Drying: Making Gravity Work
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This document appears to be the May 2009 issue of a magazine focused on the chemical and process industries. The main stories summarize: 1) Refiners facing an uncertain future due to declining demand, volatile margins, and the global recession forcing investment rethinking. 2) Properly designed bulk solids bins or silos offer advantages for slow, diffusion-limited drying operations. 3) Integrating fire-and-gas detection and mitigation systems into overall process safety control can help ensure fast responses to emergencies.
![Letters
Shaping GHG policies
Edison Electric Institute (EEI) member companies
support action to lower the country’s carbon and other
greenhouse gas (GHG) emissions by 80% from current
levels by 2050. And we want to do so in a way that
softens electricity price increases for families and our
energy-intensive customers, such as chemical manufac-
turers. A critical factor for achieving this goal within a
federal cap-and-trade program is by allocating rather
than auctioning emissions allowances.
Under a cap-and-trade program, the government sets
a national cap on GHG emissions. Over time, this cap
becomes lower until the ultimate GHG reduction goal is
met. The government would create allowances for electric
utilities and others to emit GHG emissions under the cap.
The method by which the government initially introduces
these allowances into the market — by allocation or auc-
tion — is crucial.
Auctioning allowances sharply increase costs by re-
quiring companies to pay both for the allowances and for
the cost of actually reducing emissions. All of these costs
would be passed on to consumers. In contrast, if allow-
ances are allocated, only the costs of actually reducing
emissions are passed along.
A portion of the revenue raised through an auction may
be returned to customers via a tax rebate. But this isn’t
an efficient mechanism for channeling relief to all custom-
ers. Nor is it assured that all of the revenue raised would
be directed to mitigating energy prices or developing the
technologies that we as a nation need to transition to a
vibrant, low-carbon economy.
Support is growing for allocating allowances. The U.S. Cli-
mate Action Partnership — an alliance of major businesses,
such as Dow and DuPont, as well as leading climate and
Circle 07 on p. 70 or go to adlinks.che.com/23014-07
environmental groups — is in favor of allocating emissions
allowances. So is the Pew Center on Global Climate Change,
the National Association of Regulatory Utility Commission-
ers, and a number of labor groups among others.
Although additional measures will certainly need to play
roles in lessening energy cost increases under a national
climate change program, allocating emissions allowances
will be vital. Please contact your members of Congress and
ask that they support allocating allowances in any climate
change legislation. For more information on EEI and its
climate principles, please visit www.eei.org/climate.
Thomas R. Kuhn
President
Edison Electric Institute
Poscripts, corrections
April, Capital Costs Quickly Calculated, pp. 46–52: In
three places in the box at the top of p. 47, the factor
0.8 should have been rendered as an exponent and
was not [30.8 at the bottom of the first column, 20.8
at the top of the second column, and (0.635/2)0.8 at
the third line from bottom of second column]. A cor-
rected version of the article can be found by searching
for the title of the article at www.che.com.](https://image.slidesharecdn.com/chemicalengineering200905-130204112943-phpapp02/85/Drying-Making-Gravity-Work-8-320.jpg)
![Bookshelf
Hazards of Oil Refining Distillation Units.
By BP International Ltd. (BP Process
Safety Series). Institution of Chemical
Engineers, Davis Building,
Railway Terrace, Rugby CV21 3HQ, U.K.
Web: icheme.org. 2008. 81 pages, £27.
Reviewed by Stanley S. Grossel,
Process Safety & Design, Inc.,
Clifton, N.J.
T
his booklet was written as a reference tool for opera-
tors, engineers and technicians working on crude and
vacuum distillation units (CDUs and VDUs) in the
petroleum industry. It outlines the main hazards associated
with these units and promotes the adoption of safe operat-
ing practices and procedures in order to prevent the recur-
rence of serious incidents.
The book contains seven chapters, a list of relevant ref-
erences, an incidents list, and a glossary. Chapter 1, the
introduction, opens with a process description of crude
oil distillation with a schematic of CDU and VDU process
flows and products, followed by a summary of the main
hazards in these units, and a breakdown of when CDU
and VDU incidents occur. Chapter 2 discusses the chemi-
Circle 09 on p. 70 or go to adlinks.che.com/23014-09 cals found in crude oil that contribute to the hazards in
distillation, such as hydrocarbons, inorganic and other
materials imported with crude oil, and other hazardous
substances in common use on CDU and VDUs [super-
heated steam, water, ammonia, chemicals used for break-
ing desalter emulsions and for corrosion control, nitrogen,
and nucleonic sources (used in liquid level instruments)].
In Chapter 3, entitled Physical Hazards, a number of
incidents are described that occurred during startup and
shutdown, normal operation, and unit turnarounds. The
chapter covers a large number of causes, and is very infor-
mative. Hazards related to equipment failure of columns
MIXING MAGNESIUM HYDROXIDE IS EASY, and other associated equipment are discussed in Chapter
FAST, EFFICIENT, MONEY-SAVING 4. Among the topics covered are: columns and other pres-
AND MAINTENANCE-FRIENDLY
sure vessels and piping (corrosion and inadequate design
Let’s You Mix Sodium Hydroxide, Pulsair’s and construction), desalters, fired heaters, rotating equip-
Sodium Hypochlorite, TM/ETM-2000 ment, heat exchangers and distillation column overfilling.
Series Mixers
Magnesium Hydroxide Much useful information is presented in this Chapter.
and others with just a little Chapter 5 covers safe operating practices and proce-
compressed air dures, discussing startup, shutdown, and normal operating
and ... and emergency procedures. Also briefly discussed are trou-
NO MOVING bleshooting and the concept of a safe operating envelope.
PARTS in the
In Chapter 6, some serious incidents that have oc-
tank!
curred on CDU and VDUs are described. These include:
Pulsair Systems offers a full line of mixers for poly, fiberglass and steel fire and casualties at a crude unit tower, electrocution
tanks. The mixers are either electronic or pneumatic control depending incident at a CDU desalter, hazards of water entering
on customer needs. The in-tank accumulator plates can be made from vacuum towers, hazards of atmospheric relief valves, an
materials compatible with the liquids being mixed. internal VDU tower fire during a turnaround, and four
fatalities during the repair of piping. Chapter 7 is a self-
Pulsair Systems, Inc. test questionnaire containing 21 questions designed to
P.O.Box 562, Belevue, WA 98009 assess the effectiveness of knowledge transfer following a
1-800-582-7797
review of this booklet. The incidents list is a compilation
PHONE: 425-455-1263• FAX: 425-451-7312
E-MAIL: sales@pulsair.com •WWW.PULSAIR.COM of 144 accidents that have occurred to refinery columns
and associated equipment.
Circle 28 on p. 70 or go to adlinks.che.com/23014-28
8 ChemiCal engineering www.Che.Com may 2009](https://image.slidesharecdn.com/chemicalengineering200905-130204112943-phpapp02/85/Drying-Making-Gravity-Work-10-320.jpg)
![Choosing a
Control System
Department Editor: Kate Torzewski
TECHNOLOGY REQUIREMENTS [1] an outdated HMI platform or abandon it 6. Asset management
entirely, control-system suppliers should pro- Does the solution focus on the entire process?
1. Control architecture vide the means to leverage existing invest- A supplier’s asset-management solution
Does the solution provide an integrated ments and intellectual property, and at the should be “process centric.” Users have an
automation platform? same time migrate plant control rooms and enterprise-wide view of the relationships
New systems should manage process knowl- engineering stations to newer, more robust between all installed assets, and as such,
edge through a combination of advanced technology. This can include field upgrade can make informed decisions affecting plant
technologies, industrial domain expertise, “kits” allowing users to retain their existing availability. This approach allows the user
and Six Sigma methodologies. hardware and industrial-class furniture, to determine: 1) the impact of equipment
Choose an open, scalable control system while expediting the transition to the latest problems on the process; 2) the association
that is fully redundant, includes robust operator environment. between these problems and the business;
control algorithms and provides on-process and 3) the priority of needed repairs.
upgrades to minimize plant downtime. The 4. Networks
system should be embedded with best-in- Does the solution employ open CHOOSING a dCS OR a PLC [2]
class applications for advanced control, asset or proprietary protocols?
management and control monitoring, and Control systems employing open network When choosing a control system for a par-
include a human interface integrating plant- protocols provide process plants with ticular process application, there are many
wide information and delivering realtime new levels of connectivity. Users have considerations that can help influence the
process data. Additionally, the system should the freedom to select the best control and decision. Remember that a DCS is optimally
comply with open industry standards. instrumentation solutions for a given task. Be designed for process control with refinery
sure the control system you choose makes control origins and a PLC is optimally
2. Field instrumentation full use of recognized open standards, and designed for machine or motion control
Does the solution integrate “smart” devices? is equipped to integrate the industry-leading with car factory relay panel origins. While
Control solutions should support digital field network protocols. These include Foun- PLCs are sometimes used for process-control
integration of field instruments, allowing dation Fieldbus, Profibus, HART, DeviceNet applications, there are some trade-offs in
processes to be linked with monitoring and ControlNet, among others. terms of degree of programming, robust-
and control equipment, and providing the ness and operational suitability. This is most
platform needed to operate plants more 5. Optimization often attempted with small or non-hazardous
profitably. An automation provider should Does the solution support processes where the loss of benefits is less
offer a maintenance-management program redesigned work processes? visible. Below, each type of system and
incorporating all of field assets — tradi- When selecting a new control system, it is those areas where it typically performs best
tional and fieldbus alike — and providing important that the vendor offer a solution are listed.
tools for integrating all device information in tightly integrating optimization, multivari-
a single database. able control and advanced process control References
(APC). Moreover, these tools should be 1. Gregg, J., Control System Selection, Chem.
3. User interface embedded in a system architecture that Eng., August 2002, pp. 62–66.
Does the solution support complex human- captures and leverages process knowledge 2. Bohan, J., Industry Solutions Manager,
machine interface (HMI) requirements? over time. A methodology will also be in Honeywell Process Solutions (Phoenix, Ariz.),
Instead of requiring customers to support place for continuous improvement. personal communication, Apr. 6, 2009.
