Category Archives: Industrial Equipment

The Future of Gas Boilers – Hydrogen or Heat Pumps?

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Due to the international crisis of global warming, the majority of western countries are now set on a course to become carbon neutral and at the Paris Accord, they agreed to achieve this by 2050. This is an impressive feat for countries still so reliant on fossil fuels for major industries like heating and transport.

Residential heating is one area that is currently in the spotlight, for instance, in countries like the UK, it is currently responsible for around one-third of carbon emissions. As a result and understandingly it is set to undergo major reform over the next 10 years.

What’s the problem with current heating?

Heating in the UK is still heavily reliant on fossil fuels, either directly or indirectly. For instance, the vast majority of homes are supplied with natural gas which is burned in fireplaces and gas combi boilers to provide homes with heat.

heating-radiator

The major issue is that burning natural gas releases carbon into the atmosphere, which is a gas that doesn’t leave the atmosphere, resulting in heat being trapped in the atmosphere, leading to global warming.

Therefore, the UK government is looking at low carbon heating alternatives as a route to transforming the current situation, which includes the likes of heat pump, hydrogen boiler and solar.

As Heatable states, residential boilers have already been under considerable scrutiny and the government has banned non-condensing boilers, driving up the efficiency of boilers to above 90%, as well as a total outlaw on all gas boilers in new homes from 2025.

Yet, it’s important to note that most industry commentators consider replacing gas boilers with solar and heat pumps completely unrealistic. Major concerns include their expensive and disruptive installation, as well as their reliability when compared to conventional boilers.

As a result, replacing the fuel is seen as a much more realistic approach with the fuel of choice being hydrogen. This can be fed into the current infrastructure and used with hydrogen-ready boilers, which are almost identical to current natural gas versions.

Hydrogen Boilers vs. Heat Pumps

There are many issues when it comes to the transition from high to low carbon heating technologies. So much so, that the Environmental Audit Committee (EAC) estimated that it would take almost 1,000 years to make the switch if the current trajectories continued.

Even worse, the Committee on Climate Change (CCC) highlighted that it would cost on average £26,000 for each home to install a low carbon heating alternative, rending the whole idea completely unviable.

hydrogen-boiler

The only sensible solution is the adoption of hydrogen fuel as an alternative to natural gas instead. This fuel is able to make use of the current gas networks infrastructure which is already connected to the vast majority of properties.

From an environmental standpoint, hydrogen is also seen as highly desirable.

Why? When hydrogen is burned it produces only vapour and absolutely no carbon dioxide making it ideal for a carbon-neutral future.

Disadvantages of Heat Pumps

As well as that, there are also other issues with heat pumps, of which there are three main types: air source, ground source and hybrid. All of which works by sucking in heat from the surrounding air, ground or water and are able to supply heat to water and central heating.

Hybrid heat pumps are different in that they utilise a boiler to provide supplemental heat if the weather becomes severely cold.

The good point of heat pumps is that they only use small amounts of electricity to operate and combined with the fact that they absorb heat from the environment, they are extremely efficient. In fact, they can achieve energy efficiency ratings exceeding 300%, compared to modern gas boilers that are around 94%.

However, it’s not all positive sadly and heat pumps are unable to provide the same, consistent heat output that gas boilers are able to. For this reason, they are usually installed with oversized radiators and/or underfloor heating and only in properties that are extremely well insulated.

Conclusion

Heating is without a doubt going to change and countries like the UK are going to transition away from gas boilers, but what will win – heat pumps or hydrogen?

It seems that hydrogen has the advantage from a feasibility standpoint, but there’s little doubt that heat pumps will be part of the mix too.

It’s becoming more common for gas boilers to be installed with a hybrid heat pump system.

The first homes fitted with hydrogen boilers and appliances are going to be installed in Fife, Scotland from next year, so progression is certainly accelerating.

Recommended Reading: Benefits of Regular Boiler Maintenance

ABS Plastic Warping: How to Avoid It

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Warping is a defect in 3D printing characterized by dimensional distortion of printed parts, i.e., the print’s corners lifting and separating from the build plate due to uneven shrinkage during cooling and printing. The defect also occurs in custom plastic machining due to temperature differences between layers as the plastic contract while cooling. As a result, machining services must ensure proper temperature to prevent warping.

how to avoid ABS plastic warping

Although warping can occur in any plastic, it is more frequent with ABS plastic and can lead to the printed part being non-functional or visually unacceptable. ABS plastic warping occurs majorly due to the great temperature difference during cooling. However, it may occur under the conditions below:

  • Unleveled printed bed
  • High print speed
  • Unstable printing temperature
  • Dirty printing bed
  • Weak adhesive

To prevent the defect, this article will introduce warping in liaison with ABS plastic and how to avoid the defect during printing.

Tips to Avoid ABS Plastic Warping

ABS plastic is highly susceptible to warping. However, you can avoid this defect by following the following tips below:

1. Use a Heated Bed

Using a cold bed can cause the ABS plastic part to harden before it can lay flat. Furthermore, it can also result in temperature differences between the first layer and subsequent layer during cooling. As a result, warping can occur, leading to a failed print.

