THALE-mail www.thaletec.

com

EASY TO INTEGRATE
THALETEC DEVELOPS
ADAPTER FOR VEGAPULS 64 page 2

DESIGNS ARE STANDARDISED

CE TYPE REACTORS USED
page 3

ELECTROSTATICS IN FOCUS AGAIN

CONDUSIST - ELECTRICALLY
CONDUCTIVE GLASS-LINING page 5

SCHEDULED DATES
TRAINING SEMINARS AND
WORKSHOPS page 12

THALETEC GmbH
Steinbachstraße 3 | D - 06502 Thale
Telefon: + 49(0)3947 778-0
Telefax: + 49(0)3947 778-110

79
newsletter@thaletec.com
www.thaletec.com
Hotline: + 49(0)3947 778-111

e
1 Ausgabe 60 • 2014 www.thaletec.com
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Easy to integrate
THALETEC has developing an adapter set for establishing the new VEGA radar filling
level probe VEGAPULS 64 on all manufacturers’ glass-lined equipment

The company VEGA (www.vega.com) is

known as a highly innovative and compe-
tent company in the field of level measure-
ment technology.

The bright yellow radar sensors for the

recording of filling levels in process vessels
are familiar to many operators.

VEGA has recently been offering a new

radar filling level probe of the type
VEGAPULS 64

This probe, working with 80 GHz radar

technology, is characterised by high
measuring accuracy, universal usability
even under harsh process conditions, and
dependable reliability.

To make such probes particularly simple

for operators and users to integrate them
in their facilities with glass-lined equip-
ment, THALETEC has developed an adapter
set.

The adapter set serves to easily establish Figure 1:

a VEGAPULS 64 sensor on glass-lined Base flange V and FlushRing V for the instal-
equipment. lation of a VEGAPULS 64 radar level probe
on a glass lined reactor
It consists of a standard Type V base flange
for tank nozzle nominal sizes DN 100 to
DN 400.
Figure 2: Figure 3:
Optionally available is a self-draining Base flange DN 100 up to DN 250 Base flange DN 300 and DN 400
CIP nozzle ring with an additional DN 25
(Flush Ring V), which allows rapid and safe
cleaning of the radar filling level probe.

A possibility of cleaning the level probe

using a flush ring is, however, provided.
For nominal sizes 100, 150, 200 and 250,
base flanges with the possibility of const-
ructing a VEGAPULS 64 directly or additi-
onally with Flush Ring V for cleaning the
filling level probe surfaces in contact with
the product are available. (Figure 2).

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For DN 300 and 400 nozzles, THALETEC The comprehensive modular system makes THALETEC
VEGAPULS 64 Adapter Set
Basisflansch V und CIP-System
offers a base flange with the possibility of it easy for customers to integrate the new FlushRing V

connecting the probe and an additional
DN 50 process nozzle (Figure 3).
All glass-lined components are glass-lined
with the quality and universally usable
THALETEC Pharma Glass TPE 2000.
VEGAPULS 64 filling level measurement VEGAPULS 64 Adapter set
Base Flange V and CIP-System
FlushRing V
technology in both new and existing
plants.
For more information see Flyer K103 ,
which you can download here.

CE-type reactors used safely

In DIN 28136, the designs glass lined reactors are standardised. In the case of reac-
tors from 1,600 I volume, the designs BE and CE are preferably used (see Figure 4).

As the BE reactor has a low total sealing the CE reactor comes from the assembly Figure 4:
length compared with the CE tank, the BE opening, which has the CE design on the CE (left) and BE (right) type eactor
tank is often preferred to the CE reactor. upper base.
The greater sealing length in the case of

Ausgabe 79 • 2016 3
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Yet even today, many reaction tanks with

the CE design are still used, because in AGR – Premium gasket (Flyer K025) GRX – Premium gasket (Flyer K099)
addition to the sealing length there are
yet further reasons to favour this type of THALETEC
AGR Premium-Dichtung
THALETEC

equipment in preference to the 'BE-reac-

»FLEXIBEL und STARK« Weich-Graphit Flanschdichtungen
AGR Premium-Gasket GRX PREMIUM
»FLEXIBLE and STRONG«
tor', or the greater sealing length should Soft graphite Flange gaskets
GRX PREMIUM

not necessarily be a critical factor.