DistributeD control system (Dcs) Programmable logic controller (Plc)
Should be used when: Should be used when/for:
• fair amount of continuous control is required — DCS
A • igh speed processing (faster than 1 ms). This is the hallmark of PLC
H
systems typically have more built-in capability in this systems
area, such as selectors, calculators, stepped outputs and • 0%+ discrete application (digital inputs/outputs). PLCs are optimized
9
initialization for discrete applications, due to their packing line heritage
• he application will be changing frequently (several times a
T • our application is predominantly machine/motion control. The nature of
Y
year or more — adding new feed lines, tanks, and so on). ladder-logic processing is ideal for machine/motion control applications
Tools in the DCS are fool-proof and make changes quickly • he application will not change frequently, or if so, the changes are
T
• ou have a batch process — sequence capability and
Y small. PLCs are very flexible for making small changes, but lack integ-
handling is built into the DCS rity checks and built-in functionality for making large-scale changes to
• ou want to assign specific areas of the process to opera-
Y an automation strategy
tors. Again, this is built-in • ou need to control single pieces of equipment or single workstations
Y
• he system must be integrated with other applications
T that are loosely integrated at a higher level. Many end users deploy
and/or systems. DCS systems have a number of open SCADA architectures with PLCs that are effective for capturing data
protocols built-in for integration across the systems, while preserving autonomy for each controller
• oss of control or operational view during production
L • perators of the application have responsibility over a piece of
O
is unacceptable. DCS systems are robust due to their equipment only. PLCs offer many options for closely coupled operator
refinery heritage, and robustness is built-in because it is touch panels
expected • ou anticipate that the controllers for various pieces of equipment have
Y
• ou anticipate having multiple controllers that need to
Y minimal communication between them, and the communication will not
“talk” to each other in a peer-to-peer fashion (sharing a change much. Building messaging in the PLC system is costly and must
lot of data throughout the application). This is built-in to a be maintained
DCS system • ou will require valve line-up logic for numerous (close to 100), multi-
Y
• ou need a highly available production system (control-
Y position valves. Ladder logic is a very clean, effective way to handle
ler, HMI, server, network, etc). A DCS system is pre-built this requirement
ready to go out of the box • our application has many areas, separated by distance, that each
Y
• istorical data about your application is important to your
H require only a small amount of I/O (less than 100). PLCs can be scaled
company. History collection is built-in and very robust to cost-effectively handle tens of I/O at multiple locations](https://image.slidesharecdn.com/chemicalengineering200905-130204112943-phpapp02/85/Drying-Making-Gravity-Work-51-320.jpg)
![50
Mass flow Funnel flow
40
Wall friction angle, ’
Uncertain region
Shear stress
30
Funnel flow
20
Mass flow
10
Stagnant
’
0
material 0 10 20 30 40 50
Normal pressure Hopper angle, C
Figure 2. In general, there are two Figure 3. The angle of wall friction is Figure 4. Design charts are useful
types of flow patterns in a vessel: funnel the angle that is formed when a line is in determining combinations of wall
flow and mass flow. The preferred flow drawn from the origin to a point on the friction angle and hopper angle that
pattern in a gravity dryer is mass flow wall yield locus provide mass flow
• Cohesive strength. Used to deter- of the moving solids. Funnel flow oc- are on the vertical axis. Any combina-
mine outlet dimensions that prevent curs when the walls of the hopper sec- tion of ϕ' and Θc that falls within the
a cohesive arch from developing tion of the vessel are not steep enough mass flow region of the chart will pro-
• Wall friction. Needed to calculate or its friction is not low enough for the vide mass flow.
hopper angles that ensure flow of bulk material to flow along them. Designing right to the limit of the
the bulk material along the vessel The preferred flow pattern in a grav- mass flow region is not recommended
walls at an appropriate velocity to ity dryer is mass flow. In mass flow, the for conical hoppers. Figure 4 shows a
maintain overall residence-time- entire bed of solids is in motion when region of uncertainty where the flow
distribution goals material is discharged from the outlet. pattern cannot be predicted with con-
• Compressibility. Provides the re- This behavior eliminates stagnant re- fidence. In actuality, this region rep-
lationship between solids pressure gions in the vessel, which provides a resents a margin of safety to account
and bulk density more uniform velocity profile. In addi- for slight differences in material flow
• Permeability. Used to specify op- tion, mass flow minimizes the transi- properties and wall surfaces. If the
erating conditions that circumvent tion time during grade changes when combination of wall friction angle and
flooding, to determine outlet dimen- more than one product is processed hopper angle lies too close to the fun-
sions that allow the desired solids in the vessel [1]. Hence, in order for nel-flow line, a switch to funnel flow
discharge rate, and to determine the a gravity dryer to operate properly, can occur. Hence, a 4–5-deg. margin of
gas pressure profile in the column mass flow is vital. safety is used with respect to the mass
• Phase equilibria. Used to calculate The first step in designing vessels flow boundary.
the minimum gas-injection rate for mass flow is to measure the wall The uniformity of the solids velocity
• Kinetic information. Used to cal- friction between the bulk material and in a vessel depends on how close the
culate the required solids residence the wall material. Wall friction is mea- hopper angle is to the mass flow bound-
time. sured by a method described in ASTM ary. As the hopper angle is steepened,
Modified bins or silos can also be used D-6128 [2]. A sample of bulk material the velocity profile in the hopper sec-
to remove undesirable components of is placed inside a retaining ring on a tion becomes more uniform. In a mass
a gas stream. Here, a zeolite or other coupon of wall material, and various flow hopper, the velocity differences di-
suitable bulk material flows down- normal loads are applied. Material minish in the cylinder section and the
ward in the vessel and selectively ad- in the ring is forced to slide on the solids velocity becomes nearly uniform
sorbs unwanted species from a coun- stationary coupon, and the resulting unless the solids level is very low.
tercurrent gas stream. Although the shear force is measured as a function
focus of this paper is devolatilization, of the applied normal force. The wall Outlet size
the same concepts can be applied to yield locus is constructed by plotting The outlet of the dryer must be large
moving bed adsorbers. shear force against normal force. enough to prevent a flow obstruc-
Design charts originally developed tion from developing. If the cohesive
Achieving mass flow by Jenike [3] provide allowable hop- strength of the bulk material that de-
In general, there are two types of flow per angles for mass flow given val- velops as a result of its consolidation
patterns in a vessel: funnel flow and ues of the wall friction angle (ϕ'). The in a vessel is greater than the stresses
mass flow. These flow patterns are il- angle of wall friction is the angle that imparted onto it at the outlet, a cohe-
lustrated in Figure 2. In funnel flow, is formed when a line is drawn from sive arch will develop.
an active flow channel forms above the origin to a point on the wall yield The cohesive strength of a bulk solid
the outlet, with stagnant material re- locus. A representative wall yield locus is a function of consolidation pressure
maining at the periphery. This pattern is shown in Figure 3. and is determined by the method de-
leads to a non-uniform velocity profile An example design chart is shown scribed in ASTM D-6128 [2], where a
inside the vessel, a dramatic reduction in Figure 4. Values of the allowable direct shear tester is used to measure
in solids residence time, and gas flow- hopper angle (Θc, measured from ver- the shear strength of a material under
ing preferentially in the central chan- tical) are on the horizontal axis, and varying consolidation pressures. A
nel due to the decreased permeability values of the wall friction angle (ϕ') sample of powder is placed in a split
ChemiCal engineering www.Che.Com may 2009 35](https://image.slidesharecdn.com/chemicalengineering200905-130204112943-phpapp02/85/Drying-Making-Gravity-Work-53-320.jpg)
![Yield strength or arch stress
Cover Story
Slope = 1/ff
cell and then pre-sheared (consoli- 1. The flow function lies below the
dated by exerting a normal compact- flow factor and the two curves do
ing load and then shearing it until not intersect. When this is the case,
Flow function
the measured shear stress is steady). the stress imparted on the arch is
Next, the shear step is conducted, in always greater than the material’s critical
which the vertical load is replaced cohesive strength, and there is no
Consolidation pressure
with a smaller load, and the sample is minimum outlet dimension.
again sheared until it fails. The pre- 2. The flow function lies above the flow Figure 5. The relationship between
shear and shear steps are repeated factor and the curves do not inter- strength and pressure is known as the
flow function
for a number of normal stresses, and a sect. The bulk solid will not flow due
yield locus is then determined by plot- to gravity alone. Gas distribution
ting the failure shear stress against 3. The flow function and flow factor Uniform distribution of the stripping
normal stress. From the yield locus, intersect, as shown in Figure 5. At gas is essential. Otherwise, the bulk
the major consolidation pressure and the point where the two lines inter- solid’s exposure time to the gas can be
cohesive strength are determined [3]. sect, the arch stress is equal to the non-uniform, severely impacting uni-
By conducting the test over a range strength of the bulk solid. The value formity of purging. If the distributor
of consolidations, the relationship be- of the stress or strength is equal to is not properly designed, the gas may
tween consolidation pressure and the the critical stress σcritical. The mini- bypass a significant portion of the
cohesive strength of the bulk mate- mum outlet diameter to prevent a solids. If introduced at a point where
rial can be determined. The relation- cohesive arch from developing in a the solid’s stresses are low, the gas is
ship between strength and pressure is cone, Bmin, can then be calculated likely to cause localized fluidization of
called the flow function. An example from Equation (1): the solids.
flow function is given in Figure 5. Localized fluidization frequently oc-
The greater the material’s cohesive H( ) curs when gas is introduced at high
Bmin C critical
(1)
strength, the greater will be the ten- velocities via nozzles or perforated
dency for the formation of a stable plates, which can lead to flow instabili-
obstruction, such as an arch or dome Where the function H(Θc) is approxi- ties propagating throughout the dryer.
