated solutions.

 

HIGH CONTAINMENT AND DELTA

WHEN POWDER IS DRY

Process machines face high-containment issues when dry product is outside the main chamber. This usually happens during:

  • Dry product loading
  • Product discharge and post discharge treatment, like milling, weighting, and packaging
  • Sampling
  • Venting and Dust filter replacement

Delta offers specific solutions for containment issues for all our process machines, helping customers choose the correct approach based on the product, danger level, and operating procedures. Delta expertise can transform a simple process vessel to a process machine with high-containment features by (among others):

  • Adding a simple continuous liner to the sampling valve and discharge nozzle
  • Attaching a glove box to the filter dryer body
  • Adding flexible isolators for vessel loading & unloading
WHEN POWDER IS DRY

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