To prevent this, you use a heated bed. A heated bed ensures that the print bed’s temperature is higher than the ambient temperature. As a result, the first extruded layer stays soft for a long time. This gives more time for the first layer adhesion to occur. Furthermore, a balanced temperature reduces uneven shrinkage of subsequent layers and the force of curling and contraction.

To prevent ABS printing from warping, a heated bed between 90 and 100-degree Celsius is necessary. Furthermore, avoid setting your heated bed at a temperature higher than ABS’ glass transition temperature as the print’s initial layers may melt due to overheating.

2. Clean the Print Surface

Dirt and grease weaken the adhesion of the first printed layer to the print bend, further encouraging warping. Therefore, ensure that the print bed is clean and smooth before printing. You can clean with ammonia-based cleansers, water, and soap solution, or isopropyl alcohol. However, ensure that the cleanser is compatible with the print surface

Note: The human fingerprint contains oil residues. As a result, avoid touching the print bed surface before, during, and after printing.

3. Tune Your First Layer Settings

The first layer of your print serves as the bonding layer. As a result, it must be perfect to avoid warping. Therefore, you need to adjust some slicer settings

  • Initial Layer’s Extrusion Width: To create a solid foundation for the model, you can increase the initial layer’s extrusion width. This helps the layer adhere to the bed more.
  • Initial Layer’s Height: Lower the extruder depending on the layer’s width so that the molten plastic can compress to the bed and create a greater surface contact. The first layer’s height should be 90% of the layers above.

Note: Avoid excessive bonding because it will make it harder for you to remove the final print.

4. Print in an Enclosure

Place an enclosure around the printer to maintain temperature conditions. An enclosure is one of the best ways to prevent ABS plastic warping. This works because it maintains a warmer ambient temperature to prevent your print from cooling quickly and drafts from cooling your model.

Enclosures are highly recommended for ABS printing because they create a controlled environment during printing. Furthermore, they protect the printer from external forces such as dirt and fumes and stabilize the print.

ABS plastic warping

5. Use an Adhesive

Using an adhesive to prevent warping is a practical technique in ABS printing as it keeps the first layer firmly attached to the print surface. As a result, the good adhesion ensures that the first layer of the part does not curl up as they cool. Furthermore, it serves as a layer for glass protection. Common adhesives you can use include Painter’s tape, PEI sheets, and washable glue sticks.

5. Use a Brim or Raft

A raft is a platform for printing parts. It consists of a base made of a 3D-printed structure that resembles a grid and extends past the initial layer of the model. Compared to rafts, a brim’s appearance is similar to a skirt that does not extend past the print’s edge.

Brims and rafts improve bed adhesion during ABS plastic printing. As a result, this prevents warping. Furthermore, they establish a solid foundation for the upper layers of your part.

Note: Raft takes considerably longer to print than the brim.

Other ABS Plastic Defects

ABS plastic printing has other defects such as:

1. Cracking (delamination)

Cracking is a printing defect where the layers of a part separate because of unsecured bonding. Unsecured bonding occurs when subsequent layers cannot adhere to one another due to a temperature difference. Using an enclosure to control the room temperature is the best solution.

2. Z-wobble

Z-wobble occurs when a printer’s z-axis movement component is skewed or inclined. This ultimately causes the printhead to move incorrectly. To prevent this, tighten all z-axis components.

3. Stringing

Stringing is when tiny plastic strings remain on a 3D-printed model. This often happens when the extruder moves to a new spot and plastic leak out of the nozzle. You can avoid stringing by changing the printing speed and using unclogged nozzles.

4. Layer Shifting

This happens when the layers of the printed part move from where they are supposed to be. It is caused by an abnormal X and Y axis motion leading to the extruder head becoming misaligned. To avoid this, reduce the printing speed.

ABS plastic warping

5. Overheating

This happens when the cooling rate of the plastic is low, you are printing too fast, or the printing temperature is high. Overheating results in melted plastic parts. However, you can prevent this by controlling the cooling rate and the printing/print bed temperature

Conclusion

Warping ranges from a minor, aesthetic flaw to a problem that completely undermines the part’s functionality. As a result, it is a serious plastic printing defect. Warping is prominent in ABS plastic printing. This article explained how to prevent ABS plastic warping and other defects. Using our plastic machining service, you can also consider switching to custom plastic machining if printing processes are challenging.

Use of PKS in Circulating Fluidized Bed Power Plants

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Palm kernel shells are widely used in fluidized bed combustion-based power plants in Japan and South Korea. The key advantages of fluidized bed combustion (FBC) technology are higher fuel flexibility, high efficiency and relatively low combustion temperature. FBC technology, which can either be bubbling fluidized bed (BFB) or circulating fluidized bed (CFB), is suitable for plant capacities above 20 MW. Palm kernel shells (PKS) is more suitable for CFB-based power plant because its size is less than 4 cm.

palm-kernel-shell-uses

Palm kernel shells is an abundant biomass resource in Southeast Asia

With relatively low operating temperature of around 650 – 900 oC, the ash problem can be minimized. Certain biomass fuels have high ash levels and ash-forming materials that can potentially damage these generating units.

In addition, the fuel cleanliness factor is also important as certain impurities, such as metals, can block the air pores on the perforated plate of FBC unit. It is to be noted that air, especially oxygen, is essential for the biomass combustion process and for keeping the fuel bed in fluidized condition.