at the vessel outlet. A stable cohesive mately equal to 2 and is given by Je- If gas is introduced through screens in
arch is formed when the strength nike [3], and γ is the material’s weight the converging section of the vessel,
of the bulk solid is greater than the bulk density. only a relatively small amount of gas
stresses acting upon it. Jenike [3] While an outlet diameter greater can be injected in the lower portion
showed that the magnitude of these than the minimum will prevent cohe- of the cone, since at higher injection
stresses depends on a material’s bulk sive arching, it may not necessarily rates, the minimum fluidization veloc-
density, the outlet dimension, and the be large enough to allow the desired ity will be readily exceeded due to its
geometry of the hopper. The stresses discharge rate when fine powders are small cross-sectional area.
acting to overcome a cohesive arch and processed. The maximum flowrate of a To avoid fluidization, a gas dis-
cause flow are described by a hopper’s fine powder can in fact be several or- tributor may be accompanied by an
flow factor (ff), which is a function of ders of magnitude lower than that of inverted conical insert. Gas is intro-
the internal friction of the bulk solid, coarser materials. Two-phase flow ef- duced underneath the inverted cone,
the hopper angle, and the wall friction. fects are significant due to the move- directly into the material through
The flow factor can be obtained from ment of interstitial gas as the powder the free surface that forms. Gas may
design charts given by Jenike [3] or compresses or expands during flow. also be introduced through screens
formulas given by Arnold and McLean A limiting condition occurs when the around the perimeter of the inverted
[4, 5]. By comparing the flow factor and compaction in the cylinder section cone or through the outer hopper sec-
flow function and ensuring that the forces too much gas out through the tion or both. If properly designed, an
stresses at the outlet are greater than material top surface. When the bulk insert will expand the flow channel
a critical value, the minimum open- material dilates in the converging and eliminate stagnant regions of
ing size required to prevent a cohesive section of the vessel, a slight vacuum bulk solids in the vessel.
arch from forming can be calculated. forms, resulting in gas counter flow An improperly designed gas distrib-
Since the flow factor is a constant through the outlet. At a critical solids utor, however, can cause non-uniformi-
for a given material and bin, a plot of discharge rate, the solids contact pres- ties to occur in gas or solids flow or to
the arch stress against consolidation sure drops to zero, and efforts to exceed result in unstable flow. An insert that
pressure is a straight line through the this limiting discharge rate will result is too small or too large, or is placed too
origin. Superimposing the material’s in erratic flow [6]. For fine powders, high or too low relative to some critical
flow function on the same graph al- permeability testing is recommended size and position, will expand the flow
lows the cohesive strength and arch to determine the outlet size required channel very little, if at all. Even if
stress to be compared (see Figure 5). to achieve the desired discharge rate. optimally located, an inverted conical
There are three possible results of Calculation of limiting flowrates is de- insert is unlikely to convert a funnel
such a comparison: scribed by Johanson [7]. flow pattern to mass flow, since simple
36 ChemiCal engineering www.Che.Com may 2009](https://image.slidesharecdn.com/chemicalengineering200905-130204112943-phpapp02/85/Drying-Making-Gravity-Work-54-320.jpg)
![volatile component, gas phase
Minimum gas
injection rate
Concentration of
Equilibrium
line
Gas
injection
rate decreases
Operating
lines
Solids outlet Solids feed
Figure 6. Notable improvements in gas uniformity can be achieved by injecting Concentration of volatile component,
gas via an annulus and a set of crossbeams located at the intersection of the cone solid phase
and cylinder [9]
inverted cones have little effect on the tion can be placed in a sealed container, Figure 7. The minimum gas-injection
flow pattern below their base [8]. and the vapor phase composition can rate is such that the concentration of the
volatile component in the gas leaving the
Notable improvements in gas unifor- be determined by gas chromatography column is in equilibrium with the solids
mity can be achieved by injecting gas or other analytical methods. feedstream. The gas injection rate should
via an annulus and a set of crossbeams The minimum required gas injec- be set safely above the minimum, and the
located at the intersection of the cone tion rate is determined by plotting the column diameter must be sized to ensure
and cylinder [9]. By properly sizing the equilibrium line and an operating line stable operation of the dryer
annulus and crossbeam components on the same graph. The operating line quired, since otherwise, unacceptably
of the distributor, high gas injection is determined as follows. First, the high gas velocities will result, causing
rates can be achieved with gas veloci- target volatiles level of the solids and fluidization and unstable operation.
ties low enough to prevent localized the concentration of volatile species in The cross sectional area of the col-
fluidization. The crossbeams can also the inlet gas are located on the graph. umn must be large enough to prevent
be used to support a conical insert. By Next, a gas injection rate is assumed, the solids stresses from approaching
properly choosing the dimensions and and points on the operating line are too close to zero. Solids stress and gas
material of construction of the inner calculated using a material balance. If pressure profiles can be determined
cone, mass flow can be achieved with the gas and solids streams are lean in by an analysis given by Johanson [7].
a hopper angle that is twice as large volatiles, the solids and gas rates are Expected gas-interstitial pressure
as would be required if an inner cone nearly constant throughout the cylin- and solids stresses in a 3-m dia. dryer
were not present. This results in a sub- der, and the slope of the operating line having a 20-m tall cylinder are shown
stantial saving of headroom compared is constant and equal to the ratio of in Figure 8 and 9, respectively. (See
to mass flow designs without inserts. the solids-to-gas, mass flowrates. Table 1 for other parameters used in
Distributor designs that employ cross- Example equilibrium and operat- the calculations.) Note that there is
beams are shown in Figure 6. ing lines are given in Figure 7. The a significant increase in the solids
horizontal axis represents the solids stress at the cylinder-hopper junction,
Minimum gas-injection rate volatiles content; the vertical axis de- and therefore, a load analysis should
As the solids travel countercurrent to notes the volatiles content of the gas be performed during the structural
the stripping gas inside the dryer, the stream. Note that for a constant sol- design of the dryer. The interstitial
driving force for mass transfer of the ids feedrate, the slope of the operating gas pressure increases and solids
volatile species is not constant, since line increases as the gas injection rate stress decreases with increasing injec-
the compositions of both the solids is reduced. The minimum gas-injection tion rate. The gas-pressure and solids-
and gas streams vary along the vessel rate is such that the concentration of stress profiles depend on the bulk
height. For a specified solids feedrate, the volatile component in the gas leav- solid’s permeability and compressibil-
a minimum required gas injection rate ing the column is in equilibrium with ity and the feedrates of the solids and
exists. If an injection rate less than the the solids feedstream (see Figure 7). sweeping gas.
minimum is used, the driving force The gas injection rate should be set As the gas injection rate is in-
will vanish in a portion of the column, safely above the minimum, and the creased, the particle-to-particle con-
and the desired level of devolatiliza- column diameter must be sized to en- tact stresses decrease. The reduction
tion cannot be reached. sure stable operation of the dryer. in solids stress is most severe where
To determine the minimum gas re- the gas is injected into the vessel. In
quirements, a relationship is needed Cylinder diameter Figure 10, the minimum solids stress
to describe the phase equilibrium be- There is a trade-off between gas injec- is plotted against gas injection rate.
tween the solids and gas phases. In tion rate and required solids-residence The analysis illustrates the impor-
the case of polymers, the equilibrium time. Higher gas rates allow a shorter tance of properly sizing the vessel, as
relationship can be determined from residence time, since at high rates, the the solids stress decreases with in-
Flory-Huggins theory. Flory-Huggins volatiles in the gas phase are more di- creasing gas rate. If solids stress is low
parameters are tabulated for several lute, the driving force for mass trans- enough, the solids may become fluid-
solvents and polymers [10]. In the ab- fer is greater, and hence drying rates ized, resulting in severe flow instabili-
sence of published data, a bulk mate- are higher. At high gas flows, however, ties throughout the vessel.
rial with a known volatiles concentra- vessels with greater diameters are re- Note that the gas rate in the purg-
ChemiCal engineering www.Che.Com may 2009 37](https://image.slidesharecdn.com/chemicalengineering200905-130204112943-phpapp02/85/Drying-Making-Gravity-Work-55-320.jpg)
![25 25
Cover Story
Distance from outlet, m
Distance from outlet, m
20 20 Gas rate = 5 kg/min
7.5 kg/min
10 kg/min
15 15 12.5 kg/min
ing section of the vessel (the
cylinder) does not necessarily 10 10
12.5
equal the gas injection rate. kg/min
Usually, the outlet of the dryer
5 Gas rate = 5
is equipped with a rotary valve 5 kg/min 10
7.5 kg/min
or other feeding device. De- kg/min
pending on the pressure down- 0 0
50 60 70 80 90 100 110 120 130 0 10 20 30 40 50 60 70 80
stream of the feeder and the Intersticial gas pressure, kPa Solids stress, kPa
pressure buildup that results
from injecting gas into the col- Figures 8 and 9. Expected gas interstitial pressure (left) and solids stresses (right) are
umn, additional gas may leak illustrated for a 3-m-dia. dryer having a 20-m-tall cylinder
through the vessel outlet or a
fraction of the injected gas may flow For batch stripping, where the con- required bed height is made, and the
cocurrently with the solids stream out ditions at the particle surface are con- diffusion and mass-balance equations
the outlet. This addition or reduction stant, the diffusion equation has an are solved to determine the volatiles
of gas flow in the cylinder must be analytical solution, which can be inte- content of the solids leaving the dryer.
taken into account when determining grated to give the average concentra- Adjustments in the bed height are
gas injection rate and solids residence tion of the volatile component, –, as a then made until solving the system of
x
time requirements. function of time [11]: equations gives the target solids-vol-
2 2
n Deff t atiles content at the outlet. Usually,
x xs 6 1
Required residence time exp (3)
additional height is specified to allow
The required residence time, which di- x0 xs 2
n 1n
2
RP2
surge capability.
rectly determines the cylinder height, In the analysis, the Sauter mean
depends on the relative rates of the In the case of a gravity dryer, how- radius is used. Sauter mean radius is
bulk solid and gas streams, the phase ever, where the gas passes countercur- defined as the radius of a sphere that
behavior of the volatile species, and rently to the solids stream, the surface has the same volume-to-surface-area
the local rate of mass transfer of the volatiles content is not constant. The ratio as a particle of interest. Because
species. To describe the transport of a concentration of volatiles in the vapor the average volatiles concentration of
trace volatile species in a particle, the stream, and hence the equilibrium con- a solid particle is based on its volume
diffusion equation written in spherical centration at the particle surface, var- while devolatilization takes place at
coordinates is used: ies with axial position in the column. its surface, the Sauter mean is appro-
x 1 x Hence, Equation (3) cannot be applied priate for tackling transport phenom-
Deff r 2 (2) to moving beds unless the volatiles ena problems.
