Salt water, sour gas and other corrosives play havoc with metallic instruments and vessels. However, the use of correct materials can prevent failures and resulting damage. So where can you find guidance as to how to select the right metals? The National Association of Chemical Engineers (NACE International) sets standards "To protect people, assets and the environment from corrosion". Learn more about NACE and their processes by viewing this paper.05/24/2016
Optical Dissolved Oxygen Measurement in Power and Boiler Applications
Over the past decade a few trends have started to gain pace within the industry, driving a change in instrumentation requirements for operations managers and plant chemists:
- Maintenance and operations budget cuts have resulted in fewer plant personnel, forcing plant staff to optimize their workload even further
- As the cost of building new power and boiler systems increase, many operators now look to plant life extensions as a solution to bridge gaps in production capacity at a lower investment premium
These trends have changed the requirements in these applications. Starting from these trends, this article analyzes the options for oxygen measurements that are precise, reliable, stable, and above all require low to zero maintenance.04/27/2015
While all manufacturers have standard operating procedures (SOPs) in place for quality operations, how do executives know if individuals across the company’s various business units and geographic regions are following procedure?
Global chemical manufacturers are turning to enterprise quality management systems (EQMS) to take control over quality operations. As a result, manufacturers can quickly identify and address deviations and complaints, uncover potential issues and implement global continuous quality improvements to cut up to 40% in quality management costs.
In this paper, we examine:
- The regulatory, operational and economic challenges facing chemical executives today as they work to deliver safer chemicals products in an increasingly regulated and competitive business environment
- How a disconnected approach to quality management increases risks and costs for global chemical manufacturers
- How an EQMS implemented as part of a company’s overall business strategy delivers operational and cost benefits that transform quality management from a cost center to a revenue driver
Pneumatic conveying is an effective form of moving dry materials. However, the long lengths of conveying pipe present a challenge when it comes to addressing cleanliness and sanitation.
While the closed nature of pneumatic conveying systems protects material from outside contamination, like debris, insects, etc., it is difficult to identify and protect against internal forms of contamination, such as buildup, microbial growth, etc. A plant HACCP or sanitation plan that does not address thousands of feet of pipe and dozens of elbows is incomplete and at risk for a recall.03/24/2015
The phrase “Vacuum Cleaning System” refers not only to cleaning by means of vacuum hose and tools, but also to a multitude of tasks which can be accomplished by the same basic system components: a vacuum producer and separators. In this paper, we cover the vacuum cleaning system as a tool for good housekeeping. Such a system is generally designed to pick up and convey dry and free-flowing material that can enter and pass through the vacuum cleaning tool and hose. Further, the system is designed to allow for a selected number of operators.02/24/2015
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
Economic growth, industrialization and population growth are driving the increasing demand for water, while factors such as climate change, pollution and regulation are affecting the supply and costs related to water.” The chemical industry, being highly water intensive, certainly is exposed to water-related risks. Any efforts to manage these risks and capitalize on opportunities begin with the measurement and appreciation of how water may impact business, followed by the development of strategies to protect the business both now and in the future. In this Chemical Processing Special Report we take a look at water challenges and potential solutions for chemical processors including:
- Water-related risks and opportunities
- How chemical makers strive to cut water consumption and improve treatment
- The Importance of visible TOC levels
During industrial manufacturing, many companies use a wide variety of chemicals from methanol, acetone and benzene to foodstuffs like wine and edible oils stored in large tanks at different points in the manufacturing process. In a technique called “chemical tank blanketing,” or “padding” nitrogen is commonly applied to protect chemicals stored in tanks against contamination, degradation or chemical change as well as to prevent fire or explosions. This white paper first discusses blanketing basics and benefits. It reviews considerations for tank blanketing systems and discusses a newer approach, which is typically more cost effective for most applications, is that of generating nitrogen on-demand in the plant itself.09/12/2014
Medium voltage variable frequency drives (VFDs) are often the best choice to capitalize on opportunities to significantly reduce the operating and maintenance costs associated with relatively large rotating equipment. Even a seemingly modest energy savings of a few percent of the operating load can translate into significant energy savings. In this special report we take a look at how to make the most of VFDs: how optimum performance depends upon proper installation and control; how controlling the speed of VFDs can help eliminate waste and promote efficiency, reliability and quality and; considerations for changing drive speed over pumps. Download now.03/25/2014
In recent years, TOC analysis has become accepted in the industry as the standard method and the only reliable online method used to determine contamination in waters, to control processes, to prevent product losses and to minimize waste. It is especially important to monitor this parameter in applications such as condensate return water, boiler/feed water, etc. In boiler/feed water and in industrial steam generating systems, carbonic acid corrosion of condensate lines is often a serious problem. Depending on the application type, analysis of only one parameter (e.g., TC) is generally not sufficient to make any useful process decisions. Multiple-parameter analysis (TOC, TC, TIC, VOC etc.), as carried out in the Hach BioTector B3500c analyzer, is proven to be more useful and always superior to single-parameter analysis in the industry.03/18/2014