The requirements for clean fuel must be met by the provider or seller of the biomass fuel. Usually the purchasers require an acceptable amount of impurities (contaminants) of less than 1%. Cleaning of PKS is done by sifting (screening) which may either be manual or mechanical.

In addition to PKS, biomass pellets from agricultural wastes or agro-industrial wastes, such as EFB pellets which have a high ash content and low melting point, can also be used in CFB-based power plants. More specifically, CFBs are more efficient and emit less flue gas than BFBs.

The disadvantages of CFB power plant is the high concentration of the flue gas which demands high degree of efficiency of the dust precipitator and the boiler cleaning system. In addition, the bed material is lost alongwith ash and has to be replenished regularly.

A large-scale biomass power plant in Japan

The commonly used bed materials are silica sand and dolomite. To reduce operating costs, bed material is usually reused after separation of ash. The technique is that the ash mixture is separated from a large size material with fine particles and silica sand in a water classifier. Next the fine material is returned to the bed.

Currently power plants in Japan that have an efficiency of more than 41% are only based on ultra supercritical pulverized coal. Modification of power plants can also be done to improve the efficiency, which require more investments. The existing CFB power plants are driving up the need to use more and more PKS in Japan for biomass power generation without significant plant modifications.

8 Essential Tools For Weather Risk Management

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Weather risks include extreme temperatures, floods, hurricanes, tornadoes, earthquakes, droughts, and other natural disasters. The cost of these events can be devastating for both households and businesses.

But with strategic planning and early preparation, you can reduce the risk of weather-related losses. It all starts with a solid understanding of essential weather risk management tools.

This article will help you better understand the various weather risk management tools and their uses.

Tools For Weather Risk Management

What is Weather Risk Management?

Weather Risk Management (WRM) is an umbrella term that refers to any combination of strategies used to protect against the impact of weather on business operations. WRM includes everything from developing contingency plans to managing customer expectations.

The key to successful WRM is understanding how weather impacts businesses and what steps can be taken to mitigate those effects. For example, if you’re in the logistics business, you need to know about the most common weather hazards and how they could impact your customers. If you own or manage real estate, you should know about the potential damage caused by flooding and the best ways to prepare for such events.

Why is Weather Risk Management Important?

In today’s world, extreme weather events have become more frequent and severe. The impact on human lives and property has been significant. According to the Insurance Information Institute, weather-related claims hit USD$42 billion in just the first half of 2021.

Climate change is a leading cause of these extreme weather events, and different tools, such as weather sensors, would be required to monitor the changes in climate patterns. There are many reasons why weather risk management is important. Some of them are listed below:

  • To protect against life & property loss
  • To improve business continuity
  • To ensure the safety of workers
  • To avoid legal liability
  • To save money
  • To provide emergency services

It’s without a doubt that weather risk management is vital for every business. But it’s not always easy to implement. That’s why tools are needed to help make informed decisions and take appropriate actions.

Here are some essential tools for weather risk management that every organization should know about:

1. Storm Surge Protection System

The most common type of natural disaster is a storm surge. A storm surge occurs when large amounts of water move into coastal areas during heavy rainstorms. When this happens, high tides cause the sea level to rise, which can flood low-lying land and buildings.

Storm surge protection systems are designed to prevent this kind of damage. One of the main components of a storm surge system is a berm. A berm is a wall made up of sandbags or concrete blocks. These walls act like barriers between the ocean and the shoreline. They also absorb the energy of the waves, keeping them from breaking over the beach.

2. Weather Station Sensors

A weather station sensor measures temperature, humidity, wind speed, precipitation, pressure, etc. It’s usually placed at strategic locations within the building where it will collect data.

These devices are beneficial because they allow you to measure the conditions outside your building. You can use the data to predict future weather conditions and plan accordingly. For example, you can see whether there will be a lot of rain the next day and decide whether you’ll need to close down operations.

3. Flood Warning and Mitigation Systems

Flooding is another common hazard faced by people near rivers, lakes, streams, and other bodies of water. Flooding can occur due to natural disasters (like hurricanes) or manmade activities (like construction).

When floods happen, it’s hazardous for people who live nearby. If you’re caught in a flood, your chances of survival decrease significantly if you aren’t prepared.

One way to prepare for flooding is by installing a warning system. These systems alert you whenever there’s an imminent threat of flooding.

In cases of severe flooding, mitigation systems may be used. These systems are designed to reduce the impact of flooding on your home or business. The most common types of mitigation systems include:

  • Sandbag Walls: These are built from sandbags filled with soil. They are meant to hold back the flow of water until it recedes.
  • Dikes: These are constructed using reinforced concrete. They are meant to keep out the water completely.
  • Levees: These are built using earth and rock. They are intended to protect against overflow from rivers and creeks.
  • Pumps: They drain out excess water from the ground and are usually located near drains and sewers so the water can flow directly into them.

4. Drought Monitoring Devices

Droughts are also very common in certain parts of the world. Farmers often struggle to get enough water to grow crops during droughts, leading to lower crop yields and higher food prices.

