Chemical plants vary widely in size and complexity yet share common goals for maximizing efficiency safely and cost effectively. This Chemical Processing Special Report tackles two areas in chemical processing - compressed air systems and powder handling - where gains can be achieved for improving efficiency. We also address the concerns of safety as it relates to drying compressed air in hazardous atmospheres.
Whether compressed air systems are centrifugal, rotary screw, reciprocating compressors or a combination, this Special Report provides and understanding of what’s involved in getting a suitable supply of compressed air.
Efficient powder handling can be achieved through optimized humidity management.
Safe drying practices in hazardous air locations
HACH BioTector 3500c Analyzer For TOC, TC, TIC and VOC Analysis
In recent years, TOC analysis has become accepted in the industry as the standard method and the only reliable online method used to determine contamination in waters, to control processes, to prevent product losses and to minimize waste. It is especially important to monitor this parameter in applications such as condensate return water, boiler/feed water, etc. In boiler/feed water and in industrial steam generating systems, carbonic acid corrosion of condensate lines is often a serious problem. Depending on the application type, analysis of only one parameter (e.g., TC) is generally not sufficient to make any useful process decisions. Multiple-parameter analysis (TOC, TC, TIC, VOC etc.), as carried out in the Hach BioTector B3500c analyzer, is proven to be more useful and always superior to single-parameter analysis in the industry.
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.
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.
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
Find out how to master flow challenges. Download your copy of this Chemical Processing Flow eHandbook now.
Bristol-Myers Squibb Works hard to be a Good Neighbor
Bristol-Myers Squibb manually monitored dissolved oxygen (DO) periodically and ran aeration blowers more than necessary to guard against variable loading rates. After upgrading the system to use online DO monitoring operators now have continuous DO readings in the aeration tanks, substantially reducing energy and maintenance costs.
7 Applications You Didn’t Know Were Compatible with Microwave
Microwave energy in chemical processing has really come of age over the past few years. Many companies are experiencing the benefits that microwave offers over conventional drying technologies. Other functions include: sterilization, pasteurization, cooking, tempering, dehydration and heating.
While you may have guessed a few of the applications we’re profiling, or may even work with them yourself, we hope at least one or two applications off our list will catch your eye and perhaps start you thinking.
• Analytical Chemistry
• Treatment of Biomass & Biosolids
• Powder Processing
Animal Blood Plasma
• Pyrolysis for Recycling & Waste-to-Energy
Plastics and Rubber
• Petro Chemicals
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.
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.
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.
Reducing Water Consumption in Compressed Air Systems
Compressed air systems are sometimes called the "4th Utility" due to their presence in almost all industrial processes and facilities. As US water consumption continues to increase, compressed air systems provide an opportunity for energy managers to reduce associated cooling water consumption and costs. In this white paper, we focus on the opportunity to reduce the water consumption of compressed air systems. Understanding the costs and the alternative types of cooling systems is an important first step. This white paper provides background on US water consumption in both the public and industrial sectors; it provides detail on industrial water consumption -- including industrial cooling water -- and its associated costs; it also details six different types of cooling systems available.
Chemical Processing Special Report: Make the Most of Water
Chemical Processing has taken an in-depth look at just industrial wastewater -- how it is used, processed and potential management and compiled a comprehensive Special Report titled: Make the Most of Water. This informative Special Report covers such topics as:
Is water the new carbon -- what path will regulating water take
How to optimize water use
Micropollutants -- defining, managing, and communicating potential risk
Download your copy.
Training Your Staff About Energy Efficiency -- A Chemical Processing Special Report
Certainly over the last few years, how plants consume energy has made an impact on that plant's efficiency and profitability. But is everyone at your plant doing their part? From Process Engineers to Plant Managers, everyone can have a role in implementing and adhering to energy efficient practices and exploring ways to improve energy efficiency. Chemical Processing has taken an in-depth look at just how this can been accomplished and compiled a comprehensive Special Report titled: Training Plant Staff About Energy Efficiency. Now available for download, this informative Special Report covers such topics as training operators, available energy tools, assessing equipment and more.
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.