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Burkert has provided a complete process control system for a new moulding station and an effluent treatment plant at Mersen’s new production facility at Eurocentral in Scotland.

The control system includes level and flow monitoring, fluid control and process actuation and is integral to the new moulding and treatment facilities, automating what was previously a manual manufacturing process in order to improve its quality, yield and output volume.

Mersen Scotland Holytown supplies carbon-based thermal insulation and precursor materials.

The company’s products are used in a range of industries, including electronics, aerospace, automotive, special castings, vacuum and high-pressure sintering, vacuum treatment and graphitising/CVD applications.

Mersen, with partial funding from the Scottish government, recently invested GBP24m in a 70,000ft2 (6,500m2) facility, housing its global headquarters and extended manufacturing facility.

Integral to the latter facility was the installation of a wet moulding station along with a wastewater treatment process plant.

Burkert was asked to put forward proposals for these projects, initially for providing level and flow instruments.

This was later extended to include process valves and, finally, Burkert was asked to tender for the complete process control systems for the wet moulding station and the wastewater plant.

This specification included all instruments, valves, a control panel (housing Burkert’s Airline 8644 system, which integrates solenoid valves with input/output [I/O] from various PLC vendors), installation and commissioning.

The wet moulding station is a fully automated processing plant comprising large mixing tanks where carbon, water and resin are mixed according to a specific recipe.

The mix is then pumped to a mould tank where, under vacuum, the required mould profile is formed.

The slurry drawn down in the mould process is pumped to vacuum tanks, where it is then discharged to the water treatment plant.

In the mould plant, Burkert 8110 vibrating level switches provide high- and low-level monitoring in the mould tanks and resin mix tanks; Type 8175 ultrasonic non-contact level transmitters monitor levels in mix tanks and vessels that are linked to pump sets; and Type 8185 guided microwave level transmitters monitor the levels in the vacuum tanks.

In addition to level control, Burkert also provides flow monitoring.

One of the company’s Inline Type 8035 flow transmitters provides the monitoring and batch control of water supply to the resin mix tanks, while two Type 8045 electromagnetic flow transmitters are used to monitor the slurry flow rate, to control the slurry pump speed and to monitor effluent discharge to the water treatment plant.

The fully automated mould plant is controlled by a PLC-driven control panel that incorporates twin HMI systems and Burkert’s 8644 airline process actuation control system.

The Airline 8644 integrates with the Allen-Bradley PLC used for the overall control of the plant.

Calculated to save anywhere up to 40 per cent on total system costs through the engineering efficiencies it achieves, the Type 8644 provides users with a remote field I/O network that is compact, reliable and not exclusive to any specific communication protocol.

It combines digital I/O, including a full complement of solenoid pilot valve outputs, analogue I/O and Fieldbus connectivity in a single node.

The Airline 8644 system provides the actuation of the Burkert process valves used in the mould plant.

These include actuated butterfly valves, which control mains water supply to the resin mix tanks and discharge from the mould tanks to the vacuum tanks.

In addition, Burkert T-ported ball valves provide a drain function on the mix tanks and Type 330 solenoid valves control the supply of Teepol dosing, used as a wetting agent.

Finally, the company’s full-bore, actuated ball valves control the mains water supply valve to the effluent treatment plant.

Neil Saunders, Burkert UK and Ireland sales manager, said: ’Our current product range extends from solenoid valves – direct and servo assisted – to process and analytical valves, mass flow controllers, pneumatic actuators and one of the widest ranges of sensors for process applications.

’In this project, we have taken a broad cross section of these products and integrated them to provide a complete control solution – including system design, panel building and system commissioning – from a single source and one that exactly meets our customer’s needs,’ he added.

Burkert Fluid Control Systems

Burkert Fluid Control Systems has been manufacturing products and systems for over 60 years that can be used wherever fluid media and gases need to be measured, controlled and regulated.

Burkert Fluid Control Systems has been manufacturing products and systems for over 60 years that can be used wherever fluid media and gases need to be measured, controlled and regulated.Whether the application is filling, level, flow, pressure or temperature we have a solution and a uniquely comprehensive range of products to handle it, including solenoid, process and analytical valves, pneumatic actuation, sensors and controllers.

For Burkert it is not enough to simply offer individual products.Our aim is to provide complete system and application solutions that meet the specific needs of our customers.Tell us what you need and our engineers will find an appropriate solution using our vast experience and a wide range of services such as advice and engineering, installation, testing, and after-sales support.

Burkert’s global presence offers our customers an additional advantage.Products and systems are constantly developed and optimised according to international standards.Through this process synergy effects evolve which ensure technological leadership and competitive advantage

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