Continuum Approach to Optimizing Downstream Final Drying With Upstream Solid-Liquid Filtration, Cake Washing & Dewatering
This article reviews the optimization of the final drying technology in conjunction with the upstream continuous solid-liquid filtration, cake washing, and dewatering technology. This article illustrates that by taking a holistic approach and looking at each step not individually but as a continuum, the process solution becomes much more efficient.07/15/2019
Properly storing, moving and blending solids can be crucial for efficient plant operations. However, powders can pose a wide variety of problems.
To help you avoid problems and succeed, Chemical Processing has put together an eHandbook. It includes insight on:
- Properly Instrument Your Solids Process -- Four types of measurements usually make sense
- Bulk Bags Can Change Your Life -- The containers afford advantages if applied appropriately
- Smart Feeders Enhance Detergent-Making Process -- New facility benefits from process controls and equipment that optimize production
Dry mixing plays an important role in many processes. The wide variety of mixer types — dynamic and static, as well as in-tank and in-line — and the design options for the mixers and vessels can make selecting the right unit tough.
To ensure you’re on solid footing, Chemical Processing has put together an eHandbook. It includes insight on:
- Is The Homogeneity Of Your Dry Mix Acceptable? -- Understand how to correctly validate the results of mixing
- First, Select the Right Blender -- Understand the pros and cons of three key kinds of devices
- Maximize Polyethylene Operations with 80-GHz radar -- Accurately detect and measure flake and pellet density variations and anomalies
Combustible dust fire and explosion hazards continue to challenge process safety practices throughout industries that store, handle or use combustible particulate solids.
To help realize sound ideas and solutions to eliminate fire and explosion threats from combustible dusts, Chemical Processing has put together an eHandbook. It includes insight on:
- Take Key Steps Against Combustible Dust Hazards -- Having a sound mechanical integrity program in place is crucial.
- Defuse Dust Dangers -- Carefully consider and then counter risks of fire and explosion.
- Prevent Dust Explosions With Pressurization Systems -- Technology provides safe, economical option for installing electrical equipment in a hazardous location.
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.
Often, due to compression dynamics in multi-staged vacuum-pressure systems there is a mismatch of capacities between the vacuum and compressor pumps (with vacuum pumps having a much larger nominal pumping speed than the compressors).
In this first case study, find out how Busch was able to identify an operational solution utilizing different control instrumentation, as well as design considerations including recycle lines and safety features to enable simple vacuum and pressure operation seamlessly. In the second case study, find out how dry vacuum technology improves operational reliability and eliminates oil costs in phenolic resin production.10/10/2018
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.08/15/2018
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.07/17/2018
The problem with solids is that sometimes they don’t want to move. This often results in solids settling out of slurries. Many believe that to monitor solids reliably, they must use an expensive technology. Another problem is dust. Being sure you stay on top of housekeeping is a must. Lucky for you, there are several techniques that can make solids stop behaving so badly.
To help you secure solid success, Chemical Processing has put together an eHandbook. It includes insight on:
- Stop Struggling with Your Slurry -- Convert a settling solids suspension into a non-settling one.
- Make Sense of Ultrasonic Sensors -- Understand the relationship among equipment, materials and environment when selecting the appropriate technology.
- Consider an Industrial Central Vacuum System -- A fixed tubing network simplifies housekeeping, reduces equipment wear and eliminates trip hazards.
- Save Time on Viscosity Measurements -- The cone plate method makes the most of small sample sizes.
- Choose the Right Equipment -- Certain processing technologies can help increase a powder’s flow capabilities.
Powder handling can be dangerous and unpredictable. Indeed, many processes generate dust, which can lead to explosions. Preventing the generation of dust is easier, cheaper and more reliable. This eHandbook offers a few preventative measures. Another problem with powder handling and solids is you often have to pray you don’t have flow issues. In most cases, clumping is the culprit. This eHandbook highlights 10 causes of clumping and 10 solutions. And yet another concern is physically moving the solids. Inside is a top 10 list that addresses pneumatic conveyor systems and lists tips for planning and modifying existing ones.
