Chemical Processing eHandbooks

  Chemical Processing eHandbooks package together current topics that impact and influence your chemical facility. These eHandbooks offer a wealth of information on a single topic. Aimed at providing best practices, key trends, developments and successful applications, the eHandbooks will hopefully help make your faculties as efficient, safe, environmentally friendly and economically competitive as possible.

Automation

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eHandbook: Understand Control and Other Issues in Level Measurement

Are you challenged by level measurement issues? Are you looking for more information on control and performance?

This Chemical Processing eHandbook takes a look at how chemicals manufacturers are finding level measurement solutions. Download this Chemical Processing eHandbook and gain access to these articles:

  • Neglect Level Control at Your Peril: This first article in a four-part series examines reset mode tuning issues.
  • Be Levelheaded About Surge-Tank Control: Vessels used to smooth out flow pose special tuning issues.
  • Understand Ultrasonic Sensor Performance: Frequency, beam patterns and a target’s reflection characteristics all play a role.
  • Get Data Where and When You Need It: Advances in level sensor technology help to improve inventory management.
  • More!

Download your copy of this Chemical Processing Level Measurement eHandbook now.

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eHandbook: Leverage These Level Best Practices

Level measurement, which is the detection of the phase split between vapor/liquid, liquid/liquid, vapor/solid and even liquid/solid, is a key parameter in the operation and control of modern industrial processes. A reliable outcome depends on the phase conditions being relatively consistent under all process conditions. Unfortunately, the importance of level control isn’t always understood. In this Chemical Processing Level Instrumentation eHandbook, we discuss best practices for level management including:

  • Interpret Level Readings Right – how the type of instrument can make a big difference in deciphering measurements
  • Choose the Correct Level Sensor – key considerations and questions for identifying the most appropriate choice
  • Customize Your Level Detection – a myriad of options help you achieve optimal level indicator performance

Download your copy of this Chemical Processing Level Instrumentation eHandbook now.

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Level eHandbook: Tackle Level Management Challenges

Level measurement, which is the detection of the phase split between vapor/liquid, liquid/liquid, vapor/solid and even liquid/solid, is a key parameter in the operation and control of modern industrial processes. A reliable outcome depends on the phase conditions being relatively consistent under all process conditions. Unfortunately, the importance of level control isn’t always understood. Failure to measure level reliably has resulted in some of the most serious industrial accidents, including those at the Buncefield, U.K., fuel storage depot and BP’s Texas City refinery. In this Chemical Processing Level Management eHandbook, we discuss best practices for level management including:

  • How to Select the Right Liquid Level Sensor - It’s important to consider a variety of factors when choosing the type of technology
  • Multivariable devices - gain operating and maintenance benefits
  • Achieving level control with dP transmitters - it appears simple but really is not

Download your copy of this Chemical Processing Process Level Management eHandbook now.

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Chemical Processing’s Level eHandbook: Best Practices for Level Management

Level measurement, which is the detection of the phase split between vapor/liquid, liquid/liquid, vapor/solid and even liquid/solid, is a key parameter in the operation and control of modern industrial processes. A reliable outcome depends on the phase conditions being relatively consistent under all process conditions. Unfortunately, the importance of level control isn’t always understood. Failure to measure level reliably has resulted in some of the most serious industrial accidents, including those at the Buncefield, U.K., fuel storage depot and BP’s Texas City refinery. In this Chemical Processing Level Management eHandbook, we discuss best practices for level management including:

How to Select the Right Liquid Level Sensor - It’s important to consider a variety of factors when choosing the type of technology

Properly Measure Liquid/Liquid Interfaces - Follow a simple rule for location of level gauge nozzles

Improve Reactor Vessel Measurement - Non-contact radar level meter speeds production and boosts worker safety

Download your copy of this Chemical Processing Process Level Management eHandbook now.

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Energy

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eHandbook: Keep Your Cool about Steam Systems

Are you feeling stressed about your steam systems? Feeling challenged by issues such as energy loss, hot surfaces, plant downtime and personal injury risks?

This Chemical Processing eHandbook takes a look at how to keep your cool when things get hot in your steam system management. Download this Chemical Processing eHandbook to discover insights and information on:

• Improving Insulation: Hot surfaces can lead to significant energy losses and pose personal injury risks.
• Don’t Get Steamed: Avoid plant downtime and potential injuries by addressing steam-generation chemistry issues.
• Changing Your Approach to Steam System Management: Improve plant productivity and reduce unplanned downtime with this three-step process.
• More!

Download your copy of this Chemical Processing Steam System eHandbook now!

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eHandbook: Effectively Manage Energy

Higher energy efficiency ranks as a top priority in many chemical makers’ efforts to enhance sustainability and competitiveness. Are you challenged by energy efficiencies? Are you perplexed by planning the scope of your audit and investigation? Do you want to better understand how to develop an implementation plan to act on your findings?

This Chemical Processing eHandbook takes a look at how chemicals manufacturers are meeting the energy efficiency challenge head on. Download this Chemical Processing eHandbook for insights and strategies including:

  • Plants Strike Down Energy Efficiencies: Large chemical manufacturers achieve improvements on many fronts
  • Break Energy Audits into Phases, Part I: A four-phase approach that cyclically repeats can yield improved energy savings
  • Break Energy Audits into Phases, Part II: After approval of projects, implementation can begin
  • More!

Download your copy of this Chemical Processing Energy eHandbook now.

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Steam eHandbook: Take the Heat Off Your Steam System

According to a U.S. Department of Energy survey, steam accounts for one-third of all the energy used in process plants. Monitoring and optimizing the cost of your steam system can yield big rewards. Ignoring inefficient operation easily could drain profits.

Operating and maintaining a reliable steam system is vital to chemical processing plants and can have significant cost impact on a plant's annual budget. Typical profit drainers in operating and maintaining a steam system include excessive fuel cost, inefficient steam generation, less-than-optimal steam utlilization and poor condensate recovery. This Chemical Processing Steam eHandbook presents strategies for reducing cost associated with using and generating steam, a 4 step approach for improving efficiency and insight on heat exchanger selection criteria. Specifically:

  • Control Steam System Energy Costs - Steam system losses can silently drain profits
  • Optimize Your Steam System - A simple four-step approach can improve steam efficiency
  • Head Off Exchanger Errors - Selecting the most-appropriate heads for a shell-and-tube unit is crucial

Learn how to generate savings through steam use and generation. Download your copy of this Chemical Processing Steam eHandbook now.

