Customer-specific solutionsDesign and construction
We develop and design customer-specific solutions and implement them. Pharma-compliant design and documentation are part of the work.
Engineering
Calculation and Design
A team of specialists that validates products and processes by calculation before anything is built.
- FEM – Finite Element Analysis
- CFD – Flow Simulations
- Design Services
- Custom Designs
- Failure Analysis
01·Services
Design, calculation and simulation
For process plantsSpecial constructions
Solutions for demanding tasks and partial functions in process plants, designed for low maintenance and safe operation.
Finite element methodFEM
Strength analyses using current calculation methods. Fracture and failure analyses start from the component's process function; the required detailed data are calculated.
Computational fluid dynamicsCFD
Analysis of detailed process data and sequences. Both components and processes are examined.
02
Mixing time rises with viscosity.
Seven simulations of a BMA 1200 at 287 rpm in a vessel with torispherical head, 1.5 m in diameter and 1.5 m high (2.45 m³), computed on a mesh of 5.6 million cells. Up to about 1000 mPa·s the whole vessel is mixed — above that, the upper region stays still.
1 mPa·slike water · Re 300,000
15 s
10 mPa·sRe 30,000
20 s
100 mPa·sRe 3,000
34 s
1000 mPa·sRe 300
55 s
2000 mPa·sRe 150
not fully mixed after 95 s
Power
In the simulation the BMA's power number came out lower than the design program assumes: the agitator needs less power than its design allows for.
03
150 m³ food tank: two agitators compared.
A BMA at 260 rpm against a fast-running propeller agitator at 409 rpm, computed transiently over 1500 seconds, with a particle study.
- Vessel 3.85 m in diameter, 13.15 m filling height, torispherical head to DIN28011
- BMA: more even velocity field, flow from the bottom all the way up
- With the BMA, particles move vigorously at the bottom and spread evenly through the upper two thirds
- Propeller agitator: homogeneous sooner, but less effect in the lower region
- Both mix completely — the task decides which one fits
04
Scale-up from 20 to 2500 litres.
A cell culture line in four reactor sizes with a two-stage agitation system, scaled up at the same power input per volume of 100 W/m³, so that the cells see comparable oxygen supply and mechanical stress at every size. For comparison, the speed at the same tip speed of 1.5 m/s.
| ReactorL | Speed at equal P/V1/min | Speed at equal tip speed1/min |
|---|---|---|
| 20 | 155 | 239 |
| 100 | 113 | 143 |
| 500 | 78 | 83 |
| 2500 | 55 | 49 |
05
FEA Strain in the o-ring.
Maximum principal strain in the o-ring of the
20 °C · peak 19 %bio-plus®
Axial travel 2.00 mm. The strain spreads evenly across the cross-section.
20 °C · peak 39 %DIN11864
Axial travel 3.00 mm. Well over twice as high, concentrated at the clamping point.
140 °C · peak 35 %bio-plus®
Axial travel 2.00 mm. Even when hot the load stays spread across the cross-section.
140 °C · peak 73 %DIN11864
Axial travel 3.00 mm. The peak grows disproportionately with temperature.
06
Natural frequencies ruling out resonance.
A steel tank with a mounted foam separator: the first six mode shapes of the empty vessel, so that no operating speed excites a resonance.
- Material
- Outer shell A516 Grade 70, 36 and 40 mm; inner liner 316L, 4 mm; explosion-clad
- Model
- 3D, four firmly anchored feet, 325,221 elements
- Modes 1 and 2
- 15.26 Hz — equivalent to 916 rpm
- Modes 3 and 4
- 20.43 and 20.51 Hz — 1226 and 1231 rpm
- Modes 5 and 6
- 22.71 Hz — 1363 rpm
- Cross-check
- With additional supports and openings only minor deviation — the simplified model holds.
07
From development into the products.
Calculations that are built into series products today.
Magnetic field FEAMagnetically closing non-return valve
Position and size of the magnets for five valve sizes, and from them closing force and contact pressure on the o-ring.
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Pressure lossStrainers and orifices
In-house calculation models for flat and conical strainers and for orifices, cross-checked against ISO 5167-2.
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Materials testingLaser weld on the magnet rotor
Micrographs and penetration depth of the laser weld seam, tested in a materials laboratory.
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