This Week's Top Stories
Particles From Piping Pose Pump Problems
Magnetic separators remove black powder to improve performance. Read more...
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Comical Processing: You Write The Cartoon Caption
Chemical Processing introduces "Comical Processing," featuring drawings by award-winning cartoonist Jerry King. Read more...
U.S. Lead in Science and Engineering Erodes
Biennial report points to gains particularly by Asian countries. Read more...
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Leadership Focus Podcast: CFATS
Chemical Facility Anti-Terrorism Standards (CFATS) are now in the process of implementation. Listen to this podcast the learn about the challenges of becoming compliant. Read more...
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Best Practices in the Chemicals Industry Webcast
This on-demand Webcast will help improve operational efficiency, safety and compliance within the chemicals industry. Read more...
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Quick Poll: Condition Monitoring
Take the anonymous survey now. Read more...
What Your Peers Are Reading
- Compressed Air Systems: The Secret is in the PipeThere’s no such thing as too large a compressed air line. A common error in compressed air systems is line sizes too small for the desired air flow.
- Comical Processing: You Write The Cartoon CaptionChemical Processing introduces "Comical Processing," featuring drawings by award-winning cartoonist Jerry King.
- Comical Processing: You Write The Cartoon Caption Winner March 7, 2010Congratulations to Rob Falconer of Lakeland, Fla., for submitting the winning caption to the Comical Processing cartoon. A new cartoon has been posted.
- How Much do Chemical Engineers Make? Chemical Processing Reveals all in 2008 Salary SurveyIs it a tragedy or comedy for engineers? Survey results peak behind the curtain of readers' salaries and job satisfaction
- U.K. Risks Losing Chemical Company HeadquartersFirms threaten moves because of tax policy.
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New Feedstock Beckons for Transportation Fuels
Biomass-based material provides alkenes via simple route.
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Quick online polls can provide a variety of insights.
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New Products
Solution Provides Machinery Vibration Monitoring And Protection
Hybrid Stepper Motors Offer Improved Torque Characteristics
Instrument Diagnoses Common Mechanical Problems
Alarm Management Software Features SMS Notification
Wireless Transmitter Identifies The Most Efficient Communication Path
Fan Motors Tout Operational And Energy Savings
Flow Meter Monitors High Dynamic Range
Monitor Addresses Space-Constrained Installations
Critical Topics
Reducing energy consumption and your plant's environmental impact is a hot topic. Creative thinking in your energy efficiency projects will give you the competitive edge during these tough times.
Drive up energy efficiency
The constant-speed approach to AC motors made a lot of sense when energy was cheap and drives technology was in its infancy. With their latest advances, adjustable speed drives can provide one of the best energy efficiency options for a plant.
Consider Three Ways to Energy Efficiency
Now’s the time to make radical changes in funding energy projects
It’s time for a design check
Pay closer attention to energy efficiency and impose standards.
Special Report: Energy Efficiency
Reducing energy consumption and your plant’s environmental impact is a hot topic. In this Special Report we take a look at the organizational obstacles to avoid, how to enroll your employees in the quest, and the steps you need to take in order to manage your energy costs. We also delve in to practical energy efficient applications such as recovering exhaust heat in air conditioned facilities and the use of carbon synchronous belts.
Energy Savings Pick up Steam
More attention to steam systems and trap monitoring provides big benefits. At most chemical plants, plant management and operators face increasing pressures to improve the energy efficiency of their processes, so they should see how they can save on steam.
You can't manage what you can't measure. And what you don't measure will never improve. Enter plant optimization. Gathering data to improve operations offers a competitive advantage.
Avoid Costly Design Mistakes
Common errors keep plants from getting the most reliable and suitable vessels
Avoid costly materials mistakes
Common oversights keep plants from getting the most reliable and suitable vessels.
Avoid costly fabrication mistakes
Common oversights keep plants from getting the most reliable and suitable vessels
Pursue the perfect plant
Look into creating the “perfect plant” by integrating product and operational management into your environment. This provides the ability to respond faster and minimize impact to the business and bottom line, driving increased yields, asset utilization and order fulfillment.
Pilot plants: destined for development
Pilot plants are on the verge of an unprecedented evolution. Read about the 10 factors that'll impact the design, construction and operation of these next-generation units.
