Maintenance, reliability and dust hazards are always main concerns for manufacturers in the chemical industry, but how are these factors being weighed against extended production downtime and cost of replacement?
Identifying equipment needs isn’t as easy as it seems. A recent industry survey shows bulk-solids-handling equipment purchasing decisions are not always confident. Read this report to discover the current struggles chemical manufactures face when dealing with a handling equipment purchase.
Full research results and analysis are now available to you in this downloadable report.
Research conducted in partnership with Hapman.02/25/2019
Plant managers don’t always see solids-handling operations as influencing the bottom line until something big shows up on the balance sheet. To spur flowability, some plants have admitted to some pretty crazy practices (forklifts as battering rams). And among many solids-handling factors, articulate solids are unique materials because the particles can hold solid, gas and liquid phases at the same time. Additionally, chemical plants often must reduce the size of materials to create dramatically greater surface area of particles to improve processing. However, necessary size-reduction equipment is often massive, expensive and energy intensive.
To help you sidestep snafus, Chemical Processing has put together an eHandbook. It includes insight on:
- Conduct Flowability Tests -- Sites often suffer solid flow problems that such testing could prevent
- Stop Solvent Snags -- Success requires understanding solvent nature and level in solids
- Size Up Size Reduction -- Understand the operation and appropriate application of mills and pulverizers
Do you know how your equipment is operating? Have you done performance testing recently? If you have a general idea, be careful; generalizations can lead you astray. You must develop models for complex interacting systems and test your assumptions — and the generalizations! Then compare your various options and the capital required to the savings achieved. Use this to make an informed decision on how to proceed.
To help achieve better energy efficiency, Chemical Processing has put together an eHandbook. It includes insight on:
- Take a Closer Look at Equipment Performance -- Modern instrumentation packages reduce the need for testing — but not always
- Cast Cold Eyes on Cooling System Interactions -- Take a look at the cooling tower, refrigeration compressor and condenser
- Don’t Generalize Complex Systems -- Deviating from standard design temperatures requires careful evaluation
- Consider Refrigeration Condenser Pressure -- Operating at design condenser pressure could wind up wasting energy
Flow meters ensure accurate flow rate measurement for industrial applications. Choosing the right one ensures optimum results. Understanding factors such as flow, operating environment and performance are important when selecting a flow. A basic understanding of their differences and advantages also helps in choosing the right technology.11/07/2017
Routine testing and regular maintenance are necessary to ensure uptime and accuracy in your process. But how do you know if you're testing too much or too little? And what is the right level of accuracy to ensure you are meeting regulatory guidelines and also maximizing profit? This white paper discusses helpful actions, including:
- Determining required process tolerances to maximize profit
- Setting adequate testing and calibration schedules
- Choosing appropriate performance measures for your process
The purpose of a reliability program is to ensure that a plant’s physical assets can meet production goals at the lowest possible unit cost while mitigating safety and environmental risks. Such a program requires ongoing assessment, testing and performance reporting. It should become embedded into the culture of the plant as just “part of the way work is done.”
To help make reliability attainable, Chemical Processing has put together an eHandbook. It includes insight on:
- Successfully Implement a Reliability Program -- Avoid eight common pitfalls that can lead to failure
- Make Your Improvement Program Endure -- Decline is inevitable unless you address plant culture issues
- Establish Equipment Wellness -- Achieve longevity and reduced costs with an asset management plan for fluid sealing systems
What you really need to know when conveying powders & other bulk materials -- Despite vast research on pneumatic conveying technology for bulk solids handling, little is known about the perspective of the manufacturer designing such systems and the end-user utilizing vacuum conveying technology. White paper addresses and answers questions from the manufactures perspective, with answers that aid in the design of both the components, and fully automated bulk material handling systems, necessary to provide solutions that integrate into batch and continuous processes.10/23/2017
Refineries are faced with many challenges. Indeed, fluctuating oil prices and reduced availability of skilled workers, along with tighter environmental regulations have made it necessary to adapt their management approach. Factor in the need to lasso energy and capital savings and do it all with equipment that is well past original design life, and you’ve got a tall order to fill.