Drought monitoring devices can help identify drought conditions early before they turn into a disaster. They do this by measuring soil moisture levels and analyzing satellite data.

5. Wind Prediction Systems

The wind is another major factor that contributes to extreme weather events. It can cause damage to structures and power lines. In addition, wind can blow debris around, causing further problems.

Severe wind prediction systems predict the direction and speed of strong winds. They can also determine whether a tornado is approaching.

Weather Risk Management Tools

6. Heat Wave Warning Systems

Heat waves are extremely dangerous because they can affect people who aren’t prepared. People in hot climates are more vulnerable to heat waves than those in cooler regions.

Heatwave warning systems are designed to warn people about impending heat waves. They measure temperature and humidity levels to determine if a heat wave is coming.

7. Rain Gauges

Rain gauges are essential for tracking how much rain has fallen over time. They’re especially useful for identifying trends in precipitation patterns.

For businesses, knowing how much rain falls on their property is necessary. The amount of rain determines how many customers they’ll have at different times of the day.

8. Emergency Operations Plan

Finally, an emergency operations plan (EOP) is a document that outlines how your company will respond to emergencies, such as fires, earthquakes, tornadoes, and storms. In addition to these events, you might want to consider preparing for terrorist attacks, chemical spills, and pandemics.

The purpose of an EOP is to ensure that everyone knows what to do in an emergency. It should also contain procedures for contacting local authorities, notifying customers, and evacuating the premises.

Final Thoughts

Extreme weather events continuously increase as climate change progresses. To protect themselves against these disasters, people need to be aware of what’s happening with the weather. These eight tools might assist you in keeping track of everything that could go wrong. You never know when you’ll require any one of them.

Biochemical Method for Ethanol Production

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Ethanol from lignocellulosic biomass is produced mainly via biochemical route. The three major steps involved in the biochemical method for ethanol production are pretreatment, enzymatic hydrolysis, and fermentation. Biomass is pretreated to improve the accessibility of enzymes. After pretreatment, biomass undergoes enzymatic hydrolysis for conversion of polysaccharides into monomer sugars, such as glucose and xylose. Subsequently, sugars are fermented to ethanol by the use of different microorganisms.

Bioethanol-production-process

Pretreated biomass can directly be converted to ethanol by using the process called simultaneous saccharification and cofermentation (SSCF). Pretreatment is a critical step which enhances the enzymatic hydrolysis of biomass.

Basically, it alters the physical and chemical properties of biomass and improves the enzyme access and effectiveness which may also lead to a change in crystallinity and degree of polymerization of cellulose. The internal surface area and pore volume of pretreated biomass are increased which facilitates substantial improvement in accessibility of enzymes. The process also helps in enhancing the rate and yield of monomeric sugars during enzymatic hydrolysis steps.

Pretreatment methods can be broadly classified into four groups – physical, chemical, physio-chemical and biological. Physical pretreatment processes employ the mechanical comminution or irradiation processes to change only the physical characteristics of biomass. The physio-chemical process utilizes steam or steam and gases, like SO2 and CO2. The chemical processes employs acids (H2SO4, HCl, organic acids etc) or alkalis (NaOH, Na2CO3, Ca(OH)2, NH3 etc).

The acid treatment typically shows the selectivity towards hydrolyzing the hemicelluloses components, whereas alkalis have better selectivity for the lignin. The fractionation of biomass components after such processes help in improving the enzymes accessibility which is also important to the efficient utilization of enzymes.

The pretreated biomass is subjected to enzymatic hydrolysis using cellulase enzymes to convert the cellulose to fermentable sugars. Cellulase refers to a class of enzymes produced chiefly by fungi and bacteria which catalyzes the hydrolysis of cellulose by attacking the glycosidic linkages. Cellulase is mixture of mainly three different functional protein groups: exo-glucanase (Exo-G), endo-glucanase(Endo-G) and ?-glucosidase (?-G).

The functional proteins work synergistically in hydrolyzing the cellulose into the glucose. These sugars are further fermented using microorganism and are converted to ethanol. The microorganisms are selected based on their efficiency for ethanol productivity and higher product and inhibitors tolerance. Yeast Saccharomyces cerevisiae is used commercially to produce the ethanol from starch and sucrose.

Escherichia coli strain has also been developed recently for ethanol production by the first successful application of metabolic engineering. E. coli can consume variety of sugars and does not require the complex growth media but has very narrow operable range of pH. E. coli has higher optimal temperature than other known strains of bacteria.

Lower GHG emissions and empowerment of rural economy are major benefits associated with bioethanol

The major cost components in bioethanol production from lignocellulosic biomass are the pretreatment and the enzymatic hydrolysis steps. In fact, these two process are someway interrelated too where an efficient pretreatment strategy can save substantial enzyme consumption.

Pretreatment step can also affect the cost of other operations such as size reduction prior to pretreatment. Therefore, optimization of these two important steps, which collectively contributes about 70% of the total processing cost, are the major challenges in the commercialization of bioethanol from 2nd generation feedstock.

Enzyme cost is the prime concern in full scale commercialization. The trend in enzyme cost is encouraging because of enormous research focus in this area and the cost is expected to go downward in future, which will make bioethanol an attractive option considering the benefits derived its lower greenhouse gas emissions and the empowerment of rural economy.