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Steam eHandbook: Best Practices for Steam Systems

Operating and maintaining a reliable steam system is vital to chemical processing plants and can have significant cost impact on a plant's annual budget. Typical profit drainers in operating and maintaining a steam system include excessive fuel cost, inefficient steam generation, less-than-optimal steam utlization and poor condensate recovery. Ensuring adequate supply of steam often results in excessive capacity usage, expensive fuel choices or condensate draining to grade, leading to compromised efficiency levels and higher steam cost. Because steam systems dependency is unavoidalbe, addressing those three issues is crucial to minimizing steam costs.
This Chemical Processing Steam eHandbook presents an overview, steam technologies and strategies for reducing cost associated with using and generating steam including:

  • Controlling steam system energy costs
  • Real-time monitoring - how wireless devices help cut energy losses by detecting failed steam traps
  • Additional resources

Learn how to generate savings through steam use and generation. Download your copy of this Chemical Processing Steam eHandbook now.

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eHandbook: Target Energy Efficiency

Rising fuel costs have a direct impact on a chemical processors’ bottom line. How can chemical processors reduce their energy consumption thus reducing their cost to produce? It’s believed that the chemical industry potentially can vastly decrease energy use AND greenhouse gas (GHG) emissions with the help of game-changing technology and strong support from policymakers. In this Chemical Processing Energy eHandbook, we take a look at global, and more local, technologies and strategies for improving energy efficiency at chemical plants including:

  • A roadmap that aims to catalyze better energy efficiency – learn about a international initiative that foresees catalytic processes playing a key role in cutting consumption and emissions
  • Saving energy by optimizing boiler loads
  • How the right emission control system can help meet compliance and reduce energy costs
  • Steam injection heating systems
Learn how improve your plants energy efficiency. Download your copy of this Chemical Processing Energy eHandbook now.

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Chemical Processing’s Steam eHandbook: Generate Steam Savings

Spikes in energy costs or unplanned-for capital improvement expenses can put organizations in tricky financial situations. To solve them, they often select the option with the lowest upfront cost which leads to the “pay me now or pay me later” dilemma. Over time it’s discovered that these lower-priced alternatives cost much more due to higher failure rates, wasted energy and more intensive maintenance. This Chemical Processing Steam eHandbook presents steam technologies and strategies for reducing cost associated with using and generating steam including:

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CP eHandbook: Use Energy Effectively

Effective energy management can help achieve more efficient use of energy without reducing production levels, product quality or employee morale, and without compromising safety and environmental standards. It should not only address higher efficiency generation, energy conversion, distribution and utilization, but also explore lower-cost energy alternatives. Simply put, energy management is optimizing the energy cost per unit of product output. In this Chemical Processing Energy Efficiency eHandbook, we take a look at how to achieve effective energy management including: • Energy management programs – the roles and responsibilities needed to create an effective energy management program • Internal and external resources needed for an effective energy management program including what to expect from top management • Energy management basics – the five key activities to help reduce energy use • Compression dryers – a review of three alternatives: heat, desiccant and refrigerant. Understanding whether the purchase “cost” outweighs the “value” in terms of energy consumption and production levels.

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Environmental

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CP Pollution Control eHandbook: Preclude Pollution Problems

Are you looking for proactive solutions to pollution issues? Pondering 2016 regulation challenges? Looking to improve safety, sustainability and cost savings? Considering how to select the right VOC abatement method?

This Chemical Processing eHandbook takes a look at how chemicals manufacturers can meet some of the challenges of Pollution Control issues before they start. Download this Chemical Processing eHandbook for insights and strategies including:

  • 2016 Presents Regulation Challenges: Legislation will focus on unfinished business, work plan chemicals and green chemistry efforts?
  • Plants Plug Away at Leaks: The quest for improved safety, sustainability and cost savings drives efforts to reduce fugitive emissions.
  • Select the Right VOC Abatement Method: There’s no one-size-fits-all approach and use varies greatly by application.
  • Increase Sustainability with Thermal Oxidation: The right emission control system can help meet compliance and reduce energy costs.
  • More!

Download your copy of this Chemical Processing Pollution Control eHandbook now.

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Flow

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CP Flow eHandbook: Make the Right Choice

Is figuring out how to choose the proper pump, pick the proper flow meter or select the correct rupture discs keeping you awake at night? Do you want some guidance on how to make these decisions?

This Chemical Processing eHandbook takes a look at how chemicals manufacturers are making the right selections. Download this Chemical Processing eHandbook for insights and information on:

  • Defeat A Double Whammy: Select the proper pump to handle low suctions head and cavitation.
  • Pick the Proper Flow Meter: Consider a wide range of factors to determine the optimal choice.
  • Choose Rupture Discs Wisely: Selecting the correct pressure relief method and configuration depends on a variety of factors.
  • More!

Download your copy of this Chemical Processing Flow eHandbook now.

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Chemical Processing eHandbook: Foil Flow Failings

This Chemical Processing Flow eHandbook, Foil Flow Failings, takes a look at how manufacturers are meeting some of today’s flow system challenges. Are you faced with the challenge of understanding when to use piston and diaphragm devices for precise liquid dosing? Do nozzle nightmares keep you awake at night? Do you know the best possible options for sidestripper control? Do you want to learn more from a case study on specialty lubricants and press-fitting technology?

Download this Chemical Processing eHandbook now for insights and strategies including:

  • Mastering Meter Pumps: Understand when to use piston and diaphragm devices for precise liquid dosing
  • Nix Nozzle Nightmares: Don’t forget to check nozzle locations when altering towers
  • Carefully Consider Sidestripper Control: Analysis of three possible options provides important insights
  • Case Study: A producer of specialty lubricants speeds pipe installation using press-fitting technology

Download your copy of the Chemical Processing Flow eHandbook: Foil Flow Failings

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Flow eHandbook: Achieve Better Flow

Achieving better flow is a constant challenge for chemical processors. What happens when a liquid flashes? How do you consider the impact of inlet losses? How can you become more innovative using speed pipe installation?

