Process Engineering White Papers

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  • eHandbook: Preempt Powder Problems

    From moving materials to managing risks, so many things can go wrong where dust is concerned. Seemingly benign, dusts create an assortment of hazards that include flying particles that can lead to eye injury, slip hazards and ergonomic injuries. The most serious hazards of dust threaten lives and include respiratory ailments and explosion hazards.

    To help you preempt powder problems, Chemical Processing has put together an eHandbook. It includes insight on:

    • Take a Key Step Against Combustible Dust Hazards -- Having a sound mechanical integrity program in place is crucial.
    • Make the Right Moves With Belt Conveyors -- Understand important factors in their selection, design and operation.
    • Don’t Blow Your Safety Rating -- Industrial vacuum cleaners should be part of your dust control program.

    Download your copy of this Chemical Processing powder eHandbook now

  • eHandbook: Review These Reliability Best Practices

    Reliability improves safety, efficiency, balance sheets and competitiveness. It’s a breeze when things work as they should. It’s only when things go awry that we realize we need to focus on making things steadfast.

    To help you with your reliability game, Chemical Processing has put together an eHandbook. It includes insight on:

    • Proof Test Prudently -- Understand how to effectively evaluate low-demand safety instrumented functions
    • Enhance Your Motors’ Efficiency -- Consider more than just using variable frequency drives
    • Safely Use Mobile Devices -- Understanding ignition sources and levels of device protection are crucial to eliminating risk

    Download your copy of this Chemical Processing reliability eHandbook now

  • Sweeping Dust and Debris Could Blow Your Safety Rating

    Today’s manufacturing environments must heed to regulations set by OSHA’s Hazard Communication Standard (HCS) regarding combustible dusts - as part of OSHA’s Combustible Dust National Emphasis Program (NEP). Statistics show that over 1000 inspections that OSHA has completed, only 18 to 22 percent of the facilities followed OSHA requirements.

    In response to OSHA’s NEP, many facility and safety managers have revamped their housekeeping practices and added industrial vacuum cleaners approved for use in Class II Div II areas to mitigate the possibility of secondary explosions caused by fugitive dust.

    Learn how industrial vacuum cleaners – compressed-air driven portable, continuous duty, and central systems – are the best line of defense in mitigating combustible dust hazards.

    Download the whitepaper now.

  • Dual Seals on the Rise for Refineries and Petrochemical Plants

    For years, single seals were the go-to option for North American refineries and petrochemical companies, but now the industry preference is shifting toward dual seals. Learn about the trends driving dual pressurized seal adoption and how they are helping refineries and petrochemical plants lower emissions, increase safety, improve reliability and reduce costs.

    Download the whitepaper now.

  • eHandbook: Fight Refining Frustrations

    A modern refinery is a highly complex but integrated system, separating as well transforming heavier hydrocarbons into saleable fuels and chemicals. Improving efficiency and avoiding problems is critical, as it directly relates to sending more products to the market.

    To help you remain frustration free, Chemical Processing has put together an eHandbook. It includes insight on:

    • Simulator Training Extends Its Role -- Chemical makers now seek enterprise-wide and lifecycle opportunities.
    • Deftly Deal With Distillation Performance -- Several issues contribute to water hammer and leakage of condensate.
    • Grasp The Nuances Of Level Measurement -- The differences in the way devices work can profoundly affect readings.

    Download your copy of this Chemical Processing refining eHandbook now

  • eHandbook: Preempt Flow Problems

    So many factors can impact flow. Piping issues and hose maintenance are just a few. Indeed, poorly designed suction piping can result in pump damage and even failure. And knowing the right time to replace
    hoses in a chemical processing plant is a common concern among many plant managers and maintenance

    To help you mitigate flow problems, Chemical Processing has put together an eHandbook. It includes insight on:

    • Prevent Suction Piping Problems – Follow best practices when designing pump systems
    • Create a Preventive Hose Maintenance Plan – Follow these five steps to determine the best replacement timeline
    • Consider Portable Flow Instruments – Some circumstances warrant the use of such devices

    Download your copy of this Chemical Processing flow eHandbook now

  • Control System Selection Key Criteria: DCS, PLC, SCADA, and Future Technologies

    The importance of selecting the right process automation technology can far outweigh the cost of an automation investment itself. Selecting the right technology and the right supplier can help your company respond quickly to changing market conditions, ensure long term maintainability, and minimize the Total Cost of Ownership (TCO) over the life of your plant.

