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.11/12/2015
Reducing energy consumption and your plants environmental impact is a hot topic. In this Special Report we take a look at the organizational obstacles to avoid, how to enroll your employees in the quest, and the steps you need to take in order to manage your energy costs. We also delve in to practical energy efficient applications such as recovering exhaust heat in air conditioned facilities and the use of carbon synchronous belts.10/01/2008
The chemical processing industry has a unique set of requirements that makes shopping for Enterprise Resource Planning (ERP) systems, and business systems in general, a challenging experience. Although the more advanced business systems continue to add features applicable to functions throughout the enterprise, including operations management, supply chain, finance, and so on, only a few vendors offer systems that meet the particular needs of chemical processors.
This Chemical Processing Special Report takes a look at how chemicals manufacturers are meeting these challenges head on. Download this Chemical Processing Special Report and learn more about ERP Systems including:
- Consider Integrated Technology: An ERP system should be easy to implement, use and upgrade as business evolves. Learn more about: Vertical Integration, Horizontal Integration; Asset-vx.-Labor-Intensive; Continuous v. Discrete Manufacturing; Risk Management; Integrated Deployment
- Get the Most from Your Data: Research shows how effective ERP systems significantly impact business outcomes. Data results include: Do companies with more user-friendly and accessible enterprise resource planning (ERP) systems enjoy more positive business outcomes? Are they more profitable? Do highly effective ERP systems help create a sharper upswing of revenue growth? How much difference does effective data really make to business success?
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
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.
Even though thermal-fluid heating systems have been widely used for over 80 years, they still provoke a certain amount of fear and trepidation in users. This anxiety is reinforced by any number of horror stories that usually involve systems that suddenly develop a "problem" after years of trouble-free operation. This Chemical Processing Special Report: Make the Most of Heat Transfer Fluids delves in to the issues surrounding heat transfer fluids. Learn about:
- Thermal fluids - dispel common myths about hot oil systems
- Avert oxidation - how nitrogen can serve as an inert barrier to prevent heat-transfer fluid from contacting atmospheric air through the expansion tank
- Steam vs. hot oil - a key tradeoff complicates the choice between steam and a hot oil system to heat water
Perhaps the most critical challenge facing the automation industry is that of aging control systems at or near the end of their product lifecycles. A legacy control system can suffer from technical, functional or supply obsolescence. With a well-planned and executed control system migration, however, plants can improve availability and reliability, while increasing production flexibility. In this Chemical Processing Special Report: Making the Most of Migration, we take a look at: Obsolescence planning – addressing concerns and planning for a successful evolution strategy; Restoration Possibilities – how new tools and innovative methods support and breath new life into aging distributed control systems; DCS Migration; More! Download your copy of this Chemical Processing Special Report: Making the Most of Migration now!08/27/2013
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
Whether we are headed toward an economic rebound or continuing with the current economic downturn, specialty chemicals manufacturers should take steps now in order to get or keep a competitive edge. But what steps should specialty chemicals manufacturers take? This Special Report will discuss actionable strategies including: Reducing costs while maintaining quality and compliance; Committing not just to "lean manufacturing" but to "lean supply chain" strategies; Implementing "agile manufacturing" practices.12/01/2009
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. 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: Protect Process Control Systems, 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: Protect Process Control Systems now.10/29/2014
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
Sponsored By: Hach
In this special report, we explore several ways to identify and solve various water-based utility issues. Find out how to:
- Avoid plant downtime and potential injuries by addressing steam-generation chemistry issues
- Use a reverse osmosis unit for energy savings
- Address inefficient operations and more.
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
Industrial vessels of various types are used extensively in the processing of chemicals, petrochemicals, and pharmaceuticals. Applications commonly involve storage or process tanks, drums, blenders, reactors, kettles, mixers, fermenters or shipping containers. In addition, reusable totes and intermediate bulk containers (IBCs) provide for convenient and cost-effective storage and transport. The cleaning of this essential equipment, however, has long been a challenge.
In this Chemical Processing special report learn more about:
How modern impingement cleaning technologies improve safety and sustainability
How one chemical company profits from faster cleaning turnarounds and fully clean totes
Automation designers face many challenges and tradeoffs in the development of a successful network solution. This white paper discusses the necessary choices in selecting a network technology appropriate for various specific applications.10/12/2005
The use of spray nozzles to rapidly cool or quench gas streams is an essential application in many industrial processes, such as chemical reaction vessels, incineration, and power plant absorber gas inlet. An optimized spray quench design requires engineering analysis of the operating environment, spray nozzle performance and process reliability. This technical paper describes the design considerations for spray gas quench systems such as nozzle selection, process control, system configuration and reliability. Application of this knowledge can result in a gas quench system that operates efficiently and reliably with reduced vessel size, reduced atomization energy consumption, and minimized downtime, to achieve capital and operational cost savings for your process.09/16/2009
Have you ever received a call in the middle of the night because of a plant operational crisis that took longer to correct than you would like? What you may not know is that modeling technology, which solves these kinds of complex process issues, can be accessed by your team through an easy to use Microsoft Excel® interface. Download this white paper today and discover how your company can build a model-based culture to improve plant operations and performance.04/06/2016
Positioned at the core of most supply chains, chemical firms must deal with many challenges to growing profitably -- flat demand, deflationary prices, and emerging competitors to name a few. Both chemicals firms large and small must develop the insight to change and win in today's ever-morphing competitive landscape. This white paper identifies and discusses how chemicals companies can combine data from many sources -- multiple ERP systems, multiple divisions and multiple applications -- maintenance, human capital, CRM, and supply chain to name just a few -- to create a complete or holistic view for critical decisions. Download now.06/01/2010
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
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