This Chemical Processing eHandbook takes a look at how chemicals manufacturers are meeting these challenges head on. Download this Chemical Processing eHandbook for insights and strategies including:

• Watch Out for Two-Phase Flow where process performance can suffer dramatically when a liquid flashes;
• Nix Nozzle Nuisances and avoid flow problems by considering the impact of inlet losses;
• Case Study: Speed Pipe Installation - VIP PLUMBING of Cleveland, Ohio, used press fittings to make water- and air-tight connections when installing a stainless system at Royal Chemical's Macedonia, Ohio plant;
• More!

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Flow eHandbook: Better Manage Flow

It’s not uncommon for chemical processors to have hundreds of piping and flow instruments to monitor, maintain and repair. When do you slope a process line? What happens when a precision instrument drifts out of calibration? In this Chemical Processing Flow eHandbook, we look at what it takes for chemical processors to master flow challenges in several areas including:

  • Piping geometry – how draining, venting, fouling and other considerations affect piping geometry
  • Various methods for avoiding thermal flow meter validation pitfalls
  • Piping symmetry – why designers should consider the impact of unequal flows in branches

Learn more how to avoid common piping pitfalls. Download your copy of this Chemical Processing Flow eHandbook now.

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Chemical Processing’s Flow eHandbook: Forestall Flow Frustrations

Issues related to physical properties, process parameters, electronic features and interconnections can all affect the flow of liquids and gases. Often working around the clock to process, transfer, and store sometimes hazardous and corrosive chemicals, processors must tackle issues related to physical properties and process parameters. In this Chemical Processing Flow eHandbook, we take a look at what it takes for chemical processors to master flow challenges for several types of materials with vastly different physical properties including:

  • How non-contact ultrasonic meters can ease maintenance and improves accuracy
  • Selecting the right spray nozzle - consider several factors to determine the best choice
  • Why inferring internal flow rate in a column rarely makes sense
  • How using Coriolis mass flowmeters provides reliable indication of gas entrainment
  • Case Study: Speed Pipe Installation – when a pipe-joining system eliminates need to weld or thread connections

Learn more how to forestall flow frustrations with these best flow practices. Download your copy of this Chemical Processing Flow eHandbook now.

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eHandbook: Improve Flow Management

Half the battle with flow is choosing the proper equipment. Indeed, flow meter selection and specification is crucial. With the wrong choice you’ll be floundering or worse. In addition, process engineers identify “oversizing” as the number one control valve problem. In this Chemical Processing Flow eHandbook, we identify tips to improve flow including:

  • How to match the flow meter to the service
  • How to handle more flow
  • How to properly size control valves
  • How to tackle biogas flow measurement challenges

Learn more about these best flow practices. Download your copy of this Chemical Processing Flow eHandbook now.

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eHandbook: Take the Pressure Off Your Process

When thinking of the processing of chemicals, we think of any activity including storing, using, handling, manufacturing, or moving chemicals at a site, and any combination of these activities. A common state in many of these activities is the flow - or rate - at which the chemicals are moving through a process. Accurately measuring flow can be a challenge for many chemical processors since so many factors can influence the chemical properties and subsequently the  rate of flow. In this Chemical Processing Pressure eHandbook, we discuss considerations for flow management including:

  • Pressure transmitters -  how noise can pinpoint process problems
  • The use of orifice plates -  how insufficient flow conditioning often undermines measurement accuracy
  • Robust Inferential Sensors - easier-to-develop-and-maintain sensors offer significant benefits for chemical processes

Download your copy of this Chemical Processing Pressure eHandbook now.

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Chemical Processing’s eHandbook: Take Advantage of Tips for Better Flow

With more demanding applications than most, chemical processing requires systems and infrastructure that can maintain efficiency and safety. Relative to flow, chemical processors need to address challenges such as corrosion, leak detection and mitigation, flow pressure and volume. In this Chemical Processing Flow eHandbook, we identify tips to improve flow including:

  • Distillation columns - how gravity-flow loop can enable measuring internal liquid flow in a column
  • The importance of the Process Design Basis
  • Flowmeters  -  monitor, detect and neutralize phosgene leaks
  • Polymer Piping - Material offers numerous benefits over metallic systems and spans various applications

Learn more about these best flow practices. Download your copy of this Chemical Processing Flow eHandbook now.

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eHandbook: How To Fight Flow Challenges

In addition to flow pressure, volume and material state, achieving and maintaining desired flow performance depends upon properly addressing some complicated design and operational issues. In this Chemical Processing Flow eHandbook, we identify strategies and solutions for aerodynamic, technical, mechanical and economic constraints including:
 
Hydrogen systems – Inspections and tests for ensuring safety and flow
Axial compressors – achieving and maintaining desired performance
Fight flow recirculation – why the phenomenon occurs in centrifugal pumps and how to correct it
 
Learn more about these best flow practices. Download your copy of this Chemical Processing Flow eHandbook now.

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Chemical Processing’s eHandbook: Follow These Best Flow Practices

Corrosion, leak detection and mitigation, flow pressure and volume are all factors that maintenance managers and other decision makers need to contend with as they manage flow at their chemical processing plants. In this Chemical Processing Flow eHandbook, we delve in to solutions and strategies for managing these challenges including:

  • Leak management - treat them as calls for action against the underlying problem
  • VFDs for centrifugal pumps - such drives may provide energy savings and avoid operating problems
  • Dealing with corrosion - piping made of high-performance plastic provides unmatched performance and longevity
  • Ceramic in electromagnetic flow meters - material used for measuring tubes offers high performance, longevity and a host of other benefits

Learn more about these best flow practices. Download your copy of this Chemical Processing Flow eHandbook now.

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Chemical Processing’s Flow eHandbook: Fend Off Flow Issues

Chemical processors continually strive to find technologies and solutions for improving flow. Issues related to physical properties, process parameters, electronic features and interconnections can all affect the flow of liquids and gases. In this Chemical Processing Flow eHandbook, we take a look at what it take a look at several different flow challenges and considerations to overcome these challenges including:
 

  • Split flow - ensuring proper control of parallel flow paths demands care
  • Positive displacement pumps  - how some units offer advantages over centrifugal pumps in some services
  • How to increase process availability - using Coriolis mass flowmeters provides reliable indication of gas entrainment
  • More!