Breaking Down the Process of Biofuel Production

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Biofuels are renewable and sustainable forms of energy. They can reduce greenhouse emissions by almost 30%, which means that although they do release carbon dioxide into the atmosphere, they do so in a very limited manner.

With the aim of building a green new world, and eliminating the need for fossil fuel and other traditional energy sources, people are now turning towards biofuel to meet their daily needs. Thus, we see biofuel being used for transportation in many countries. It’s also being used to generate electricity. The rural areas in many underdeveloped and developing countries will use biofuel for their cooking purposes as well. All in all, this particular fuel has diverse uses.

Biofuel is produced from biomass, which itself is treated as a clean energy source. We can produce biofuel from biomass through a series of steps. These steps can be performed even in our houses if we have the right materials. A quick overview of the whole biofuel production process is described below.

biofuel-production

1. Filtration

The purpose of the filtration process is to get rid of the unnecessary particles from the biomass. In this step, we take the waste vegetable oil and then heat it to a certain degree. Once the liquid has been heated, the waste particles will automatically separate themselves from the main mixture. Afterward, we just have to filter it with a regular filter paper.

2. Water removal

Next, we need to remove water from the residual gangue. If the water is allowed to stay in the mixture, it’ll end up delaying the overall process. By removing all the water, we can make the reaction move a lot faster. The easiest way to remove water from the mixture is by heating it steady at 212 degrees F for some time.

3. Titration

Titration is conducted on the mixture to determine the amount of chemical catalyst (like lye) that will be needed. The catalyst is a key component in any chemical reaction. It pretty much determines how fast and how much of a product we’re going to receive. Thus, this step is very important in the biofuel manufacturing process.

4. Sodium methoxide preparation

In this step, we take methanol (18-20% of the waste vegetable oil) and mix it with sodium hydroxide. This gives us sodium methoxide, which is also used as a catalyst in the reaction. It helps perform synthesis reactions on the reagents and facilitates the overall reaction process. Sodium methoxide is a key ingredient in this manufacturing process. It’s considered to be a standard substance used to accelerate the reaction, and yield better results.

5. Mixing and heating

Next, we heat the residue between 120-130 degrees F. Afterward, we mix it properly. This process aims to evenly distribute the mixture. This will help the mixture to settle down later on, and cool off, after which we can begin the extraction process. In a way, the mixing and heating stage can be seen as the final preparation before extraction.

biofuel-production

6. Setting

Once the mixing is completed, the liquid is allowed to cool and settle down, after which we can extract the final product, i.e. the biofuel.

7. Separation

After the liquid has cooled, the biofuel can be extracted from the top of the mixture. It’ll be found floating on top, like oil in water. To get the biofuel, we’ll have to remove the glycerin underneath it. This can be done by simply draining it out from the bottom, and keeping the fuel afloat. The biofuel is finally ready.

The whole process described above is for a small-scale operation. However, it can be scaled up as needed, given that you have the right tools, ingredients, and setup.

It should also be noted that chemical catalysts (such as lye) are used in the manufacturing process as well. Recently, however, scientists and researchers are looking into the use of ultrasonics as additional catalysts. According to recent observations, a combination of chemicals and ultrasonics can lead to a higher yield of fuel, and reduce the overall processing time. This also leads to better utilization of biomass.

Companies such as Coltraco (https://coltraco.com/) are now using ultrasonic systems and technology in a wide variety of fields, one of which is the renewable energy industry. And while the technology’s use in other fields has gained more traction in recent times, it shouldn’t be long before it’s used in biofuel manufacturing, as well as in other renewable energy sectors, in full swing.

How to Manage Industrial Machinery Waste in an Efficient Way

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Industrial waste management is a process that can be both challenging and complex, with difficulty increasing depending on the particular kind of waste and its cause. Sometimes, manufacturing companies experience issues with overproduction. Other times, their machinery fails, and unexpected defects can also occur.

While it’s essential that every manufacturing plant follows a set of practices that allow them to minimize waste, often, it’s simply unavoidable and an inseparable part of running operations. Luckily, whether it’s been created by CNC router machines or 3D printers, the waste can still be reduced.

How to Manage Industrial Machinery Waste

To dispose of it correctly, manufacturing plants need to develop and follow proper waste management strategies. These can include reducing the number of packaging materials used, organizing the warehouse, and lowering water usage to the necessary minimum.

By following such practices, manufacturers can reduce their environmental impact and emphasize eco-friendliness. Here’s a closer look at some of the most effective strategies.

Better Warehouse Organization

When it comes to manufacturing operations, especially those that deal with a lot of different raw materials, having a well-organized warehouse is key. Once your warehouse has been organized, you can be sure that your workers can make the most out of their time, and everyone will be able to locate the right tools, materials, or supplies quickly.

Regardless whether your company focuses on precision casting parts or radial drilling machines, to reduce waste, you should create a flowchart that shows exactly how all materials move from one stage to another and where they should be stored. The chart should also highlight possible bottlenecks and where the expenditure of more resources would be advantageous.

