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Discussing the Issues to Expand the Areas of Application for Vortex Layer Machine

In February, the associate professors of the Dapartment of technological equipment for food production and trade of Poltava University of Economics and Trade, Mikhail Ivanovich Nikitenko and Vasiliy Nikolaevich Oberemko, delivered a joint lecture to the GlobeCore staff.

Both of them have a great experience working with the Vortex Layer Machine therefore, the lecture was dedicated to the peculiarities of operation of this machine in different industries.

In particular, the issues of upgrading the existing AVS-100 machine to widen its application fields were of particular interest.

GlobeCore’s Vortex Layer Machine AVS-100 is designed to intensify different technological processes. The intensification of physical and chemical processes is achieved by intensive blending and dispersion of the processed components , high local pressure and electrolysis.

The rotation  of ferromagnetic particles provides high specific performance and low specific energy consumption.

Traditionally, after the end of the lecture everybody present had a possibility to examine all the potential possibilities of the Vortex Layer Machine AVS-100 that was tested on the test site.

Sample

AVS_laboratory

Diesel Oil Purification: Modern approaches

GlobeCore units are designed to purify, lighten, regenerate and remove aromatics from all types of diesel fuel and restoring it to a marketable condition and restoring its original performance characteristics.  Diesel fuel is acknowledged to be one of the most marketable oil products today due to such advantages as:

(1) relatively low price; and

(2) low fuel consumption rates.

Diesel engines have gained wide acceptance due to their reliability and efficiency.  As a result, millions of tons of such fuel are delivered to the world-wide market every year.  In speaking about diesel fuel, much attention should be paid to the problem of its contamination.  The use of fuel, containing different impurities, can lead to a rapid wear and damage of engine components and the entire fuel system.

If the fuel products are stored improperly, one oil product may penetrate into another one.   Even a small amount of foreign fuel may be sufficient to make the whole batch of diesel fuel unserviceable.  Fuel therefore, It is therefor, must be purified to avoid potential harm to engines and fuel systems.

The choice of the fuel purification method depends on the type of the contaminants and the way they get into diesel oil and fuel.  For example, modern vehicles are equipped with special filters.  First, diesel fuel is drawn to the fuel pump and runs through the special fine mesh filter. Then, diesel fuel is supplied to the pump that performs the function of a high-pressure regulator.   There may also be another device for diesel fuel purification – the coarse mesh filter, used to retain larger dirt particles.  Often, it is fixed at the bottom of a fuel pump.  Filter parts are usually situated in a transparent body since they are  also used for water separation.  Moisture will be visible and then must be be removed.

Some companies have a double fine mesh filter mounted: one part retains large particles and the other – particles that are less than 2 microns.  If paraffin happens to get into diesel fuel, the filters should be replaced.  Usually, there are two filters mounted into the vehicle: a  coarse mesh filter and a fine mesh filter.

The coarse mesh filter is also called a “sump” which is usually secured next to the fuel tank.  The fine mesh filter is fixed between the fuel injector and the fuel injection pump.  The coarse mesh filter can retain such impurities as metal particles, sand, rust or non-soluble oils.  The size of the particles should be more than 0.005 millimeters to provide effective filtration.  As a rule, filters are made of special brass moulded plates with calibrated slots that retain large contaminated particles.  The fuel purification methods, listed above, are performed directly on the vehicle.

You may be asking, what if there is a great amount of contaminated diesel fuel that has become contaminated and degraded and can no longer be sold or placed into the market?  This case requires a slightly different approach that consists in applying the benefits of the GlobeCore UVR line of units.  The GlobeCore UVR lines provides for the purification, lightening, regeneration and removal of aromatics from all types of diesel fuel.  As a result, the oil product is able to meet all the performance characteristics necessary for its further commerical use.  Additionally, it is very important that purified diesel fuel does not get dark if it is stored for a long period of time.

GlobeCore’s equipment is an optimal solution to many problems that arise at industrial enterprises, petroleum storage depots and refineries!

What to Do With Used Oil?

First, we must understand what the term “used oil” means.  We suggest using the definition given by the United States Environmental Protection Agency (EPA).  It says that, “used oil is any oil that has been obtained from crude or synthetic oil that has been in use and as a result was contaminated by physical and chemical impurities.”