 
Find out how to master flow challenges. Download your copy of this Chemical Processing Flow eHandbook now.

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Chemical Processing’s Flow eHandbook: Master Flow Challenges

Issues related to physical properties, process parameters, electronic features and interconnections can all affect the flow of liquids and gases. Often working around the clock to process, transfer, and store sometimes hazardous and corrosive chemicals, processors must tackle issues related to physical properties and process parameters. In this Chemical Processing Flow eHandbook, we take a look at what it takes for chemical processors to master flow challenges for several types of materials with vastly different physical properties including:

  • How to increase process availability - coriolis mass flow meters provide reliable indication of gas entrainment
  • Overcoming the challenges of changing gas composition - new technology addresses need for more accurate and efficient biogas measuring
  • How to ensure proper control of parallel flow paths demands care
  • Case Study: Speed Pipe Installation - pipe-joining system eliminates need to weld or thread connections
  • More!
Find out how to master flow challenges. Download your copy of this Chemical Processing Flow eHandbook now.

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Chemical Processing’s Flow eHandbook: Effective Flow Management Thumbnail

Chemical Processing’s Flow eHandbook: Effective Flow Management

Chemical processors continually strive to find technologies and solutions for improving system performance and plant uptime. Often working around the clock to process, transfer, and store sometimes hazardous and corrosive chemicals, processors must tackle issues related to physical properties and process parameters. In this Chemical Processing Flow eHandbook, we take a look at what it takes for chemical processors to achieve effective flow management.

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Chemical Processing’s Flow eHandbook: The Many Facets of Flow Thumbnail

Chemical Processing’s Flow eHandbook: The Many Facets of Flow

Issues related to physical properties, process parameters, electronic features and interconnections can all affect the flow of liquids and gases. Chemical Processors know that many factors such as flow rate, material temperature and liquid viscosity can effect how easily, or difficult it is to process flow. In this Chemical Processing Powder eHandbook, we take a look at technologies and strategies for managing flow including: Properly positioning interlock valves - the obvious location may not be the most cost effective How to pick the proper centrifugal pump - the impact of startup conditions and prospective operating points Five important factors for storage tanks and how to determine the right tank for your needs Variable area meters – factors to consider when selecting this device for measuring flow Coriolis flow meters – understand how a straight-tube design provides several advantages for a varnish production application Understand the many facets of flow. Download your copy of this Chemical Processing Flow eHandbook now.

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Chemical Processing Flow eHandbook: Monitoring Flow

The purpose of installing a flowmeter system is to accurately measure flow in a reliable manner. Issues related to physical properties, process parameters, electronic features and interconnections are often given much consideration. Relatively little emphasis, however, is given as to how well the flowmeter will perform its intended purpose. Adding to the confusion are the differences in how performance is expressed and the incomplete nature of the available information. Nevertheless, the quality of flow measurement should be a concern. This Chemical Processing eHandbook takes a look at technologies and solutions affecting flow including: * Coriolis meters - steps you can take optimize performance when faced with entrained gas * Magmeters -- why you should consider using them * How to achieve effective flow control with centrifugal pumps

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Chemical Processing Flow eHandbook: Best Practices for Flow

The purpose of installing a flowmeter system is to accurately measure flow in a reliable manner. Issues related to physical properties, process parameters, electronic features, interconnections can all affect the flowmeter performance. This Chemical Processing eHandbook takes a look at technologies and solutions affecting flow as well as the impact of specific regulations on flowmeter systems including:

  • Specifying the right slurry seal – understanding dual-seal and water-management options
  • Ground EMFs with Virtual Reference - New grounding method eases electromagnetic flowmeter installation and minimizes costs
  • Determine Boiler Size Using a Flowmeter - An inline vortex meter reveals the proper steam usage, resulting in significant savings and improved energy efficiency.

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Mixing

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eHandbook: Master These Mixing Best Practices

This Chemical Processing eHandbook takes a look at some of today’s mixing challenges for chemical manufacturers and some of the best practices that can be implemented to help along the way.

Download this Chemical Processing eHandbook for insights and strategies including:

  • Prevent Problems with Fine Particles: Sampling is crucial and demands particular care.
  • Quickly Estimate Reagent Addition Time: A simple equation suffices in many situations involving batch reactors.
  • Understand Powder Flow Characteristics: A powder’s variables and external factors will greatly impact blender size and type.

More!
Download your copy of this Chemical Processing Mixing eHandbook now.

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Mixing eHandbook: Avoid Mixing Mix-Ups

For chemical processors, ensuring a long-lasting, high-quality mix is a huge challenge regardless of the physical properties of the mixing component – liquid, gas, solid. In this Chemical Processing Mixing eHandbook, we take a look at mixing technologies including “open” batch operation, static mixers, hydrogenation and inline mixing. Understanding how each of these technologies works, the benefits and challenges can help you to avoid common mixing mix-ups. Download your copy and learn about:

  • A number of technologies that can handle pipeline mixing
  • How hydrogenation reactions can achieve greater conversion rates and thus better space/time yields
  • Continuous powder wetting
  • Inline mixing systems
  • Modern in-line mixers

Avoid common mixing mix-ups. Download your copy of this Chemical Processing Mixing eHandbook now.

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Powder

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Powder eHandbook: Take Some Solid Steps Towards Better Processing

This Chemical Processing eHandbook takes a look at how chemicals manufacturers are meeting the various challenges presented by processing today.

Download this Chemical Processing eHandbook for insights and strategies including:

  • Vacuum Shelf Dryer Provides More-Uniform Cakes: Different approach to endpoint determination leads to greater consistency.
  • Stop What You’re Doing: Challenging existing practices may spur significant improvements.
  • Consider Vacuum Drying: A vacuum drying pump offers several advantages for removing vapor over other methods.
  • Understand Powder Flow Characteristics: a powder’s variables and external factors will greatly impact blender size and type.
  • More!

