Industrial vessels of various types are used extensively in the processing of chemicals, petrochemicals, and pharmaceuticals. Applications commonly involve storage or process tanks, drums, blenders, reactors, kettles, mixers, fermenters or shipping containers. In addition, reusable totes and intermediate bulk containers (IBCs) provide for convenient and cost-effective storage and transport. The cleaning of this essential equipment, however, has long been a challenge.
In this Chemical Processing special report learn more about:
How modern impingement cleaning technologies improve safety and sustainability
How one chemical company profits from faster cleaning turnarounds and fully clean totes
Are you feeling challenged by the task of improving your heat exchanger efficiency? Do you have questions about fluids allocation and more efficient tube cleaning?
This report sponsored by NLB takes a look at how manufacturers are meeting these challenges. Download this special report for insights and strategies including:
- Pick the Right Side: Allocating fluids in a tubular exchanger demands care.
- Clean Tube Bundles Efficiently: High-pressure automated water jetting speeds cleaning and reduces downtime.
Are you feeling stressed about your steam systems? Feeling challenged by issues such as energy loss, hot surfaces, plant downtime and personal injury risks?
This Chemical Processing eHandbook takes a look at how to keep your cool when things get hot in your steam system management. Download this Chemical Processing eHandbook to discover insights and information on:
• Improving Insulation: Hot surfaces can lead to significant energy losses and pose personal injury risks.
• Don’t Get Steamed: Avoid plant downtime and potential injuries by addressing steam-generation chemistry issues.
• Changing Your Approach to Steam System Management: Improve plant productivity and reduce unplanned downtime with this three-step process.
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
Being armed with the knowledge on how to best care for your equipment can produce a myriad of desirable results –improved reliability of that equipment, improved quality of your production and safety for your workforce to name a few. For chemical processors and all manufacturers the benefits for proactively caring for your equipment can translate in to gains in financial performance as a result of decreasing unexpected breakdowns, downtime and maintenance costs. In this Chemical Processing Special Report we take an in-depth look at how to successfully implement an operator care program focused on caring for your plant’s equipment. We also delve deeply into rotary impingement technology and the benefits it brings to manufacturers tasked with tank cleaning to ensure reliable, uncontaminated, quality batches during production.08/25/2015
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
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.05/12/2015
Process Safety Management (PSM), driven by the OSHA 1910.119 standard, aims to prevent the unwanted release of hazardous chemicals. This whitepaper presents an overview of PSM, explains the requirements of a Mechanical Integrity (MI) program, and illustrates how PSM and MI can be established within an asset management framework.04/21/2015
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
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
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
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
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
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.11/19/2013
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
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.10/15/2013
This expert whitepaper, sponsored by Infor, discusses market “verticalization” and its importance when selecting an Enterprise Asset Management / Computerized Maintenance Management System.08/12/2013
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