It’s also essential to remember the importance of marking your warehouse. Without the right marking, you can’t expect anyone to navigate such a huge structure. Even if they’ve been there at some point, they could’ve already faded or become outdated. This all may be extremely confusing, especially to new hires. Try to dedicate a part of your busy days to organizing the messy and mislabeled parts of your warehouse to minimize waste and increase productivity.

Volume Reduction

This term may sound quite foreign at first, especially to those who are new to the topic of managing industrial waste. It refers to quite a simple process of limiting the biological, chemical, mechanical, and thermal methods used by manufacturers to reduce the volume of waste materials. This allows them to compress them to a greater degree and put them in a form that’s the most suitable for later storage or disposal. The methods used can be divided into two main categories: source segregation and waste concentration.

Source segregation focuses on separating the solid waste that consists of different materials so that certain waste can be easier processed. For instance, when the plastics aren’t mixed with the metal waste, the latter can be processed separately with no effort, and the metal value can be recovered.

Waste concentration, on the other hand, helps increase the probability that there will be enough of certain material to recycle it into something else and reuse it later. When the small scraps of materials are collected over time to accumulate enough for recycling, the waste can be limited significantly. Both these methods require proper storage and sorting, but the benefits are worth the effort.

Recovering, Sorting, and Recycling

Just three words are all you need to keep in mind and turn into an active effort to improve the way your manufacturing plant is managing and minimizing its waste from industrial machinery.

First, it’s essential to emphasize the process of recovering as much waste as possible from both the onsite and offsite locations that are a part of a certain plant. Water can be recovered through filtration or reverse osmosis, and different scraps and particles of materials can be separated thanks to centrifugation. Apply the right methods where they’re needed and recover whatever is possible instead of letting them go to waste.

Then, you can also focus on sorting, which is the first step to proper recycling. When the waste is going into the right bins from the very beginning, it’s much easier to recycle in the next step. You can even choose someone who will be responsible for ensuring that the waste bins are monitored and used as intended by the workers.

Separated waste can then be recycled, be it paper, plastic, or metal. Recycling hazardous materials often requires chemical, thermal, biological, and physical methods, so it may be better to leave it for professionals or consider whether it will have any environmental benefits. When dealing with waste such as wood, rubber, or asphalt, industrial shredders can be used to reduce these materials to much smaller sizes and make them more manageable.

Using Proper Packaging

Creating an abundance of waste in the form of packaging materials is yet another issue that many manufacturing plants face and don’t deal with efficiently. Fortunately, a solution to such issues is quite straightforward and doesn’t require an enormous effort. In most cases, every company can find some ways to reduce the environmental impact of their packaging.

To begin with, plastic packaging can often be easily replaced with cardboard packaging. But the possibilities go far beyond just the plastic vs. cardboard issue. Depending on the kind of machinery your plant uses, you’re likely to be able to buy the materials in bulk and reduce the amount of necessary packaging this way. Your machinery will still have all the materials needed, but there won’t be as much waste created along the way.

In Conclusion

As you can see, there are always different ways to reduce the waste created by machinery used at manufacturing plants, as well as all the other operations required to keep the manufacturing processes going.

These methods outlined above may require some effort, but they can certainly be done and be immensely helpful in keeping the environment clean while also helping you keep your company afloat. It’s all about being efficient and organized and making the right decisions regarding getting rid of your waste.

That being said, try to ensure that your warehouse is well-organized, consider following steps that will allow you to reduce the volume of the waste, opt for recovering, sorting, and recycling whenever possible, and limit the amount of packaging used.

Why Eco-Friendly Industrial Coatings Deserve Your Attention?

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Industrial plants and facilities have been instrumental in propelling the modernization of human society. From that pen you use to sign your cheques to the knife you use to cut fruits for breakfast – almost every object of daily use has been manufactured at a production unit.

However, despite the numerous benefits of industries, they’ve been responsible for a wide array of environmental issues, including greenhouse gas emission, global warming, and air pollution. Also, improper waste management at manufacturing plants has adversely affected biodiversity in various regions.

The good news is that today’s industrial units are becoming more aware of their environmental impact and taking various steps to reduce their carbon footprint. This change has been propelled by increasing consumer demand for sustainable business practices, as well as federal and state regulations.

But while you’re striving to reduce energy consumption and waste generation at your plant, you’re likely ignoring the crucial aspect of industrial paint. That’s right! The paint that’s used for industrial plants, machinery, and tools is a key contributor to environmental degradation.

industrial-coatings

This, in turn, has compelled manufacturers and plant managers to look for eco-friendly industrial paint options from established distributors, such as Promain Paints. But if you’re new to the world of eco-friendly industrial paint, you might be skeptical about making the switch.

Is eco-friendly industrial paint worth the cost? Is it going to have the same characteristics as traditional industrial coatings? Is it mandatory for industrial units to use eco-friendly coatings?

If you’re looking for answers to these questions, we’ve got you covered. In this blog, we’ll delve deeper into the concept of industrial paints and understand their environmental impact. We’ll also explore the benefits of replacing traditional industrial paint with eco-friendly alternatives. Let’s get started.

Industrial Paint: A Closer Look

Industrial paint or industrial coating is specifically formulated for machinery, equipment (such as retaining rings), structural facilities, and end products at manufacturing plants and other industrial units. It’s also used to coat floors and other surfaces that endure the stress of heavy machinery.

