Process Engineering White Papers

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  • Special Report: Consider these Safety Instrumented Best Practices

    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

     

    Emerson
    01/20/2015
  • 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
  • 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: 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
  • 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
  • CP eHandbook: Wireless - Plants Benefit from Wireless Technology

    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
    ** More!

    01/17/2013
  • 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
  • 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
  • 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.

    Hitachi
    02/14/2012
  • 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.

    Pick Heaters
    08/12/2011
  • Continuous Valve Monitoring for Product Loss Prevention, Emission Reduction and ROI

    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 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
  • Special Report: Energy Efficiency

    Reducing energy consumption and your plant’s 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.

    Gates Corporation
    10/01/2008
  • Using Operator Interfaces to Optimize Performance of Industrial Wireless Networks

    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.

    Jim Ralston, Wireless Sales Engineer, ProSoft Technology
    09/30/2008
  • Why WirelessHART? The Right Standard at the Right Time

    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.

    HART Communication Foundation
    11/16/2007
  • Preparing for industrial wireless

    Plants across the world are increasingly having to make thedecision to implement wireless technology in their industrial facilities. The right decision enables an infrastructure that provides significant benefits from wire savings to improved operations. Wireless is a complex enabling technology that requires many considerations before broad deployment in an industrial facility.

    Honeywell
    09/27/2007
  • The Next Evolution in Motion Networking

    This paper examines the value benefits of a wireless approach and addresses the most obvious concerns of safety, reliability and latency.

    Parker Hannifin Corp.
    08/15/2007
  • Implementing Foundation fieldbus

    This white paper provides some insight into the process for safely implementing Foundation fieldbus in an area of your facility that has a hazardous classification.

    Moore Hawke Fieldbus
    06/14/2007
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