To help refineries improve safety, reduce operating costs and boost production from their aging assets, Chemical Processing has put together an eHandbook. It includes insight on:
- Processing Equipment Tips: Consider Modularization -- Ten emerging trends will reshape how chemical makers approach and manage safety
- Dividing Wall Column Provides Sizable Energy Savings -- Follow some pointers to succeed at sites covered by the statute.
- Reﬁneries: Rethink Corrosion Monitoring -- Consider permanently installed wireless non-intrusive ultrasonic sensors
Whether your process requires dosing a precise volume of liquid into another flow stream in a specified time period or you need to address grounding challenges in electromagnetic flow meters (EMF), understanding flow applications is crucial. To help you, we’ve put together another Chemical Processing eHandbook. It includes insight on:
- Master Metering Pumps -- Understand when to use piston and diaphragm devices for precise liquid dosing
- Successfully Ground Your Electromagnetic Flow Meters -- Unique virtual reference method helps address grounding challenges in EMFs used in harsh applications.
- Oil Recycling Company Presses On -- Pipe press helps speed installation and reduce costs at new oil recycling facility
Are you wasting money by following external weighing standards? Optimize your process tolerances for increased profitability.
External weighing standards may fulfill legal regulations, but these tolerances may not make sense for your process. With METTLER TOLEDO's exclusive Accuracy Calibration Certificate (ACC) with Good Weighing Practice, you can link your weighing equipment to tolerances that are specific to your unique process, allowing you to:
- Optimize product quality and consistency
- Document that you are weighing in the safe weighing range
- Assure accuracy of your results
- Decrease costs and increase profits
Enhanced control valve technology helps all kinds of manufacturers continually improve process efficiency and product quality, while safeguarding people, plant assets and the environment. The right solution can support a comprehensive system to track every step of the manufacturing process.09/25/2017
Being pretty good at safety may not be good enough for very long. Indeed, the practice of safety in the chemical industry has changed and matured significantly over the past several decades and will continue to evolve. Astute leaders will develop future-centered safety strategies. For the less astute, the future always will be a dark journey full of unpleasant and potentially fatal surprises. Fear of fines and jail time shouldn’t be the motivation for “doing the right thing.”
To offer the best process safety pointers, we’ve put together another Chemical Processing eHandbook. It includes insight on:
- Process Safety: Get Ready for 10 Changes -- Ten emerging trends will reshape how chemical makers approach and manage safety
- PSM Demands Better Maintenance Planning -- Follow some pointers to succeed at sites covered by the statute
- Mitigate Explosions in Spray Drying System -- Available mitigation approaches depend on the spray dryer system and design limitations
The quest to optimize water re-use and anticipate regulatory pressures is driving many plants to give increasing attention to their wastewater. There are several ways to establish world-class production practices and create safe, clean and environmentally conscious processes. One way is seal-and-support system design that insulates the process from sources of contamination. Another way is careful choice of cooling-water treatment technologies and programs that can avoid problems in your cooling tower system.
To help you put a damper on water difficulties, we’ve put together another Chemical Processing eHandbook. It includes insight on:
- Rethink Your Seal Support System -- Consider how its cleanliness impacts your process
- Conquer Cooling Water Treatment Challenges -- Advances in technology can help forestall fouling, scaling and corrosion in cooling systems
- Wastewater Treatment Gets a New Spin -- Newly commercialized and emerging technologies promise significant benefits
ISO 9001:2015 is a new version of ISO 9001, replacing the 2008 version. Organizations have a 3 year transition period to adopt the changes, with a deadline of September 2018. This white paper will be relevant for managers from any organization who follow ISO 9001 and use any type of weighing devices or processes in the course of their business.
This white paper aims to:
Explain the changes in the revised standard of ISO 9001:2015 and describe the timeline associated with transition to the new version.
Look at the effect of these changes on weighing devices and weighing processes, as weight measurements are a critical process step which can significantly affect quality.
Provide guidance and recommendations on how to consider weighing devices in order to meet the process requirements and risk-based thinking approach outlined in the revised version of ISO 9001.
