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.
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.
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
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
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.
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
Learn how improve your plants energy efficiency. Download your copy of this Chemical Processing Energy eHandbook now.
To maximize a plants performance, it is critical to fully understand the equipment being used, their mechanisms of operation, limitations and capabilities. This includes furnaces, exchangers, pumps, and mass transfer devices for distillation columns: fractionation trays, random and structured packing and associated liquid and vapor distributors. The purpose of this paper is to provide an overview of the key factors to successfully revamp with the goal of maximizing capacity without compromising efficiency.
The purpose of installing a flowmeter system is to accurately measure flow in a reliable manner. Issues related to physical properties, process parameters, electronic features and interconnections are often given much consideration. Relatively little emphasis, however, is given as to how well the flowmeter will perform its intended purpose. Adding to the confusion are the differences in how performance is expressed and the incomplete nature of the available information. Nevertheless, the quality of flow measurement should be a concern. This Chemical Processing eHandbook takes a look at technologies and solutions affecting flow including:
* Coriolis meters - steps you can take optimize performance when faced with entrained gas
* Magmeters -- why you should consider using them
* How to achieve effective flow control with centrifugal pumps
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
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.
The purpose of installing a flowmeter system is to accurately measure flow in a reliable manner. Issues related to physical properties, process parameters, electronic features, interconnections can all affect the flowmeter performance. This Chemical Processing eHandbook takes a look at technologies and solutions affecting flow as well as the impact of specific regulations on flowmeter systems including:
Specifying the right slurry seal – understanding dual-seal and water-management options
Ground EMFs with Virtual Reference - New grounding method eases electromagnetic flowmeter installation and minimizes costs
Determine Boiler Size Using a Flowmeter - An inline vortex meter reveals the proper steam usage, resulting in significant savings and improved energy efficiency.
Reliability programs are now standard business practice in companies that rely heavily on machines, equipment and other physical assets. But, in today’s lean economy, companies have fewer resources than ever to manage and maintain these assets. Plants face challenges in identifying new and cost-effective ways to ensure their assets are performing and that they are managing to minimize operational risks. In this Chemical Processing Reliability/Asset Management eHandbook we take a look at proactive approaches for improving reliability and maintenance in today’s processing plant including:
• Equipment rotation: identify damaged and worn components before they cause problems • Backflush strategies: flow reversal can remove fiber buildup in heat exchangers • Advanced Reliability Management: key steps for leveraging limited resources and critical assets • Predictive Maintenance: detailed analysis of maintenance records can further improve equipment reliability • More!
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!
For chemical processors, changing process conditions demand quick responses in order to keep processing effective and to keep processes running properly. For processes undergoing such changes, accurate and timely measurements, such as vibration monitoring, redundant tank level measurement and steam header temperature profiling can be difficult to collect. In well-established plants it’s both very expensive and time consuming to get measurement points online using conventional wired instrumentation. Many processors are now turning to wireless devices that can supply data from numerous points that never could have been justified otherwise. In this Chemical Processing Wireless eHandbook we take a look at wireless technology solution successes:
** How installing a wireless pH analyzer for crucial insights on seal integrity provided Fuji Film with a low-cost monitoring solution for protecting a pricey pump ** How one of the world’s largest producers of chlorine, caustic soda and vinyl chloride embraced wireless technology and achieved operating economies and more efficient control of its chemical processes ** More!
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.