Category Archives: News

Atmospheric air drier ‘Mohave Heat’ commissioned in Oman

News

On 17 December commissioning of an automated Mohave Heat air drying unit was completed in Oman.

This product is designed to dry atmospheric air to dew point of -50… -70ºС and to remove dust and particles. The unit is used while installing or repairing transformers. Some of the applications are:

  • opening transformers
  • draining oil from transformers (used oil removal)
  • drying smaller transformers up to 110 kV with hot dry air (air drying with new heating system globe core)
  • oil paper insulation drying.

Besides, the unit can restore sorbents in external equipment by purging it with 400-430ºС air. In agriculture, Mohave Heat is used to dry grain, hay etc.

The automated model is controlled from a touch screen, setting the required mode of operation. Air flow rate is set by frequency variators (one for each blower). Temperature setting is maintained by PID.

Using automation in Mohave Heat units allows to reduce energy consumption and labot costs, as well as ensure air tightness of electrical equipent during repairs and maintenance.

For specifications of the product, follow this link. To get more information on Mohave Heat air drying unit, contact GlobeCore’s engineering or management staff.

Successful commissioning in Uganda

News

On 3 December 2015, GlobeCore specialists successfully commissioned a CMM-4D unit in Uganda.

This unit employs heat and vacuum to purify electrical insulation oils. The oil is finely dispersed in the vacuum chamber, where special activator filters increase the surface area of treatment.

СММ-4D units can:

  • purify transformer oil, removing particulate matter, water and gas;
  • heat electrical systems with hot oil;
  • vacuum-dry transformers;
  • vacuumize external equipment.

The unit is simple to operate and service and ensures consistent oil treatment parameters (5 micron filtration and purification to class 9).

As necessary, GlobeCore’s СММ-4D units can be operated in one of the following modes:

  • oil transfer;
  • transformer heating;
  • heating, filtration and vacuum purification of oil;
  • vacuumizing.

The unit is equipped with the required protection and automation systems to improve reliability. In particular:

  • control and visual indication of oil temperature;
  • overheating protection;
  • control of oil flow through the heater;
  • keeping the oil temperature according to the selected mode of operation.

If you require a reliable system for soft and careful purification and degassing of transformer oil with several other useful functions, the CMM-4D is the ideal choice! Refer to contact list to make your order.

Removal of Heavy Metals from Wastewater Generated at Electroplating Workshops

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We discuss Electroplating Wastewater Treatment in this article.

At the beginning of the twenty first century, the urgency of solving the issues of global environmental problems significantly increased. Today, humanity has almost come to the point where further ignoring of the need to preserve the Earth’s ecosystem will be very costly for future generations.  There are many global environmental problems and each of them deserves attention.  This article will discuss the protection of the hydrosphere from all forms of pollution.

As a result of human activities, industrial wastewater is constantly being generated all over the world. The draining of industrial wastewater into open waters without the proper treatment can lead to irreparable consequences for the environment.  The situation becomes more complicated each day by the fact that industries are developing rapidly and the amount of wastewater increases proportionally to the increases in the size and scope of modern human industries.

According to the World Health Organization (WHO), human diseases caused by the consumption of contaminated water and food can be as high as 80% of the total number of health problems reported each year.  Treatment of industrial wastewaters therefore, is one of the most urgent and priority tasks faced by modern man.

General Characteristics of the Electroplating Industry   

The Electroplating Industry got its name from an electrochemical method of applying mechanical and chemical coatings on various materials to impart hardness and wear resistance as well as anti-corrosion protection and protective-decorative properties.

The electroplating industry can perform galvanizing, chemical passivation of stainless steel, anodizing of aluminum, chemical oxidation of aluminum and steel.  The generation of wastewater is due to the need for washing parts in the process of preparation and applying the electroplate coatings.

Composition of Wastewater Generated from Electroplating Facilities

The composition of wastewater generated from the electroplating industry typically includes washing waters (diluted effluents) and concentrated solutions (pickling, washing, degreasing, chrom- and cyano-containing electrolytes).