t r2 r r
content of the gas stream is negligible, The temperature of the solids is
Where x is the concentration (wt.%) such as when large amounts of purge usually set by upstream process
volatile species in the solid, r is the gas are used. In most cases, having a conditions, such as the temperature
radial coordinate, t denotes time, and low volatiles level in the gas stream of the bulk solids leaving the flash
Deff is the effective diffusivity. The ini- exiting the dryer is undesirable, since dryer, fluidized dryer or other process
tial and boundary conditions are: recovering volatiles from a lean gas unit. The gas may be preheated, but
stream can be difficult. The diffusion considering its small thermal mass
t 0, x x0 equation must therefore be solved nu- compared to that of the bulk solids
x merically, using an overall mass bal- stream, the gas and solids tempera-
r 0, 0 ance to track the volatiles level in the tures are usually approximately
r
gas stream. equal in most of the cylinder [12]. If
r RP , x xS
One should note that not all particles temperatures are expected to vary
are spherical or can be approximated greatly inside the dryer, the solids-
where RP is the Sauter mean-particle as spheres. Powders have many shapes, and gas-phase temperature profiles
radius, x0 is the initial concentration and engineering judgment must be can be estimated using a procedure
of the volatile component and xs is the used to assess the results of analyses described by Munjal and Kao [13].
surface concentration. The first bound- that assume a spherical symmetry. When specifying the height of the
ary condition signifies symmetry of the To determine the required residence cylinder section, the designer should
intraparticle volatile-component con- time, the diffusion and mass-balance account for the length required for
centration profile. The second bound- equations are solved iteratively. The the injected gas to become uniform.
ary condition describes equilibrium at gas injection rate is specified, one that The height at which the gas velocity is
the interface of the solid and gas and is safely greater than the minimum, considered uniform is typically on the
assumes that the devolatilization pro- and a dryer diameter that ensures order of either one vessel diameter, if
cess is diffusion limited (that is, there that the superficial gas velocity is gas is injected through or near the cyl-
is negligible resistance to mass trans- low enough to prevent fluidization is inder walls, or one half the diameter,
fer in the gas phase). determined. Next, an estimate of the if the gas injected near the centerline
38 ChemiCal engineering www.Che.Com may 2009](https://image.slidesharecdn.com/chemicalengineering200905-130204112943-phpapp02/85/Drying-Making-Gravity-Work-56-320.jpg)
![Table 1. SimulaTion inpuTS 1.50 1
Mass fraction volatiles remaining
Gas rate =
Column Diameter, m 3
Minimum solids stress, kPa
1.25 5 kg/min
Height of solids above 20
gas distributor, m 1.00 7.5 kg/min
Height of solids above 20
cylinder-cone junction, m 0.75 0.1 10 kg/min
Hopper angle from verti- 20
cal, deg. 0.50
Outlet dia., m 3.0
0.25
Angle of wall friction, 15
deg. 0.00 0.01
2.5 5.0 7.5 10.0 12.5 0 5 10 15 20
Bulk density, kg/m3 450–525
Gas injection rate, kg/min Distance from top surface, m
Permeability, m/s 0.05–0.17
Figure 10. Solids stress decreases Figure 11. In this case, if 25 m.t./h of
Design pressure (gauge), 50 with increasing gas rate and can become solids are fed to a gravity dryer having a
kPa too low, causing solids to become fluid- 3-m-dia., 20-m-tall cylinder, a 10 kg/min
Design temperature, °C 80 ized and resulting in severe flow insta- gas injection rate is necessary to achieve
bilities throughout the vessel a 99% reduction in volatile components
Solids feed rate, metric 25
ton/h
and the volatiles concentration of the flow instabilities do not occur due to
Gas (air) rate, kg/min 10 solids is measured over time. A least- high gas velocities. Gas must be in-
Effective diffusivity, m2/s 1.9E–11 squares fit of the data to the analytical jected at a rate high enough to provide
Particle Sauter mean 1.0 solution to the diffusion equation pro- a driving force for purging throughout
dia., mm vides the diffusion coefficient used in the vessel, and the volume of the ves-
Volatile component- 316
the design of continuous dryers [14]. sel must be large enough to afford the
vapor pressure, kPa Figure 11 shows the effect of gas necessary residence time. Obtaining
injection rate on the performance of a fundamental, bulk-solid flow proper-
Flory-Huggins interaction 1.5
coefficient gravity dryer. (See Table 1 for design ties — including cohesive strength,
parameters.) In this case, if 25 metric wall friction, compressibility, and per-
Initial solids volatiles 0.001
content, mass fraction
tons per hour (m.t./h) solids are fed meability, along with phase equilib-
into a gravity dryer having a 3-m-dia., rium and kinetic data — is necessary
20-m-tall cylinder, a 10 kg/min gas in- to ensure that the gravity dryer will
and near the cylinder walls. If cross- jection rate is necessary to achieve a operate as desired. ■
beams are used, most of the cylinder 99% reduction in volatile component Edited by Rebekkah Marshall
section is available for solids purging. level. If a greater degree of devolatil-
Finding an appropriate value for ization is desired, a dryer with a larger Author
Greg J. Mehos is a project
the effective diffusivity may be chal- diameter may be required to keep gas engineer at Jenike & Jo-
lenging. Using published values of velocities low enough to prevent fluid- hanson, Inc. (400 Business
Park Drive, Tyngsboro, MA
diffusion coefficients and adjusting ization and to provide additional resi- 01879; Phone: (978-649-3300;
them by accounting for porosity and dence time. The height of the cylinder Email: gmehos@jenike.com),
an engineering consulting
tortuosity will not necessarily give may also need to be increased to pro- firm specializing in the stor-
results that predict reality. Although vide the required residence time. age, flow, and processing of
powder and bulk solids. He
the analytical solution to the diffusion has been involved in a wide
range of bulk solids handling
equation in most cases cannot be used Summary projects including flow property testing, hopper
to calculate the required residence Silos or bins used to handle bulk sol- and feeder design, and the design and analy-
sis of purge and conditioning columns. Mehos
time in a continuous purge vessel, it ids can also be used for devolatiliza- is a member of AIChE and currently serves on
can be used to determine the effective tion provided that they are properly the executive committee of AIChE’s Particle
Technology Forum. He received B.S. and Ph.D.
diffusivity from batch stripping data. designed. The vessel must allow uni- degrees in chemical engineering from the Uni-
Gas is passed through a fluidized bed form flow of the solids and gas, and versity of Colorado and a masters degree from
the University of Delaware. He is a registered
or a thin, fixed layer of bulk material, the vessel dimensions must ensure professional engineer.
References
1. Buchelli, A., Golden J.R., and Beran, D.L., pers, Powder Technol., 15, 279 (1976). 10. Bartan, A.F.M., CRC Handbook of Polymer-
Determination of Polyolefins Powder Flow 6. Royal, T.A. and Carson, J.W. Fine Powder Liquid Interaction Parameters and Solu-
Characteristics during Product Transitions, Flow Phenomena in Bins, Hoppers, and bility Parameters, CRC Press, Boca Raton,
Ind. Eng. Chem. Res., 46, 24, 8120 (2007). Processing Vessels, presented at Bulk 2000: Florida, 1990.
2. ASTM D-6128, “Standard Test Method Bulk Material Handling Towards the Year 11. Bird, R.B., Stewart, W.E. and Lightfoot, E.N.,
for Shear Testing of Bulk Solids Using the 2000, London, 1991. “Transport Phenomena,” John Wiley & Sons,
Jenike Shear Cell”, ASTM International 7. Johanson, R., Two-phase-flow Effects in Sol- New York, 1960.
(2006). ids Processing and Handling, Chem. Eng., 72, 12. Mehos, G.J. and Pittenger, B.P. Using Bins
3. Jenike, A.W., Storage and Flow of Solids, Bul- 1, 77 (1979). and Silos to Heat or Cool Bulk Solids, Chem.
letin 123, University of Utah Engineering 8. Pittenger, B.H., others, “Uniform Purging Eng., 114, 8, 57, August 2007.
Station, 1964 (revised, 1976). of Resins in Contact Purge Vessels”, Polym. 13. Munjal, S. and Kao, C., Mathematical Model
4. Arnold, P.C. and McLean, A.G., An Analytical Eng. Sci., 39, 9, 1802 (September 1999). and Experimental Investigation of Polycar-
Solution for the Stress Function at the Wall 9. Dick, D.S., and Hossfeld, R.J., Versatile bonate Pellet Drying, Polym. Eng. Sci., 30, 21,
of a Converging Channel, Powder Technol., BINSERT System Solves Wide Range of 1352 (1990).
13, 255 (1976). Flow Problems, Proceedings of the 12th An- 14. Colaykyan, M. and Eisinger, R.S., Removal of
5. Arnold, P.C. and McLean, A.G., Improved nual Powder & Bulk Solids Conference, 302 Residual Monomers from Polymers in Fluidized
Analytical Flow Factors for Mass-Flow Hop- (1987). Beds, Ind. Eng. Chem. Res., 42, 2654 (2003).
ChemiCal engineering www.Che.Com may 2009 39](https://image.slidesharecdn.com/chemicalengineering200905-130204112943-phpapp02/85/Drying-Making-Gravity-Work-57-320.jpg)
![Engineering Practice
Feature Report
Optimal Cooling Systems
For Coastal Plants
When all economic and environmental Process
factors are considered, Sea Hot
seawater Cold
a cooling tower may be the best option outlet
Hot
DM
water
DM
water
Seawater
inlet
Mahdi Gougol and Jamshid Pouresfandiary Cham
Research Institute of Petroleum Industry
Plate and frame
Hassan Dezvareh Resnani heat exchanger
Kaviyan Petrochemical Co.