When servicing commercial and equipment, oil is often mixed with dirt, water, metallic parts and chemical substances, and as a result, it can no longer perform its functions efficiently.  To resume the normal operation of the equipment, oil should be changed or regenerated.

According to the regulations of EPA, oil should comply with three criteria:

(1)    Origin. Used oil is refined from crude oil, coal, oil shale or other material, based on polymers.  Animal and vegetable oils therefore, do not belong in  the “used oils” catagory.

(2)     Application.  One should know where used oils may be applied.  Used oil includes lubricating oils, heat-transfer fluids, coolants, insulating oil, solutions for copper and aluminum wire rolling, and gearbox fluids.  This list is non-exclusive and only provides an incomplete list of industries where used oils may be applied.

(3)     Contaminants. Oil is considered to be used only if it is contaminated as a result of practical use.  Physical contaminants include metal chips, filings, and dirt. Such substances as solvents, halogens or mineralized water are also considered to be chemical impurities.

Used Oil Disposal

Oil that is no longer able to perform its functions should be disposed of or recycled.  According to worldwide estimates, about 1.5 billion liters of used oil is being disposed of annually.

In general, a recycled product is used by the same industry sector, but sometimes it may be applied in quite a different sector of industry.   For example, reclaimed motor oil may be either sold in the auto shops or used as residual fuel oil.   Solutions for aluminum wire rolling that are supposed to be reused, are being restored directly on-site.

There are several ways to recycle used oil such as follows:

(1)    On-site recycling.  Such a method extends the service life of oil though does not provide for complete oil restoration.

(2)     Recycling at oil refineries. In such a case, used oil serves as raw material or coker when producing petrol or coke.

(3)    Reclamation. In the course of this process, all impurities are being removed so that oil can continue to be used in the present or the future. In theoretical terms, due to reclamation, oil may serve you forever.

(4)    Used oil is burned for energy recovery.  In this case, water and impurities are removed to a level that allows for the oil to be burned.  This method is less preferred since oil may be recycled only once.

The following facts favor the reclamation/regneration process:

(1)    Reduced energy resources.  Reclamation technologies require three times less of the energy needed to process crude oil to lubricating oil.

(2)     67.2 liters of crude oil are needed to get 1 liter of fresh oil, when only 1.6 liter of used oil is required to get the same amount of fresh oil.

Used Oil Applications

The following is the list of institutions that deal with used oils:

(1)    Service stations, while servicing vehicles and different industrial equipment;

(2)    Used oil collection centers that accept, stores and aggregate used oil;

(3)    Used oil transporters that deliver used oil to the used oil collection centers; Used oil transfer facilities are institutions that store oil for more than one day and up to 35 days.

(4)     Oil refineries;

(5)    Used oil burners; and

(6)    Used oil fuel marketers.

As mentioned above, reclamation is considered to be the most effective method of used oil recycling.  It will be reasonable and cost effective for the companies that deal with huge amounts of oil products to buy their own oil reclamation equipment.  It allows the companies to reduce energy costs, hazardous waste and transportation costs.

GlobeCore has produced universal equipment, designed for regeneration of transformer oil, industrial oil, turbine oil, transmission fluids and other types of oil.  There is no need to change the design of the units when switching to a different type of oil or fluid for processing.

Due to advanced GlobeCore regeneration technology, used oil is being restored to its original new like condition, thereby contributing to environment and energy resources preservation.

The Reasons for Diesel Oil Contamination and the Methods of its Purification

There are two main problems facing the owners and operators of diesel fueled equipment; (1) diesel fuel loss and (2) degradation of the equipment’s performance characteristics.   Both problems will lead to increased costs and lowered efficiency.

All oil product contamination may be divided into the followoing groups:

(1)    organic (fuel oxidation products) and

(2)    non-organic (mineral dust, corrosion products of metals).

In theoretical terms, fuel may become contaminated at oil refineries, during transportation and when the equipment is being serviced.  Dusty air is the main reason for atmospheric contamination of diesel fuel.  Atmospheric dust consists of silicon and metal oxides.  These components are very solid and therefore, may accelerate the wear process of internal parts.  Very often, acclerated wear of precision parts in the fuel injection pump will lead to the following consequences:

(1)    fuel feed consistency is disturbed;

(2)    air tightness of nozzles is damaged; and

(3)    oil leaks/dribbles.