Download your copy of this Chemical Processing Powder eHandbook now.

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eHandbook: Handle Powders With Care

Are you looking for more information about handling powders?

Do you want to prevent problems before they start and consider alternative methods?

This Chemical Processing eHandbook takes a look at how chemicals manufacturers are meeting the challenges of handling powders. Download this Chemical Processing eHandbook for insights and strategies including:

  • Prevent Problems with Fine Particles: Sampling is crucial and demands particular care.
  • Don’t Err About Fluidization: Consider its under-appreciated advantages and broader utility.
  • Get the Most Out of Your Sterilization Process: Take a close look at two commonly used methods and their associated vacuum technology.
  • More!

Download your copy of this Chemical Processing Powder eHandbook now.

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Powder eHandbook: Make Solid Progress

Are you looking for more information about solids processing operations? The practice of chemical engineering underpins chemical processing. Universities teach design methods for unit operations such as distillation and heat transfer. However, colleges seldom cover solids processing operations. If any discussion takes place, it only focuses on basic particle physics issues related to drag and turbulence. Yet, many processes require extensive handling of solids.

This Chemical Processing eHandbook takes a look at how chemicals manufacturers are meeting the challenges of solids processing head on. Download this Chemical Processing eHandbook for insights and strategies including:

• Solve Solids Processing Conundrums: Understand more about the unique issues posed by solids and why it is crucial for success.
• Measure Viscosity to Improve Your Mixing Process: Get tips on how to select the proper measuring instrument to better monitor your product quality.
• Make Some Sense of Sensors: Learn more about the variety of solutions that exist for flow level detection and inventory management.
• Consider Used Equipment: Get some guidelines to help you select the right pre-owned machine for an application.
• More!

Download your copy of this Chemical Processing Powder eHandbook now.

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Powder eHandbook: Get a Better Handle on Your Solids Process

Getting a better handle on Solids Process is an on-going challenge for chemical processors. Are you struggling with multiphase sampling? Do you want to conquer pilot plant challenges? Do you want to learn more about how automatic sampling can help control process safely?

This Chemical Processing eHandbook takes a look at how chemicals manufacturers are meeting these challenges head on. Download this Chemical Processing eHandbook for insights and strategies including:

  • Don’t Be Fazed By Multiphase Sampling: An isokinetic system can provide accurate samples;
  • Conquer Pilot Plant Challenges: Use design of experiments to minimize the number of runs and ensure meaningful data;
  • Case Study: Sampler Helps Control Process Safely: Automatic samplers can be key to ensuring process samples are repeatable and reliable;
  • More!

Download your copy of this Chemical Processing Powder eHandbook now.

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eHandbook: Tame Your Pesky Powders

A material’s characteristics – adhesiveness, cohesiveness, aeratibility, pressure-sensitivity – often change during processing and can cause both flow and hidden hazard challenges. And while poor flow is one of the most common problems encountered in handling or storing solids, dust control issues also need to be identified and addressed. This includes combustible dust as the repercussions can result in costly downtown and in some instances, explosions, serious injury and possibly even death. In this Chemical Processing Powder eHandbook, we take a look at strategies and solutions for taming pesky powder processing challenges including:

  • Defuse Dust Dangers - Carefully consider and then counter risks of fire and explosion
  • Clamp Down On Clumping - First understand what’s really causing the problem
  • What You Don’t Know About Powder Flow - Shear cells can quickly reveal information about flow behavior
  • Know Your Vacuum Pumps - Understand the differences between liquid ring and rotary screw dry pumps for distillation

Learn how to tame your pesky powder challenges. Download your copy of this Chemical Processing Powder eHandbook now.

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Powder eHandbook: Combat Powder Processing Challenges

In chemical production and processing, process design and process safety are crucial considerations – especially when powders are part of production and processing. Inherent challenges such as increasing throughput, accurately measuring powders to manage inventory and removing excess solvents are all challenges that chemical processors need to contend with. In this Chemical Processing Powder eHandbook, we take a look at these powder processing challenges and identify solutions and strategies to overcome them. Learn more about:

  • Vacuum conveying - customization, automation and safety
  • Matching level measurement system to a job - consider materials and work environment when choosing a device
  • Removing solvent vapors in diverse applications - dry and liquid ring vacuum pumps are alternatives to oil-sealed pumps
  • Meeting combustible dust compliance – how a facility tackles combustible dust with aportable central vacuum system

Download your copy of this Chemical Processing Powder eHandbook now.

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Powder eHandbook: Preclude Powder Problems Thumbnail

Powder eHandbook: Preclude Powder Problems

Process design and process safety are critical considerations in chemical production and processing. With design and safety paramount at the outset of any new development or equipment retrofit, firms can minimize risk exposure, maximize productivity and position themselves to remain compliant and competitive. Whether retrofit or new, chemical processing is continually challenged by combustible dust. Combustible dust can pose a hidden hazard when accumulation occurs in unseen locations such as in mechanical spaces, above false ceiling, ventilation systems and dust collection systems. In this Chemical Processing Powder eHandbook, we take a look at strategies and solutions for mitigating combustible dust hazards including:

  • Identifying hidden hazards - a case study outlining how a facility finds danger from accumulated dust and effectively addresses it
  • Powder flowability - how new measurement methods now make it easier to evaluate flow
  • Process safety -  properly designed weigh model can optimize safety and improve efficiency
  • A multivariate approach to powder processing -  an overview of several methods that can help determine which powder properties have the greatest influence on performance

Learn how to preclude powder problems. Download your copy of this Chemical Processing Powder eHandbook now.

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eHandbook: Make the Right Moves with Powders Thumbnail

eHandbook: Make the Right Moves with Powders

When designing a system to transport powders and granules there is a wide variety of considerations. Different applications, installation environments, equipment, material characteristics and how they may change during the process are all part of the equation. While many plants aim to keep costs low and often times use old equipment for a new project this can also further compound a complex challenge. And that's not even taking in to consideration our increased awareness of the risks of an explosion and the need to avoid hazardous emissions. In this Chemical Processing Powder eHandbook, we take a look at key considerations affecting today’s best practices for transporting and processing powders and granules including:

  • Installing pneumatic conveyors correctly - 10 steps to prevent a variety of common problems
  • How to understand accuracy in a bin level monitoring system
  • Tubular drag conveying - an alternative to pneumatic conveying
  • Vacuum Conveying equipment and the issues of safety, security and sanitation

Learn how to process powders efficiently. Download your copy of this Chemical Processing Powder eHandbook now.

