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
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
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
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.
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.
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.08/21/2018
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
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.
Sometimes using a radar sensor for liquid level measurement is child’s play. Sometimes. But not always. This paper covers a few challenging applications that prove through-air radar can reliably measure some of the toughest media and vessels to benefit the user.07/17/2018
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 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
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.06/20/2018
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.
This paper discusses the use and selection of filter aid and filter media with clarification technologies for removal of fines from process liquids. BHS provides case studies and testing to determine the ideal ratios of “body feed to suspended solids” and to the particle size distribution of these fines.06/11/2018
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.06/11/2018
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.
Thermal fluids have the potential to directly affect the safety, maintenance, efficiency and reliability of overall plant operations. These fluids deserve dedicated considerations on how they can impact the protection of your plant personnel — safety of your people, the protection of your equipment investment, the ability to run an efficient operation in terms of energy cost and scheduling, and the avoidance of production downtime that can be associated with unscheduled maintenance activities. From safety to efficiency, this Special Report covers all the basics on how to optimize your heat transfer fluid selection. Download now.05/16/2018
In Kaeser Compressors’ white paper, "Applying Variable Speed Compressors in Multiple Compressor Applications,” system design expert, Neil Mehltretter, provides guidance on how to properly apply variable frequency drive (VFD) compressors. A key topic is "control gap", a common problem caused by improper sizing and application of variable speed compressors.05/08/2018
The drive by some chemical companies to improve energy efficiency extends well beyond their production processes. Indeed, steam is a major focus and innovations in water-related energy efficiency are top of mind. But great care must also accompany the pursuit of efficiency. Engineers understand the role of insulation for heat conservation and freeze protection. But pipe installation on jackets, coils, reactors and heat exchangers is tricky.
To help you avoid costly and sometimes deadly steam mistakes, Chemical Processing has put together an eHandbook. It includes insight on:
- Energy Efficiency Soars -- Broad-ranging efforts are providing substantial savings.
- Provide Better Protection from Hot Pipes -- Use more conservative limits for insulation skin temperature.
- Keep Cool Designing Heat Exchanger Piping -- Consider these points when working with exchangers, coils and jackets.
Poorly designed and overly simplistic energy performance indicators often drive energy savings at the expense of product yield or quality. To identify opportunities for substantial reductions in energy consumption in your refining operations, look to modern simulation tools and optimization methods to enable investigating all the potential alternatives for distillation separation sequences and selecting the best sequences.
To help you with opportunities, Chemical Processing has put together an eHandbook. It includes insight on:
- Save Energy In Distillation -- Revamping may cut consumption considerably
- EMISs Evolve to See the Bigger Picture -- Adding process considerations improves energy savings and production performance.
- Consider Liquid Ring Technology for Dry Chlorine Compression -- Liquid ring compressors offer lower cost and other advantages for chlorine processing applications