Process Engineering White Papers

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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.

    06/29/2015
  • 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.

    05/21/2014
  • 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.

    10/16/2013
  • 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:

    • How a Texas-based plant pared steam consumption - Thinking differently about energy management lead to substantial savings
    • Steam trap selection - A life cycle analysis approach can help reduce maintenance and prolong steam trap life
    • Reduce consumption with a simple formula to determine the proper steam demand for DSI heaters

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

    06/19/2013
  • Heating Water by Direct Steam Injection

    Direct steam injection provides a solution where large volumes of hot water at precise temperatures are required, and saving space and energy are factors in the system design.

    Pick Heaters
    05/03/2012
  • Productivity Improvement with Wireless Steam

    When steam traps leak or fail, energy is lost and there could also be steam equipment failure or damage and potential safety hazards. A major food manufacturer improved their steam trap program and enhanced their ongoing leak repair campaign with remote steam trap monitoring using Smart Wireless Solutions from Emerson.

    Emerson
    03/13/2012
  • Drying Compressed Air in Hazardous Atmospheres

    Hazardous locations have or could potentially have high concentrations of flammable gases, vapors, combustible dusts, etc. A small spark can lead to a horrific explosion dangerous to equipment and workers in the area. Equipment located in hazardous areas must be specifically designed to prevent ignition and explosion.

    Parker Hannifin
    02/24/2012
  • Gas And Dust Explosions -- Relief Sizing Formula

    A large number of analytical and highly empirical correlations including monograms reflecting changing standards have been or are being proposed separately for gas and dust explosion relief venting. This white paper provides a generalized formula that is applicable to both gas and dust deflagrations including subsonic and sonic pressure relief conditions and is consistent with available experimental data and industry experience. Application of the model is illustrated for dust explosions. Download now.

    Fauske & Associates
    05/06/2011
  • Energy Savings From Synchronous Belt Drives

    Approximately one-third of the electric motors in the industrial and commercial sectors use belt drives. If the efficiency of these systems were improved by just 5%, plants would see tremendous energy savings. Such savings are not out of reach. Synchronous belt drives operate so efficiently that they enable savings across many industrial applications.

    Gates
    09/23/2010
  • 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.

    PdMA Corp.
    03/08/2010
  • 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.

    Bete Fog
    09/16/2009
  • Benefits of State Based Control

    State Based Control is a plant automation control design based on the principle that all process facilities operate in recognized, definable Process States that represent a variety of normal and abnormal conditions of the process. State Based Control, implemented with the latest developments in object-based technologies, delivers direct benefits to its adopters in a variety of Operational Excellence categories. It results in productivity increases, higher asset utilization of both people and process, automated responses and recovery for abnormal conditions and provides an environment for knowledge capture directly into the control design.

    David Huffman, ABB Inc.
    05/14/2009
  • Improving Plant Production with Wireless Condition Monitoring

    Mechanical failure of motors, drives and other vital electromechanical equipment are among the most common reasons for production stoppages. Fortunately, recent advancements in vibration monitoring and data analysis have lead to condition monitoring systems that can accurately detect a problem before failure, thus reducing costly machine shutdowns and maximizing production output. These systems are installed on the monitored equipment and are typically networked back to a central computer for data analysis and alarm annunciation. Because the machines may be in remote locations where network infrastructure is not available, or on moving platforms where hardwired network connectivity is not practical, wireless communications is a networking alternative that offer installation cost savings, quicker deployment and even improved reliability in certain situations.

    Jim Ralston, Wireless Sales Engineer, ProSoft Technology
    09/30/2008
  • Removing Liquid From Gas

    Liquid entrainment in a gas stream can be a disturbance in many industrial processes. In natural-gas processing, higher-order hydrocarbons, water or impurities have to be separated from the main methane stream. Upstream of gas compressors, droplets that can damage the impellers, have to be removed. With the recently acquired Knitmesh technology and the strategic alliance with Shell Global Solutions, Sulzer Chemtech can supply a broad portfolio of advanced, tailor-made systems for gas/liquid separation to customers in all industries.

    Sulzer Chemtech USA
    09/17/2007
  • Biodiesel Fuel From Palm Oil – Too Good to be Used as Fuel?

    The high prices for oil and gas have spotlighted other sources of fuel for internal combustion engines. Biofuel, a fuel derived from ethanol, and biodiesel fuel, a dieselequivalent derived from biological sources, are 2 possible substitutes for petrochemical fuel. Palm oil is increasingly used as feedstock for the production of biodiesel, but certain palm oil fractions have other uses, e.g., in the cosmetics and food industries. Sulzer Chemtech’s technology supports the separation of crude palm oil (CPO) in its valuable constituents.

    Sulzer Chemtech AG
    01/11/2007
  • Oxygen in cell culture/venting ozonated vessels

    This white paper outlines trends and opportunities for gasket standardization in processing plants ... including the potential for more reliable sealing, cost savings, inventory reduction, easier installation and safety practices. Steps are outlined for achieving success in gasket standardization across steel, glass-lined and FRP piping.

    W. L. Gore & Associates, Inc.
    10/18/2006
  • Biodiesel Fuel From Palm Oil – Too Good to be Used as Fuel?

    The high prices for oil and gas have spotlighted other sources of fuel for internal combustion engines. Biofuel, a fuel derived from ethanol, and biodiesel fuel, a dieselequivalent derived from biological sources, are two possible substitutes for petrochemical fuel.

    Sulzer Chemtech USA, Inc.
    08/29/2006
  • Gasket Standardization in the CPI

    This white paper outlines trends and opportunities for gasket standardization in processing plants ... including steps outlining how to achieve gasket standardization across steel, glass-lined and FRP piping.

    W. L. Gore & Associates, Inc.
    06/12/2006
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