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Chemical Processing’s Powder eHandbook: Make the Most of Powder Processes Thumbnail

Chemical Processing’s Powder eHandbook: Make the Most of Powder Processes

Powders developed to meet certain product performance targets often suffer from inconsistent and unpredictable flow. The reasons for this are many. A material's characteristics - adhesiveness, cohesiveness, aeratability, pressure-sensitivity - often change during processing and can cause flow problems to crop up. Couple this with changes in the processes themselves and costly downtime can be the result. In this Chemical Processing Powder eHandbook, we take a look at strategies and solutions for overcoming powder processing challenges including:

  • Making the most of flow additives - understand their impact on overall powder behavior to optimize flow
  • Improving performance of gravimetric feeders - tips to avoid poor accuracy and frequent downtime
  • Protecting against combustible dust explosion - economical approaches for protecting spray dryer processes and solutions

Make the most of your powder processes. Download your copy of this Chemical Processing Powder eHandbook now.
 

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Powder Processing Best Practices Thumbnail

Powder Processing Best Practices

A material’s characteristics and how they may change during processing can affect HOW these materials are processed. Key factors affecting powders include aeration, moisture absorption, electrostatic charging to name a few. Many bulk solids are sensitive to heat and humidity. As these levels rise, either in the feeder system or via outside conditions, flow problems crop up. As the powder gains strength, jams and poor flow conditions begin to appear. Costly downtime and a loss of product are incurred while a search is made for a solution to the flow problems. In this Chemical Processing Powder eHandbook, we take a look at key factors affecting powders and today’s best practices for overcoming the processing of powders including:
 

  • Looking beyond the physical properties of particles and treating powder as a bulk entity
  • How scanners take volume to a new level - acoustics-based sensors can help accurately measure the volume of powders in vessels
  • How to determine a coating’s volatile content  - advancements in rapid loss-on-drying techniques significantly reduce testing time
  • Testing powder flow - advances in test methods help better predict flow behavior at elevated temperature and humidity levels

Learn how to process powders efficiently. Download your copy of this Chemical Processing Powder eHandbook now.

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Powder eHandbook: Efficient Powder Process Handling Thumbnail

Powder eHandbook: Efficient Powder Process Handling

The mechanisms of powder flow are complex. They are influenced by an array of different parameters; some relate to the particles’ physical attributes, such as size and shape, and others, such as humidity, to the system itself. Although there is a general understanding of these individual mechanisms, the multitude of interactions that govern the specific behavior of a given powder can many and in turn, affect how these powders are processed. In this Chemical Processing Powder eHandbook, we take a look at technologies and strategies for handling powders

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Chemical Processing’s Powder eHandbook: Tips for Successful Powder Processing Thumbnail

Chemical Processing’s Powder eHandbook: Tips for Successful Powder Processing

Powders and the dust they create have a tendency to create a myriad of material handling headaches. For example, dust can wreak havoc on the performance and accuracy of many level sensors, rendering them inaccurate and unreliable. Powder particles under the influence of gravity can become compacted resulting in inter-particle friction that may prevent flow movement. In this Chemical Processing Powder eHandbook, we offer a few tips for optimizing powder processing.

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Chemical Processing’s Powder eHandbook: Optimize Powder Processing Thumbnail

Chemical Processing’s Powder eHandbook: Optimize Powder Processing

Some chemical makers are missing opportunities to reduce operating costs and increase profits because they aren’t striving to re-engineer and streamline their processes. A plant often can achieve substantial benefits through simplified steps that do more and work better with less complexity. In this Chemical Processing Powder eHandbook, we take a look at strategies and solutions for optimizing powder processing including: • Streamlining the chemical processing process – enhancing operations by removing complexities that creep in over time • Suppression systems – How a properly designed and engineered suppression system offers many advantages including explosion aversion • Mitigating the impact of uncertainty - how the correct weighing system and a proper maintenance schedule can ensure accuracy Learn strategies for optimizing your powder processing. Download your copy of this Chemical Processing Powder eHandbook now.

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Chemical Processing’s Powder eHandbook: Process Powders with Ease

Processing powders can be tricky. During processing, powder properties can be affected by many different factors including if the materials are stored for long periods, if the materials are exposed to moisture, and by fluctuations in the mechanical processes that handle powders. In this Chemical Processing Powder eHandbook, we take a look at technologies and strategies for handling powders including: Options for large drivers – with a focus on variable-speed electric motors Innovative level measurement technologies How shear cell instruments and relative humidity tests can determine a powders flow behavior Indoor flameless venting – how modern technology can help eliminate the risk of damage and reduce maintenance costs Learn how to process powders with ease. Download your copy of this Chemical Processing Powder eHandbook now.

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CP Powder eHandbook: Effectively Handle Powders Thumbnail

CP Powder eHandbook: Effectively Handle Powders

Learn more about how to effectively handle powders during processing. Download your copy of this ChemicalProcessing Powder eHandbook now.

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Chemical Processing Powder eHandbook: Address Challenges Posed by Powders Thumbnail

Chemical Processing Powder eHandbook: Address Challenges Posed by Powders

One of the trickiest materials to process, powders are comprised of solids or particulates, a continuous gaseous phase (usually air) and, almost always, a liquid component. Many factors influence powder composition including size and distribution, surface roughness and hardness. And, how powders are processed -- vibration, compaction, attrition, segregation -- can influence how powders react. In this Chemical Processing Powder eHandbook, we take a look at how to effectively handle powders, safer dryer operations and how to manage phase changes when processing powders. Download your copy today. Download your copy today.