Figure 1. In the once-through cooling system,
B
ecause temperature control is is not sufficient for cooling, so seawater makes a single pass through the system
important in any process, a wa- a continuous flow of water is before returning to the sea
ter-cooling system is a common used as a cooling medium. Wa-
Evaporation
component in chemical process- ter-cooling systems can be clas-
ing plants. For facilities located near sified as two main types: once
coastal areas, the tendency is toward through, and recirculating [1]. Process
the use of seawater instead of river Once-through cooling sys- Makeup Cooling
Hot
tower
water for cooling purposes. Seawater tems. This type of cooling sys- seawater
Sea outlet
has the advantage of having nearly a tem is usually available near
constant quality (chemical analysis), large, natural sources of cold Hot Cold
Inhibitor DM DM
nearly a constant temperature and is water. In once-through cooling, Blow water water
available in large amounts. This option there is no equipment or facil- down
is not without its challenges, though. ity for recirculating, cooling
Presented here is an economic- and reusing the cooling water. NaOCl Plate and
frame heat exchanger
environmental approach for selecting The water is entirely supplied
the best cooling system for operation from the sea, and after flow-
at the sea shore. An actual facility, lo- ing through the heat exchang- Figure 2. In the recirculating cooling-water
system, a cooling tower is used to recycle the
cated in the Persian Gulf, is used as ers it leaves the system and seawater. Such systems have significantly smaller
an example. is discharged back to the sea investment costs than once-through systems, and
(Figure 1). a smaller environmental impact
Cooling system options When seawater is used, the
Air and water are the least expensive, most important problems in the pro- in which the construction material is
most available and accessible fluids cess heat exchangers are corrosion, resistant to corrosive seawater.
for removing heat from equipment and scaling, deposition, and microbiologi- For this reason, plate-and-frame
processes. When cooling is achieved cal growth. Because the equipment is type heat exchangers are typically
directly with ambient air (air-cooled in direct contact with seawater, these used. This type has some advantages
systems), the minimum temperature problems are more severe than in sys- over shell-and-tube heat exchangers,
difference between the ambient air tems that use other sources of water such as high turbulent streams, high
and the warm outlet media — the (rivers, lakes or groundwater). velocity, low approach temperature,
so-called approach temperature — is To prevent the above-mentioned low scale deposition, and so on.
about 10–15°C. problems and reduce the damages, an Microbiological growth in heat ex-
Air cooling is typically used in indirect method of heat transfer is ap- changers and associated equipment in
processes such as condensation of plied. That means desalinated or de- contact with seawater is controlled by
low-pressure steam, where the tem- mineralized (DM) water is used to cool injection of sodium hypochlorite solu-
perature of condensation does not nec- hot process fluids. Then, the warm DM tion or other chlorine solutions.
essarily need to be low. But in many, water is collected and sent to a num- Recirculating cooling systems. In
if not most, processes, the air supply ber of seawater/DM heat exchangers this type, water after the heat adsorp-
ChemiCal engineering www.Che.Com may 2009 45](https://image.slidesharecdn.com/chemicalengineering200905-130204112943-phpapp02/85/Drying-Making-Gravity-Work-63-320.jpg)
![Engineering Practice
tion is sent directly to a cooling tower
where it is cooled through simultane-
ous heat and mass transfer to the air
(Figure 2).
The hot water is sprayed at the
top, then trickles through the cooling
fills while the air is drawn or forced
through the cooling fill from the bot-
tom. The unsaturated air absorbs hu-
midity and will saturate to the equi-
librium state (namely, the wet bulb
temperature). The energy required for
water evaporation is supplied by the
remaining bulk of warm water.
When seawater is the cooling
source, the cooling system is called Figure 3. Seawater cooling towers can use natural draught (left), induced draught
a seawater-cooling tower. Apart from (middle) and forced draught (right)
sources of makeup water, there are
significant differences between sea- As mentioned before, the major cool- 40, 45 and 50°C. The verticle lines
water cooling towers and other types ing effect of a cooling tower is due to at these four temperatures have the
of cooling towers. water evaporation. When designing a same length (same absolute humidity),
As with once-through systems, in- cooling-tower system, the question to but cross different constant enthalpy
direct heat transfer is preferred in ask is, will the tower operate properly lines. To determine the corresponding
recirculating systems to prevent the in the local ambient conditions? The wet bulb temperature, the constant
corrosion, scaling, deposition, and mi- most important parameter in the de- enthalpy line for each temperature is
crobiological growth problems. sign and selection of a cooling tower followed to where it crosses the 100%
is ambient wet-bulb temperature. In relative humidity curve, and a verticle
Cooling tower types theory, this is the lowest water tem- line extended downwards. So, for dry
Cooling towers are categorized accord- perature that can be reached in a bulb temperatures for 35°C and 50°C,
ing to the flow directions of air and cooling tower. However, due to very the corresponding wet bulb tempera-
water — that is, either counter cur- high investment costs, achieving such tures derived from Figure 4 are 27.4°C
rent or cross flow types. Airflow in the temperatures is usually not practical. and 30.6°C, respectively. This shows
tower is supplied through two main Instead, the minimum water tem- that for a 15°C difference in dry bulb
mechanisms: mechanical draft and perature that is normally reached temperature, a nearly 3°C difference
natural draft. Mechanical draft can be in a cooling tower is 3 to 5°C higher in wet bulb temperature is observed.
either forced or induced. than the ambient wet-bulb tempera- However, the assumption of con-
In the forced-draft type, motor ture [1, 2]. As a consequence, an en- stant absolute humidity in Scenario 1
driven fans located at bottom periph- gineer should decide on the operation is not realistic, because an increase in
ery of the tower cause the air to flow of a cooling tower, after analyzing dry-bulb temperature will cause some
through the tower. This type of cool- the wet-bulb temperature variation. seawater to evaporate. In this case, the
ing tower is used for capacities ex- Up to dew-point temperature, the water content of air does not remain
ceeding 30,000 m3/h. For capacities water content of air is not changed constant. Therefore, the relative hu-
below 30,000 m3/h, the induced-draft although the relative humidity varies. midity as well as wet bulb tempera-
type is used [1, 2]. In this case, the During daytime, the dry-bulb tem- ture increases so slightly that it does
fans are installed at the top of the perature is going to increase. In this not have an effect on the operation of
tower (Figure 3). condition, if water content of air re- the cooling tower. This can be observed
mains constant, the relative humidity in Scenario 2 of Figure 4.
Seawater cooling towers reduces [Equation (1)]. At the same During nighttime, both the dry-bulb
Throughout most of the year, coastal time, the wet-bulb temperature is and the wet-bulb temperature are
areas have high relative humidity going to increase, although its rate of going to decrease though relative hu-
(RH), which is defined by Equation (1). variation is less than that of the dry- midity increases. In this condition the
bulb temperature. This difference can cooling tower operates through the fol-
be observed by examining Scenario 1 lowing mechanism.
(1) on the psychrometric chart shown in When the hot water comes in con-
where Figure 4. tact with cold/saturated air, the air is
ˆ
Pwater = Partial pressure of water at Consider a situation where air with getting a little warm due to the trans-
air in ambient temperature a constant absolute humidity of 0.02 fer of sensible heat from hot water to
sat
Pwater = Saturation pressure of water kg water per kilogram of dry air, and the air. Thereafter, the air is not satu-
at air in ambient temperature the four dry bulb temperatures of 35, rated and it can take up some water
46 ChemiCal engineering www.Che.Com may 2009](https://image.slidesharecdn.com/chemicalengineering200905-130204112943-phpapp02/85/Drying-Making-Gravity-Work-64-320.jpg)
![If the temperature difference between
Percent: 100 80 60 40 hot-water inlet (43°C) and cold-water
Humidity ratio, kg H2O per kg dry air
0.028 outlet (35°C) of the cooling tower is
8ºC, and if it is assumed that all of the
h = 90 kJ/kg 30 heat load is removed by evaporation,
0.024
2 the process heat balance is:
Relative humidity, %
0.020
h = 70 kJ/kg 1
(5)
0.016 20
where
h = 50 kJ/kg
0.012 QR.R = Recirculating rate of cooling
water
0.008 10 lEV = Latent heat of evaporation
DT = Range (difference between
0.004 hot inlet water and cold outlet
water from the cooling tower)
0.000
0 5 10 15 20 25 30 35 40 45 50 CP = Specific heat capacity of sea-
Dry bulb temperature, °C water
Figure 4. A psychrometric chart is a graph of the physical properties of moist air Substitution of lEV and CP for an av-
at constant pressure erage recirculating seawater tempera-
ture of 39°C and DT = 8°C results in:
vapor. As the cold air rises upward temperature of the seawater and the
through the tower, its temperature high turbulent flow in the plate-and- (6)
increases more and more because of frame heat exchangers) [2]. From Equations (4–6) it is seen that
its long contact time with warmer According to material balance of the blow-down and makeup water are
water moving downward. cooling tower, 3.2% and 4.6% of QR.R, respectively.
In contrast, hot water that moves Comparing these two flowrates
downward becomes colder and colder (2) with a once-through cooling system in
due to simultaneous heat and mass And for salts, which QMU = QBD = QR.R reveals that
transfer to the air. As a result, the a once-through system, with the same
cooling tower maintains its water- heat load as a forced-draft type cool-
cooling ability, not only during the ing tower, has a flowrate of hot water
day but also at night. (3) discharged to the sea that is 31 times
higher than that of the recirculating
Environmental impact Where system, and the makeup water is 21
In a cooling system, hot water dis- CC = concentration cycle. times higher.
charged to the sea has the most im- CBD = TDS of recirculating seawater This means that, for the example
portant environmental impact. The in the cooling tower that is the above, the flowrate of discharged hot
temperature of discharged seawater same as blow down water to the sea is 100,000 m3/h for
should be controlled, and limited to CMU = TDS of fresh seawater that is a once-through cooling system and
an acceptable value that usually is used as makeup water 3,200 m3/h for a cooling tower. Besides
specified by environmental protection QMU = flowrate of makeup the problems caused by local heating
organizations and regulatory bodies. QBD = flowrate of blow down due to the larger volume of water dis-
As an example, let us consider an In the Persian Gulf, the TDS of water charged, other problems associated
olefins plant located in Assaluyeh near is 38,000 ppm. From Equation (3) we with the once through system are the
the Persian Gulf. Two cooling systems find that the concentration cycle of larger amount of chemicals present in
are compared: a forced-draft, round seawater cooling tower is 1.45 [3]. the discharged water, such as chlorine,
cooling tower, and a once-through We want to know how much makeup dispersants, anti-corrosion additives
system. The cooling water flowrate is water and blow-down water is needed and non-oxidizing biocides.
