Safe Media Transfer in the Chemical Industry
Customized Double-Hose Systems for Maximum Safety and Efficiency
The safe transfer of aggressive and sensitive media is essential for the reliable operation of production facilities in the chemical and agrochemical industries. Companies are under increasing pressure to meet growing requirements for safety, environmental protection, and plant availability at the same time. Even the smallest leaks can have significant consequences for people, the environment, and production processes.
Particularly in facilities handling frequently changing media, conventional hose systems often reach their limits.
What is needed are solutions that combine chemical resistance with maximum mechanical safety and practical usability.
An internationally operating agrochemical company runs complex test facilities handling a wide range of media, including highly aggressive substances. PTFE hoses combined with highly corrosion-resistant Hastelloy fittings were already being used for the safe transfer of these media.
However, an internal risk assessment revealed that while the existing solution met all chemical compatibility requirements, there was still room for improvement regarding mechanical safety.
- Minimize the risk of media leakage
- Improve structural safety
- Optimize handling during daily operation
The challenge was to develop a hose system that:
- Provides maximum chemical resistance against aggressive media
- Withstands mechanical stresses in daily operation
- Incorporates an additional safety barrier in the event of damage
- Remains ergonomic and user-friendly
A key requirement was to balance safety and handling. A robust system must not become too heavy or inflexible for practical use.
Based on our extensive experience, particularly in marine applications and safety-critical fuel transfer systems, we developed a customized double-hose solution.
The Principle:
A media-carrying inner hose is protected by an outer safety hose designed for the same operating conditions.
If the inner hose is damaged, the escaping medium is safely contained within the outer hose. This additional safety layer virtually eliminates the risk of uncontrolled emissions.
- Maximum safety through a redundant design
- Protection against abrasion and external mechanical influences
- Additional barrier in the event of a leak
- Improved monitoring and control capabilities
The customized system was precisely adapted to the application's requirements.
Inner Hose
- Type: PTFE Smooth Bore Hose (HygienicPureflex)
- Stainless steel braid reinforcement
- Sizes: DN 25 and DN 50
- Benefits:
- Excellent resistance to aggressive media
- Ideal for frequent product changes
Outer Hose
- Type: PTFE Convoluted Hose (Type CB6)
- Optimized polypropylene braid reinforcement
- Sizes: DN 50 and DN 75
- Functions:
- Secondary safety barrier
- Mechanical protection
- Optional leak monitoring capability
Fittings
- Material: Hastelloy
- Benefits:
- Outstanding corrosion resistance
- Maximum process reliability
During operation, opportunities for further improvement in weight reduction and handling were identified. Working closely with the customer, the system was further optimized.
- Weight-optimized fitting geometry
- Lighter hose construction
- Optimized outer braid design
- Use of lightweight material combinations
The redesign delivered measurable benefits:
- More than 30% weight reduction
- Significantly improved ergonomics
- Easier installation and handling
- Increased operational safety in daily use
The system is now ideally suited to the requirements of the test facility and meets the highest safety standards.
The developed double-hose system offers clear and sustainable benefits:
- Maximum safety when handling aggressive media
- Reduced risk of leaks and emissions
- Improved working conditions for operators
- Longer service life of components
- Reduced maintenance and downtime costs
To further improve handling, we also recommend the use of balancers and hose supports, which reduce physical strain on personnel and facilitate hose operation.
This project demonstrates how targeted engineering expertise and close collaboration with customers can significantly improve existing systems.
With our customized double-hose systems, we set new standards for safe media transfer and provide a future-proof solution for demanding applications in the chemical industry.