The CE equipment has a larger inspection

opening and thus partly makes greater
flexibility possible in the choice and use
of reactors.

Thus the freedoms of configuration when

using the agitating elements are some-
times greater - especially when even
metallic reactors are to be inbuilt in the
glass-lined tank.

Glass-lined agitating systems are usually

operated as divided reactors, i.e. agitator
shaft and agitating elements are two Sofiflex T (tape) (Flyer K087) Sofiflex S (sheet) (Flyer K088)
components which are then connected to
each other in the equipment by means of THALETEC Sofiflex T (Tape) THALETEC Sofiflex S (Sheet)

Dichtungsband aus Dichtungsplatten aus

the THALETEC MultiFlex system. multidirektional expandiertem
PTFE
multidirektional expandiertem
PTFE

Gasket tape made of Gasket sheets made of

multidirectionally multidirectionally
Metallic reactors are often undivided, viz expanded PTFE expanded PTFE

designed as one-piece tanks, and therefo-

re require the major installation opening
on the upper base of the equipment so
that the reactor may be brought in and
assembled there 'as a whole'.

To seal the large assembly opening,

THALETEC keeps various sealing sys-
tems ready:

• AGR - Premium seal (Flyer K025)

• GRX - Premium seal (Flyer K099)
• SofiflexT (tape) (Flyer K087)
• Sofiflex S (sheet) (Flyer K088)

It is important, when selecting a suitable
sealing system, that the application of
each item of equipment and the process
values present, such as pressure, tempe-
rature and the number of thermal cycles,
should be considered.
These are essential features which
determine the selection of the optimum
sealing system.
All THALETEC sealing systems are, of course,
corrosion-resistant for a pH range of 0-14
and are also able to compensate for the
deviations permissible according to DIN of a
glass-lined flange or also profile ring.
THALETEC has also taken other internal,
quality assurance measures which make
sealing a major assembly flange connection
safer.
If you need more information on this sub-
ject, be sure to contact us!
So do not shy away from using an item of
equipment of CE design.
THALETEC has the appropriate product
solutions whereby the CE reactor can also
be operated safely.

4 Ausgabe 79 • 2016
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Electrically conductive glass-lining for process

plant equipment
Conventional chemical glass-linings are electrically insulated. Should an electrical
charge occur when stirring, filling or emptying the equipment, it must be ensured,
using appropriate measures, that this charge does not pose a risk to the equipment
and the surrounding area.

Figure 5:
Defects at the tip of an glass lined agitator
blade due to electrostatic discharges

As an example, an electrical charge In the

kV range can cause notorious ‘electrostatic
discharge’ One spark pierces the entire
glass-lining, creating a channel with a dia-
meter of a few tenths of a millimetre, which
extend as far as the steel body of the equip-
ment A corrosive medium can penetrate
this channel and corrode the steel which
will ultimately lead to major damage.

Figure 5 shows the end of an agitator

blade of a glass-lined agitated tank. It is
good to see a variety of whitish-coloured
dot-shaped damaged areas at the tip of
the blade. The damage arose in a technical
process in a glass-lined reaction tank in
which a powdery solid (plastic granulate)
was suspended in toluene.
Closer examination of these damaged areas
reveals typical electrostatic damage (Figure
6): The individual damaged areas display a
continuous channel from the glass-lining
surface to the base material. The diameter
of the channel is about 0 3 mm. Scale-like
flaking occurs on the glass-lining surface
in the initial phase and there are web-like
crack structures or desquamation on the
breakdown channel .
The crack structures and desquamation
often begin to appear significantly because
structures accumulate product residues.
Depending on the degree of corrosiven-
ess of the medium in the tank, intensive
corrosion of the exposed steel then begins
in the area of the damaged sites, resulting
in large-scale glass-lining damage to break-
throughs.