To help you properly handle dangerous and unpredictable powders, Chemical Processing has put together an eHandbook. It includes insight on:
- Deftly Deal with Dust -- Minimize generation and consider either collection or suppression
- Clamp Down on Clumping -- First understand what’s really causing the problem
- Install Pneumatic Conveyors Correctly -- Follow 10 steps to prevent a variety of common problems
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
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
Pharma processing is easy! You just cool the solution and out drops your product – right? That’s a delusion as numerous plants can attest. Many products that start out in this manner cause problems in downstream processing. Pharmaceutical manufacturing often requires efficient drying at less than ambient temperatures among other nuanced processes.
To help you address potential problems, we’ve put together another Chemical Processing eHandbook. It includes advice on:
- Vacuum Shelf Dryer Provides More-Uniform Cakes -- Different approach to endpoint determination leads to greater consistency
- Conquer Crystallization Challenges -- Five alternative routes for cooling and drying.
- Corral Compliance with Dry Vacuum Technology -- Controlled vacuum helps meet environmental regulations in the pharmaceutical and ?ne chemical industries
Powders and solids are a tricky business. You have to be proactive to ensure catastrophic events like dust explosions don’t happen. You have to be able to convert laboratory findings into a meaningful process design all while taking into account forces unknown or unseen. And you have to make it all flow according to plan and specs.
To help you address potential problems, we’ve put together
another Chemical Processing eHandbook. It includes advice on:
Talk to a Chemist
You may get valuable insights for successfully scaling up a process
Surmount Sticky Situations
A properly designed ﬂuid-bed dryer can handle sticky solids
Support Good Housekeeping Practices
Implement a proactive approach using industrial vacuum cleaners to
prevent secondary dust explosions
Predicting Powder Flow Behavior Just Got Easier
New shear cell tests help to ensure product consistency
Understand Powder Flow Characteristics
A powder’s variables and external factors will greatly impact blender size05/16/2017
There’s an art form to solids processing. Sure, science is the major backbone but “art is why we install a device whose operation we can’t explain scientifically but which has performed successfully in the past,” according to Chemical Processing’s Tom Blackwood. To help you combine the best of both art form and science, the editors of Chemical Processing have put together the newest eHandbook.
Download this Chemical Processing eHandbook for strategies including:
- How to improve performance and meet specifications via size reduction.
- The Do’s and Don’ts to reduce particle segregation.
- Put STEAM Into Your Efforts – The A is for Art
Maintaining constant control of pressure in chemical processing and refining equipment is vital in order to avoid the risk of catastrophic damage, injuries, and environmental risks. This paper from Fike outlines the importance of assessing process risks and designing effective pressure relief systems accordingly and provides guidance to ensure that your systems are up to the task.12/01/2016
This Chemical Processing eHandbook examines some of today’s Powder challenges and way to navigate solutions for chemical manufacturers.
Do you want to learn more about how to mitigate crystallization challenges? Perplexed by blending myths? Do you want to know more about the mystery of time effects and conducting a time consolidation test? Interested in several methods for condensing water vapor?
Download this Chemical Processing eHandbook for insights and solutions including:
- Conquer Crystallization Challenges: Question the need for cooling and ensure you have the right data.
- Beware of Blending Myths: But first determine if blending really is required.
- Solve the Mystery of Time effects: Conduct a time consolidation test to determine the flow performance of a bulk solid.
- Handle Water Vapor within Oil-Sealed Vacuum Pumps: Evaluate several methods for condensing water vapor.
This white paper discusses highly acidic chemical process slurries and the use of continuous vacuum filtration technologies for filtration, cake washing and drying.
First, the basics and benefits of continuous vacuum filtration technologies are reviewed followed by case-studies. In this first process, the precipitated solids are in sulfuric acid slurry. The challenge is to process 2200 kg/hour of dry solids for filtration, counter-current washing and drying in a contained environment.
In this second process, the objective is to process precipitated solids in an hydrochloric acid slurry. The white paper concludes with a framework for vacuum technology selection and how this can be applied to other toxic and difficult chemical process filtrations.10/18/2016