The greatest damage to the environment is made by metal compounds that are washed out in wastewater from the electroplating industry.  For example, cyano-containing effluents contain free sodium cyanide (potassium), complex cyanide salt of zinc, cadmium, copper and other metals, as well as salts of alkali and alkaline earth metals.  The concentration of cyanide can range between 5 and 300 mg/l with an acidity level that exceeds the  “7” mark.

Wastewater from Electroplating facilities using chromium contain hexavalent and trivalent chromium, ions of metal, copper, nickel, zinc and sulfuric acid.

Cadmium compounds, even in relatively small quantities, have a dramatic negative impact on fish and other inhabitants of fresh and saltwater resources.  Other negative effects of heavy metals are also well-studied.  They can enter the human body through food and water and can cause the pathogenesis of liver disease, heart disease, brain cancers, and even tumors.

Existing Methods of Treating Wastewater from Electroplating

The main objective of galvanic wastewater production treatment is to reduce the content of heavy metals to the maximum allowable concentrations.  This allows you either to dump purified water into a sewer system, or return it back to use in production.

Since electroplating effluents contain a wide range of heavy metals, each of which requires a different disposition, you will have to resort to a multi-step treatment plan.  Dissolved heavy metal ions must be converted into insoluble chemical compounds, followed by separating and dewatering solids.  In general, the purification process consists of the following stages:

  1. Neutralization – A process that is necessary for the chemical disposition of metals. It comprises of setting the pH level to a certain value using sodium and calcium hydroxides;
  2. Flocculation – formation of macro floccules by the addition of organic flocculants;
  3. Precipitation – separation of the solid phase.  At this stage sludge is also de-watered; and
  4. Polishing filtration by means of ion exchange or sorption.

Despite of all the achievements, ion exchange, reagent and coagulation methods do not fully address the issue of effective and economic efficient cleaning. Besides this, when using these methods of wastewater treatment for removing heavy metal ions, a so-called galvanic slime is formed.  These substances can not be placed in landfill sites designed for solid wastes.  Burial of galvanic slime requires the use of special landfills.  The number special landfills is very small.  Most businesses generating galvanic slime materials therefore, have to store such waste on its own property by creating temporary sludge storage areas.

Ion-exchange and reagent purification methods, using conventional equipment, are very time-consuming.  The reagents are costly, have a greater metal content, and are characterized by the need for expensive and cumbersome equipment.

Use of Vortex Layer Devices in the Process of Purifying
Wastewater Generated by Electroplating Facilities

Given the aforementioned, it can be argued that the search for new and more effective approaches to the problem of wastewater treatment in the electroplating industry is highly relevant.  GlobeCore manufactures a modern and effective vortex layer devices.  Today, in a variety of industries there are many successful production lines equipped with such GlobeCore devices.

When analyzing the intensifying factors that occur in a vortex layer device, it can be assumed that the process of wastewater treatment will be subjected to a significant impact from:

  • electrochemical factors, electromagnetic treatment, and activation of substances in the vortex layer;
  • phase dispersing; and
  • geometrical parameters of the operational mode of the vortex layer, and its hydrodynamic factors that provide intensive mixing of the processed media.

We have carried out studies on electroplating wastewater treatment that remove heavy metals using a GlobeCore AVS-100 type (laboratory) vortex layer device.  As the reducing agent, we used sulfuric acid iron FeSO4.  Recovery of the trivalent and hexavalent chromium at the expense of the reagent was carried out in an alkaline medium for which milk of lime Ca(OH)2 was introduced into the water.

Because the alkaline medium of iron hydroxide additionally acts as a reducing agent, there is no need for acidification drains.  The 0.5 liters of water intended for cleaning had a 10 mg of 10% solution of ferrous sulphate added to it.

For treatment included the use of ferromagnetic particles with a length of 20 mm and a diameter of 1.8 mm with a total weight of 200 grams.  The treatment time made lasted three seconds.

Table 1 below shows the results of the electroplating wastewater treatment process that removed heavy metals using a GlobeCore Magnetic Mill AVS-100 vortex layer device.  The table also contains comparison data obtained with reference values and concentration limits valid for the countries of the European Union.

