This Chemical Processing eHandbook examines some of today’s energy efficiency challenges and way to navigate solutions for chemical manufacturers.
Do you want to conduct more accurate energy assessments? Interested in better managing excess air? Curious about how revamping of distillation columns could reap potential benefits?
Download this Chemical Processing eHandbook for ideas and strategies including:
- Pump Out Energy Inefficiencies: Prioritize pumps to analyze before conducting energy assessments.
- Better Manage Excess Air: Implementing an oxygen trim control system offers significant advantages.
- Plants Polish Towers: Revamping of distillation columns often can provide important benefits.
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
From process engineers to plant managers, it is critical that everyone plays a role in implementing and adhering to energy efficient practices and exploring ways to improve energy efficiency. This special report takes an in-depth look at how organizations can increase profitability by educating and training their staff to understand the importance of energy. Topics covered include:
- Energy Saver- Educate Your Peers
- Train Your Operators on Energy Efficiency
- Train Your Project Manager on Energy Efficiency
- Train Your Plant Manager on Energy Efficiency
- Some training courses are worth the price
- Energy Saver: Do Your Own Stream Survey
- Direct Stream Injection Hot Water Systems for Jacketed Heating
- Innovation in Direct Stream Injection Heaters Since 1945
Optimize your operation in four critical areas – production, quality, energy efficiency and safety – with pressure instrumentation. This paper reviews pressure, flow and level solutions that work across all points of the operation to minimize process variability, gain process insight, reduce maintenance and downtime, and meet regulatory demands. Learn more.06/23/2015
For chemical processors, assuring safe operations is always top of mind. In this Chemical Processing Special Report we take a look at three distinct areas of operations and steps to insure best safety practices in each.
- HIPS for Reactive Processes – how this safety-instrumented systems offer advantages over pressure relief valves
- HART DIAGNOSTICS - in safety instrumented system (SIS) field devices have been used for many years by several different SIS vendors. HART diagnostics provide much more information on the health of a field device than can be determined from a standard 4–20 mA signal.
- Proof testing - how this modern method improves efficiency, reduces errors, and meets compliance requirements
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
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
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
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
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:
** How installing a wireless pH analyzer for crucial insights on seal integrity provided Fuji Film with a low-cost monitoring solution for protecting a pricey pump
** How one of the world’s largest producers of chlorine, caustic soda and vinyl chloride embraced wireless technology and achieved operating economies and more efficient control of its chemical processes
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
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.05/03/2012
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.03/13/2012
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.02/14/2012
This white paper takes an in-depth look at the advantages and disadvantages of steam and hot water for jacketed heating, and compares indirect and direct steam injection systems for making hot water.09/15/2010
One of the challenges that companies have faced in implementation of continuous monitoring systems is the lack of infrastructure for sensing and data collection. The devices to be monitored are widely dispersed throughout plants with large areas, have no existing power or signal transmitting wire infrastructure, so the capital costs associated with the power and communication services have historically prohibited continuous monitoring. This white paper will unearth best practices to prevent product loss, reduce emissions and ensure ROI.05/26/2010
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.03/08/2010
Reducing energy consumption and your plants environmental impact is a hot topic. In this Special Report we take a look at the organizational obstacles to avoid, how to enroll your employees in the quest, and the steps you need to take in order to manage your energy costs. We also delve in to practical energy efficient applications such as recovering exhaust heat in air conditioned facilities and the use of carbon synchronous belts.10/01/2008
The performance of wireless networks can change over time due to increased performance demands, changes in the radio frequency (RF) environment and changes in the physical environment. This article will explore the use of a wireless diagnostic OLE for Process Control (OPC) server technology to embed diagnostic information in human machine interfaces (HMIs), thus optimizing industrial wireless network performance.09/30/2008
The WirelessHART standard provides a robust wireless protocol for the full range of process measurement, control and asset management applications. Based on the proven and familiar HART protocol, it enables users to quickly and easily gain the benefits of wireless technology while maintaining compatibility with existing devices, tools and systems.11/16/2007