Process Engineering White Papers

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  • eHandbook: Ponder These Process Control Best Practices

    If an out-of-control situation is detected, you can quickly make changes to bring the process back into control. It’s a dance that requires monitoring and action.

    To help you with process-control footwork, Chemical Processing has put together an eHandbook. It includes insight on:

    • Perform A Proper Pre-Startup Safety Review -- Protect personnel and processes by conducting a thorough review before operating new or updated units.
    • Online Monitoring Optimizes Polymerization Processes -- Plant enhances product quality and reduces cycle times.
    • Promptly Address Control Valve Issues -- Testing process helps screen for issues quickly without the need to pull equipment

    Download this eHandbook now. 

  • Hazardous Area Classification Considerations

    Specifiers are increasingly citing requirements for equipment suitable for use in classified areas. Kaeser’s white paper, “Hazardous Area Classification Considerations” by industry expert, Wayne Perry, explains how an open mind and a little ingenuity can avoid excessive costs for compressors and other equipment, without compromising safety.

    Download the white paper now.


    Kaeser Compressors
  • eHandbook: Improve Batch Processing

    In batch processing, there are several things to consider. It’s not unusual for a facility to average more than 1,000 alarms per month. But alarm-remediation projects can reduce total alarms by over 70%. When it comes to blenders, choice can affect end results. As for quality control, what you must understand is you need to focus first on your ingredients, not the product.

    To help you improve your batch processing, Chemical Processing has put together an eHandbook. It includes insight on:

    • Rethink Batch-Manufacturing Alarm Systems -- You can avoid common failings and improve performance.
    • First, Select The Right Blender -- Understand the pros and cons of three key kinds of devices.
    • Quell Quality Control Quagmires -- Understand the limits of possible improvements and when enough is enough.

    Download your copy of this Chemical Processing batch eHandbook now

  • Special Report: Take the Pressure Off Overpressure Protection

    Sponsored By: Emerson

    With increased attention to operational issues, such as product purity and losses, as well as regulator demands for more stringent leak detection and repair (LDAR) strategies, the quest to reduce fugitive emissions has taken on new urgency at many sites.

    In this report you will learn about:

    • Regulations requiring pressure relief devices
    • Effectively monitoring pressure relief devices and valves
    • Adopting enhanced leak detection and repair strategies

    Read this report to see how leak detection and repair technology is adapting to increased regulatory demands and becoming a reliable, effective and economic way to monitor pressure relief valves.

    Download the special report now.

  • Choosing Functional Safety Field Instrumentation

    There is a lot of confusion around Safety Instrumented Systems (SIS) and the associated protection layers. While some may claim that “IEC 61508 certified equipment” is the way to go, others defend the concept of using field data collection and analysis of previously used general purposes instrumentation as the way to select appropriated instruments.

    This white paper addresses the controversy surrounding discussions about determining the equipment to use in safety instrumented systems (SIS) and the rules for maintaining them.

    Download this whitepaper now.

  • Research Report: Maintenance, Product Choice Prove Challenging Hapman

    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.

    Download the research report now.


  • Special Report: Put Steam Into Your Efforts

    The U.S. Department of Energy estimates that steam generation, distribution and cogeneration offer the most cost-effective energy efficiencies in the short term with potential energy savings at over 12%.

    However, it is important that you ensure steam reaches the point of use at the correct quality, quantity and pressure, and that you look at some of the key areas to consider in reducing maintenance costs and energy losses, namely, the impact poor steam quality will have on the steam system and how this can be improved.

    This report sponsored by Spirax Sarco takes a look at how manufacturers are meeting these challenges and seeing real energy savings.

    Download this Spirax Sarco Special Report for insights and strategies including:

    • The importance of steam in the Oil, Gas and Chemical Industry
    • Steam projects provide fast payback
    • Ensuring steam system reliability
    • More!

    Download your copy of this Special Report “Put Steam Into Your Efforts” now.


    Spirax Sarco
  • eHandbook: Put Powder Processing On Solid Footing

    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

    Download your copy of this Chemical Processing powder and solids eHandbook now

  • eHandbook: Favor These Flow Best Practices

    There are many factors to figure when managing flow -- piping, mixing and vacuums are just a few. But if you master these, it’ll be much easier to go with the flow.

    To ensure flow is forever in your favor, Chemical Processing has put together an eHandbook. It includes insight on:

    • Mind Piping System Mechanics -- Ensure your layout can handle anticipated stresses.
    • Stop Inconsistent Mixing -- A range of factors can contribute to erratic performance.
    • Make The Case For Vacuum Boosters -- Reduce costs while increasing flow and improving energy efficiency.

    Download your copy of this Chemical Processing flow eHandbook now

  • DCS Migration Strategies: Everything you need to know about control system migrations

    Many companies have old DCS platforms. In computing terms, they’re ancient. Considering all that is connected and controlled by the DCS — thousands of field instruments, valves, operator interfaces and other devices working together to make the process run efficiently and reliably, having an ancient platform is flirting with disaster.

    The risks are many:

    • System failures
    • Part availability issues
    • Difficulty integrating new apps and systems
    • Reduced support availability
    • Operation inefficiency

    While the headache of migration is sometimes too much to bear, fortunately, the DCS you install today may never have to be completely replaced because its modularity will allow it to be improved incrementally.

    This white paper will detail the steps to make proper migration choices and manage the process to get more out of your DCS system.

    Download the white paper now.


  • eHandbook: Deter Dangers From Dust

    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.

    Download your copy of this Chemical Processing dust hazards eHandbook now.


  • Compressed Air System Leaks: The Cost, Common Culprits, Detection and Repair

    The US DOE estimates that 25% of compressed air is lost to leaks— resulting in unnecessarily high operating costs. In many plants the leak losses are much higher. Kaeser’s white paper, “Compressed Air System Leaks: The Cost, Common Culprits, Detection, and Repair” explains how to determine the annual cost per compressed air leak, sheds light on where most leaks occur, and describes best practices for leak detection.

    Download the whitepaper now.

    Kaeser Compressors, Inc.
  • eHandbook: Bank On Energy Efficiency Savings

    Have you looked around your site for condensate that could be put to good use? Do you know what happens when a partial pressure causes poor performance in ancillary equipment? Do you know if off-standard operations are costing you energy dollars? Unless you can confidently respond yes to all these questions, it’s in your best interest to learn more.

    To help you with the answers, Chemical Processing has put together an eHandbook. It includes insight on:

    • Energy Saver: Justify Condensate Recovery -- Consider some potential opportunities for achieving energy savings.
    • Distillation: Do You Understand Partial Pressures? -- Non-azeotropic mixtures can cause problems in ancillary equipment.
    • Energy Hog Restricts Plant Production Rates -- A seemingly minor change causes a major problem.
    • Deftly Deal with Distillation Performance -- Several issues contribute to water hammer and leakage of condensate.

    Download your copy of this Chemical Processing energy efficiency eHandbook now.

  • 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

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