In the decade before Stuxnet attacked process control systems in Iran, there were just five known supervisory control and data acquisition (SCADA) vulnerabilities for all control systems in the world, according to the U.S. Department of Homeland Security’s Industrial Control Systems Cyber Emergency Response Team (ICS-CERT). In 2011, the year after Stuxnet, that vulnerability count jumped to more than 215. Last year, it reached 248 (Figure 1). No surprise then that Chemical makers are increasingly focusing on protecting their process control systems from intrusion both from the inside and outside. In this Chemical Processing Special Report: Secure plan(t), we take a look at:
How to better protect your control system - “Defense in depth” is crucial, and new and maturing technologies may help
Cyber Security Challenges – learn about countermeasures to protect control systems
Case Study: A vulnerability assessment reveals critical gaps in the security of a natural gas pipeline
How to mitigate security risks in legacy process control systems - several steps can help protect against threats and extend the life of legacy equipment
Learn how to secure your process control systems – and your plant. Download your copy of this Chemical Processing Special Report: Secure plan(t) now.12/17/2013
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
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 accessible09/19/2013
Microwave energy in chemical processing has really come of age over the past few years. Many companies are experiencing the benefits that microwave offers over conventional drying technologies. Other functions include: sterilization, pasteurization, cooking, tempering, dehydration and heating. While you may have guessed a few of the applications we’re profiling, or may even work with them yourself, we hope at least one or two applications off our list will catch your eye and perhaps start you thinking. • Analytical Chemistry • Treatment of Biomass & Biosolids • Powder Processing Carbon Black Animal Blood Plasma Powdered Eggs • Pyrolysis for Recycling & Waste-to-Energy Plastics and Rubber Farm Waste • Petro Chemicals Frac Sand Grease Processing • Minerals06/18/2013
Manufacturing organizations face a critical balancing act – achieving the highest levels of efficiency, while ensuring that they are not over or under supplying the marketplace. This need to be flexible and efficient requires exceptional visibility into all of the factors that influence productivity and output. This white paper will look at the challenges manufacturing organizations face and how automation of key workforce management processes helps manufacturers not only improve efficiency, but also better manage labor spend, reduce compliance risk and improve productivity.05/14/2013
Many industrial plants use dissolved air flotation to remove fats, oils and grease, and suspended solids from wastewater. Chemical additions are often kept higher than necessary to account for variations in influent water quality that are characteristic of industrial facilities. Continuous monitor04/02/2013
Reactor temperature control typically is very important to product quality, production rate and operating costs whether a processor is employing continuous or batch reactors. And with many process plants currently using steam or hot water to heat jacketed devices such as tanks, kettles, dryers, reactors, glass lined vessels, or similar adaptations such as coiled tubing placed inside or outside tanks or vessels – much emphasis is placed on achieving optimized control of these processes. In this Chemical Processing Special Report: Jacketed Heating we take a look at:
- Improving Batch Reactor temperature control - Understand the likely causes and fixes for common problems in reaching set points
- Rethinking Reactor temperature control - Cascade strategy offers simplicity and fast response
- Keeping cool when designing Batch Reactors - in designing such a unit, focus on effective temperature control to achieve optimum performance
- Consider Hot Water for Jacketed Heating - Hot water offers significant advantages over traditional steam-heated systems.
Most chemical processors use precious-metal-bearing catalysts for facilitating and/or speeding chemical reactions. These catalysts are typically composed of platinum group metals (PGMs). After a number of process cycles the catalysts lose their efficacy and must be replaced with fresh catalysts. Spent catalysts are sent to a precious-metals refiner for recovery and refining of the valuable PGMs remaining in this material. Selecting—and working with—a precious-metals refiner is critical to ensure highest possible returns and peace of mind with regard to environmental concerns. Download and read this 22-page white paper to learn more about recovering precious metals from spent catalysts.01/28/2013
As the Department of Homeland Security (DHS) moves forward with the Chemical Facility Anti-Terrorism Standards (CFATS), the program continues to evolve. This white paper describes the ongoing CFATS compliance process (which is a combination of technical, procedural, and personnel security) and also provides insight regarding how to develop or revise a comprehensive Site Security Plan (SSP) and prepare for a CFATS Authorization Inspection (AI). Recommendations are relevant to SSPs for all tier levels and should be considered for a facility's initial SSP submission and/or any required SSP resubmission. Download this white paper now: Tips for Inspection and Resubmission.07/25/2012
Preventing Phenolic Resin Reactor Accidents: Easy to Use Procedure for Checking Adequacy of Emergency Relief Vent Sizes
An easy to use generalized vent sizing formula is illustrated to be consistent with large scale industry experience and dedicated phenolic runaway reaction tests performed by Fauske & Associates, LLC. The formula also clearly explains the 1999 catastrophic failure of a phenol-formaldehyde reactor resulting from a grossly undersized relief system.06/25/2012