If one of the nozzles fails to supply fuel properly, there may be a 25 to 35% fuel overrun.  Clogging of the fine mesh filter may also lead to the reduction of fuel system pressure that prevents atomizing and combustion.  Additionally, cylinder liners and piston rings wear out if there is unwanted contamination in diesel fuel.

In practical terms, it is advised to increase fuel feeding or gear down to avoid such consequences.  Sometimes, to prevent ingress of atmospheric dust, there are special fuel tanks with a gas-holder (made of polyethylene) mounted into the equipment.  It prevents oil products from making contact with atmospheric air.  Such a device however, does not remove mechanical impurities from the oil.

Another way to protect oil products from dust is to improve the design of filling tubes and openings.  It is much more difficult to reclaim diesel fuel from sulphur and hydrogen sulphide.  This problem however, may be successfully solved by use of GlobeCore’s UVR units.  They are used to purify and decolor different oil products such as diesel fuels, stove fuels, gas condensates, benzines and kerosenes.  Diesel fuel, reclaimed on the UVR units is of a high purity class, does not have an unpleasant odor or a negative impact on the engine and fuel supply system.

GlobeCore knows how to keep your diesel fuel clean and with the utmost pleasure will teach you how to put this knowledge to practical use in your business.

Anhydrite Binder Production by the Vortex Layer Machine

Introduction

Today’s modern alabaster industry produces products based on alabaster binding materials.  Such products are obtained by burning natural material at low temperatures to obtain hemihydrate of calcium sulfate.  It is worth noting that fired and non-fired alabaster binders are rarely used in this process.  This is due to the fact that such binders need to be grinded for long periods of time (non-fired binders) and consume large amounts energy (fired finders).

GlоbeCоre’s recent technological advances has made it possible to start applying non-fired binding material again by accelerating the technological processes.

Main body

The technical department of GlobeCore has proved that the quality of non-fired anhydrite binders may be improved when using the AVS-100 Vortex layer machine (Magnetic Mill).

The AVS-100 Vortex Layer machine grinds down anhydrite stone by exposing it to ferromagnetic particles.  A great importance is placed on the duration of the ferromagnetic particle exposure.  The performance characteristics of the anhydrite binder depends on the time it is being grinded in the AVS Vortex Layer machine.

Table 1

The impact of the grinding duration on performance characteristics of anhydrite stone

The grinding duration, s

Sieve residues, %, No

Passed through the sieve, %

Specific surface area, cm2/g

02

008

30

18.1

12.7

69.2

2615

60

11.2

4.0

84.8

3700

90

2.7

3.7

93.6

3955

120

1.5

3.2

95.3

4545

150

1.2

2.3

96.5

5150

180

0.9

2.4

96.7

5600

210

0.8

2.0

97.2

6085

As the table shows, the specific surface area of the product is increased with the increase of the grinding duration (from 2615 to 6085 cm 2 /g ).  In ball mills, the material needs to be grinded down for between five and eight (5-8) hours to obtain the desired analogues fineness.

Conclusion

The production of the non-fired binders has become capable due to the GlobeCore technologies since the raw material is grinded down being exposed to ferromagnetic particles.  Additionally, the advanced GlobeCore technologies allow for the reduction in energy consumption and operating costs due to the reduced processing time.

Non-fired anhydrite binder, produced by GlobeCore branded equipment, may be applied in such areas as:

  • masonry mortar production;
  • artificial marble production;
  • seamless poured flooring; and
  • mixed anhydrite binders production.

Accelerate your technological processes with the help of the GlоbeCоre equipment!

Vegetable Oil Hydration: What Equipment to Choose?

Vegetable oil hydration consists in removing the phospholipids from the raw product.  These lipids are of high biological value.  The amount of the phospholipids in the vegetable oil ranges from 0.2 tо 4.5% and depends on the kind of the raw material and the way the vegetable oil is obtained.

When the product is first manufactured, the phospholipids are dissolved in oil but they may settle out when it is stored.  The hydration method is that phospholipids connect with water and form a non-soluble substance that settle down.  There may be needed from 0.5 to 6% of water  in order to carry out this process.