Table 1

Results of the Electroplating Wastewater Treatment Process Removing Heavy Metals Using a GlobeCore AVS-100 Magnetic Mill

No

Parameter name

Parameter value

Maximum allowable concentration  (European Union)

before treatment

after treatment
1 рН 1.75 6.74 6.5-8.5
2 Fe, mg/l 9.7 2.77 2-20
3 Cu, mg/l 18.29 0.65 0.1-4
4 Ni, mg/l 5.8 <0.02 (not found) 0.5-3
5 Cr+6, mg/l 19.08 <0.005 (not found) 0.1-0.5

The following conclusions can be made about Electroplating Wastewater Treatment:

1) Use of the GlobeCore AVS-100 type vortex layer device in the process of electroplating wastewater treatment will effectively reduce the concentration of heavy metals to values ​​not exceeding the maximum permissible concentrations in the European Union.  The results showed a complete absence of nickel and hexavalent chromium in the treated water.  This shows that the use of the vortex layer devices in countries where there are more stringent requirements for concentrations of hexavalent chromium and nickel will be very popular.

2) Purification of water is instantaneous and does not require the overuse of reagents.

3) The process of sediment settling is achieved much faster than when using agitators.

Grinding of Coal to a Pulverized State

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Today, a significant amount of the energy generated and consumed around the world is produced by burning fossil fuels.  In addition to oil and natural gas, coal  is also quite actively used as an energy source.

At modern electric power plants, solid fuels are ground into a pulverized state and, in an admixture with air, are fed into a combustion chamber for burning.  This is preceded by the preparation of large pieces of wet coal, which includes coarse crushing of coal into pieces the size of a few of millimeters.   It is subsequently dried and ground into a pulverized state.

The main advantage of using pulverized coal is the substantial increase in the surface reaction.  This improves the combustion conditions and increases the efficiency of the burners.  Additionally, the use of pulverized coal does not limit the power of the boiler’s combustion conditions.  It allows the operator to fully mechanize the combustion process and makes it easier to control.

There are also alternative ways of using pulverized coal for energy.  First of all, we are talking about co-firing of coal with biomass and preparation of coal-water fuel.

At thermal power plants operating in Europe and North America, co-combustion of coal with wood pellets has been increasingly practiced in recent years.  Such innovation has been able to reduce harmful emissions when burning coal alone.  There are several possible options for co-burning of coal and biomass:

  • the parallel incineration;
  • indirect co-incineration; and
  • direct co-incineration.

In direct co-burning, the coal and biomass are prepared, crushed and fed into the boiler at the same time.  Indirect co-burning is characterized by separate preparation of the coal and the pulverized biomass.  In parallel co-burning, coal and biomass are combusted using separate boilers.

Another option for reducing the amount of harmful emissions is the use of coal-water slurries (coal-water fuels).  They are characterized by low combustion temperature, thereby reducing the nitrogen oxide emissions by as much as 70%.

Existing Methods of Coal Grinding

In practice, special devices, called mills, are used for the grinding of coal.  Ball pulverizer mills can grind and dry soft fuels with a high humidity content at the same time.  They can grind coal to the pulverized state, but have the disadvantages of bulkiness and complexity, as well as a high rate of electricity consumption.

Ball and roller mills are not very effective when processing objects of high strength and/or hardness.  This is reflected in the slow deterioration of crushing capabilities whereby a steady increase in the proportion of large pieces and reduction of the discharge of dust.

There are also difficulties in grinding wet ash coals that merge and become compressed under the grinding elements.  This results in poor milling.

Hammer mills enable simultaneous grinding and drying of fuel using air or a gas-air mixture.  The main drawback of such devices however, is a relatively rapid wear of the beaters (hammers) and the need to replace them after 300 to 600 hours of work.

What does GlobeCore offer?

All known methods of coal grinding are characterized by the complexity and bulkiness of the equipment and the large amounts of energy used.  Vortex layer devices structurally resemble an asynchronous motor.  The main difference is the absence of a rotor.  The device is powered by a three-phase network that generates a rotating electromagnetic field of industrial strength frequency.  The processed material is fed into the working zone where special ferromagnetic particles are added into the material being processed.  The latter begin to rotate under the influence of the magnetic field performing multiple striking impacts on the processed material.

