Getting the chemistry right

For decades, Grace has relied on analogue weighing technology from Minebea Intec. Precise measurements in harsh conditions and early technical consultancy assistance form the basis for stable processes – and for future-proof decisions on new silo projects.

The extensive production site of Grace’s European headquarters in Worms is characterised by silos weighing several tonnes and complex piping systems. This is where specialised chemical materials and process solutions are produced, which are used in resource-efficient refining and fuel processes, high-performance industrial plastics, durable building materials, and the manufacture of vaccines and medicines, amongst other applications. The chemical products are processed under demanding conditions – involving abrasive and corrosive substances, high temperatures and continuous operation. In this environment, precise and robust weighing technology is a decisive factor for stable processes and consistently high product quality.

Analogue measurement data acquisition as a stable system foundation

For decades, Grace has relied on analogue compression load cells from Minebea Intec, which are integrated safely and with process stability into silo and tank structures using the Flexlock® mounting kit. The Flexlock® mounting kit ensures defined force transmission, compensates for installation- and temperature-related movements, and reliably protects the load cells from lateral forces and overloads. Unlike digital load cells, which have an analogue-to-digital converter integrated directly into the sensor, analogue load cells transmit only a voltage signal, which is then converted into a digital signal by the weighing electronics. With fewer electronic components, the load cell is significantly more durable, particularly in demanding environments, which saves on long-term service costs. Thanks to the high quality of the analogue load cells, there are no concerns regarding signal stability or accuracy.

Technical sales consultancy assistance as the basis for new silo projects

Against the backdrop of a planned expansion project involving three new silos, Grace approached Minebea Intec to use the existing, long-proven measurement concept as a reference for future silo designs. The aim of the joint meeting was to provide technical consultancy assistance as part of the project preparation. In consultation with Minebea Intec application specialist Stefan Christians, the existing configuration was analysed and discussions took place on how the established weighing system could be meaningfully and reliably transferred to new projects. The focus was not on the need for short-term adjustments. “Particularly for new construction projects, we support our customers at an early stage with comprehensive application-specific expertise,” says Christians. “This includes, among other things, taking into account environmental conditions, wind loads, seismic influences, as well as structural and metrological requirements.” This sales consultancy assistance provides planning certainty, reduces project-specific risks and forms the basis for a technically sound, future-proof solution.

Close coordination right from the early project phase provides Grace with a sound basis for decision-making regarding the further
planning of the new silos. At the same time, it ensures that the subsequent weighing solution is optimally tailored to the respective process requirements and site conditions.

“What I particularly appreciate about Minebea Intec’s weighing technology is its reliability over many years. The systems have been running stably in continuous operation at our site for decades. Especially in our environment, it is crucial to be able to rely on the measured values at all times – this gives us peace of mind in our day-to-day operations and significantly reduces unplanned downtime.”

Mathias Rau, Industrial Foreman, Central Maintenance, Electrical/I&C Engineering

INFOBOX

Key facts

Grace relies on analogue compression load cells from Minebea Intec with Flexlock® mounting kits for its production and benefited from on-site sales and technical consultancy assistance during a silo expansion project.

Application & products
At Grace, Minebea Intec’s load cells and electronics are used for weighing silos and process vessels in the speciality chemicals sector. They measure the fill level during continuous filling and control the automatic transfer of batches to the respective
end-product silos.

• Inteco® analogue compression load cells, PR 6201 and PR 6211
• Mounting kits PR 6143/00N Mini-Flexlock 25kN and mounting kits PR 6003
• Weight transmitter PR 5230

Customer benefits

• Technology resistant to harsh, corrosive environmental conditions
• Long-term stable measurement accuracy in continuous operation
• Rapid fault detection via simple voltage measurement
• Proven technology with high reliability