First, water is added to the raw oil that has been previously warmed up to 45-50 ºС / 113-122 ºF. Then, this mixture is delivered to a special unit to form the hydrogenated phospholipids.  At the next stage, oil is separated from sediments and dried in the drying units at 85-90ºС/185-194ºF.  The process continues  until the moisture content of the product is 0.05%.  The oil, treated in such a way, contains no more than 0.2 to 0.3 % of phospholipids.  Additionally, the hydration allows for acid number reduction, improvement of oil colour and removal of proteins, carbohydrates or solid particles.

The substance, separated from oil, is being dried to obtain phosphatide concentrate. The latter can be used in margarine production or while baking bread.  Wax substances have to be removed for the oil not to become cloudy when stored at low temperatures.  The details of this process are described in this article.

Free fatty acids are neutralized by alkali solutions or salts of strong basis to reduce their content in the oil.  The result of this processing is oil-insoluble salts called soaps.  Such chemical substances as sodium or potassium hydroxide, ammonia, or calcined water are used to carry out the neutralization. The concentration and the temperature of alkali solution are determined by the acid number of oil.  The product needs to be washed three to four times with hot water and then dried to remove soap residue.

The design of equipment is no less important when hydrating vegetable oil.  The production output, the quality of final products and consequently the profits largely depend on the quality of the equipment in the process.

GlоbeCоre has developed the “Vortex Layer” machine AVS -100 to intensify the production processes in the food industry.  The existing equipment does not provide the desirable effect of  blending and, as a result, there is an overrun of raw material and low quality of the product.

Vegetable oil hydration, performed on the Vortex Layer machine, provides for the content reduction of such substances as:

  • phospholipids by 88.2 -90,3 %;
  • unsaponification matters by 26.8 -34,6 %;
  • ash by 94.7 –  96.2 %.

The “Vortex Layer” Machine: Patent Search

The “Vortex Layer” Machine AVS-100  can be used in the chemical and power industries. Additionally, this machine is designed to purify industrial and household waste water.

The “Vortex Layer” machine consists of a working chamber (pipeline) with a diameter that ranges from 60 to 330 mm (millimeter).  This working chamber is arranged in the inductor that creates a rotating magnetic field.  Inside the pipeline there are cylindrical ferromagnetic particles.  The amount of these particles depends on the volume of the pipeline’s active zones.

The main parts of the “Vortex layer” machine are as follows: (1) an inductor that creates a rotating magnetic field; (2) the cooling system, and (3) the working chamber with the ferromagnetic particles.  Under the influence of a rotating magnetic field, the ferromagnetic particles move around in the active zone and create a so-called “vortex layer.”  Such a design allows for proper processing of liquids as well as trouble-free machine servicing.

The following is the discussion of the counterparts that had been previously patented.

There exists a counterpart of the vortex layer machine that consists of: (1) two consecutive active zones of the pipe with active ferromagnetic particles inside; and (2) external electromagnetic inductors, which create a rotating magnetic field (can rotate in both directions). The input deflectors of the pipe’s active zones direct the liquid opposite to the rotating magnetic field direction.  The output deflectors retain particles in the active zones of the pipes.  In both active zones, there is a rotating magnetic field, which voltage, frequency, and rotation direction may be adjusted.

But still, this machine has disadvantages such as:

(1) the design of the equipment is poorly adapted for use;

(2) high levels of material and energy consumption while processing liquid; and

(3) the wear of the machine’s active zone surfaces may result in the breakdown of the equipment.

Due to high quality of the liquid processing and trouble-free servicing,  the Vortex Layer  machine AVS -100 is considered to be  much better than its counterpart.

Fig. 1 shows an electromagnetic unit with vortex layer.

Figure 1.

The schematic diagram of the electromagnetic unit with the vortex layer: 1 – Protective bushing, 2 – inductor that creates rotary electromagnetic field, 3 – inductor frame, 4 – the working chamber (non-magnetic material), 5 – ferromagnetic particles

The AVS-100 unit typically consists of two parts: the unit itself and the control unit.

The unit is secured to the support with pivot bolts that makes it possible to set the desired tilt angle of the active chamber with a subsequent installation on the processing line.  Control and protection devices are in the upper part of the control unit.  At the bottom of the unit there is the inductor’s cooling system.

The “Vortex Layer” machine may be applied in various industries because of its unique design.