Figure 7:
cracks around the discharge channel

Figure 6:
defect caused by electrostatic dischargen.
The diameter of the hole is approx. 0,5 mm

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Type of damage

Damage caused by electrostatic discharge

Tips for the agitator
occurs mainly in places with a high relative
speed between the medium and the glass-
lined component (e.g. at the tip of the Front surface and edges of baffles
agitator blades or in the area around the
tank bottom and outlet nozzle) as well as
at the phase boundary between the liquid lower head nuckle
and the gas compartment (Figure 8).
liquid level
Furthermore, tank nozzles at the upper
base are at risk if it is used for filling the
equipment with solids or non-conductive feeding nozzles
liquids or suspensions and no other pre-
cautions have otherwise been taken.

Therefore in processes during which

there could potentially be an electrostatic
charge or discharge, the following aspects
should be carefully noted:

• prevention of electrostatic charge by • materials used in the fitted components Figure 8:

adjusting the process • electrically conductive shaft-hub connec- Areas in the glass lined reactor where
• glass-lining type: electrically conductive tions of the divided agitator elements damages due to discharges occur more
glass-lining • electrically conductive flange gaskets frequently

Adjusting the process

The adjustment of, and amendment to,
process engineering conditions is the
most effective step, even if certainly one
of the most difficult. Difficult because
the adjustments usually mean that the
application of the process is not opti-
mal, the duration of the procedure is
prolonged, unwanted by-products arise
or, in the most critical case, the changes
lead to new difficulties in upstream or
downstream process steps. Nevertheless,
it is first useful to examine, in a systematic
approach, to what extent process para-
meters can be changed in order to avoid
the risk of electrostatic damage to the
glass-lining from the outset.
Possible measures include
• Raising the temperature level of the the Technical Regulations for Operating
process
• Reducing the degree of turbulence and
the speeds in the tank
• Ensuring a sufficiently high conductivity
of the medium
• Consideration of cleaning processes
Further information on possible mea-
sures to be taken where there is a risk
of electrostatic charges is contained in
Safety TBRS 2153 (in German language)
- Avoiding ignition hazards due to electro-
static charges.

Raising the temperature level of the process

The electrical conductivity of the glass-
lining depends on its temperature.
If the temperature level of the process is
raised, damage due to electrostatic dis-
charge becomes increasingly unlikely.
An increase in the temperature level by a
few Kelvin can already reduce the risk. The
specific electrical resistance of glass-lining
is generally in the order of > 1014 Ωcm at
room temperature. It decreases linearly to
400°C to about 105 Ωcm [1].

6 Ausgabe 79 • 2016
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Reducing the degree of turbulence

The degree of turbulence in the equipment
and the level of relative velocities between
the medium and the walls of the compo-
nent parts, of the agitated tank and of the
agitator determine, inter alia, the level
of electrostatic charge. Accordingly, the
amount of charge can be reduced when
turbulence reduces and speeds are lowered
Even without any major impact on the
quality of the agitation process, reducing
the agitator rotation speed by a few U/min
can, for example, contribute to a significant
reduction in static electricity. The use of agi-
tated elements which have a low shearing
action can also help to reduce the level of
the resulting electrostatic charge.