100,000 m3/h with an inlet (outlet) to maintain the concentration cycle at Accordingly, the environmental im-
temperature of 35°C (43°C). The wet- 1.45. Therefore: pact of a once through cooling system
bulb temperature of the Assaluyeh is so extensive that it can affect irre-
region is 31°C and the maximum dry- versibly the seawater ecology and de-
bulb temperature is 48°C. stroys the seawater eco-system.
Assume that the maximum-admis-
sible, total-dissolve solid (TDS) of the Economic comparison
recirculating cooling water is 55,000 (4) For the economical assessment of the
ppm to prevent scaling (with this TDS, same example, three main param-
scaling cannot occur due to the low eters are considered, the benefits and
ChemiCal engineering www.Che.Com may 2009 47](https://image.slidesharecdn.com/chemicalengineering200905-130204112943-phpapp02/85/Drying-Making-Gravity-Work-65-320.jpg)
![Engineering Practice
the operating and investment costs.
TABLE 1. A COMPARISON BETWEEN
The investment costs include all three ECONOMIC PARAMETERS IN THE STUDIED CASE
phases of engineering, procurement
and construction. Seawater cooling tower Once through
(million $) (million $)
All equipment considered under
procurement (water pumps and drives, 3.9 4 Engineering cost
filters, chlorinator, piping, electrical 32.5 53.6 Procurement cost
work, instrumentation, spare parts
13 33.8 Construction cost
and steel structure), and the corre-
sponding construction phase for the 49.4 91.4 Investment cost
seawater cooling tower are also used 0.61 0.57 Commissioning cost
in the once-through system. However,
the equipment sizes, and amount of 14.72 14.02 Operating cost per year
time and labor required for construc-
tion are mostly different. same, the investment cost for a once- Reference
If the required temperature of sup- through system is 45% more than that 1. Hensley, J.C., “Cooling Tower Fundamen-
plied water in the once-through sys- of the seawater cooling-tower system, tals,” 2nd ed., Marley, 1985.
tem is lower than the surface water or $42 million more. Therefore, all the 2. Kessel, F., “Seawater Cooling Towers” SPX
near the coastline, especially in the economical factors are considered, Cooling Technologies Lecture, 2006.
hot seasons, the user should install such as payback period and net pres- 3. Gougol, M., Feasibility study of cooling
systems, RIPI Final Report, NO.31480542
a pipeline on the seabed and proceed ent value, the seawater cooling tower Aug., 2007.
through the sea to achieve required is the better option. 4. Eftekharzadeh, S., Baasiri, M. M., and
water temperature. Lindahl, P. “Feasibility of Seawater Cool-
ing Towers for Large-scale Petrochemical
As the seawater is transferred from Salt emissions Development,” proceedings of The Cooling
the seabed by gravity, the onshore For seawater applications, today’s cool- Technology Institute Annual Conference,
Tex., TP03-17 (2003).
basin shall be constructed in a depth ing technologies are now able to guar-
lower than the point of seabed water antee a maximum drift of 0.0005% of
intake. It is these parts of the once- the total cooling water flowrate — a
through system (that is, offshore pip- rate that is the measurement limit Authors
ing and basin) that dominate the cost of existing test equipment. This salt Mahdi Gougol is a senior
process engineer with the
of a project. In cases where the intake becomes mixed with the fan air flow Research Institute of Pe-
point to reach water with sufficiently released from the selected seawater troleum Industry (P. O. Box
14665-1998, Tehran, Iran.
low temperature is far from the coast, cooling tower. Therefore, the maxi- Phone: +98-21-4473-9768;
Fax:+98-21-4473-9779; Email:
the investment cost of a system could mum concentration of salts (in the gougolm@ripi.ir), where he is
drastically increase. drift) traveling with the plume is sev- responsible for water optimi-
zation and cooling tower mod-
Operating costs include operating eral times lower than the concentra- eling projects. His key projects
materials, labor (to operate the sys- tion of salts in the air that originates include: water optimization in
Kahngiran gas refining co., Razi Petrochemical
tem), maintenance, and electricity. from seawater spray and aerosol [4]. Co., Tehran Oil Refining Co., Ilam Petrochemi-
(For this example, one of the chemicals cal Co., and Bidboland Gas Refining Co. Gougol
has a M.S.ChE from the Mazandaran University
produced in the plant is NaOCl, so it Final remarks of Science and Technology, Babol, Iran. He is
currently responsible for preparation of cooling
is not included in the calculation for From both economical and environ- tower simulation and optimization software.
the operating costs.) The maintenance mental points of view, a seawater cool- Hassan Dezvareh Resnani
cost associated with a once-through ing tower has noteworthy advantages is utility project manager at
Kaviyan Petrochemical Co.
system is higher than that of seawa- compared to a once-through system. (4th floor, Engineering Depart-
ter cooling tower, while the cost for in- The once-through option should only ment, No.54, Karimkhan St.,
7'th Tir Square, Tehran, Iran;
hibitors is lower for the once-through be considered in the case where the Phone: +98-21-8884-6125;
Email: hdezvareh@bpc.co.ir).
system. Because fans are used in the yearly average wet-bulb temperature He has over 15 years experi-
forced-draft, round-type cooling tower, is so high that the required cooled ence in operation and design
of utility units. Dezvareh has
electricity demand is almost the same water temperature cannot be provided a B.S.ChE from Sharif Uni-
as for a once-through system. When by a cooling tower. versity of Technology, and a M.S.ChE from Teh-
ran Polytechnic University, Iran.
all these different factors are consid- If the process designer does not Jamshid Pouresfandiary
ered, the total operating cost is almost consider all aspects in the design of Cham is the CFD special-
ist at the Research Institute
equal for both systems. Also, the total a cooling system, he or she might of petroleum industry (same
amount of supplied cooling water is select the once-through system sim- address as Gougol; Phone:
+98-21-4473-9554; Email:
the same for both systems. ply on the basis of high air humidity. pouresfandiarij@ripi.ir). His
The results of the cost-comparison This can waste millions of dollars and current research interests in-
clude CDM and energy man-
calculation is presented in Table 1. One cause extensive damage to the ma- agement. Pouresfandiary has
can see that, although commissioning rine environment. ■ a Ph.D. degree in mechanical
engineering from the Shinshu
and operating costs are almost the Edited by Gerald Ondrey University, Japan.
48 ChemiCal engineering www.Che.Com may 2009](https://image.slidesharecdn.com/chemicalengineering200905-130204112943-phpapp02/85/Drying-Making-Gravity-Work-66-320.jpg)
Drying: Making Gravity Work
- 1. May gulf Coast 2009 special advertising section Page 55 www.che.com 5 Gravity dryers • fire & Gas safety Page 34 Refiners Face Uncertain Future Heat Automating Transfer Batch Processes Optimal Cooling Selecting an Facts at Your Fingertips: Systems for ERP Package Choosing a Control System Coastal Plants Fire and Gas Safety vol. 116 No. 5 may 2009
- 2. Circle 01 on p. 70 or go to adlinks.che.com/23014-01
- 3. Circle 04 on p. 70 or go to adlinks.che.com/23014-04
- 4. Circle 05 on p. 70 or go to adlinks.che.com/23014-05
- 5. may 2009 In ThIs Issue Volume 116, no. 5 Commentary 5 Editor’s Page Keep GHG de- bates on point While the spotlight is on carbon diox- www.che.com ide, care should be taken in keeping the broader per- Cover story spective in mind 34 Cover Story Designing and when discussing Operating Gravity Dryers greenhouse gases, Properly designed, bulk solids bins particularly when or silos offer numerous advantages shaping regulations in slow, diffusion-limited drying operations departments neWs Letters . . . . . . . . . . . 6 11 Chementator Petroleum refiners seek to increase distillation yield, Bookshelf . . . . . . . 8, 9 decrease emissions, knock out NOx, Who’s Who . . . . . . . 32 and control SOx; Reducing foundry Reader emissions; Cold-war cleanup; Service page . . . . . . 70 Ammonia from biomass; Solid catalyst simplifies turning algae into Economic biodiesel; A better way to make effi- Indicators . . . . . 71, 72 cient catalysts; Spinning yarns of CNTs; Alkaline-earth-based catalysts advertisers for C—C bond formation; and more equipment & serviCes Gulf Coast 19 Newsfront Refiners Face Uncertain 30 Focus Heat Transfer New line of Special Future Declining product demand, blown film coolers is designed for Advertising Section . 55 volatile margins, and a global recession warm climates; These heat exchangers are forcing many refiners to rethink offer high heat-transfer coefficients; Product Showcase . . 64 investment decisions Withstand harsh outdoor conditions Classified with this heat exchanger; Mobile cool- Advertising . . . . .65–68 25 Newsfront Staying Alive Repeatability, ers designed for demanding oil applica- flexibility and visibility via automated control tions; and more Advertiser Index . . . 69 systems can help batch processors make it through the recession 32D-1 New Products & Services Coming (Domestic Edition) Splice detection in June engineering system for paper and packaging; Flow Look for: Feature calibrator with extended range dual- 33 Facts At Your Fingertips Choosing a Reports on Distilla- manifold capability; Achieve consistent Control System This one-page guide tion; and Flow Mea- dispensing over 8 or 12 pipette chan- details the technology requirements to surement; A Solids nels; This flow controller is unaffected by consider when choosing a control system Processing article temperature and pressure; This thermal- 40 Feature Report Fire and Gas Safety Sys- on Vibratory Feeders; imaging camera is portable; Communica- tems Integrating fire-and-gas detectors and An Environmental tion blocks for field devices into control mitigation systems into overall process safety Manager article systems; These thermal transfer printers control can help ensure fast responses to on Controlling Elec- feature internal memory; and more emergencies trostatic Charges; 32I-1 New Products & Services A Focus on Pumps; 45 Engineering Practice Optimal Cooling (International Edition) Realtime vis- News articles on Systems For Coastal Plants When all eco- cosity monitoring, even at high pres- Seals & Gaskets; and nomic and environmental factors are consid- sure; The IS1 remote I/O interface now Practical Applications ered, a cooling tower may be the best option comes in a FF HSE version; A versatile for Renewable Feed- 49 Engineering Practice EPC Contractors level switch for monitoring bins, silos stocks; Facts at Your Selecting an ERP Package The goal of any and hoppers; This booster allows fast Fingertips on Mate- engineer-procure-construct (EPC) arrange- control, even with high flowrates; Ana- rials of Construction; ment is to manage risk, prevent cost overruns, lyze molten liquids at very high tem- and more and deliver the project on time . The right peratures; This valve seal keeps emis- enterprise resource planning (ERP) sions at bay without excessive friction; Cover Photo: system can help and more Jenike & Johanson ChemiCal engineering www.Che.Com may 2009 3
