Process Engineering White Papers

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  • Semi-Automated Systems Take Water Jetting to a New Level

    High-pressure water jetting is powerful and versatile, helping contractors and industrial companies do hundreds of challenging jobs.

    While many jobs are still done manually, new semi-automated systems can maximize three elements crucial to any company’s success: productivity, safety and environmental responsibility.

    Download the white paper now.

    NLB Corp.
    05/12/2015
  • Optical System Sets New Standards in Oxygen Measurements

    Optical Dissolved Oxygen Measurement in Power and Boiler Applications

    Over the past decade a few trends have started to gain pace within the industry, driving a change in instrumentation requirements for operations managers and plant chemists:

    • Maintenance and operations budget cuts have resulted in fewer plant personnel, forcing plant staff to optimize their workload even further
    • As the cost of building new power and boiler systems increase, many operators now look to plant life extensions as a solution to bridge gaps in production capacity at a lower investment premium

    These trends have changed the requirements in these applications. Starting from these trends, this article analyzes the options for oxygen measurements that are precise, reliable, stable, and above all require low to zero maintenance.

    Download the white paper now.

    Hach
    04/27/2015
  • How Chemical Processing Companies can cut up to 40% in quality management costs

    While all manufacturers have standard operating procedures (SOPs) in place for quality operations, how do executives know if individuals across the company’s various business units and geographic regions are following procedure?

    Global chemical manufacturers are turning to enterprise quality management systems (EQMS) to take control over quality operations. As a result, manufacturers can quickly identify and address deviations and complaints, uncover potential issues and implement global continuous quality improvements to cut up to 40% in quality management costs.

    In this paper, we examine:

    • The regulatory, operational and economic challenges facing chemical executives today as they work to deliver safer chemicals products in an increasingly regulated and competitive business environment
    • How a disconnected approach to quality management increases risks and costs for global chemical manufacturers
    • How an EQMS implemented as part of a company’s overall business strategy delivers operational and cost benefits that transform quality management from a cost center to a revenue driver


    Download white paper now.

    Sparta
    03/31/2015
  • 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.

    11/14/2014
  • 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.

    11/11/2014
  • 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.

    10/29/2014
  • eHandbook: Improve Your Maintenance Practices

    More than 25% of maintenance done today is unnecessary and can introduce additional failure risks. Developing and implementing predictive maintenance strategies and practices can lead to improved safety and reduced operating costs. In this Chemical Processing eHandbook, we take a look at strategies and solutions for overcoming predictive maintenance challenges including:

    • Asset management software - identifying the most relevant and accurate data on which to build maintenance and repair strategies
    • The importance of maintenance on smaller component - using gauges as early warning devices can improve uptime, safety and profits
    • Uncovering important insights from your data and the use of statistics such as regression analysis for emulating pump curves or control valves

     
    Download your copy of this Chemical Processing Predictive Maintenance eHandbook now.

    09/26/2014
  • Research Paper: Investigating the Relationship between Gypsum Purity and Hydrogen Sulfide Production under Anaerobic Conditions

    Calcium Sulfate (CaSO4) more commonly known as gypsum is a naturally occurring white crystalline mineral that has many different uses and applications. Gypsum in its hydrated form (CaSO4•2H2O) is used in the construction industry for fire resistance in buildings. Outside of the construction industry, gypsum is used in the food and fertilizer industry for calcium and sulfate fortification respectively. When gypsum is no longer usable, it is deposited in construction and demolition(C&D) landfills where anaerobic (low oxygen) conditions and the presence of sulfate-reducing bacteria promote the decomposition of wallboard/gypsum into hydrogen sulfide gas (H2S). Due to local and state regulations on odor control, these C&D sites monitor their fill for hydrogen sulfide gas.  This paper will couple two methods of analysis to observe the relationship between the purity of gypsum (calcium sulfate dihydrate) and hydrogen sulfide concentration as a sample is fermented by sulfate-reducing agents (e.g. bacteria). The scope of this research may be beneficial for industrial hygienists concerned with C&D landfill H2S levels or for incoming gypsum processing plants who suspect poor quality gypsum.

    09/12/2014
  • Tips On Controlling Dissolved Oxygen in a Wastewater Treatment Plant

    Breakdown of organic wastes entering a wastewater treatment plant is accomplished by using a biomass or blend of beneficial microscopic organisms, bacteria, and solids. This converts the nonsettleable solids (dissolved and colloidal matter) into settleable solids, carbon dioxide, water, and energy. This paper reviews the most common stages for measuring and controlling dissolved oxygen in a wastewater treatment plant.

    Hach
    05/13/2014
  • Heat Exchanger Challenges with Light Tight Crude

    Energy consumption remains one of the largest controllable costs in oil refineries. Heat exchanger fouling can have a significant impact on energy efficiency and production loss. Asphaltene Precipitation is caused when refiners blend incompatible crudes. This is a major source of fouling and leads to performance limitations within days. Heat exchanger fouling is a major challenge for refinery operations. With the increase in crude blending from opportunity crudes such as tight oil, the traditional “manual” monitoring approach may no longer be effective. This White Paper discusses how on-line monitoring and analysis can enable refineries to:

    • Better Understand Accelerated Fouling Due to Crude  Incompatibilities
    • Learn How to Use Online Monitoring to Detect Fouling
    • Identify Which Tube Bundles Require Cleaning

    Emerson
    05/13/2014
  • 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.

    04/16/2014
  • Save Money, Time, and Water With Rotary Impingement Tank Cleaning

    Tank cleaning has always been viewed as a necessary evil for manufacturers. During the cleaning process, a significant amount of resources (time, chemicals, water, electric and labor) is required between batches to ensure a reliable, uncontaminated, quality batch is produced. Although these repeating expenditures have a significant effect on the bottom line, many chemical manufacturers continue to rely on outdated processing for cleaning, not realizing the potential opportunity for substantial cost reductions and revenue recovery through CIP optimization.This whitepaper includes specific case studies on the benefits of rotary impingement and CIP optimization vs. the standard tank cleaning processes. These benefits include drastic savings in time and water usage as well as employee safety.

    Gamajet
    11/19/2013
  • Know Your TCO: A look at Medium Voltage VFDs

    Medium voltage VFDs are high cost, high consideration assets that greatly improve process control and efficiency in manufacturing facilities. It is vital that you and your company understand the TCO of this asset. Download the white paper for more information.

    Siemens
    10/29/2013
  • Five Keys to Avoiding Ethylene Valve Failures

    This concise, compelling overview of best practices in purchasing and maintaining ethylene valve packages is an essential read for industry professionals. The white paper will tell you how to: 1) Select the right seats and seals; 2) Select the right coating materials; 3) Know the quality of the valves you're buying; 4) Find a trusted single resource for your valve package purchases; 5) Keep up with required maintenance.

    Metso
    10/15/2013
  • 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.

    Hach
    08/12/2013
  • 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 including:

    • Streamlining processes – how removing complexities that creep in over time can enhance operations
    • Orifice plates – when insufficient flow conditioning undermines measurement accuracy
    • CPVC for Chlor-Alkali Applications – why chlorinated polyvinyl chloride offers many advantages over other materials

    Understand the many facets of flow. Download your copy of this Chemical Processing Flow eHandbook now.

    07/22/2013
  • Probe-type TDL Oxygen Analyzers in Critical Applications

    Oxygen measurement for safety and control is essential for process optimization in many chemical manufacturing processes. This white paper provides application details of probe-style TDL oxygen analyzers.

    Mettler Toledo
    07/15/2013
  • 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
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