The chemical industry is starting to unwrap the potential benefits of “going green."
Renewable Feedstocks are in the Bag
Chemical firms show growing interest in bio-based production.
Environmental Protection
Environmental Protection by Dave Russell, president, Global Environmental Operations Inc.
Chemical industry sees green
Developments target economics, not just environmental benefits. While pollution prevention was the original goal of green chemistry, today’s efforts promise to have a substantial economic impact.
Special Report: Chemical Industry Sees Green | Bio-Based Fuels and Feedstocks
For years the industry has been “talking green.” But what real strides have been made? Will a Presidential Executive Order compel the industry to speed up efforts to actually go green?
Defining "Green Chemicals"
As the Industrial Water Treatment Program Manager at the federal installation, I am interested in resorting to "green chemicals" in the chemically treating all the boilers, cooling towers and closed loop systems at this installation. Is there a clear definition of what constitutes "green chemicals?" Does that vary from state-to-state, region-to-region, and who has the final word on what is or isn't "green chemicals?"
Feedstock change is hot and poppin’
Corn, other renewable resources garner increasing interest and investment. Read here about the progress that is being made in discovering a new generation of feedstock.
Wastewater treatment is a critical process for chemical plants. Keeping on top of how to recycle and reuse will ensure you get the most of your water-treatment operations.
Act Before There’s Not a Drop to Drink
Ground water protection is the responsibility of everyone including the chemical industry. An energetic group of state and federal ground water agencies, industry, environmentalists and other stakeholders, however, has made it a key area of their focus. The Ground Water Protection Council (GWPC) is a nonprofit Section 501(c)(6) organization dedicated to promoting and ensuring the use of best management practices and “fair but effective” laws regarding comprehensive groundwater protection.
Expect More Water Regulation Everywhere
EPA gets tough on arsenic levels in drinking water
What’s on tap for water?
This increasingly precious resource is attracting more attention
Better water technology is on tap
The drought in many parts of the U.S. so far this summer points out the preciousness of water supplies. There’s greater demand for waste-minimization and recycle-and-reuse technologies as well as more awareness of utility usage and the impact of life-cycle costs on water-treatment operations. Here’s a look at new technologies that will help.
Optimize Water Use
Four major drivers are spurring increasing interest in optimizing water use.
Boosting worker performance benefits the bottom line. Understanding what operators need is critical to your site's success.
Operators Get More Help
Efforts aim to provide insights and tools to boost performance.
Fitting the Workplace to the Worker
Process Industry Control Rooms Would Be Designed a Whole Lot Differently if Air-Traffic Controllers Were Working in Them
Operator Performance Takes Center Stage
Industry/university alliance aims to address human factors in process control.
Help Your Operators
Automating procedures within control systems can serve to make your operators more effective and more consistent. With studies showing more than 40% of all plant incidents stemming from some form of human error, it makes sense to give automation a larger role in day-to-day operations.
An Alert Operator Is a Safe Operator
Maintaining a good work environment can contribute to a safer plant
More Topics:
- Automation & IT
- Compressors
- Control Systems
- Design & Simulation
- Distillation
- Drying
- Environmental, Health & Safety
- Filtration
- Fluid Handling
- Instrumentation
- Powder & Solids
- Pumps
- Reaction & Synthesis
- Reliability & Maintenance
- Security
- Separations Technology
- Software
- Utilities & Energy
- Valves
- Wireless
White Paper Library
- Automation & IT
- Design & Simulation
- Environmental, Health & Safety
- Fluid Handling
- Powder & Solids
- Reaction & Synthesis
- Reliability & Maintenance
- Security
- Separations Technology
- Utilities & Energy
Automation & IT
Measurement of Oxygen Concentration in Blanketing and Inerting Operations
Gaseous oxygen measurement with amperometric sensors is the most direct and easiest solution for oxidation and explosion protection.
Unwelcome oxygen Tank blanketing is the process of filling the headspace in storage vessels and reactors with an inert gas to prevent its contents from exploding, degrading or polymerizing and to protect equipment from corrosion. A blanketing system is normally designed such that it operates under higher than atmospheric pressures, therefore preventing outside air from entering the vessel. As oxygen and moisture in the air can be undesired in numerous processes and applications, blanketing is done in a wide range of industries, varying from (petro)chemical to food and beverage, pharmaceutical to pure water.
