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
  • 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
  • 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: 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
  • 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
  • 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
  • Chemical Processing’s eHandbook: 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.

    11/14/2013
  • 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
  • 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
  • Chemical Processing Special Report: Jacketed Heating

    Reactor temperature control typically is very important to product quality, production rate and operating costs whether a processor is employing continuous or batch reactors. Download your copy of this Chemical Processing Special Report: Jacketed Heating now!

    Pick Heaters
    03/19/2013
  • 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 including:
     

    •    Equipment rotation: identify damaged and worn components before they cause problems
    •    Backflush strategies: flow reversal can remove fiber buildup in heat exchangers
    •    Advanced Reliability Management: key steps for leveraging limited resources and critical assets
    •    Predictive Maintenance: detailed analysis of maintenance records can further improve equipment reliability
    •    More!

    12/13/2012
  • 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.

    09/26/2012
  • Impact of Formula-Based ERP Applications on Chemical Manufacturers

    By understanding the key functions and architecture of a process-oriented, formula based ERP application, you will have a better foundation for choosing a solution that best suits your company and type of manufacturing.

    This practical guide and checklist ties the unique operations of chemical manufacturers to specific ERP functionality and architecture. Topics include:
    • Formula Specifications
    • Variability and Quality
    • Product Accountability and Costing
    • Traceability
    • IT Maintenance
      Don't settle for a "one size fits all" ERP solution. With the "right fit" ERP solution, you will be able to streamline operations, reduce costs and scale production, while complying with federal regulations -- all with minimum customization.

    CDC Software
    06/07/2012
  • 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
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