    The convergence of process automation technologies such as PLC, DCS and SCADA systems have created a situation where it is more challenging than ever for process manufacturers to select the best technology for their application.

    Download this white paper and learn:

    • DCS vs. PLC vs. Hybrid - 5 Factors to consider
    • Who to Include in the Decision Process
    • Vendor Selection Criteria- 6 Key Considerations

    Download the white paper now.

  • eHandbook: Achieve Better Water/Wastewater Efficiency

    Not every water optimization program suits every wastewater. Indeed, there are several new technologies to consider as well as strategies to upgrade what’s already in place. Not only will sound programs and technologies improve efficiency, they will aid in sustainability, too.

    To help achieve water efficiency, Chemical Processing has put together an eHandbook. It includes insight on:

    • Plants Zero in on Wastewater Discharges -- Efforts increase to drastically reduce or even eradicate releases
    • Drive Retrofit Improves Water Treatment Plant’s Efficiency -- Compact stand-alone matrix drives replace aging 18-pulse drive
    • Oil Recycling Company Presses On -- Pipe press helps speed installation and reduce costs at new oil recycling facility

    Download your copy of this Chemical Processing water/wastewater eHandbook


  • eHandbook: Optimize Process Safety

    The need for process safety in the chemical industry is paramount. Technical knowledge and understanding of hazards and risks associated with operations in addition to the implementation of that knowledge into practice are the keys to keeping workers and the environment safe.

    To help optimize process safety, Chemical Processing has put together an eHandbook. It includes insight on:

    • Successfully Reduce Process Safety Events – Other companies can emulate the approach proven effective for Dow.
    • Tackle Combustible Dust Safety Challenges – Indoor collection systems and proper venting help extinguish flames and contain extra-fine particulates.
    • Use Asset Management Software To Improve EH&S Programs – Ability to capture events and link documents improves environmental, health and safety efforts.

    Download your copy of this Chemical Processing process safety eHandbook.

  • eHandbook: Avoid Mixing Mishaps

    Some companies think that their problems relate to mixing. In most cases, the difficulties result from not paying enough attention to the process and, sometimes, just from inadequate attention to the details. The results can be disastrous.

    To help avoid mishaps, Chemical Processing has put together an eHandbook. It includes insight on:

    • Stop Inconsistent Mixing – A range of factors can contribute to erratic performance.
    • Get Educated On The Basics Of Particle Size Reduction – Proper methodology depends on solid materials and their properties.
    • Consider Agitated Photo Reactors For Industrial Synthesis – Technology can help lower reaction temperatures and reduce byproducts.
    • Prepare For Industry 4.0 – Integrated, holistic, smart operations help manufacturers gain a competitive edge.

    Download your copy of this Chemical Processing mixing eHandbook now


  • A Dozen Ways to Measure Fluid Level

    The demands of sophisticated automated processing systems, the need for ever-tighter process control, and an increasingly stringent regulatory environment drive process engineers to seek more precise and reliable level measurement systems. Improved level measurement accuracy makes it possible to reduce chemical-process variability, resulting in higher product quality, reduced cost, and less waste. Regulations, especially those governing electronic records, set stringent requirements for accuracy, reliability and electronic reporting. The newer level measurement technologies help meet these requirements.

    Download Now

    ABB Process Measurement
  • eHandbook Practice These Powder Best Practices

    Drying problems, level sensing and explosions – no worries.

    Have a drying problem? Consult a drying curve. Need to manage bulk solids? Laser technology brings a number of unique advantages to the table. Worried about dust explosions? Although pneumatic conveying processes are highly effective in transporting chemical products, if an explosion were to occur, the system could be extremely dangerous and pose a threat to personnel and equipment. Learn to mitigate this threat.

    To help your powder game, Chemical Processing has put together an eHandbook. It includes insight on:
    • Develop Drying Curves -- They can provide insights for solving many problems.
    • Consider Laser Level Measurement Technology -- Its characteristics make it ideal for level measurement of bulk solids and liquids in silos, bins and beyond.
    • Stop Explosions in Pneumatic Conveying Systems -- Mechanical isolation systems help mitigate explosions and protect equipment from potential damage.

    Download your copy of this Chemical Processing powder eHandbook now.

