Process Engineering White Papers

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  • CP Powder eHandbook: Effective Powder Processing

    As many chemical processors know, processing powders can be tricky. Powder properties can be affected if the materials are stored for long periods. Powders can be compressed, vibrated, aerated and exposed to moisture. And specific processes like granulation, blending, drying, milling, lubricating and compression put requirements on how powders can be handled. In this Chemical Processing Powder eHandbook, we take a look at how to effectively process powder including:
    • Compression dryers – the case for choosing a solution that produces optimal air quality and low energy consumption
    • GHS – understanding the requirements and what it means to chemicals processors
    • Predicting powder flow behavior
    • Vibratory screen cleaning methods
    • Fine powder flushing - eliminating a common bin-afflicting problem caused by trapped air
    • Tubular Drag Conveying Technology – an alternative to pneumatic conveying
    • Addressing dust hazards – including explosions

  • Fired Up: Combustible Dust Raises Explosive Issues

    Combustible dust fires happen in plants everyday. This white paper helps manufacturers learn more about combustible dust hazards and ways to handle combustible dust in your manufacturing plant in order to comply with OSHA's NEP. Learn more about choosing the right cleaning tools for your facility.

    Nilfisk Industrial Vacuums
  • CP Powder eHandbook: Tips for Effective and Safe Handling of Solids

    One of the trickiest materials to process, solids are comprised of powders or particulates, a continuous gaseous phase (usually air) and, almost always, a liquid component. Processors that handle solids know only too well the types of throughput problems that come up on a recurring basis. Effective, economical and safe slurry management; flowability during processing, accurate inventory and volume level management are all very real challenges faced by processors of solids. In this Chemical Processing Powder eHandbook, we take a look at how to effectively handle solids including:
    • Properly accounting for how bulk solids actually will flow in a vessel or overall process -- we take a look at some simple parameters that can often provide a good sense of flowability
    • Strategies for avoiding slurry trouble
    • Mitigating pipe segment force imbalances with Reactor Excursion and Leakage Analysis Program
    • Acoustics-based level measurement for accurate powder measurement in bins, tanks and silos
    • Explosion protection methods including suppression, isolation and venting

  • Chemical Processing Powder eHandbook: Succeed at Solids Handling

    One of the trickiest materials to process, solids are comprised of powders or particulates, a continuous gaseous phase (usually air) and, almost always, a liquid component. Processors that handle solids know only too well the types of throughput problems that come up on a recurring basis. Clumping; effective, economical and safe slurry mixing; dust management and dust explosion risk mitigation are all very real challenges faced by processors of solids. In this Chemical Processing Powder eHandbook, we take a look at how to effectively handle solids including:
    • Clumping – the 10 most common sources of agglomeration in bulk solids and how to effectively manage them
    • Strategies for optimal slurry mixing
    • Level management detection in storage vessels
    • Dust explosion risks – how to identify and mitigate when processing solids
    • Managing solid cohesiveness with flow strategies

    Download your copy of this Chemical Processing Powder eHandbook now.


  • Improve Plant Safety - A Chemical Processing Special Report

    In chemicals processing, significant hazards exist -- such as those from fire, explosions or toxic release. The processes themselves, the chemicals being processed and the procedures followed, or lack thereof, can all contribute to the risk exposure of these hazards. What can processors do to mitigate these risks? For chemicals processors, it's crucial to implement processes and solutions to detect and prevent these hazards from occurring in the first place.

    Chemical Processing has taken an in-depth look at plant safety -- how to identify the hazards and implement processes and procedures to ensure a safer working environment. This comprehensive Chemical Processing Special Report titled: Improve Plant Safety is now available to download for free.

  • Gas And Dust Explosions -- Relief Sizing Formula

    A large number of analytical and highly empirical correlations including monograms reflecting changing standards have been or are being proposed separately for gas and dust explosion relief venting. This white paper provides a generalized formula that is applicable to both gas and dust deflagrations including subsonic and sonic pressure relief conditions and is consistent with available experimental data and industry experience. Application of the model is illustrated for dust explosions. Download now.

    Fauske & Associates
  • What Does It Cost To Own Your Dust Collector Filters?

    When choosing filters for your cartridge dust collector, a Total Cost of Ownership (TCO) calculation allows you to make the most economical and sustainable choice. TCO is a step-by-step evaluation that explores energy use, maintenance and other factors to compare the real costs of operating a dust collector with different filters. This white paper explains how to perform TCO calculations to save money, time and energy.