Industrial paint can be in the form of a liquid, powder, or paste. When exposed to natural air, the paint gets cured and dried, thus forming a protective layer over the surface on which it’s been applied.

The primary purpose of industrial coating is to protect equipment, goods, and other substrates from physical and chemical damage. Depending on its chemical composition, the paint can also prevent the accumulation of dirt and grime. It even goes a long way to improve safety by making surfaces, such as floors, less slippery.

Typically, industrial paint comprises the following components:

  • Pigments
  • Binders
  • Solvents
  • Additives

Pigments are the chemicals or dyes that give the paint its color. Commonly used pigments include titanium oxide, iron oxide, and phthalocyanine derivatives. Binders are polymers, such as alkyd and acrylic resins, that allow the paint to adhere to the substrate and form a protective film on drying.

A solvent is a liquid that’s added to the paint to reduce its viscosity and improve its consistency so that it can be sprayed or applied with a brush. Typical solvents used in industrial paint include aliphatic hydrocarbons, aromatic hydrocarbons, esters, ethers, alcohols, ketones, etc.

Additives are special chemicals that give specific characteristics to the paint. Common examples of industrial paint additives include wetting agents, drying agents, fungicides, biocides, and plasticizers.

Effect of Industrial Coating on the Environment

The solvents used in industrial paint contain toxic chemicals known as volatile organic compounds (VOCs). VOCs have low boiling points and react with other gases present in the air when exposed to sunlight. They’re also responsible for giving paint its characteristic smell.

Short-term inhalation of VOCs can cause a wide array of health problems, including headaches, nausea, dizziness, and skin rashes. Prolonged exposure to these chemicals can lead to serious diseases, including cancer and liver ailments, as well as damage the central nervous system.

However, the impact of VOCs isn’t restricted to health-related disorders. They also adversely affect the environment and cause air pollution. It’s because these chemicals react with nitrogen oxides present in the environment in the presence of sunlight. This, in turn, results in the formation of tropospheric or ground-level ozone.

Ground-level ozone is a harmful air pollutant that creates smog and damages plants. It could affect the natural habitat of various animals and, in turn, destroy biodiversity. Also, it acts as a greenhouse gas, thereby contributing to global warming. That’s why increased use of conventional industrial paint is proving to be catastrophic for the environment.

The Search for Eco-Friendly Options

The harmful effects of industrial coating have forced manufacturers to look for environmentally-friendly alternatives. Eco-friendly industrial paint usually contains special solvents that emit negligible or very low amounts of VOCs into the air.

industrial-valve

The biggest benefit of using eco-friendly paint is that it helps you comply with the environmental regulations in your area. The Environmental Protection Agency has outlined specific limits for VOC emissions in different regions. Non-compliance with these regulations could result in legal ramifications.

Also, many eco-friendly paints are formulated to be more durable. Some of them are even made using bio-renewable or post-consumer waste raw materials. This further reduces the environmental impact of your unit and takes you a step closer to creating sustainable business operations.

What other steps are you taking to minimize the environmental impact of your business? Share your suggestions in the comments section below.

An Essential Guide to Catalytic Converters

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In the early days, cars were way more toxic than they are today. As vehicles became more widespread and their pollution more prevalent, manufacturers decided that it was necessary to install catalytic converters to keep cars exhaust fumes out of our bodies and the environment. Today, catalytic converters are used around the world in all vehicles. Many online shop even sell the Honda Jazz Catalytic Converters for replacement to your car. This is the part of a car that converts toxic gases into less harmful pollutants.

Catalytic converters, like cars, only have a certain lifespan and will to be replaced at some point. Given that they are required by law all around the world, it is important to know when your car’s needs replacing, but how can you tell? And, just as tricky, what should you do about it?

Here’s an essential guide to determine when your catalytic converter needs replacing.

Signs of a Failing Converter

Catalytic converters use precious metals such as rhodium, platinum and palladium. These are the catalysts to transform pollutants into less harmful gases. As gases from the engine fumes pass over the catalyst, the pollutants break down into gases that are safe enough to be expelled. Over time, however, converters can become damaged, blocked or contaminated, which reduces the engine’s performance.

Here are the common symptoms of a faulty catalytic converter:

Smell of sulfur

If you begin to smell a rotten egg-like odor coming from your car, that’s an indication your catalytic converter is starting to wear down. A converter in good working order should produce an odorless sulfur dioxide, but this smell means it is no longer converting the hydrogen sulfide produced in the combustion process. The smell of sulfur will often be accompanied by a stream of thick and black smoke coming out of your exhaust pipe. The black smoke alone would be enough to suspect your catalytic converter is not working as it should.

Poor engine performance

A faulty converter will quickly affect your engine because it is built into the vehicle’s exhaust system. As a result, it will reduce engine power, fuel economy, and acceleration. Any of these symptoms could result from either:

  • A clogged converter that is no longer circulating air properly
  • Or a cracked converter that is now leaking harmful gas

A clogged converter is a common reason for losing acceleration or power going uphill. To test if your converter is clogged, ask a friend to hold your car’s revs per minute between 1800 and 2000. If exhaust flow is hot, that means your converter is clogged.