- 6. We’re raising expectations. The presence of polar gas or steam is no match for dynamic gas phase compensation When highly accurate liquid level measurement is required, Levelflex M goes to work. Microwave pulses are directed down the instrument’s probe and reflected from the medium’s surface. Level is determined by the time required for the pulse to travel to the surface and back. This means reliable measurement is not affected by changes in process conditions, turbulence or foam. Continuous gas phase compensation technology is one way Endress+Hauser is raising expectations. With traditional level instruments, the presence of polar gas or steam can cause an error of 28% or greater depending on the pressure in the application. Levelflex M uses dynamic gas phase compensation to virtually eliminate this error. One more reason Endress+Hauser is the preferred supplier for difficult and critical level measurement applications. www.us.endress.com/level Endress+Hauser, Inc 2350 Endress Place Greenwood, IN 46143 Sales: 888-ENDRESS inquiry@us.endress.com Service: 800-642-8737 www.us.endress.com Fax: 317-535-8498 Circle 06 on p. 70 or go to adlinks.che.com/23014-06
- 7. Winner of Eight Jesse H. Neal Awards for Editorial Excellence Editor’s Page Published since 1902 Keep the GHG debate on point T An Access Intelligence Publication he anthropogenic global warming debate experienced a reawakening PublisHEr Art & dEsiGN last month, following the U.S. Environmental Protection Agency’s pro- MikE O’rOurkE dAvid WHitCHEr posed finding that greenhouse gases contribute to air pollution that may Publisher Art Director/ endanger public health or welfare. In an effort to keep the debate from head- morourke@che.com Editorial Production Manager dwhitcher@che.com ing far off course, I must comment on one particular argument that is, in my EditOrs PrOduCtiON view, nonsensical and ultimately distracts attention away from the inter- rEbEkkAH J. MArsHAll Editor in Chief MiCHAEl d. krAus ests of the chemical process industries (CPI). VP of Production & Manufacturing rmarshall@che.com mkraus@accessintel.com The argument is that carbon dioxide is somehow exempt from being con- dOrOtHy lOzOWski stEvE OlsON sidered a pollutant simply because it is a naturally occurring substance Managing Editor dlozowski@che.com Director of Production & that is essential for plant life — and, therefore, human life. In addition to Manufacturing GErAld ONdrEy (Frankfurt) solson@accessintel.com letters and emails, I’ve seen this argument everywhere from small-town Senior Editor gondrey@che.com WilliAM C. GrAHAM newspapers to well-known trade and consumer publications — and, of Ad Production Manager kAtE tOrzEWski bgraham@che.com course, on their blogs. Each time, numerous contradictions come to mind. Assistant Editor MArkEtiNG Carbon dioxide is not the first substance with positive use to be classified ktorzewski@che.com HOlly rOuNtrEE as a pollutant. Many well-established precedents already exist throughout suzANNE A. sHEllEy Contributing Editor Marketing Manager hrountree@accessintel.com the CPI. At certain concentrations these substances are indeed valuable — sshelley@che.com AudiENCE if not essential — to human life. Like the current proposals for regulating COrrEsPONdENts dEvElOPMENt carbon dioxide and other greenhouse gases (GHGs), the natural existence CHArlEs butCHEr (U.K.) sylviA siErrA of these substances is not controlled. And in many cases, the industrial cbutcher@che.com Senior Vice President, Corporate Audience Development emission of these substances into the air, water or ground is all but ignored PAul s. GrAd (Australia) ssierra@accessintel.com pgrad@che.com up to a certain point (which is usually defined on the basis of concentra- JOHN rOCkWEll tEtsuO sAtOH (Japan) Vice President, tion or mass). A simple, yet important fact that is seemingly ignored in the tsatoh@che.com Audience Development Chemical argument “CO2 is automatically exempt from pollutant status” is that the JOy lEPrEE (New Jersey) jrockwell@accessintel.com jlepree@che.com lAuriE HOfMANN distinction of pollutant applies exclusively to human activities that exceed GErAld PArkiNsON Audience Marketing Director certain emission thresholds. lhofmann@Accessintel.com (California) gparkinson@che.com Perhaps the simplest of these examples is warm water, which arguably is tErry bEst EditOriAl Audience Development Manager essential to the developed world but is also classified by the U.S. EPA and AdvisOry bOArd tbest@accessintel.com others as “thermal pollution” when released into a nearby stream, river, JOHN CArsON GEOrGE sEvEriNE Jenike & Johanson, Inc. Fulfillment Manager lake or ocean. Indeed, in the design of industrial cooling water systems, dAvid diCkEy gseverine@accessintel.com warm water discharge is a key consideration (for more see p. 45). MixTech, Inc. JEN fElliNG Ozone (O3) is classified as a pollutant even though it naturally sustains MukEsH dOblE List Sales, Statlistics (203) 778-8700 IIT Madras, India j.felling@statlistics.com life on earth (in the stratospheric ozone layer) and has beneficial commer- HENry kistEr CONfErENCEs cial applications (such as water treatment). Meanwhile, hydrochloric acid Fluor Corp. dANA d. CArEy is considered a hazardous air pollutant in the U.S. and elsewhere, yet it is Director, Global Event Sponsorships trEvOr klEtz dcarey@chemweek.com produced naturally by the human body for digesting food. Loughborough University, U.K. PECk siM The point is that once again a group of scientists has developed a hy- GErHArd krEysA DECHEMA e.V. Senior Manager, pothesis about the potentially harmful effects of human activities and Conference Programming rAM rAMACHANdrAN psim@chemweek.com has presented enough supporting evidence to raise concern in substantial BOC bEAtriz suArEz numbers of the scientific community and the public alike. Regulation is Director of Conference Operations iNfOrMAtiON bsuarez@chemweek.com now unavoidable. Flawed arguments don’t do anything to change that and sErviCEs rObErt PACiOrEk COrPOrAtE actually hurt the interests of CPI by distracting everyone from the im- Senior VP & Chief Information Officer stEvE bArbEr portant decisions that are already taking place — how those regulations rpaciorek@accessintel.com VP, Financial Planning & Internal Audit sbarber@accessintel.com should be defined and carried out. CHArlEs sANds Senior Developer briAN NEssEN True industry advocates should instead focus on helping shape green- Web/business Applications Architect Group Publisher house gas policies that are both effective and realistic in terms of their csands@accessintel.com bnessen@accessintel.com immediate and longterm impacts on global economics (see p. 6). In this HEAdquArtErs effort, I agree with the premise that more education on greenhouse gases 110 William Street, 11th Floor, New York, NY 10038, U.S. Tel: 212-621-4900 Fax: 212-621-4694 and their effects is needed. But, instead of diverting to EurOPEAN EditOriAl OffiCEs carbon dioxide’s life-giving characteristics, which are Zeilweg 44, D-60439 Frankfurt am Main, Germany part of most elementary-school science classes anyhow, Tel: 49-69-2547-2073 Fax: 49-69-5700-2484 I suggest, for one, raising awareness of other, lesser- CirCulAtiON rEquEsts: Tel: 847-564-9290 Fax: 847-564-9453 known greenhouse gases with higher estimated global Fullfillment Manager; P.O. Box 3588, warming potential. For instance, hydrofluorocarbons, Northbrook, IL 60065-3588 email: clientservices@che.com perfluorocarbons, sulfur hexafluoride and N2O global AdvErtisiNG rEquEsts: see p. 70 warming impacts are estimated to be 298–22,800 times For photocopy or reuse requests: 800-772-3350 or info@copyright.com For reprints: chemicalengineering@theygsgroup.com that of CO2 (per unit mass) over a 100 year period. ■ Rebekkah Marshall ChemiCal engineering www.Che.Com maY 2009 5
- 8. Letters Shaping GHG policies Edison Electric Institute (EEI) member companies support action to lower the country’s carbon and other greenhouse gas (GHG) emissions by 80% from current levels by 2050. And we want to do so in a way that softens electricity price increases for families and our energy-intensive customers, such as chemical manufac- turers. A critical factor for achieving this goal within a federal cap-and-trade program is by allocating rather than auctioning emissions allowances. Under a cap-and-trade program, the government sets a national cap on GHG emissions. Over time, this cap becomes lower until the ultimate GHG reduction goal is met. The government would create allowances for electric utilities and others to emit GHG emissions under the cap. The method by which the government initially introduces these allowances into the market — by allocation or auc- tion — is crucial. Auctioning allowances sharply increase costs by re- quiring companies to pay both for the allowances and for the cost of actually reducing emissions. All of these costs would be passed on to consumers. In contrast, if allow- ances are allocated, only the costs of actually reducing emissions are passed along. A portion of the revenue raised through an auction may be returned to customers via a tax rebate. But this isn’t an efficient mechanism for channeling relief to all custom- ers. Nor is it assured that all of the revenue raised would be directed to mitigating energy prices or developing the technologies that we as a nation need to transition to a vibrant, low-carbon economy. Support is growing for allocating allowances. The U.S. Cli- mate Action Partnership — an alliance of major businesses, such as Dow and DuPont, as well as leading climate and Circle 07 on p. 70 or go to adlinks.che.com/23014-07 environmental groups — is in favor of allocating emissions allowances. So is the Pew Center on Global Climate Change, the National Association of Regulatory Utility Commission- ers, and a number of labor groups among others. Although additional measures will certainly need to play roles in lessening energy cost increases under a national climate change program, allocating emissions allowances will be vital. Please contact your members of Congress and ask that they support allocating allowances in any climate change legislation. For more information on EEI and its climate principles, please visit www.eei.org/climate. Thomas R. Kuhn President Edison Electric Institute Poscripts, corrections April, Capital Costs Quickly Calculated, pp. 46–52: In three places in the box at the top of p. 47, the factor 0.8 should have been rendered as an exponent and was not [30.8 at the bottom of the first column, 20.8 at the top of the second column, and (0.635/2)0.8 at the third line from bottom of second column]. A cor- rected version of the article can be found by searching for the title of the article at www.che.com.