Introduce the firmly established Good Weighing Practice™ strategy which fully supports the risk-based process approach and explain how this already complies with ISO 9001:2015 and can be easily implemented into a Quality Management System.09/11/2017
With cyber incidents and reported vulnerabilities on the rise, industrial cybersecurity leaders must deploy proactive industrial endpoint detection and response (EDR) across the entire process control network – including the proprietary industrial control systems and smart field instruments.
This paper will examine how EDR should extend to proprietary endpoints, what security controls have the greatest effect on reducing risk for these cyber assets, and what best practices apply.09/11/2017
Powders pose problems. But if you address issues upfront you can sail over them. The keys are understanding that vendors aren't clairvoyant when it comes to your concerns; knowing that the interaction of powder and air cause flooding and flushing problems; and realizing that combustible dust is an accident waiting to happen.
To ensure you don’t stumble over solids, we’ve put together another Chemical Processing eHandbook. It includes insight on:
- Run a Pneumatic Conveyor Test -- Use a vendor’s facility to get information on a number of important parameters
- Prevent Fine Powder Flushing -- Trapped air can cause fine powders to shoot through cracks and crevices. Here’s how to eliminate this bin-afflicting problem.
- Properly Handle Combustible Dusts -- Specialized vacuum cleaning and pneumatic conveying systems can help prevent dust explosions
Achieving blend uniformity is like trying to catch a leprechaun while riding a unicorn. Ingredient characteristics, blend hold times and mixing equipment all affect final quality. In fluid handling, what was once simple with universally standard impellers operating in standard vessels with standardized vessel internals has morphed into more individualized solutions. When it comes to solids, no two powders are alike – ever.
To assist your mixing, we’ve put together another Chemical Processing eHandbook. It includes insight on:
• CFD Stirs Up Mixing -- Progress in simulation provides improved mixer performance
• Carefully Evaluate Blending Requirements -- When choosing a mixer, consider these four key components that can lead to improved mixing
• Industrial Mixing Technology Challenges Require New Approach --Individually adapted mixing systems improve productivity and reduce costs
• Aim for Blend Uniformity -- Ingredient characteristics, blend hold times and mixing equipment all affect final quality08/08/2017
Weighing is just one step in your chemical production or laboratory process, but it can have a big impact on the outcome and quality of your final product. Weighing within the "Safe Range" ensures your results are right the first time.
Download the guide and learn about these key weighing process concepts which will help to ensure optimal production quality:
- Determining "acceptable" product quality using your process tolerances
- What is the safe weighing range and why is it so important?
- Absolute and relative measurement uncertainty
- Maintaining accurate weighing results from start to finish
Loss of level control has contributed to significant industrial incidents that have caused catastrophic results and numerous fatalities. It is imperative that you do not underestimate the risk of overfilling and that you consider all factors involved in proper level oversight. Do you know the “Golden Rule” for nozzle placement for level measurements? Have you heard of the seven simple steps that can provide proper protection? Our latest eHandbook addresses these issues and more.
To help stay level, we’ve put together another Chemical Processing eHandbook. It includes advice on:
• Properly Measure Liquid/Liquid Interfaces -- Follow a simple rule for location of level gauge nozzles
• Don’t Underestimate Overfilling’s Risk -- High level can pose serious hazards but seven simple steps can prevent them
• Select the Correct Non-Contact Sensor -- 3D, radar and laser scanners all provide continuous level measurement but suit different applications.
• Increase Ultrasonic Sensor Reliability -- Familiarity with application environments, transducers and product design can help inform purchasing decisions07/19/2017
There are many things to consider when evaluating your flow equipment – namely sealless pumps, nozzles and settlers. Did you know that seals cause more than half of all unscheduled shutdowns of centrifugal pumps? And that most spray applications receive insufficient attention and design consideration because they are subsystems of unit operations?
To help you better manage flow, we’ve put together another Chemical Processing eHandbook. It includes advice on:
• Select the Right Sealless Pumps -- Understand the advantages and limitations of the two main options
• Spray Effectively -- Consider new technology as well as operational issues before choosing a nozzle
• Be Clear About Clarifers -- Understand the design and uses of different types of settlers.07/11/2017