Process Engineering White Papers

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  • eHandbook: Effectively Manage Energy

    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
    • More!

    Download your copy of this Chemical Processing Energy eHandbook now.

  • Special Report: Effectively Deal With Waste Gas

    Waste gas incinerators react oxygen with waste hydrocarbons at high temperature to produce a clean flue gas. A perfect incinerator would have a destruction and removal efficiency (DRE) of 100%, zero fuel usage and zero emission of carbon monoxide and nitrogen oxides. A small amount of the original hydrocarbons always remains, though. If 1% is left, the DRE is 99%. Some CO and NOx always are produced, too. However, NOx emissions are lower for a regenerative thermal oxidizer (RTO) than for almost any other type of thermal oxidizer. With the U.S. Environmental Protection Agency and local air boards requiring DRE values from 95% upward, effectively dealing with waste gas means ensuring compliance with the added benefit of reduced energy costs. In this Special Report we take a look at how an RTO often can offer an effective and fuel-efficient options for cutting the cost of waste gas incineration, how technologies transform greenhouse gas into a feedstock for chemicals, how the right emission control system can help meet compliance and reduce energy costs and several steps that play a crucial role for setting up an effective greenhouse gas monitoring plan. Download now.

  • Powder eHandbook: Get a Better Handle on Your Solids Process

    Getting a better handle on Solids Process is an on-going challenge for chemical processors. Are you struggling with multiphase sampling? Do you want to conquer pilot plant challenges? Do you want to learn more about how automatic sampling can help control process safely?

    This Chemical Processing eHandbook takes a look at how chemicals manufacturers are meeting these challenges head on. Download this Chemical Processing eHandbook for insights and strategies including:

    • Don’t Be Fazed By Multiphase Sampling: An isokinetic system can provide accurate samples;
    • Conquer Pilot Plant Challenges: Use design of experiments to minimize the number of runs and ensure meaningful data;
    • Case Study: Sampler Helps Control Process Safely: Automatic samplers can be key to ensuring process samples are repeatable and reliable;
    • More!

    Download your copy of this Chemical Processing Powder eHandbook now.

  • Keep Your Pressure Instruments Safe from Corrosion

    Failure of a pressure instrument due to corrosion can lead to the expulsion of volatile liquids and gases into the surrounding environment. Understanding the causes of corrosion and preventative measures is crucial to operators. To help counter this threat, valuable information is available from dedicated organizations. Learn about these resources and gain the insight you’ll need to protect your people, processes and profits. Download now.

  • eHandbook: Put the Spotlight on Process Safety

    How do we make safety in our processes second nature? The concept of inherent safety goes beyond simply not having materials that potentially could damage the pipes, vessels and equipment that make up manufacturing facilities. We need to understand all the ways those materials can be involved in incidents that harm people, the environment and our facilities.

    Without a thorough understanding of those scenarios and how they can occur, we can’t properly evaluate the risks posed by different technological approaches and effectively apply inherently safer technologies.

    In this Chemical Processing Process Safety eHandbook, we delve in to what it means to embrace the concept of inherent safety and provide tips for safer processing including:

    • A variety of strategies that can eliminate hazards from operations
    • Improving alarm management – how adopting a pragmatic approach can achieve significant benefits
    • A rational approach to combustible dust explosion protection

    Download your copy of this Chemical Processing Process Safety eHandbook now.

  • Training Your Staff About Energy Efficiency -- A Chemical Processing Special Report

    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

    Pick Heaters
  • Wastewater eHandbook: Avoid the Whirlpool

    Today’s global challenges — climate change, water scarcity, food provision, declining ecosystem services, human development, and the overall transition to a sustainable society and planet — require solutions of unprecedented scale. Public policy and behavior change will play a significant role in addressing these challenges. So, too, will business and technology. In the decades ahead, these challenges offer tremendous opportunity for organizations that can contribute to tackling them.

    This Chemical Processing eHandbook takes a look at how chemicals manufacturers are meeting these challenges head on. Download this Chemical Processing eHandbook for insights and strategies including:

    • How organizations such as Dow, Solvay, Dupont and BP are adapting strategies for their water conservation efforts;
    • How a new purification process that’s carbon-negative and energy-positive can save energy;
    • Why sustainability metrics spur product development efforts to improve conservation efforts
    • More!

    Download the eHandbook now.

  • Mixing eHandbook: Avoid Mixing Mix-Ups

    For chemical processors, ensuring a long-lasting, high-quality mix is a huge challenge regardless of the physical properties of the mixing component – liquid, gas, solid. In this Chemical Processing Mixing eHandbook, we take a look at mixing technologies including “open” batch operation, static mixers, hydrogenation and inline mixing. Understanding how each of these technologies works, the benefits and challenges can help you to avoid common mixing mix-ups. Download your copy and learn about:

    • A number of technologies that can handle pipeline mixing
    • How hydrogenation reactions can achieve greater conversion rates and thus better space/time yields
    • Continuous powder wetting
    • Inline mixing systems
    • Modern in-line mixers

    Avoid common mixing mix-ups. Download your copy of this Chemical Processing Mixing eHandbook now.