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Chemical Processing Powder eHandbook: Succeed at Solids Handling

One of the trickiest materials to process, solids are comprised of powders or particulates, a continuous gaseous phase (usually air) and, almost always, a liquid component. Processors that handle solids know only too well the types of throughput problems that come up on a recurring basis. Clumping; effective, economical and safe slurry mixing; dust management and dust explosion risk mitigation are all very real challenges faced by processors of solids. In this Chemical Processing Powder eHandbook, we take a look at how to effectively handle solids including:

  • Clumping – the 10 most common sources of agglomeration in bulk solids and how to effectively manage them
  • Strategies for optimal slurry mixing
  • Level management detection in storage vessels
  • Dust explosion risks – how to identify and mitigate when processing solids
  • Managing solid cohesiveness with flow strategies

Download your copy of this Chemical Processing Powder eHandbook now.

 

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CP Powder eHandbook: Tips for Effective and Safe Handling of Solids

One of the trickiest materials to process, solids are comprised of powders or particulates, a continuous gaseous phase (usually air) and, almost always, a liquid component. Processors that handle solids know only too well the types of throughput problems that come up on a recurring basis. Effective, economical and safe slurry management; flowability during processing, accurate inventory and volume level management are all very real challenges faced by processors of solids. In this Chemical Processing Powder eHandbook, we take a look at how to effectively handle solids including:

  • Properly accounting for how bulk solids actually will flow in a vessel or overall process -- we take a look at some simple parameters that can often provide a good sense of flowability
  • Strategies for avoiding slurry trouble
  • Mitigating pipe segment force imbalances with Reactor Excursion and Leakage Analysis Program
  • Acoustics-based level measurement for accurate powder measurement in bins, tanks and silos
  • Explosion protection methods including suppression, isolation and venting

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CP Powder eHandbook: Effective Powder Processing Thumbnail

CP Powder eHandbook: Effective Powder Processing

As many chemical processors know, processing powders can be tricky. Powder properties can be affected if the materials are stored for long periods. Powders can be compressed, vibrated, aerated and exposed to moisture. And specific processes like granulation, blending, drying, milling, lubricating and compression put requirements on how powders can be handled. In this Chemical Processing Powder eHandbook, we take a look at how to effectively process powder including:

  • Compression dryers – the case for choosing a solution that produces optimal air quality and low energy consumption
  • GHS – understanding the requirements and what it means to chemicals processors
  • Predicting powder flow behavior
  • Vibratory screen cleaning methods
  • Fine powder flushing - eliminating a common bin-afflicting problem caused by trapped air
  • Tubular Drag Conveying Technology – an alternative to pneumatic conveying
  • Addressing dust hazards – including explosions

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Refining

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eHandbook: Tackle Refining Industry Challenges

Are you feeling stressed about how to navigate current refining industry challenges? The downstream oil sector has had more than its share of ups and downs recently. Market dynamics, regulatory forces, and advancing technologies are keeping the refining industry on its toes.

This Chemical Processing eHandbook takes a look at how the refining industry is rising to today’s challenges. Download this Chemical Processing eHandbook to discover insights and strategies including:

• Rising to the Challenges of Today’s Refining Industry: Focus on performance sustainability and safety to navigate a volatile market.
• Taming Your Transient Operations: Use a special method to identify and address potential hazards.
• Minimize Oil and Gas Refinery Downtime: Shutdown and turnaround logistics become easier to coordinate with operational planning tools.
• Take the Guesswork Out of Corporate Safety: Several key elements help drive long-term success of world-class safety programs.
• Improve Vacuum Tower Performance: Advanced temperature measurements can help increase yield and product quality.
• More!

Download your copy of this Chemical Processing Refining eHandbook now!

 

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Reliability & Asset Management

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CP Reliability eHandbook: Manage Your Assets

Reliability programs are now standard business practice in companies that rely heavily on machines, equipment and other physical assets. However, plants are continually challenged in identifying new and cost-effective ways to ensure their assets are performing and that they are managing to minimize operational risks. In this Chemical Processing Reliability eHandbook we take a look at proactive approaches for improving reliability and maintenance in today’s processing plant including:

  • Rotating equipment - how to take advantage of improved internals and better seals
  • Meeting process requirements and protecting equipment with strainers
  • Insights from surface temperature measurements and the critical role IR thermography is to maintenance

Download your copy of this Chemical Processing Reliability eHandbook now.

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CP eHandbook: Reliability/Asset Management

Reliability programs are now standard business practice in companies that rely heavily on machines, equipment and other physical assets. But, in today’s lean economy, companies have fewer resources than ever to manage and maintain these assets. Plants face challenges in identifying new and cost-effective ways to ensure their assets are performing and that they are managing to minimize operational risks. In this Chemical Processing Reliability/Asset Management eHandbook we take a look at proactive approaches for improving reliability and maintenance in today’s processing plant.

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Safety

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eHandbook: Put the Spotlight on Process Safety

How do we make safety in our processes second nature? The concept of inherent safety goes beyond simply not having materials that potentially could damage the pipes, vessels and equipment that make up manufacturing facilities. We need to understand all the ways those materials can be involved in incidents that harm people, the environment and our facilities. Without a thorough understanding of those scenarios and how they can occur, we can’t properly evaluate the risks posed by different technological approaches and effectively apply inherently safer technologies. In this Chemical Processing Process Safety eHandbook, we delve in to what it means to embrace the concept of inherent safety and provide tips for safer processing.

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Chemical Processing’s Process Safety eHandbook: Tips for Safer Processing

Major accidents with multiple fatalities continue to occur worldwide in theprocess industries, causing distress to those involved and massive costs to companies. Almost daily, facilities in the process industries face a number of specific major accident hazard scenarios depending upon the nature of the substances they handle and their processing activities. These are caused by known initiating events such as failure of hardware or control systems, or errors by operating or maintenance staff. In this Chemical Processing Process Safety eHandbook, we provide tips for safer processing.

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Wireless

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CP eHandbook: Wireless - Plants Benefit from Wireless Technology

For chemical processors, changing process conditions demand quick responses in order to keep processing effective and to keep processes running properly. For processes undergoing such changes, accurate and timely measurements, such as vibration monitoring, redundant tank level measurement and steam header temperature profiling can be difficult to collect. In well-established plants it’s both very expensive and time consuming to get measurement points online using conventional wired instrumentation. Many processors are now turning to wireless devices that can supply data from numerous points that never could have been justified otherwise. In this Chemical Processing Wireless eHandbook we take a look at wireless technology solution successes.