Special Report: Prepare For The Economic Recovery
Whether we are headed toward an economic rebound or continuing with the current economic downturn, specialty chemicals manufacturers should take steps now in order to get or keep a competitive edge. But what steps should specialty chemicals manufacturers take? This Special Report will discuss actionable strategies including: Reducing costs while maintaining quality and compliance; Committing not just to "lean manufacturing" but to "lean supply chain" strategies; Implementing "agile manufacturing" practices.
Design & Simulation
ChemicalProcessing Special Report: Pilot Plants
Read about the 10 factors that will impact the design, construction and operation of these next-generation pilot plant units.
Learn about new pilot plant development methods.
Understand the role operational guidance plays in successful pilot plant development.
Design and Rating Shell and Tube Heat Exchangers
This 30-page paper discusses the basic design, construction and performance of shell and tube heat exchangers.
Environmental, Health & Safety
The Green Solution
The ever present emphasis on technological efficiency is just one of several forces behind the pressure on companies to "go green" despite a trying economy. The ultimate criterion that determines whether a motor is truly green is energy efficiency. Technology, long the key to efficiency, can help resolve this issue.
Measurement of Oxygen Concentration in Blanketing and Inerting Operations
Gaseous oxygen measurement with amperometric sensors is the most direct and easiest solution for oxidation and explosion protection.
Unwelcome oxygen Tank blanketing is the process of filling the headspace in storage vessels and reactors with an inert gas to prevent its contents from exploding, degrading or polymerizing and to protect equipment from corrosion. A blanketing system is normally designed such that it operates under higher than atmospheric pressures, therefore preventing outside air from entering the vessel. As oxygen and moisture in the air can be undesired in numerous processes and applications, blanketing is done in a wide range of industries, varying from (petro)chemical to food and beverage, pharmaceutical to pure water.
Fluid Handling
Spray Gas Quench Design Considerations
The use of spray nozzles to rapidly cool or quench gas streams is an essential application in many industrial processes, such as chemical reaction vessels, incineration, and power plant absorber gas inlet. An optimized spray quench design requires engineering analysis of the operating environment, spray nozzle performance and process reliability. This technical paper describes the design considerations for spray gas quench systems such as nozzle selection, process control, system configuration and reliability. Application of this knowledge can result in a gas quench system that operates efficiently and reliably with reduced vessel size, reduced atomization energy consumption, and minimized downtime, to achieve capital and operational cost savings for your process.
Peristaltic Pumps: A Simple Solution for Abrasive and Corrosive Chemicals
Finding the right pump for metering abrasive and aggressive chemicals can be challenging. The pump of choice needs to withstand harsh chemicals, accurately meter, and be simple to maintain and operate. More and more process engineers are turning to peristaltic pumps to solve their pumping problems, reducing life cycle costs and driving gains in process efficiency.
Powder & Solids
How Well Do You Know Your Dust?
The collection and testing of dust samples is a long-established practice used by many powder and bulk processors to make informed dust collection decisions. Dust testing protocols have not changed markedly in recent years. The importance of dust testing, however, has changed, and the implications are significant. While knowing your dust has always been good practice, it is rapidly becoming a necessity in today's regulatory climate.
This article will review two separate types of testing: (1) explosibility testing, which is used to determine whether a dust is combustible; and (2) bench testing, which pinpoints numerous physical properties of the dust. Both categories of tests are needed to determine the best dust collection system for your application and whether explosion venting equipment must be part of that system.
Chemical Processing Special Report: Conveyors
No matter what industry you’re in, chances are you use some form of conveying. Whether it be pneumatic, flexible screw, aeromechanical or other, different conveyors are required to handle different products. But which conveyor is best suited for your operation? Despite the fact that conveyors have been around for almost a hundred years, this question still baffles many industries. In order to choose the right conveyor for your operations, you need to consider your conveyor's use - production, processing, packaging, and you need to consider your business objectives - improve operations? reduce labor?
In this special report, we look at the different types of conveyors, discuss the use of tubular bag conveyors, and provide 10 tips to prevent a variety of common problems that could occur with pneumatic conveyors.
