GEA VARICOVER product recovery systems

The pigging of product-carrying pipelines makes it possible to save water in the long term during pipe cleaning and to minimise product losses in liquid processes.

GEA product recovery systems ensure that raw materials are used with as little waste as possible, while at the same time optimising water consumption during the complex process of pipe cleaning.

The GEA VARICOVER product recovery systems allow real-time monitoring of the pig position via magnetic sensors. Their mechanical and electronic components form a coordinated unit based on the combination and service-friendly GEA VARIVENT modular system.

Consistent automation simplifies the set-up for processes that can be validated with a modern IO-Link plant control system, enabling early integration in Industry 4.0 environments. It is also possible to extend networking through the company ERP for optimal resource utilisation.

At the heart of product recovery systems is the pig, a movable plug whose principle is derived from monitoring technology for oil and gas pipelines. The pig, equipped with sensors for control measurements, is moved through the pipeline to the control section to be examined. This is done by a propellant medium such as air, water, carbon dioxide or nitrogen.

In GEA systems, the pig housing is extended in diameter and is equipped with special grippers and springs. The pig is continuously surrounded by the flowing propellant with a defined range of motion and thus remains hygienically clean. If the pig is subsequently used, a pig catching station awaits it at the end of the pipe section and the return to the sending station. Two valves each control the required inflow and outflow of the motive medium.

The investment in pigging technology can pay off in new construction, but also when retrofitting plants. The recovery technology can be used in all process stages, from raw material reception to transport, to process and storage tanks, to filling. Pigging systems are also available in explosion-proof versions, such as for alcoholic products. Due to the wide range of solutions, the recovery technology can be used for almost any type of flow product.