Ensuring a sufficiently high conductivity of the medium

Even the smallest amounts of conductive the risk of an electrostatic discharge, and
substances which are subsequently distilled thus damage to the glass-lining.
off again or filtered out, can help to reduce

Consideration of cleaning processes

In some cases it is not the actual process should be checked to what extent adding charge. In addition, the temperature level
which is critical in relation to electrostatic conductive media to non-conductive sol- of the cleaning process could also be
charges, but just the cleaning process vents (or the use of conductive solvents) increased, with equally positive effects.
following a batch or campaign. Here it can reduce the risk of an electrostatic

THALETEC CONDUSIST electrically conductive glass-lining

As mentioned above, adapting the chemical
process, whereby the risk of electrostatic Emaillierung
charges is avoided, is, viewed methodolo- Glass-lining
gically, most effective. If not all approaches
in this direction are possible, however, then
controlling the risk of glass-lining damage
through an electrically conductive lining
suited to the process remains the only way.
Grundwerkstoff
An optimal way to achieve electrically
Base material
conductive glass-linings is being pursued by
THALETEC with a new glass-lining system:
The patented THALETEC CONDUSIST glass-
lining (Flyer K098 ), which has proved its Figure 9a: Figure 9b:
worth time and again in practice, conti- Cross sectional view of the glass layer principal sketch to visualize the 3D net-
nuously conducts electrostatic charges structrure
away from the glass-lined reactor and
thereby prevents damage to the glass coa-
ting. In addition, the risk of a spark being CONDUSIST is based on a concept deve- HAKKO Sangyo Ltd. Since 2013, THALETEC
ignited is reduced and the area of applica- loped, patented and introduced on the has held the exclusive license to process this
tion for glass-lined reactors is significantly Japanese market in 2005 in Japan by the new glass-lining system at the site in Thale
expanded. Japanese process equipment manufacturer and to market the products worldwide.

Ausgabe 79 • 2016 7
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CONDUSIST conducts the electrical charge

away from the surface of the glass-lining
which is in contact with the product. The re-
maining residual charge is about 1% of the
electrical charge of a conventional technical
glass-lining.

The CONDUSIST glass-lining comprises

an electrically conductive ground coat as
well as several cover coats which are also
electrically conductive. In order to achieve
conductivity the ground and cover glass-
linings contain ceramic particles arranged
in a network-type pattern (without a cata-
lytic effect!), which dissipate the electrical
charge on the steel body of the glass-lined
equipment (Figure 9). In contrast to the
concepts described above, the semicon-
ductor ceramics do not have any known
catalytic effect on the media processed in
glass-lined equipment.

The major advantages of THALETEC

CONDUSIST therefore are:
• The glass-lining conforms to the criteria
of DIN EN ISO 28721-1
• The entire glass-lining layer is electrically
conductive; the conductivity is thereby
maintained even following a corrosive
attack of the glass-lining up to its limit of
use
• The chemical resistance of THALETEC
CONDUSIST corresponds to that of the
renowned RAS GLASS
• CONDUSIST can be tested by means of a
high voltage test (5kV, alternating voltage
or pulsed DC voltage).
• CONDUSIST has no known catalytic effect
• CONDUSIST is particularly suitable for
the initial glass-lining process within the
scope of the manufacturing process of
glass-lined equipment and components,
as well as for reglassing.
CONDUSIST is light blue in colour which is
preferred by the manufacturers of phar-
maceutical agents and such companies for
whom a visual inspection of the equipment
is relevant following a cleaning cycle.
In principle, all components of process
engineering equipment which are to be
glass-lined can be made using CONDUSIST,
whereby from a functional perspective it
only makes sense for those parts which come
into direct contact with the (moving) media
in the equipment.
It is also worth mentioning that split
agitators for BE reactors compliant with
DIN 28136, the agitator shaft and agitating
element of which are connected by friction
contact with the aid of a thermal interference
fit, do not require additional conductive ele-
ments in the shaft-hub connection in order
Figure 10:
Agitator-shaft connection that is electically
conductive without any additional conduc-
tive element inside the connection
to ensure the conductivity of the glass-lining
of the agitating element. (Figure 10).
The use of CONDUSIST makes sense in parti-
cular also in multi-purpose systems:
Because if the process engineering system
has to ‘react’ to changing and not always
foreseeable demands in the future,
CONDUSIST considerably extends the area
of application and sustainability.