The Sulphur Process Intensification in the Vortex Layer Unit

Sulphur is one of the most widely used chemical elements inthe industrialized world.  In the petrochemical industry, sulphur is considered to be a waste product and needs to be recycled.

There has been no optimal solution for the recycling of sulphur for a long period of time. But, in the 1970s in the USA and later in the former USSR, industry began using sulphur as a binding agent while producing concrete.

The advantages of the “Sulphur Concrete” are as follows:

(1) Expensive portland cement may be substituted with cheap waste sulphur;

(2) The waste products of mineral additives may be substituted for materials with the specified fractional composition; and

(3) The expensive polymer additives may be replaced by polymer-modified sulphur.

As we can see, three expensive components can be easily replaced by cheap ones.  But, why hasn’t sulphur concrete gained a widespread acceptance in the construction industry?  It is due to such reasons as:

  1. The amount of polymeric sulphur in sulphur concrete is decreasing as the years go by;
  2. The polymeric sulphur may take a monoclinic form therefore, chemical stabilization is needed; and
  3. Sulphur concrete is not as heat-resistant since the fusion temperature of sulphur is 120ºС/248ºF.  Therefore, some thermal stabilizers are required.

Biophil Sulfur Characteristics

If there is moisture in the mixture, some types of bacteria can eat sulfur as if it were sugar.  Microbiological corrosion inhibitors are necessary to exclude such  phenomena.  Sulfur is a low-toxicity substance, but it can be sublimated even while being solid.  Sulphur concrete therefore, must contain a special insulation layer.  The above listed disadvantages affect the cost of sulfur concrete and reduce to zero all the economic benefits as described above.

It is therefore, very relevant to start using waste products or cheap components instead of inhibitors and stabilizers without involving expensive chemical equipment.

GlоbeCоre offers AVS ‘Vortex Layer’ units to companes involved in construction material manufacturing and building companies.

The AVS ‘Vortex layer’ units allow for processing such substances as:

(1) Heavy fuel oil.  Being processed in the vortex layer units, heavy fuel oil is considered to be a good stabilizer for polymeric sulphur;

(2) Metal-based wastes, that subsequently act as thermal stabilizers of solid sulphur;

(3) Halogenated wastes.  They serve as microbiological corrosion inhibitors;

(4) Sand (serve as antipyrogen); and

(5) waste oils.

Being a part of sulphur concrete, waste oil improves its insulation characteristics.  The molecules of sulphur are strengthened if liquid sulphur is processed together with heavy fuel oil in the ‘Vortex Layer’ units.   As a result, there is the poly sulphur binding substance based on copolymer sulphur.  The reactive surface resulted from the sand being grinded down and reacting to poly sulphur binding substances thereby increasing the durability of the product.

The sulphur concrete is saturated with sulfides and polysulfides as a result of grinding the mineral components based on metal oxides.

The waste oil processing in the ‘Vortex layer’ units results in drying oil used to cover the surface of the sulfur concrete products.

Pre-Sowing Treatment of Grain by the “Vortex Layer” Machine

The quality of the grain seeds can be defined by some external factors as well as by its biological characteristics.  It is very difficult to control all the factors that affect the grain seed during its time of germination.  But there is however, a defined set of methods in the agriculture industry that reduce the negative effects of the undesirable factors and intensify the effects of the factors that benefit an increased harvest yield.

The pre-sowing stimulation and disinfection can be defined as the seed-preparation procedures that are considered to be essential.

The methods of the pre-sowing treatment can be divided into the following groups: (1) biological; (2) chemical; and (3) physical.

The biological methods consist in the seeds being soaked in different extracts that include desirable vitamins and enzymes.  But, these methods have some disadvantages such as:

(1) the promotoring agents are difficult to obtain;

(2) multiple tests are needed to meter desirable doses; and

(3) the seeds may react to one substance in different ways.

The chemical methods consist in the seeds being processed by special chemical inputs such as:

(1) inhibitors; and

(2) major mineral elements and their salts.

The main disadvantage of the chemical methods is that the substances being used are very toxic. Additionally,  they can have a negative impact on human health while decomposing.

The physical methods of the treatment of grain can be divided into such groups as (1) physical and mechanical methods; (2) thermal methods; and radiation methods.