    Camfil Farr APC
  • Inerting and Blanketing: New Cost-efficient Solution with Polarographic Sensors

    In this white paper, we review the new possibilities offered by measurement systems based on polarographic technology. Unlike other systems, polarographic sensors are built directly into the process gas stream, eliminating the need for cumbersome gas sampling and conditioning systems. Further, polarographic sensors require very little maintenance.

    Mettler Toledo
  • OSHA & NFPA Compliant: Keeping Your Plant Safe

    In March 2008, OSHA reissued its Combustible Dust National Emphasis Program (NEP) notifying approximately 30,000 companies nationwide that they will be targeted for inspections over the next few years. Mettler Toledo recognizes that many manufacturers are not up-to-date on the latest hazardous area compliance regulations or may not know that their industry is subject to those regulations. Don't wait until your facility receives a surprise visit from OSHA or worse yet, for a catastrophic incident to occur. Take the proactive approach to addressing the "hazardous area advisory level" in your facility.

    Mettler Toledo
  • Asking The Right Questions About Cartridge Dust Collection

    Over the past decade, cartridge-style dust collectors have overtaken baghouses as the preferred technology for dust collection in the chemical processing industry. Combining high efficiency filtration with compact size and reduced pressure drop, a high efficiency cartridge dust collector will in most cases be the system of choice.

    Choosing the best cartridge collection system for a given application, however, involves research and attention to detail. This article will review four key areas of investigation. By reviewing these topics with a knowledgeable equipment supplier and knowing the right questions to ask, chemical manufacturing professionals will be better equipped to make informed dust collection decisions. Download this whitepaper now.

    Camfil Farr
  • How Well Do You Know Your Dust?

    The collection and testing of dust samples is a long-established practice used by many powder and bulk processors to make informed dust collection decisions. Dust testing protocols have not changed markedly in recent years. The importance of dust testing, however, has changed, and the implications are significant. While knowing your dust has always been good practice, it is rapidly becoming a necessity in today's regulatory climate.

    This article will review two separate types of testing: (1) explosibility testing, which is used to determine whether a dust is combustible; and (2) bench testing, which pinpoints numerous physical properties of the dust. Both categories of tests are needed to determine the best dust collection system for your application and whether explosion venting equipment must be part of that system.

    Camfil Farr
  • Measurement of Oxygen Concentration in Blanketing and Inerting Operations

    Gaseous oxygen measurement with amperometric sensors is the most direct and easiest solution for oxidation and explosion protection.

    Unwelcome oxygen Tank blanketing is the process of filling the headspace in storage vessels and reactors with an inert gas to prevent its contents from exploding, degrading or polymerizing and to protect equipment from corrosion. A blanketing system is normally designed such that it operates under higher than atmospheric pressures, therefore preventing outside air from entering the vessel. As oxygen and moisture in the air can be undesired in numerous processes and applications, blanketing is done in a wide range of industries, varying from (petro)chemical to food and beverage, pharmaceutical to pure water.

    Mettler Toledo
  • Chemical Processing Special Report: Conveyors

    No matter what industry you’re in, chances are you use some form of conveying. Whether it be pneumatic, flexible screw, aeromechanical or other, different conveyors are required to handle different products. But which conveyor is best suited for your operation? Despite the fact that conveyors have been around for almost a hundred years, this question still baffles many industries. In order to choose the right conveyor for your operations, you need to consider your conveyor's use - production, processing, packaging, and you need to consider your business objectives - improve operations? reduce labor?

    In this special report, we look at the different types of conveyors, discuss the use of tubular bag conveyors, and provide 10 tips to prevent a variety of common problems that could occur with pneumatic conveyors.

  • Rectifier design for fuel ethanol plants reduces energy

    Plants have traditionally used trays in the distillation columns to produce fuels grade ethanol. Trays of various configurations have been adequate in this service and their technology is well founded. The ever-present desire to reduce the energy needed to produce a gallon of ethanol has opened the doors to structured packings being used in the rectification sections of ethanol distillation columns.

    Sulzer Chemtech USA
  • Process Moisture Analysis using FT-NIR

    Manufacturing a pure product can be critically important to the next steps in the manufacture of a powder-based product. As a result the removal of residual moisture and solvents from the crystallization, filtration and drying steps can be crucial to producing a stable product.

    Bruker Optics
  • Preventing Segregation During Powder Drying

    This 4-page case history by Jeroen van den Berg of Bolz-Summix discusses how changing process conditions within a conical screw dryer eliminated granulation and minimized product segregation.

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