Proof of functionality and testing conductive glass-linings

In order to prove the functionality glass-lined test plates are positioned left in the image there is an ion source
(electrical charge dissipation) THALETEC opposite on a turnable, earthed rotatable which in addition can provide an elec-
developed a testing device, the set-up of disc made of a highly conductive copper trical charge up to a magnitude of 30 KV
which is shown in Figure 12. Up to two material. Above the test plate on the to the test plate. After a prescribed time

8 Ausgabe 79 • 2016
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the rotatable disc is programmed to turn

Ionizer
180° clockwise. In so doing the test plate
RAS-gass sample
moves beneath a charge sensor which (standard glass)
works according to the field mill principle
without contact.

A field mill (ionizer) measures electrical

fields and thus for a known distance the charge sensor
potential, the voltage of a measurement
object, without drawing energy from the
measurement object.
rotating platform
Thus the field mill is incredibly suitable
for measuring the voltage of high resis- CONDUSIST
tance, electrostatic sources. sample

In principle, the field mill represents a

variable capacitor which is charged at a
constant voltage, namely the voltage to
be measured. Figure 12:
Testing setup
The altered capacity causes an altered
charge and the charge difference in
relation to the previous state causes an al-
ternating current through the measuring As shown, the initial charge of the test pla- about 60 seconds there is almost a charge-
amplifier connected to the measuring te lined with the conductive glass-lining, less state. In contrast, the initial charge of
capacity. CONDUSIST, after a 10 second load of the the conventionally glass-lined test plate
test plate is about -1 KV with -10 KV. (THALETEC glass-lining type RAS GLASS
This test current is proportional to the ca- blue) is -6 KV; the charge dissipates here
pacity change and the capacitor voltage Within the first 20 seconds of the measu- very slowly and only after 60 seconds drops
and since the capacity change remains rement the charge is halved, so that after to a value of about -4.5 KV (25% reduction).
constructively constant, the test current
is a measurement for the applied voltage
[2].

If one works with two test plates, whereby

one is coated with an electrically conduc-
tive glass-lining, the other with a conven-
tional glass-lining, it is possible to achieve
a quick comparison measurement.

Figure 11 shows the characteristic process

of the discharge of the glass-lined speci-
mens recorded with the load detector.

Figure 11:
Discharge curve of CONDUSIST and the
conventional glass "RAS"

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If one establishes the quotients from the

measured values of both glass-linings
(Figure 13), one can see that the conduc-
tive glass-lining at the beginning of the
test only has about 14% of the charge of
the conventional glass-lining. As the test
progressively continues the value reduces
to about 6%. Not only is the initial charge
significantly smaller in the electrically con-
ductive glass lining, but also the further
discharge occurs faster in the conductive
glass-lining.

Figure 13:
Relative electrostatic charge

Electrostatic charge when stirring

Using a further test set-up the effect of
conductive glass-linings can be demonst-
rated practically (Figure 14).

In this respect a glass-lined reaction tank

open at the top is firstly filled with (elec-
trically insulating) hydraulic fluid and then
PMMA particles are added.

Using a charge sensor floating on the

liquid's surface, the electrical charge
building in the medium is measured
depending on different parameters such
as the agitator speed and the stirring
time as well as on the type of glass-lining
(electrically conductive or conventional
glass-lining).

Figure 14:
Test setup to measure the electrostatic
charges during stirring

10 Ausgabe 79 • 2016
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Figure 15 shows the progress of the elec-

trical charge of the medium depending
on the test duration and the glass-lining
used.