  • eHandbook: Do Your Level Best

    People have been using various devices to measure level since about 3000 BC. The first historical references to a measuring device were dipsticks or staff gauges used to indicate the amount of water stored in reservoirs for farming. Next came crude float-type devices to indicate the height of drinking water reserves in underground cisterns or storage caverns.

    Modern instrumentation uses more than 20 different technologies to satisfy the ever-growing requirements for level measurement in a wide variety of applications. Some instruments measure level directly, while others measure some other variable that is related to level.

    To help you do your level best, Chemical Processing has put together an eHandbook. It includes insight on:

    • Get To The Bottom Of Level Limitations – Positioning the lowest tap for a measurement demands care
    • Consider FMCW Radar For Level Measurement – Technology helps plant continuously monitor inventory in dust-prone environment.
    • 3D Level Sensors Help Address Storage Challenges – Technology and software advances provide greater visibility into a vessel’s inventory.

    Download your copy of this Chemical Processing level eHandbook now.

  • Dry Vacuum Solutions for Chemical and Pharmaceutical Applications

    Through the years many different vacuum technologies have been used to provide vacuum for chemical and pharmaceutical processes, including steam jet ejector, liquid ring, and rotary vane. Each of these technologies continue to have a place in chemical and pharmaceutical applications, but dry screw technology has become the technology of choice for most applications.

    Download now.

  • Make The Right Moves In Fluid Handling

    The ability to see what is happening inside a pipe can be invaluable to process operators. Despite technological advances, no sensor can equal the human eye, which has more than 94 million photo receptors. While your eyes are peeled you must also understand the tolerances allowed under API-610 with regard to pump shutoff head and rated differential head can avoid costly rework and schedule delays.

    To help you keep your eyes on fluid handling and to help with your moves, Chemical Processing has put together an eHandbook. It includes insight on:

    • Head Off Centrifugal Pump Problems -- Attention to head tolerances can prevent poor performance and rework
    • Set Your Sights on Better Flow -- Use this primer to determine the right sight flow indicator for the application
    • Pressing System Aids Copper Recycling Plant -- Piping installation method helps eliminate bottlenecks and leaks and meet capacity needs

    Download your copy of this Chemical Processing flow eHandbook now.

  • Machine Learning to Revolutionize Industrial Maintenance with Advanced Analytics

    While machine learning has been researched for decades, its use in applying artificial intelligence in industrial plants and asset operations and maintenance is now advancing exponentially. This is due to the growth in big data and the expansion of the Internet of Things (IoT); the ability to provide the processing power needed to analyze larger data sets; the availability of machine learning methods; and the need for superior predictive and prescriptive capabilities required to manage today’s complex assets. This provides the basis for machine learning to be applied across a variety of industrial challenges.

    This white paper focuses on some of the principles within machine learning and those industries that are primed to take advantage of it to maximize the benefits it brings to improve situational intelligence, performance, and reliability. Download now.

    Bentley Systems
  • eHandbook: Bank On These Batch Processing Best Practices

    The nature of batch operations poses unique problems. Ensuring reagent chemicals are added at the optimal time so as not to cause a temperature change is crucial. Additionally, there are several questions you must ask in order to properly bridge your batch operations and continuous ones. Topping it all off, you must improve energy efficiency.

    To help you do a whiz-bang job on your batch processing, Chemical Processing has put together an eHandbook. It includes insight on:

    • Quickly Estimate Reagent Addition Time -- A simple equation suffices in many situations involving batch reactors.
    • Bridge Batch And Continuous Operations Better -- Developing an accurate timeline can lead to important insights.
    • Improve Energy Efficiency Of Batch Processes -- Such processes often offer substantial opportunities for savings.

    Download your copy of this Chemical Processing batch processing eHandbook now.

  • The Benefits of Circulating Oil in Ring-Lubricated Hydrodynamic Bearings

    Hydrodynamic bearings depend on a steady flow of lubricant onto the shaft, among other factors, in order to generate the film that separates the shaft and bearing during operation. In many applications, such as fans, motors, and gearboxes, oil rings are used to deliver this lubricant. However, there are limitations to oil ring lubrication, especially during startup, slow speed conditions, and in the presence of solid contamination. Adding an external circulating oil system can overcome these limitations while offering benefits to bearing reliability, providing cooling, and allowing for easier condition monitoring.

    Download now.

    Steven Pasternak – C.O. Engineering
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