  • Special Report: Focus On Better Equipment Care For Increased Productivity

    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.

    Download the special report now.

  • eHandbook: Leverage These Level Best Practices

    Level measurement, which is the detection of the phase split between vapor/liquid, liquid/liquid, vapor/solid and even liquid/solid, is a key parameter in the operation and control of modern industrial processes. A reliable outcome depends on the phase conditions being relatively consistent under all process conditions. Unfortunately, the importance of level control isn’t always understood. In this Chemical Processing Level Instrumentation eHandbook, we discuss best practices for level management including:

    • Interpret Level Readings Right – how the type of instrument can make a big difference in deciphering measurements
    • Choose the Correct Level Sensor – key considerations and questions for identifying the most appropriate choice
    • Customize Your Level Detection – a myriad of options help you achieve optimal level indicator performance

    Download your copy of this Chemical Processing Level Instrumentation eHandbook now.

  • Steam eHandbook: Take the Heat Off Your Steam System

    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.

  • 7 Ways to Improve Process and Productivity with Pressure Instrumentation

    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.

  • Process Filtration Scale-Up from Lab to Commercial Operation

    This article discusses process filtration approach developed for each technology stage starting from batch filtration in the lab to continuous filtration for the full-scale commercial operation. Process engineers must not “jump to conclusions”, a reference from Sherlock Holmes and Dr. John Watson who prove time and again is that there is no benefit to jumping to conclusions. Therefore, laboratory / bench top filtration testing is covered for problem analysis, technology selection and pilot and demonstration scale-up. The paper continues with the filtration testing and then scale-up to the commercial size. Finally, the paper concludes with a general review of the problem-solving skills of Holmes and Watson and how these skills can be utilized by process engineers as a framework for “idea-generation” when analyzing a new process scale-up.

    Download now.

  • Powder eHandbook: Tame Your Pesky Powders

    A material’s characteristics – adhesiveness, cohesiveness, aeratibility, pressure-sensitivity – often change during processing and can cause both flow and hidden hazard challenges. And while poor flow is one of the most common problems encountered in handling or storing solids, dust control issues also need to be identified and addressed. This includes combustible dust as the repercussions can result in costly downtown and in some instances, explosions, serious injury and possibly even death. In this Chemical Processing Powder eHandbook, we take a look at strategies and solutions for taming pesky powder processing challenges including:

    • Defuse Dust Dangers - Carefully consider and then counter risks of fire and explosion
    • Clamp Down On Clumping - First understand what’s really causing the problem
    • What You Don’t Know About Powder Flow - Shear cells can quickly reveal information about flow behavior
    • Know Your Vacuum Pumps - Understand the differences between liquid ring and rotary screw dry pumps for distillation

    Learn how to tame your pesky powder challenges. Download your copy of this Chemical Processing Powder eHandbook now.

  • Semi-Automated Systems Take Water Jetting to a New Level

    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.

    Download the white paper now.

    NLB Corp.
  • Loss-On-Drying vs. Thermogravimetric Analysis

    Thermogravimetric analyzers (TGAs) deliver valuable information about a material’s response to temperature. But while the information they deliver is critical, TGAs themselves tend to be bulky and difficult to use, and can cost tens of thousands of dollars. This paper explores how you can gather the same data as a TGA using an instrument which is considerably easier to use, more durable, and less expensive: the Computrac MAX 5000XL. The materials examined in this paper are certain flue gas desulfurization byproducts—gypsum, calcium sulfite hemihydrate, and calcium hydroxide—but the principles in question can apply to all manner of materials, from biofuels to pet food to landfill waste.

    Download the white paper now.

  • Special Report: Safety is No Accident

    For chemical processors industrial safety is a top concern. Industrial accidents can lead to lost production, injury and in some cases even death. This special report examines how organizations can reduce risk, prevent incidents and ensure safety and compliance in hazardous environments with improved processes. Topics covered include:


    • How to Achieve Effective Process Safety Management (PSM) -- Senior managers play an important role in improving PSM. Their efforts should be visible and their leadership felt to ensure success.
    • Getting To The Root Of Accidents -- Accident investigations usually focus on operator error or technical failures. However, applying systems thinking may provide greater insights on underlying causes and, in the long run, prevent more incidents.
    • Optimizing Safety and Efficiency Through Modern Design-- This ignition protection method helps ensure accuracy, safety and compliance in hazardous environments

    Download Now

    Mettler Toledo
  • Optical System Sets New Standards in Oxygen Measurements

    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.

    Download the white paper now.

  • Eastman Deploys ProjectWise to Drive Collaboration, Greater Efficiency, and Cost Savings

    Eastman Chemicals, one of the world’s largest chemical companies, recently decided to strengthen their information security and reliability, as well as develop a path forward to lower software maintenance costs. This Case Study shows how Eastman achieved their goals by globally standardizing on Bentley's ProjectWise software in order to replace an aging, but critical, in-house records management system. The ProjectWise solution has enabled Eastman to significantly reduce their IT costs, and is helping them achieve greater security of their vital plant information while providing a modern data-centric environment to move beyond engineering records into asset performance improvement.

    Download the white paper now.

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