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Wastewater

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eHandbook: Enhance Water/Wastewater Efficiency

This Chemical Processing eHandbook examines some of today’s efficiency challenges for chemical manufacturers and some of the best practices that can be implemented to help along the way.

Download this Chemical Processing eHandbook for insights and strategies including:

  • More Efficient Wastewater Treatment Looms: New technologies could lead to greener, less-expensive manufacturing processes.
  • Keep Calm and Save Water: Processors adopt diverse approaches to cut consumption.
  • More!

Download your copy of this Chemical Processing Water/Wastewater eHandbook now.



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CP eHandbook: Address Wastewater Challenges

Are you challenged by wastewater issues? Looking to improve your water quality and cut costs? Wondering about biological water treatment? Thinking about on-site testing to verify equipment performance?

This Chemical Processing eHandbook takes a look at how chemicals manufacturers are meeting some of the challenges of today’s wastewater issues. Download this Chemical Processing eHandbook for insights and strategies including:

• Refinery Tackles Water Issues: Skid-mounted treatment unit improves water quality and cuts costs.
• Really Get Bugged: Biological treatment can handle many industrial wastewater streams.
• On-Site Tests Verify Equipment Performance: Two-stage water treatment pilot study established an effective chemical coagulation protocol.
• More!

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CP eHandbook: Waylay Water System Woes

This Chemical Processing Water/WastewatereHandbook, Waylay Water Systems Woes, takes a look at how manufacturers are meeting some of today’s water system challenges. Are you faced with the challenge of properly applying plastic piping? Is PH troubleshooting concerning you? Would you like to learn more about treating condensate water with activated coconut based carbon?

Download this Chemical ProcessingeHandbook nowfor insights and strategies including:

  • Properly Applying Plastic Piping: Use of such piping requires careful consideration of a number of issues.
  • Succeed at PH Troubleshooting: Heed some pointers to properly diagnose the cause of a problem.
  • Treat Condensate Water with Activated Carbon: High-purity coconut based carbons reduce silica leach, rinsing requirements

Download your copy of the Chemical Processing eHandbook: Waylay Water System Woes now.

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CP eHandbook: Waylay Wastewater Worries

The Carbon Disclosure Project (CDP), London, has released its Global Water Report 2014. Water challenges, especially in the chemicals industry have not diminished and in fact, are becoming an increasingly larger concern for processors. As stated by Paul Simpson, CEO of the CDP , “Leading companies increasingly recognize that business-as-usual approaches to water management are no longer sufficient.” Download this Chemical Processing eHandbook for:

  • Additional findings from the latest CDP report – with a focus on the chemicals industry
  • An overview on simple monitoring actions and how adopting best practices may lead to significant savings
  • How water conservation efforts can pay off
  • How to handle more flow – success often depends upon lowering head losses or raising pump pressure

Download your copy of this Chemical Processing Water WasteWater eHandbook now.

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CP eHandbook: Consider These Water Best Practices

Water is a critical utility at process plants, often serving both as a heating and a cooling medium. Many process plants rely on this water for processing and other applications. Providing the water, usually by heating via steam coils or direct steam injection nozzles, takes significant energy. In this Chemical Processing Water eHandbook we take a look at water best practices including:

  • How to cut energy consumption in water systems in both hot and cold water applications
  • Polymer piping - we identify benefits over metallic systems
  • TOC analysis challenges - techniques that address barriers to standard online TOC measurement methods

Download your copy of this Chemical Processing Water WasteWater eHandbook now.

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CP eHandbook: Widen Your Perspectives on Wastewater Thumbnail

CP eHandbook: Widen Your Perspectives on Wastewater

Treating and reusing process water is a multidimensional challenge for process plants. Compliance with regulatory requirements to prevent and mitigate industrial pollution can require significant capital investment as well as ongoing maintenance outlays. The increasing scarcity and cost of fresh water for production processes also compounds the problem. In this Chemical Processing Wastewater eHandbook we take a look at how to widen your perspective on wastewater including:

  • Optimizing water cleanup with activated carbon - including a few pointers to make the most of absorption systems
  • Improving plant performance with solids/turbidity monitoring - how continuous monitoring in the liquid processes stages of a wastewater treatment plant offers important benefits
  • How to solve partially filled pipe flow measurement challenges
  • How variable frequency drives can reduce installation and programming costs while providing a host of other benefits

Download your copy of this Chemical Processing Water Wastewater eHandbook now.

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CP eHandbook: How to boost wastewater improvement efforts

Chemical facilities are under mounting pressure to process ever larger quantities of wastewater to increasingly higher standards while staying within a variety of cost constraints. Plant operators face the dilemma of how to maintain treatment throughput at reasonable cost even when the plant reaches design capacity. Potential changes to production mixes can compound the challenge. Fortunately, adopting the latest wastewater-treatment technology can inject new life into a plant, extending useful asset life without heavy upfront capital investment. In this Chemical Processing Wastewater eHandbook we take a look at how to boost wastewater improvement efforts including:
 

  • An exploration of an innovative system that enables wastewater capacity expansion
  • Why chemical makers are increasingly focusing on water-related risks and opportunities

 Download your copy of this Chemical Processing Wastewater eHandbook now.

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CP eHandbook: Step Up Water Conservation

Chemical makers increasingly are focusing on water-related issues. In particular, concern over availability is spurring leading operating companies to implement a host of novel strategies and technologies to optimize water use. Chemical makers are implementing strategies and solutions to scale back on their overall usage of water, reuse water and put clean water back in to circulation. In this ChemicalProcessing Water Optimization eHandbook we take a look at how chemical companies are dealing with water challenges

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CP eHandbook: Dealing With Water Challenges

For chemical processors, the use of water in their processing can correlate to significant costs. Cost, coupled with an increasing focus on the environmental impact of both water usage and wastewater creation, are challenging processors to take a closer look at both their consumption of water and production of wastewater. Wide-ranging water optimization efforts, from fixing pipe leaks to minimizing cooling tower blowdown, are providing significant savings to chemical makers, but there’s more. In this ChemicalProcessing Water/Wastewate eHandbook we take a look at how to deal with water challenges.

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