Rotates silently and unobtrusively

SeccoMix R with DiamondFace for the agitators of mobile vessels

CaseStudy_DF-SeccoMixR_Mobilbehälter_3

Situation

  • Unacceptable noise development in phases of inadequate lubrication

Challenge

  • Ensure flexible handling of the mobile containers

Solution

  • Dry-running DF-SeccoMix R from EagleBurgmann

Sealing the agitator shaft of a mobile vessel is a very special task when dealing with a process in vaccine production. Liquid lubricated seals offer the best conditions for this application, but require a supply system. This conflicts with the flexible handling of the mobile vessels. With dry running seals this effort is eliminated.

At an international pharmaceutical company, EagleBurgmann demonstrated that the operation of dry running seals is as convenient as it is reliable and safe.

At the shaft passage, the seal must prevent the highly sensitive substances from becoming contaminated and from leaking into the atmosphere and endangering production personnel. The leakage of the supply medium for liquid lubricated seals must not exceed specified values; the supply medium itself must be matched to the product and installed in a vessel near the seal.

A further hurdle is synthetic carbon, the classic material for mechanical seals, which is not always approved for use in pharmaceutical production. The risk that particles will separate from the sliding faces due to abrasion and get into the product is too high. It would not only be very time-consuming to clean the vessel from wear particles; if the active ingredients were to become so heavily contaminated that they were no longer usable, production losses would be in the millions.

CaseStudy_DF-SeccoMixR_Mobilbehälter_1

At the Asian production site of the pharmaceutical group, the agitator shafts of a mobile vessel were therefore equipped with seals of the SHJ series from EagleBurgmann in hard-hard pairing. During operation, however, the combination of silicon carbide on silicon carbide repeatedly led to unacceptable squeaking noises during poor lubrication conditions.

At about the same time, the pharmaceutical company changed the requirements for explosion protection at a European location. There, SHJ seals from EagleBurgmann had also been installed on the top driven agitator shafts of mobile vessels. These now had to comply with ATEX category 1, zone 0 (temperature class T4) due to the prevailing explosive atmosphere in the vessels. The seals were lubricated with glycerin and had been in use for more than a decade.

In the meantime, EagleBurgmann had developed the SeccoMix R dry running seal, which was now the better solution as a single seal for mobile vessels. It requires no supply system and can be operated without lubrication at the low speeds of the agitator shaft. Now only the issue of "noise development through hard-hard pairing" needed to be solved.

CaseStudy_DF-SeccoMixR_Mobilbehälter_2

EagleBurgmann relied on the experience with DiamondFace for this. The surfaces of the seal faces were coated with microcrystalline, artificially produced diamonds in a special process. This makes them extremely wear-resistant and very effective at dissipating heat from the seal.

The SeccoMix R was then extensively tested in several stages. The basic technical principle of the seal was initially tested for wear and noise development. The subsequent test was meant to show whether the temperature development on the surface of the seal faces remains below the maximum permitted value despite dry running. A few weeks for optimization were necessary and then the field test started in the original machine. There was no noise, temperatures remained very low and the conditions of ATEX category 1, zone 0 were met. The sliding faces of the seal were as good as new thanks to DiamondFace. The pharmaceutical company gave the green light for use in production.

The advantage of the SeccoMix R is that it can be cleaned and sterilized without requiring disassembly. The smooth, dead space-free design allows easy cleaning according to the high sterile level in vaccine production. The materials for sealing elements such as sliding elements and secondary seals that come into contact with the produced active ingredients are approved by the FDA (U.S. Food and Drug Administration).

Since the end of 2018, twelve DF-SeccoMix R have been installed on the agitators of the vessels with a capacity of 200 to 500 liters at the European location. They prove their reliable and robust properties from batch to batch.

 

Operating conditions

  • Shaft diameter: d = 35 mm (1.37")
  • Pressure: p = 3 barg (43.5 PSIG)
  • Temperature: t = 40 °C (104 °F)
  • Sliding velocity: vg = 1.5 m/s (5 ft/s)
  • Medium: pharmaceutical media

Solution: Rotates silently and unobtrusively

SeccoMix R with DiamondFace for the agitators of mobile vessels 

PDF download - 861.9 KB

Further reference projects

KeyVisual_CaseStudy_Hengli.jpg
China, Mainland

10 years ahead

Between June 2017 and March 2019 the Hengli Group constructed an integrated refining and chemical complex in the Chinese harbor town Dalian where 20 million tons of crude oil are processed every year. EagleBurgmann advised the company Hengli concerning the selection of mechanical seals and supply systems for the whole plant and supplied more than 95 % of the components in use. 

Read the complete case study
KeyVisual_CaseStudy_National Grid
United Kingdom

10 years of reliability: Protecting the heart of Great Britain’s natural gas infrastructure from failure

In Great Britain, a shortage in natural gas supply has severe consequences: Since the country switched from coal-fired to gas-fired power stations, a gas supply shortage makes households and industrial consumers not only vulnerable to failing heating and gas stoves, but also to power outages. Companies along the value and transportation chain of natural gas are therefore especially dependent on reliable equipment.

Read the complete case study
Feuer und Flamme_DRO_Head3
Germany

100 percent performance at 300 degrees

Things get hot in rotary kilns, very hot in fact. In the production of cement, for example, the thermometer measures more than 1,000 degrees Celsius. Sealing systems from EagleBurgmann, a company of the Freudenberg Group and EKK, make sustainable contributions to environmental protection, energy efficiency and process reliability under these "fiery" high-temperature conditions.

Read the complete case study
KeyVisual_CaseStudy_RamcoCement.jpg
India

A Partnership to build on

Our modern civilization is quite literally built upon cement. Today, building materials made from cement are used in buildings, roads, bridges, dams etc. Cement production is a heat-intensive process and causes thermal expansion in duct systems. To compensate this, Indian cement producer Ramco Cement needed fabric expansion joints with a diameter of several meters for two of their plants. On the basis of a close collaboration, EagleBurgmann was able to design components that increase the efficiency of the plant in the long run.

Read the complete case study
KeyVisual_CaseStudy_AGSR_Schaufeltrockner.jpg
Germany

Clean sealing solution for demanding crystal production

Seals are a risk factor in the production of liquid crystals. If there is even the slightest contamination of the liquid crystals, this will later affect the image quality of the display. Read on to see which sealing solution Merck KGaA uses in paddle dryers for the production of liquid crystals.

Read on for the entire case study
KeyVisual_CaseStudy_Schiffstechnik.jpg
Germany

Cruise liners with DiamondFace-coated mechanical seals

Cruise liners have to reduce their sulfur emissions in Emission-Controlled Areas (ECAs). To accomplish this, light fuel oil is used in coastal regions - with significant consequences for the ship's fuel supply.

Read the complete case study
Show all references
Newsletter

Excellence in Practice

With our free e-mail newsletter „Excellence in Practice“, you will receive first-hand information about current products, services, references and worthwhile industry insights.