АВЭПHere at GlobeCore, we have carried out studies on the possibility of grinding coal to a pulverized state using the GlobeCore AVS-100 type vortex layer device.  During the study, a 250 gram piece of anthracite coal was used to test the AVS-100 vortex layer device.  We used ferromagnetic particles with a diameter of 3mm.  As a result, we managed to succeed in crushing the coal to a pulverized state within one and one half minutes.

The results obtained during the experiments suggest that grinding coal by the vortex layer devices takes significantly less time and energy than the known mechanical grinding processes.

GlobeCore is able to manufacture vortex layer devices on a commercial scale through specific customized orders. This equipment can be used in the following systems:

  • preparation of fuel for powdered combustion;
  • preparation of coal-water fuel; and
  • co-burning of coal and biomass.

Using GlobeCore’s vortex layer devices, you can design and implement a completely new system and/or upgrade existing ones.

Reagent Automatic Dosers for Wastewater Treatment Systems That Operate Using Vortex Layer Devices

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GlobeCore designs, manufactures, and installs wastewater treatment systems that utilize vortex layer devices.  The main feature of these machines is the complex effect the devices have on processed materials.   The processing consists of intensive mixing and dispersion, acoustic and electromagnetic treatment, friction, local pressure, and electrolysis.

The GlobeCore Process of using the vortex layer devices consistently will achieve more efficiency in the wastewater treatment process by reducing energy consumption, reducing reagent consumption, and also decreasing  production costs.

The use of reagents reduces the amount of precipitated dirt staying in dissolved form or as a dispersion component.  For the best cleaning results, dissolved reagents are injected into the wastewater in strictly controlled amounts.  Overuse leads to higher economic costs as well as a rise in the cost of operating the treatment facilities.

In the wastewater treatment systems that use vortex layer devices, a substantial saving in reagents is achieved through the use of a specific unit that automates the process of feeding the reagents into the pipeline.  With this device, you can measure the acidity, pressure, and the percentage of metal at the inlet and outlet flow of sewage.  Based on this data, the following actions can be taken:

  • control the amount of supplied reagents;
  • change the dosage of reagents, depending on the current performance of the process and the data set with the remote control;
  • adjust the flow rate of incoming fluid;
  • switch to the backup settling sump in the case of the peak discharge of pollutants or increasing the flow to non-reprocessable level; and
  • distribute the flow between several vortex layer devices.

Design, Manufacture and Installation of Wastewater Treatment Systems on the Basis of Vortex Layer Devices

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Each year the world produces about one trillion cubic meters of wastewater.  Approximately one fifth of which receives no treatment before being discharged back into water sources.

The greatest threat to the world’s water supply is posed by industrial effluents resulting from activities in the chemical, food, machine-building, instrument-making, petrochemical, and radiochemical industries.  Wastewater discharged into rivers and other bodies of water is extremely dangerous.  This is due to the fact that:

  1. the overall regeneration process of water in the hydrosphere is much slower than air in the atmosphere; and
  2. the natural processes occurring in an aqueous environment are more susceptible to contamination.

Additionally, water is far more important for the sustenance of the Earth than the analogous processes in the atmosphere.  The feasibility of wastewater treatment therefore, is not in doubt.  The main problems that arise in dealing with this issue relate to the complexity of physical and chemical changes that occur in the process of purification.

Today’s existing ion exchange, reagent, and coagulation methods of industrial wastewater treatment to remove chromium and other heavy metals, do not fully guarantee the efficient and economical cleaning of water resources.  The main drawback of these methods is the formation of large quantities of waste requiring disposal.

When cleaning wastewater, there is a large amount of precipitation formed.   After dehydration, it is usually stored on site at the industrial plants in areas designated for storage.  On site storage makes it necessary to have extra storage spaces that are not always available due to space limitations.

