This Chemical Processing eHandbook examines some of today’s energy efficiency challenges and way to navigate solutions for chemical manufacturers.
Do you want to conduct more accurate energy assessments? Interested in better managing excess air? Curious about how revamping of distillation columns could reap potential benefits?
Download this Chemical Processing eHandbook for ideas and strategies including:
- Pump Out Energy Inefficiencies: Prioritize pumps to analyze before conducting energy assessments.
- Better Manage Excess Air: Implementing an oxygen trim control system offers significant advantages.
- Plants Polish Towers: Revamping of distillation columns often can provide important benefits.
This Chemical Processing Special Report takes a look at how chemicals manufacturers are meeting the various challenges presented by process heaters. We look at solutions to lower costs, lower temperature, save energy, and be more efficient.
Download this Chemical Processing Special Report for insights and strategies including:
- Take a Fresh Look at Heaters: A Simple four-step program can lead to significant savings.
- Don’t Get Heated Up By a Hot Stack: Consider several projects to lower temperatures and recover energy.
- Cut the Cost of Waste Gas Incineration: An RTO often can offer an effective and fuel efficient option.
- Providing High Emissivity Coatings Solutions for Process Heaters
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.
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
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
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
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
Bristol-Myers Squibb manually monitored dissolved oxygen (DO) periodically and ran aeration blowers more than necessary to guard against variable loading rates. After upgrading the system to use online DO monitoring operators now have continuous DO readings in the aeration tanks, substantially reducing energy and maintenance costs.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
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
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
Real Time Online Liquid Analysis to Prevent Product Loss, to Reduce Energy Consumption and to Minimize Waste Treatment Costs
Product losses and energy and waste treatment costs can be reduced significantly with Total Organic Carbon (TOC) monitoring. Reducing product loss results in savings in raw materials, energy consumption, and in water treatment charges. This means more products in production and less product in the waste water treatment plant.05/15/2012
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.05/03/2012
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.03/13/2012
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.02/14/2012
Heat transfer fluids -- from mineral oils to synthetic and organic-based formulas -- are the lifeblood of many critical operations within the process industries. This special, interactive PDF looks at how plant personnel can better understand various fluids and fluid properties, and track the performance of their entire heat transfer system.03/21/2011
Approximately one-third of the electric motors in the industrial and commercial sectors use belt drives. If the efficiency of these systems were improved by just 5%, plants would see tremendous energy savings. Such savings are not out of reach. Synchronous belt drives operate so efficiently that they enable savings across many industrial applications.09/23/2010
This white paper takes an in-depth look at the advantages and disadvantages of steam and hot water for jacketed heating, and compares indirect and direct steam injection systems for making hot water.09/15/2010