‘Check engine’ light is on

Vehicles today are made with oxygen sensors that monitor a converter’s efficiency at transforming harmful gases. The ‘check engine’ light will appear on your dashboard if the gases aren’t being catalyzed. While the light itself may not indicate it is a problem with the converter, you can check the error number with a car manual or a diagnostic scan tool.

What to do about it?

Catalytic converters should last for about ten years. If you are still looking to hold on to your car at that point, then it will probably be time to replace the converter.

Getting rid of your converter is easy today, as there are firms that will buy your converters to recycle the precious metals inside. All you need is the reference number for your catalytic converter and you can then check to see how much you would earn on a recycle catalytic converter price list.

Changing the converter

Most of the cost involved will be for the converter, which can cost up to $2500, but changing it should take less than an hour. If the catalytic converter is welded in place, then it is best to see a mechanic rather than change it yourself. Unless you are a mechanic, of course!

How Can Oil-Free Air Compressors Benefit The Environment?

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If you already have an air compressor, you will be aware of how they are an incredibly valuable tool for industries and DIY enthusiasts. Commonly used to power pneumatic tools but can be used for a variety of applications. Air compressors provide you with complete power over spraying, nailing, sanding and hammering at a fraction of the time it would take with manual tools.

You can also find these smaller sized air compressors everywhere that are very portable and best at doing small work. Bob Robinson of BestOfMachinery swears by these portable tools. “Small air compressors essentially push air from the tank in the unit, into the tools that you want to use for either DIY, hobbies or work purposes without the need to lug heavy stuff.”, he commented.

These machines can also be used for inflating tyres, auto repairs and even creating home-made snow machines. Sandblasters, impact wrenches, grease guns, die grinders and angle disc grindles can also be attached.

We all love our power tools and would be lost without them; however, we are becoming more aware regarding the issue of carbon emissions. Reducing our carbon footprint is one of the most important things companies and individuals can do in their lifetime. Small changes within your business and homes can be a great start to decrease our carbon emissions and help save the planet.

If you are looking to purchase your first air compressor or to update an existing model, Direct Air has created a guide on why an oil-free air compressor is a great choice, not just for the environment, but to help you save on energy bills. You can see their full range of oil-free air compressors at https://www.directair.co.uk/products/oil-free-air-compressors/.

Every air compressor requires lubrication in order to efficiently and safely draw in air to its cylinder, commonly using a piston movement. The traditional method to achieve this is using oil, while oil-based air compressors do have their benefits as they are more robust and can handle large-scale applications, they are higher in initial cost, harder to maintain and far heavier than their oil-free counterparts.

Oil-free air compressors gain lubrication through a non-stick coating, generally Teflon. As extra elements to hold oil are eradicated from these machines, they are far lighter and smaller than oil-based air compressors which make them ideal for applications that are not static. Due to less components, oil-free air compressors are often cheaper to purchase.

Oil-based air compressors must remain static and upright when in use, oil-free are far more versatile. As you do not need to consider the oil flow, they can be positioned wherever you see fit. They are also operatable at any temperature, oil can become viscous in cooler climates and can cause problems when attempted to start the motor, oil-free erases this issue.

With these benefits in mind, you can achieve even more with your oil-free air compressor by helping to reduce the use of fossil fuels maintain the planet’s natural resources. You can also make a direct impact on your running costs, saving you and your business money on your energy bills.

With an oil-free air compressor, all costs to collect and dispose of oil-laden condensate will be removed, not to mention the initial cost of the oil itself. These compressors are less wasteful as they do not require the replacement of the air/oil separator and filtration elements which are required to get rid of oil aerosols, these parts are notorious for wearing down quickly. You will not needlessly be sending these parts to landfill and be bearing the cost of new ones on a regular basis.

If you are worried about direct harmful emissions from your air compressor, oil-free air compressors produce the purest form of air which will reduce any negative impact into the atmosphere, great for the planet and for those working around it. You will also not have the trouble of potentially contaminated products from oil spills during projects.

A big bonus of oil-free air compressors is that they are safer than their counterparts, as there is no oil, you eliminate the risk of compressed air pipeline fires. An incredibly important factor to consider for the safety of you, your staff and your premises.

Oil-free air compressors can dramatically reduce your energy bills compared to the oil-based counterpart as they require less energy to run which will cut down your environmental impact. Oil-free air compressors do not need increased forces of power when the unit has a drop in the filtration in the downstream pressure, unlike oil-based. Oil-free units can, on average, unload in 2 seconds of your command which only uses around 18% of its full load horsepower.

Of course, all machines come with their downsides and oil-free air compressors are no exception. Oil-free air compressors are known to generate more noise which can be an annoyance and hazard to those using it and those around them.

There is a solution, you can invest in a low-noise air compressor. These reduce noise levels to around 40dB. The lowest safe level is considered 60 dB and anything over 80dB can cause long-term problems with hearing.

With the addition of an acoustic cylinder to contain this noise, opting for a low-noise air compressor is an investment worth making. It is recommended when using any power tool that protective gear is worn to eliminate lasting damage and long-term effects, even with a low-noise machine.

If you were considering purchasing a new air compressor or have simply been doing research on them, you should now have a comprehensive understanding of the benefits an oil-free air compressor possesses.