Ion exchange and reagent methods of wastewater treatment using conventional equipment are quite time-consuming, slow, and consume huge amounts of reagents adding greatly to operating costs.

vortex wastewater treatment

GlobeCore offers an alternative approach to wastewater treatment that involves the use of vortex layer devices.  These devices are used in many industries for intensification of physical and chemical processes.  Improving the efficiency of wastewater treatment processes in a vortex wastewater treatment layer device is achieved by the following factors:

  • electrochemical processes, electromagnetic treatment and activation of the substances in the vortex layer;
  • phase dispersion; and by
  • geometrical parameters and modes of operation of the vortex wastewater treatment, its hydrodynamic factors, that provide intensive mixing of the processed media.

For example, when cleaning wastewater and removing phenol with the GlobeCore AVS-100 type vortex layer device, energy costs are reduced by 10 to 15 times.  Reagent consumption is reduced by 1.5 to 2 times.

GlobeCore offers:

a comprehensive analysis of the chemical and bacteriological composition of the wastewater of your enterprise, definition of peak surges and identifying their causes;

  • a custom design of wastewater treatment systems, including computerized systems for management;
  • manufacture of treatment systems on the basis of vortex layer devices;
  • installation and commissioning at your facility; and
  • carrying out all testing.

To receive an expert advice or make an order of wastewater treatment systems, please contact us at one of the contacts.

Automatic Loading of the Grinding particles in the Working Chamber of the Vortex Layer Device

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Electromagnetic devices with a vortex layer of ferromagnetic particles were first proposed in the 1960s.  In these devices, complex interactions take place between ferromagnetic particles, fluids and materials that are being processed.  This speeds up the process of mixing and grinding.  Moreover, the vortex layer devices can successfully be used as reactors.

GlobeCore manufactures the AVS-100 and AVS-150 type vortex layer devices.  These units are highly versatile pieces of equipment that can be used for the following:

  • production of bone food paste;
  • production of mayonnaise;
  • processing vegetable raw materials;
  • cleaning vegetable oils;
  • intensification of the technological processes of bakery production;
  • cleaning wastewaters by removing chromium and other heavy metals;
  • production of biodiesel;
  • preparation of water-fuel emulsions; and
  • disinfection of liquid pig manure.

The effect of grinding the treated raw material depends on the nature of the movement of the ferromagnetic particles in the work chamber of the unit.  Grinding can be achieved by both free collision of the particles with the ferromagnetic elements and through a constrained collision between the two elements or elements and the housing.

During operation of the vortex layer devices, gradual abrasion of the ferromagnetic particles takes place.  This can lead to a decrease of their quantity and deterioration of the quality of processing of the feedstock.  During the technological process therefore, it is necessary to maintain the optimum amount of the ferromagnetic particles in the processing chamber.  This should be carried out in a continuous mode.  The stoppage of the production line every time the number of ferromagnetic elements falls below a critical level, in most cases, is simply not possible from the technical standpoint.

GlobeCore has developed and manufactures special devices that measure the amount of the ferromagnetic particles in the work chamber of the vortex layer devices.  In the case of critical values, the special devices are able to make the addition of new ones.  The optimal amount of the ferromagnetic elements for each technological process will vary, hence their critical amount will be different respectively.  The amount can be set on the control panel of the equipment.

Besides the production of vortex layer devices, GlobeCore also provides delivery for its work chambers and ferromagnetic particles in all corners of the globe.

Application of Vortex Layer Devices for Improving the Quality of Marine Fuels

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The first time the possible use of water, in the feed system of internal combustion engines was discussed, took place in the late nineteenth century.  Since then, there have been many studies on the effectiveness of the approach of adding water to fuels.  A couple of known benefits to adding water to fuels include:

  1. intensifies the fuel combustion process; and
  2. reduces the release of incomplete combustion products and nitrogen oxides with the exhaust gases into the atmosphere.

The quality of water used for water-fuel emulsions has a direct impact on the wear of the fuel system’s internal parts.  The most promising systems for obtaining water-fuel mixtures therefore, are those which process not only fuel, but also the water before mixing.  A vortex layer device can successfully perform this task since it causes the complete dispersion of these components.