The physical and chemical methods include bubbling, ultrasonic water treatment, and scarification.   Their disadvantages are as follows:

(1) long processing time;

(2) the seeds need to be pre-dried; and

(3) considerable labor resources are required.

The stratification, steam treatment, and variable temperature exposure are considered to be the thermal methods.  But, these methods also have disadvantages such as:

(1) long processing time; and

(2) a set temperature needs to be constantly maintained.

The radiation methods involve processing of grain by ionizing radiation.

The electro physical methods of pre-sowing treatments are of special interest nowadays. They include: (1) exposure to magnetic fields with different frequencies; or (2) exposure to electromagnetic energy of infrared (IR) or ultraviolet (UV) spectra.

The pre-sowing treatment of grain by electromagnetic fields with microwave frequencies is considered to have gained widespread acceptance as among of all electro-physical methods.

GlobeCore has developed the “Vortex layer” machine type AVS-100 to solve a wide spectrum of problems that the agricultural industry has faced for many years.  This machine is shaped like a cylinder and is made from non-magnetic materials. On the outside of the cylinder there is a mounted inductor with windings that create the electromagnetic field.  It should be noted that this machine ensures not only the pre-sowing treatment of grain, but also its disinsection and disinfection.

The pre-sowing stimulation causes the seeds react to an external irritant that is more intensive than the threshold value.  The energy of the microwave frequencies, supplied to the seeds, initiate the reactions.  The reactions take place  in the seed cells due to their own energy resources.

The microwave frequencies result in the increased amount of free radicals (unpaired electrons) that benefit such processes as: (1) the permeability of the cell membrane changes; (2) speeding up the oxidative reactions; (3) the enzymes are activated; and (4) nucleic acids are synthesized. The processes, described above contribute to dormancy breaking and growth activation.

Sunflower Oil Dewaxing by ‘Vortex Layer’ system

Vegetable oils and fats are mainly defined by their physical, chemical, electrophysical, and electromagnetic characteristics.  Nowadays, sunflower oil dewaxing, affected by the electric or electromagnetic field, is considered to be very effective.

The electrophysical effect on organic substances and materials is considered to be a relatively new approach which was first introduced in the 1960s.  The nature of electromagnetic fields has allowed for the invention of many machines, which operate according to electrophysical principles.

To improve the refining process, some factories are in the business of developing new types of equipment or applying new chemical agents that require considerable financial expenditures.  But, the refining process may be improved by implementing non-traditional approaches based on electric and magnetic principles.

According to the basic principles of the magnetochemistry, the production processes may be enhanced due to the effects of the magnetic fields on the system.

A wide range of problems may be detected if to study a traditional dewaxing process more thoroughly. They are as follows:

(1) a long wax crystallization process;

(2) poor filtration;

(3) necessity of applying additional substances;

(4) difficulties while cleaning a partition of sediments;

(5) high energy consumption costs;

(6) inadequate purification rate; and

(7) a great amount of waste products.

It is therefore, the factories that have to seek new and promising ways to improve the production process.  The use of electric and electromagnetic fields has become a breakthrough in the oil refining process.  But, special conditions should be provided to create a greater polarization of wax particles as compared with other additives.  A presence of the electromagnetic field is one of such conditions, as wax contains the components of essential oil group, that have polarity.  The waxes are dissolved in oils and their polarity is weak at 40-45 ºC / 104-113 ºF.  If to cool the vegetable oil, the energy state of wax-like substances will be changed, and the lipophilic characteristics will be reduced.  At +15-+45ºC / 59-113ºF, wax compounds are usually  in an intermediate phase, which increases their polarity.

Affected by various external factors, liquid crystals can easily change their structure since the molecular forces are quite small.  It is therefore, the application of electromagnetic fields opens up new possibilities for fat-and-oil industry.

The Vortex layer system AVS-100 is designed to enhance the chemical and physical processes.   From the outside, it is a cylinder with a mounted inductor that is the source of rotating magnetic field.  This cylinder is made of non-magnetic material.

The sunflower oil processing time, as well as the magnetic field strength, depend on the qualitative characteristics of the original product, mainly, on the amount of wax-like substances in sunflower oil.  The application of a vortex layer system, designed for sunflower oil dewaxing, allows for a reduction in the production process time and for an provement of the quality of sunflower oil processing.