For chemical processors, the use of water in their processing can correlate to significant costs. Cost, coupled with an increasing focus on the environmental impact of both water usage and wastewater creation, are challenging processors to take a closer look at both their consumption of water and production of wastewater. Wide-ranging water optimization efforts, from fixing pipe leaks to minimizing cooling tower blowdown, are providing significant savings to chemical makers, but there’s more. In this ChemicalProcessing Water/Wastewate eHandbook we take a look at how to deal with water challenges including:
• Reducing water consumption and increase recycling – including examples of achievement and strategies from BASF, Air Products, Eli Lilly & Co, and Pfizer • RO Membranes: proactive steps can maximize life and performance for water purification • More!
Water is a critical utility at process plants, often serving both as a heating and a cooling medium. Many process plants rely on this water for processing and other applications. Providing the water, usually by heating via steam coils or direct steam injection nozzles, takes significant energy. In this Chemical Processing WasteWater we take a look at water best practices including:
How to cut energy consumption in water systems in both hot and cold water applications
Polymer piping - we identify benefits over metallic systems
TOC analysis challenges - techniques that address barriers to standard online TOC measurement methods
Download your copy of this Chemical Processing Water WasteWater eHandbook now.
For the latest strategies on how to set an effective reliability program, download this Special Report: Cost-Justify Your Reliability Initiatives.
In this report youll find:
Predictive tools and technologies for enhanced equipment reliability
The four things a plant manager can do that maximize reliability
Critical equipment for an effective maintenance program
Operations staff and plant engineers also have a keen interest in the security of control networks. They are responsible for the reliability, availability, safety and integrity of the process. Their facilities are the ones producing products and earning revenues, so their concerns, priorities and knowledge must also be considered when determining security options.
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.
Organic cellulose and biomass filtration, washing and drying is very unpredictable and even minor differences in feedstock,washing or cake moisture requirements can require a different process solution.
Both vacuum and pressure operations can provide equivalvent process results.
On-site testing is required to determine the optimum filter selection.
Support for off spec materials, formula management, changeovers, parallel operations, lot trace and trace, unlimited unit of measure conversions, is key.
There are a host of enterprise resource planning (ERP) and supply chain management applications available to chemical manufacturersthe challenge is selecting the right one that offers a baseline product with industry-specific functionality. Many ERP applications available today are not industry-specific enough for chemical manufacturers and require major modifications, or, one must select from an industry template that may or may not fit specific needs.
There is also the chance that the software provider may not exist in two to three years (e.g., it may be acquired and the products future may become unknown), or the provider may not be financially secure, adding long-term risk.
In dozens of industries and in millions of applications around the world, dangerous chemicals are transferred from their original shipping containers into smaller jugs or buckets or applied to other end-use processes. Historically, the predominant dispensing method in many of these applications has been through an open system where the liquid is poured out of the container. With a poured system, the container is often flipped on its side and the liquid is poured into a secondary container.
The user then just carries the bucket to wherever it needs to go. A mental image of this technique quickly reveals its potential dangers and inefficiencies.
This article discusses the choice of thin-cake (2 25 mm) separation technologies and their benefits to optimizing the effectiveness of the production process. The paper continues with a
discussion of clean-in-place operations to meet current Good Manufacturing Practices (cGMP) guidelines including riboflavin test and validations.
Determining the most economical option to control airborne emissions during chemical process operations presents several unique challenges. As with any add-on control system, the goal is to minimize the annualized total costs while maintaining proper operation. In this white paper, learn the different options that are available and which ones fit your process the best.
Increasingly stringent clean air standards and heightened concerns over greenhouse gas emissions are driving technology enhancements in the chemical processing industry. This white paper explains some of the abatement challenges this industry faces and demonstrates how many chemical processors are integrating newer, more efficient emission control technologies for the destruction of Volatile Organic Compounds (VOCs) and Hazardous Air Pollutants (HAPs).
The paper also includes a case study, demonstrating how one Pure Terephthalic Acid (PTA) plant saved nearly one million dollars by upgrading to a newer thermal oxidizer technology.
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.
Major accidents with multiple fatalities continue to occur worldwide in theprocess industries, causing distress to those involved and massive costs to companies. Almost daily, facilities in the process industries face a number of specific major accident hazard scenarios depending upon the nature of the substances they handle and their processing activities. These are caused by known initiating events such as failure of hardware or control systems, or errors by operating or maintenance staff. In this Chemical Processing Process Safety eHandbook, we provide tips for safer processing including:
>> The role of senior management including six important steps senior management should take to insure safer processing
>> Process safety documentation – strategies for ensuring that your documentation is up-to-date and readily accessible
Powders and the dust they create have a tendency to create a myriad of material handling headaches. For example, dust can wreak havoc on the performance and accuracy of many level sensors, rendering them inaccurate and unreliable. Powder particles under the influence of gravity can become compacted resulting in inter-particle friction that may prevent flow movement. In this Chemical Processing Powder eHandbook, we offer a few tips for optimizing powder processing.
Processing powders can be tricky. During processing, powder properties can be affected by many different factors including if the materials are stored for long periods, if the materials are exposed to moisture, and by fluctuations in the mechanical processes that handle powders. In this Chemical Processing Powder eHandbook, we take a look at technologies and strategies for handling powders including:
Options for large drivers – with a focus on variable-speed electric motors
Innovative level measurement technologies
How shear cell instruments and relative humidity tests can determine a powders flow behavior
Indoor flameless venting – how modern technology can help eliminate the risk of damage and reduce maintenance costs
Learn how to process powders with ease. Download your copy of this Chemical Processing Powder eHandbook now.