Structurally, vortex layer devices consist of a tube of non-magnetic material.  Inside the tube there is a rotating electromagnetic field that reacts with with ferromagnetic particles.  The latter are found in the vortex motion.  In the workspace of such devices, there are a number of effects that make possible the deformation of crystal lattice solids, and sharply increase in the reactivity of chemical agents.

Vortex layer devices can input into base fuels up to 7% water.  Mixing actually takes place at the molecular level.  That is why the resulting product is resistant to delamination and can be stored for at least 5 to 6 months.

Another advantage of the use of vortex layer devices is the generation of a large amount of heat during operation.  The vortex layer can be used for the initial fuel and water pre-heating block.

It should be mentioned that the technology for the production of water-fuel emulsions by means of vortex layer devices can be used not only for marine fuels, but in the fuel conditioning systems at boiler plants as well.

You must pay attention however, to the following fact.  During operation of the device, collisions of ferromagnetic particles occurs.  This leads to their gradual abrasion.  The presence of metal particles in marine fuels and in boiler fuels is unacceptable therefore, you need to use the special magnetic traps to remove any unwanted metal particles from remaining in the fuel.

GlobeCore offers magnetic flow metal traps that are made specifically for use in water-fuel emulsions preparation lines equipped with the AVS-100 or AVS-150 type vortex layer devices.  At the Customer’s request, it is possible to produce magnetic metal traps of the required sizes for most other industries.

GlobeCore’s Magnetic Metal Traps for the Food Industry

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One of the many possible applications of GlobeCore’s vortex layer devices is the processing of the liquid-phase found in heterogeneous systems.  GlobeCore’s Vortex Layer device is designed to intensify technological processes in various industries that include the food industry, chemical industry, and the microbiology industry.

The principle of operation of a vortex layer device is based on the chaotic motion of ferromagnetic particles under the influence of a rotating electromagnetic field.  A layer is formed in the active zone of the unit that is known as a vortex.  In this layer, an intense mixing and pulverizing of the treated materials takes place due to the uniform effect of the electromagnetic field, acoustic vibrations, and local high pressures on the materials in the vortex.

Studies carried out by the specialists of GlobeCore’s advanced Engineering Department have shown that the vortex layer devices can be successfully used in the production of highly profitable foodstuffs.  In particular, some include:

  • mayonnaise and high-calorie sauces;
  • flour products;
  • fruit juices;
  • sunflower oil; and
  • various other cooking oils.

The modern vortex layer device can improve the quality of consumer products being produced, reduce the time of production, and extend the shelf life of the finished products.

During processing of foodstuffs however, gradual abrasion of ferromagnetic particles takes place.  The presence of metal particles in food products is unacceptable.  To solve this problem, the use of magnetic metal traps was developed to remove any traces of metal particles.  The magnetic metal traps can effectively and continuously remove ferromagnetic particles from food mixtures, thereby preventing small metal particles from intruding into the final product.

GlobeCore offers magnetic flow metal traps manufactured specifically for use in food production lines featuring the AVS-100 or AVS-150 type vortex layer devices.  Upon request, it is possible to produce magnetic metal traps of the many required sizes for other industries.

Presentations of GlobeCore Oil Purification Equipment held in Azerbaijan

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From 12 October to 16 October 2015, a delegation from GlobeCore paid a working visit to Azerbaijan.

GlobeCore’s representatives visited Baku and Ganja where they made four presentations and a demonstration of GlobeCore’s UVR-L type laboratory unit.

The power supply specialists who were in attendance at the presentation were shown in detail the different lines of fuel oil processing units and equipment designated for maintenance of electric power transformers.

GlobeCore’s products are focused on improving the reliability and economic efficiency of the processes of generation and distribution of electricity.  This is achieved by the cleaning and reclamation of dielectric transformer oil.  Judging by the large number of questions, the audience was keenly interested in the topic of discussion.

Each presentation was completed with a demonstration of the capabilities of GlobeCore equipment using a UVR-type laboratory version unit for the demonstrations. All the participants were able to observe firsthand the transformation of oxidized transformer oil into a product suitable for further use in a power transformer.

The people and managers at GlobeCore expresses their gratitude to all the participants and organizers of the presentation for your interest in our products and allowing us to answer your questions.