It can be seen that the medium as the

agitator starts has an electrical charge at
first. Whilst the glass-lining with
CONDUSIST does not go below a charge
of -1KV, for the conventional glass-lining
there are charges of up to -7.5 KV. After
the agitator was switched off after ap-
prox. 12 seconds, the solid particles start
to settle in the medium. This movement
alone is sufficient for the charge level to
drop to about -6 KV even in the tank lined
with CONDUSIST now it is no longer stir-
red. This can be explained by the fact that
the charge carrier is no longer coming
into contact with the conductive tank wall
as a consequence of the lack of mixing
and thus its charge cannot be dissipated medium is sufficiently well mixed. Only
any more. From this observation the con- through using a conductive glass-lining
clusion can be drawn that electrostatic is it then possible to dissipate the charge Figure 15:
charges can only be dissipated with any quickly and securely from the process Discharge curve of the liquid as a function
certainty from the process medium if the medium. of time and type of glass

Glass-lining checks at our customers' premises

The operators of glass-lined process engi-
neering systems consider it to be of great
importance that the equipment should be
regularly checked for the integrity of the
glass-lining.
In practice this is done by a visual check as CONDUSIST, however, can be checked using
well as by a high voltage test. high voltage test equipment up to 5 KV.
Conductive glass-lining systems to date can Pores and other damage to the glass-lining
only be checked visually. can thus be detected securely.

Conclusions
THALETEC CONDUSIST is an electrically con-
ductive glass-lining tailored to the require-
ments of the chemical and pharmaceutical
industry with outstanding properties in
terms of its chemical resistance and elec-
trical conductivity. Electrical conductivity
accommodates the safety requirements of
the operators of process engineering plants
because processes critical in terms of an
electrical charge and thus potential ignition
risks can be safely controlled.
Using suitable methods it is possible to
demonstrate the conductivity of test
specimens. It is also possible to check
the glass-lining during production. It has
been shown that a CONDUSIST glass lining
prevents damaging electrical charges in the
glass-lined equipment and accelerates their
dissipation to an already low level.
It should also be mentioned that besi-
des the use of an electrically conductive
glass-lining for components in contact
with the medium, additional measures are
recommended in order to avoid damaging
charges and thus ignition potential. This in-
cludes the use of built-in components made
exclusively from electrically conductive
synthetic materials (e.g. electrically conduc-
tive PTFE) as well as the seals of flanges and
nozzles using electrically conductive and
earthed flange gaskets.
Finally, CONDUSIST helps to develop new
markets for glass-lined equipment:
Processes for which in the past glass-linings
could not be used because of the electro-
static effects, but where the highest corrosi-
on resistance is necessary, can now also be
performed ‘in glass-linings’.

Ausgabe 79 • 2016 11
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Technical Documents
CONDUSIST Electrically conductive CONDUSEAL Electrically conductive Electrostatic Workshop
glass-lining (Flyer K098) flange gaskets (Flyer K100) (Flyer K101)

THALETEC CONDUSIST THALETEC CONDUSEAL THALETEC Workshop

Antistatische Emaillierung Elektrisch ableitfähige Elektrostatik in

Flachdichtungen emaillierten Apparaten
Antistatic glass-lining
Electrically conductive Electrostatic effects in glass-lined
flange gaskets process equipment

Important
Of course, the glass-lining is crucial for
optimising equipment to avoid damage
by electrostatic discharge and to increase
operational safety. However, the glass-lining
is not the only thing: Attachments built
onto the glass-lined equipment must also
be suited to the application in electrostatic
processes.
© kasto - fotolia.com
We will take a comprehensive look at these
attachments in the next THALE-mail.

References
[1] Petzold, A., Pöschmann, H.: Email und Emailliertechnik, Wiley-VCH; Auflage: 2., überarb. Aufl. (1992)
[2] http://www.rapp-instruments.de/static-machines/measuring/feldmuehle/feldmuehle.htm

Dates for training seminars & workshops

In this overview you will find all scheduled dates so far for workshops and seminars for
your training needs. Just download the corresponding flyer for further details. You can
register by e-mail to service@thaletec.com .

2nd half year 2016

Topic Language Location Date Remarks

EmRepEmailprüfung und Reparatur Deutsch Thale 20.-21.9.2016 Flyer K093

Wartung und Instandhaltung emaillierter Deutsch Thale 27.-28.9.2016 Flyer K038

Apparate

12 Ausgabe 79 • 2016