Reaction & Synthesis
Properly Model and Control Batch Reactors
This paper covers key aspects for modeling and design of batch reactors, including: heat-up and cool-down performance, sensitivity analysis for reactor parameters, boil-up rate predictions, thermal stability under exothermic conditions, control system design and loop tuning parameters, condenser rating, and process emissions predictions.
Maximize Returns from Precious-Metal-Bearing Catalysts
Many catalytic reactions rely on platinum, palladium and other precious metal catalysts. When the activity of the catalyst declines to the point that it must be replaced, the used catalyst can be sent to a refiner to recover precious metal. This 8-page paper discusses the variouis factors that should be considered when using a refiner.
Reliability & Maintenance
SPECIAL REPORT: Condition Monitoring
An exciting trend in the world of CMMS is the increasing sophistication of condition-based maintenance (CBM) features and functions vendors offer and maintenance professionals actually use. This Special Report covers:
* Six steps to condition-based maintenance
* Bolster your condition monitoring toolbox
* Protect your condition-monitoring program from the recession guillotine
* Go beyond condition monitoring
Dust Explosion Protection using Flameless Venting
This 18-page white paper explores a new option – flameless venting – which has recently been developed for dust explosions and is being actively marketed as an alternative to vent ducting.
Security
White Paper: Ten Tips for Completing a Site Security Plan
Working on your Site Security Plan (SSP)? The next stage in the Chemical Facility Ant-Terrorism Standard (CFATS) compliance process requires covered facilities to submit a SSP. Given the importance of the SSP, covered facilities should address a number of factors while they complete this step in the CFATS regulation. Download this complimentary whitepaper now: Ten Tips for Completing your SSP.
Understanding CFATS: What It Means to Your Business
The Chemical Facility Anti-Terrorism Standard (CFATS) is intended to establish a baseline level of security for facilities considered to pose high risk to the general population in the event of a terrorist attack. Download this whitepaper now to learn how you can be CFATS compliant.
Separations Technology
Continuous Pressure and Vacuum Filtration and Washing of Organic Cellulose and Biomass Products
Organic cellulose and biomass filtration, washing and drying is very unpredictable and even minor differences in feedstock,washing or cake moisture requirements can require a different process solution. Both vacuum and pressure operations can provide equivalvent process results. On-site testing is required to determine the optimum filter selection.
A Review of Filter Press Basics and Issues
Filtration experts, over the years, have discussed filter presses and have indicated that soon they would be a thing of the past; the last filter press would be replaced by more modern equipment. This article discusses the perceived shortcomings of the filter press as well as the batch or continuous filtration alternatives to replace them.
Utilities & Energy
The Green Solution
The ever present emphasis on technological efficiency is just one of several forces behind the pressure on companies to "go green" despite a trying economy. The ultimate criterion that determines whether a motor is truly green is energy efficiency. Technology, long the key to efficiency, can help resolve this issue.
How Automated Water Jetting Improves Tube Bundle Cleaning Efficiency
Heat exchanger efficiency is a critical factor in processing productivity, and tube bundles must be kept clear of deposits to maintain that efficiency. Automated high-pressure water jetting systems, with flexible or rigid lances, remove deposits 75% to 90% faster than manual methods and are more operator-friendly.
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Browse our content library, enlist the help of a trained career coach or simply ask an expert for career advice.
Video & Audio
Leadership Focus: Mixing
Mixing abounds at most chemical plants. Problems can arise that undermine processing. Identifying and addressing such issues are essential to remain competitive.
Traci Purdum, senior digital editor, talks to Dave Dickey, senior consultant, MixTech Inc., to unearth mixing best practices.
To download or share this podcast, click the menu button.
Leadership Focus Podcast: CFATS
Chemical Facility Anti-Terrorism Standards (CFATS) are now in the process of implementation. Traci Purdum, Chemical Processing's senior digital editor, talks to David Moore, president and CEO of AcuTech Consulting Group, about the challenges of becoming compliant, lessons learned, and how to address underappreciated issues.
Leadership Focus Podcast: Cyber Security
Each year the damage to critical infrastructure from network incidents and cyber attacks is measured in the billions of dollars.
Traci Purdum, senior digital editor, talks to Eric Byres, chief technology officer of Byres Security Inc., to understand the risks and learn how to mitigate them.
To download or share this podcast, click the menu button.
Perspectives
-
Chemical Processing Online
What's On Your Mind?
