Batching Systems

In fluid processing, "batching" refers to the accumulation of controlled quantities of one or more process materials ("ingredients") into one or more vessels to satisfy a specific batch specification (the "recipe"). By its nature, batching is a non-continuous operation.

Batching is often contrasted with "blending". Blending is the in-line combination of two or more process fluids into a single output stream - usually as a continuous operation in a closed piping system.

Go to ChemIndustrial blending systems to learn more about our blending system capabilities.

ChemIndustrial builds complete batching systems to satisfy a wide range of customer requirements.

Simple batching systems

The simplest automated batching systems are those where:

Where all these conditions are met, ChemIndustrial builds batching systems using simple mechanical devices such as venturis, self-acting pressure controllers and in-line flow control devices. Simple systems like this can satisfy a customer's batching requirements without the need for complex controls. The basic strategy is to design the fluid handling system so it provides uniform flow of each ingredient, then use timers to control the amount of each ingredient entering the batch. Some simple systems like this use existing flow sources to drive injection venturi(s), avoiding the need for additional pumps within the batching system.

These simple systems cannot satisfy every customer's batching requirements, but when they do, they can reduce capital cost. Also, since no powered instruments are needed, these configurations can be applied in explosion-proof installations and other special environments.

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Adding instrumentation

Where batching systems using simple mechanical devices and timers are insufficient, we add instrumentation. Typically, this involves basing the control system:

Our overall objective is to provide the optimal combination of function and cost, so we readily use flow-based instrumentation, weight-based controls and timer controlled additions as appropriate.

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More demanding batching requirements

Most batching systems have even more complex requirements. Examples handled by ChemIndustrial include:

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Handling liquid ingredients

ChemIndustrial uses a range of innovative liquid handling methods where necessary to achieve specific batching purposes. Some of these innovative techniques involve controlling centrifugal pumps in proprietary ways to perform volumetric metering tasks that would otherwise require piston or diaphragm pumps. The high reliability and low capital cost of centrifugal pump-based flow metering systems often make these a better choice than positive displacement pumps for the batching systems we design.

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Controller-based batching systems

When necessary, we add equipment such as pumps, valves, in-line mixing elements and instrumentation items such as load cells, flowmeters and process control computers. Simplicity remains a prime objective, so we are proactive in minimizing complexity even as system requirements become more elaborate.

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Solid ingredients

Many batching systems require the addition of solid ingredients. ChemIndustrial has an array of techniques for incorporating solids into batch runs.

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Configurations

ChemIndustrial builds batching systems as skid-mounted modules. The modules for most batching systems are built in stainless steel frames similar to portable generator frames.

Typically, one batching module handles 1 or 2 ingredients and includes all flow control devices, sensors, valves, pumps and final control elements required to achieve the batching functions for the ingredients assigned to the module.

If the system has more than 2 ingredients, we add more modules. This modular approach allows easy scale-up of batching systems to almost any number of ingredients and recipes at incremental additional cost.

Usually, all modules are installed together as a central batching station. However, our modular approach allows the modular batching skids to be distributed throughout the customer's plant if required.

If the system is controller-based, ChemIndustrial provides an intelligent batch controller on each module, and the multiple batch modules are networked. Oversight controllers can be added to the network for control room or other remote service.

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Batch recipes

Recipes are generally maintained in a desktop computer and downloaded to the batch control system on an as-needed basis. Report generation involves uploading batch data using the same data link.

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Other batching system elements

ChemIndustrial also configures and supplies the other process elements needed for a complete batching system. We supply ingredient tanks, mix tanks, surge tanks and finished product vessels. We also design and build batch ingredient valve manifolds for the inlet side of batching systems and batch distribution manifolds for the outlet side.

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Specials

We design special batching configurations to satisfy unusual batching requirements presented by customers for industrial, lab and agricultural projects.

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Let our experience work for you

ChemIndustrial's customers avoid the cost and time needed to write detailed equipment and control specifications by allowing us to adapt our technology to specific situations. This reduces project costs and decreases the time needed to quote and accomplish projects.

Since most experts agree that there is little evidence that better systems result from the customer effort spent preparing detailed specs, it makes sense for customers to leverage ChemIndustrial's substantial batching capabilities.

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Batching system questionnaire

ChemIndustrial applies proprietary batching technologies and equipment to satisfy functional descriptions of customers' desired batching operations. Use the ChemIndustrial batching system questionnaire below to provide us with a functional description of your batching requirements.

PDF Icon Batching system questionnaire [.pdf, 170kb]

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