Quick online polls can provide a variety of insights.
-
Compliance Advisor
OSHA Aims to Harmonize Standards
Aligning chemicals labeling with global rules involves major efforts.
-
End Point
U.K. Risks Losing Chemical Company Headquarters
Firms threaten moves because of tax policy.
-
Energy Saver
Innovations Promise Better Energy Efficiency
Five developing technologies may profoundly impact plant practices.
-
Field Notes
Take the Write Steps for Career Advancement
The ability to compose clear and effective documents is an important asset.
-
From the Editor
Sustainability Proves Its Worth
Study points to considerable cash flow benefits from better performance.
-
Plant InSites
Improve Your Plant's Prospects
Keep economics and the lifecycle stage of a facility in mind .
-
Process Puzzler
Add Other Options to the Mix
Readers suggest how to improve a blending operation.
Ask the Experts
We've assembled a roster of leading authorities in many fields to help you address technical issues. Pose a question or browse previous questions to find the answers you're looking for.
Recent Mixing question...
Q:I'd like to construct a computer controlled Agitation Experimental Module for students.
The tank Volume can be 1 L up to 10 L. The liquid viscosity can be water up to lubricant Oil SAE 140. We can do it with the presence or absence of baffles. We can do it with different impellers, different position of impellers. The speed will be near to 2000 rpm.
Could you please advise what kind of electro-motor I should use? Can I use 3-phase inductive motor 2800 rpm (2-pole), 1-HP power? How about the torque? Please suggest also how to calculate.
Editors' Corner
Help Us Break A Record
We are nearing record-breaking responses for the 2010 Salary and Job Satisfaction Survey. The survey is open a few more days. If you haven't participated, now's the time! And you could win an 8GB iPod Touch just for taking part. Click here to take the survey
Traci Purdum, Senior Digital Editor
tpurdum@putman.net.
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Measure your performance against your peers and discover which functional areas you can improve. Includes manufacturing, supply chain, R&D, regulatory compliance (ie REACH), and customer management.
Business Performance
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Improve performance and increase profitability with integrated, comprehensive solutions that protect your people, process and assets, while reducing costs and improving productivity.
Vital Resources
How Well Do You Know Your Dust?
Knowing your dust is rapidly becoming a necessity in today's regulatory climate. This article will review two separate types of testing: (1) explosibility testing, which is used to determine whether a dust is combustible; and (2) bench testing, which pinpoints numerous physical properties of the dust.
White Paper: Ten Tips for Completing a Site Security Plan
The next stage in the Chemical Facility Anti-Terrorism Standard compliance process requires covered facilities to submit a Site Security Plan. Download this complimentary whitepaper now: Ten Tips for Completing your SSP.
Take Part In CP Panel Discussions
Our Panel Discussion Series will gather experts to address important trends that will impact your chemical facility. As a registered audience member, you can ask questions during these 60-minute webcasts. See what discussions we have planned.
Understanding CFATS: What It Means to Your Business
The Chemical Facility Anti-Terrorism Standard (CFATS) is intended to establish a baseline level of security for facilities considered to pose high risk to the general population in the event of a terrorist attack. Download this whitepaper now to learn how you can be CFATS compliant.
How Automated Water Jetting Improves Tube Bundle Cleaning Efficiency
Heat exchanger efficiency is a critical factor in processing productivity, and tube bundles must be kept clear of deposits to maintain that efficiency. Automated high-pressure water jetting systems, with flexible or rigid lances, remove deposits 75% to 90% faster than manual methods and are more operator-friendly.
Get a Sneak Peak At Powder Show 2010
Preview what The International Powder & Bulk Solids show has to offer. The show touts it will provide leading educational sessions structured with extensive input from leading powder and processing experts.
SPECIAL REPORT: Condition Monitoring
An exciting trend in the world of CMMS is the increasing sophistication of condition-based maintenance (CBM) features and functions vendors offer and maintenance professionals actually use.
Special Report: Prepare For The Economic Recovery
Whether we are headed toward an economic rebound or continuing with the current economic downturn, specialty chemicals manufacturers should take steps now in order to get or keep a competitive edge.
Spray Gas Quench Design Considerations
An optimized spray quench design requires engineering analysis of the operating environment, spray nozzle performance and process reliability. This technical paper describes the design considerations.
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