- 9. The Original… ‘s PowerTrap® was the first combination pump/trap solution to maximize heat exchanger performance. And it’s still the best choice for your For Optimum important process applications. Why? Optimal Productivity • Increase yield by eliminating process Heat Exchanger variation caused by stall conditions • Built-in steam trap synchronizes pumping and trapping functions to maximize available tube bundle surface Performance. area Assured Uptime Reliability • Increased equipment availability through the elimination of heat exchanger stratification • Non-electric, intrinsically safe design with no cavitation or seal leakage • Precision engineered, warranted internals using INCONEL® equivalent compression spring and snap-action mechanism Improved System Efficiency • Complete condensate recovery reduces energy consumption, and lowers water treatment and sewage costs • Energy conserving, contoured body design uses less motive medium Achieve outstanding productivity, performance, and energy efficiency with the original PowerTrap from . Call to learn how the PowerTrap can optimize heat exchanger value in your process application. INCONEL is a registered trademark of the INCO family of companies Member of 13901 South Lakes Drive, Charlotte, NC 28273-6790 Tel: 704-597-9070 Fax: 704-583-1610 FLUID CONTROLS INSTITUTE www.tlv.com Circle 08 on p. 70 or go to adlinks.che.com/23014-08
- 10. Bookshelf Hazards of Oil Refining Distillation Units. By BP International Ltd. (BP Process Safety Series). Institution of Chemical Engineers, Davis Building, Railway Terrace, Rugby CV21 3HQ, U.K. Web: icheme.org. 2008. 81 pages, £27. Reviewed by Stanley S. Grossel, Process Safety & Design, Inc., Clifton, N.J. T his booklet was written as a reference tool for opera- tors, engineers and technicians working on crude and vacuum distillation units (CDUs and VDUs) in the petroleum industry. It outlines the main hazards associated with these units and promotes the adoption of safe operat- ing practices and procedures in order to prevent the recur- rence of serious incidents. The book contains seven chapters, a list of relevant ref- erences, an incidents list, and a glossary. Chapter 1, the introduction, opens with a process description of crude oil distillation with a schematic of CDU and VDU process flows and products, followed by a summary of the main hazards in these units, and a breakdown of when CDU and VDU incidents occur. Chapter 2 discusses the chemi- Circle 09 on p. 70 or go to adlinks.che.com/23014-09 cals found in crude oil that contribute to the hazards in distillation, such as hydrocarbons, inorganic and other materials imported with crude oil, and other hazardous substances in common use on CDU and VDUs [super- heated steam, water, ammonia, chemicals used for break- ing desalter emulsions and for corrosion control, nitrogen, and nucleonic sources (used in liquid level instruments)]. In Chapter 3, entitled Physical Hazards, a number of incidents are described that occurred during startup and shutdown, normal operation, and unit turnarounds. The chapter covers a large number of causes, and is very infor- mative. Hazards related to equipment failure of columns MIXING MAGNESIUM HYDROXIDE IS EASY, and other associated equipment are discussed in Chapter FAST, EFFICIENT, MONEY-SAVING 4. Among the topics covered are: columns and other pres- AND MAINTENANCE-FRIENDLY sure vessels and piping (corrosion and inadequate design Let’s You Mix Sodium Hydroxide, Pulsair’s and construction), desalters, fired heaters, rotating equip- Sodium Hypochlorite, TM/ETM-2000 ment, heat exchangers and distillation column overfilling. Series Mixers Magnesium Hydroxide Much useful information is presented in this Chapter. and others with just a little Chapter 5 covers safe operating practices and proce- compressed air dures, discussing startup, shutdown, and normal operating and ... and emergency procedures. Also briefly discussed are trou- NO MOVING bleshooting and the concept of a safe operating envelope. PARTS in the In Chapter 6, some serious incidents that have oc- tank! curred on CDU and VDUs are described. These include: Pulsair Systems offers a full line of mixers for poly, fiberglass and steel fire and casualties at a crude unit tower, electrocution tanks. The mixers are either electronic or pneumatic control depending incident at a CDU desalter, hazards of water entering on customer needs. The in-tank accumulator plates can be made from vacuum towers, hazards of atmospheric relief valves, an materials compatible with the liquids being mixed. internal VDU tower fire during a turnaround, and four fatalities during the repair of piping. Chapter 7 is a self- Pulsair Systems, Inc. test questionnaire containing 21 questions designed to P.O.Box 562, Belevue, WA 98009 assess the effectiveness of knowledge transfer following a 1-800-582-7797 review of this booklet. The incidents list is a compilation PHONE: 425-455-1263• FAX: 425-451-7312 E-MAIL: sales@pulsair.com •WWW.PULSAIR.COM of 144 accidents that have occurred to refinery columns and associated equipment. Circle 28 on p. 70 or go to adlinks.che.com/23014-28 8 ChemiCal engineering www.Che.Com may 2009
- 11. This booklet contains much useful and practical infor- mation on problems that have occurred in distillation of crude oil. Although it pertains primarily to CDUs and VDCs in the petroleum industry, many of the incidents discussed and the lessons learned can be applied to distil- lation columns in chemical, petrochemical and pharma- ceutical plants. The Green Book: Flow, Level and Environmental Handbook and Ency- clopedia. 8th Edition. Omega Engineer- ing, Inc. One Omega Drive, Stamford, CT 06907. Web: omega.com. 2007. 1,300 pages. Free. Modern Drying Technology: Ex- perimental Techniques. Volume 2. Edited by E. Tsotsas and A. S. Mujum- dar John Wiley & Sons, Inc. 111 River St., MS 8-01, Hoboken, NJ 07030-5774. Web: wiley.com. 2009. 412 pages. $215. Handbook of Maintenance Man- agement and Engineering. By M. Ben-Daya, S. O. Duffuaa, A. Raouf, J. Knezevic, D. Ait-Kadi. Springer, 233 Spring Street, New York, NY 10013. Web: springer.com. 2009. 741 pages. $209. Ultraviolet Light in Food Technol- ogy: Principles and Applications. Second edition. By T. Koutchma, L. J. Forney and C. I. Moraru. CRC Press, 6000 Broken Sound Parkway, NW, Suite 300, Boca Raton, FL 33487. Web: crcpress.com. 2009. 296 pages. $179.95. PVC Formulary. By G. Wypych. ChemTec Publishing, 38 Earswick Drive, Toronto, Ontario M1E 1C6, Canada. Web: chemtec.org. 2009. 324 pages. $275. Engineering Materials Properties and Selection: International Edi- tion. By K. Budinski and M. Budinski. Pearson Higher Education, One Lake St., Upper Saddle River, NJ 07458. Web: pearsonhighered.com. 2009. 784 pages. $135.20. Manufacturing of Pharmaceuti- cal Proteins: From Technology to Economy. By S. Behme. John Wiley & Sons, Inc. 111 River St., MS 8-01, Hobo- ken, NJ 07030-5774. Web: wiley.com. 2009. 404 pages. $130. ■ Kate Torzewski Circle 11 on p. 70 or go to adlinks.che.com/23014-11 ChemiCal engineering www.Che.Com may 2009 9
- 12. Circle 12 on p. 70 or go to adlinks.che.com/23014-12
- 13. Edited by Gerald Ondrey May 2009 Petroleum refiners seek to increase Wireless add-on distillate yield, decrease emissions . . . aBB instrumentation (warmin- ster, Pa.; www.abb.com/instru- S trategies for extracting more dis- Grace Davison and other cata- mentation) has made its entry tillate from petroleum to meet the lyst manufacturers have devel- into wireless communications growing demand for diesel fuel con- oped new catalysts that crack technology with the wire- lessharT upgrade adapter, stituted a major theme of the recent more of the bottoms to obtain LCO. previewed at aBB’s recent au- annual meeting of the National Pet- Grace’s latest catalyst, Midas 300, tomation & Power world. This rochemical and Petroleum Refiners can increase LCO yield by 6 vol% adapter is used to connect Association (NPRA, Washington D.C.; www. without slurry recycle. Hunt adds that re- existing harT transmitters that npra.gov) in San Antonio, Tex. Worldwide, cycling part of the feed can also boost LCO are wired to existing systems the demand for distillate is expected to in- yield. In laboratory tests, using a Midas that do not take full advantage crease by more than 5 million bbl/d over the catalyst, Grace found that the highest LCO of the transmitters’ functionality. next 10 years, says Richard Rossi, business yield was achieved by recycling the fraction most harT instruments manager for conversion technologies with that boils at 650–850°F. “Recycling isn’t continuously monitor over UOP LLC (Des Plaines, Ill.; www.uop.com). that common,” he says, “but it may become 15, possibly up to 50 condi- tions and these instruments Many of the diesel-boosting technologies more common in the future.” are likely to hold valuable discussed at the meeting involve modify- Albemarle Corp. (Houston, Tex.; www.al- maintenance and process ing the operation of fluid catalytic crackers bermarle.com) offers a new family of FCC information that the user (FCCs) and the use of new FCC catalysts catalysts, called Upgrader, for processing may be unaware of, accord- to increase distillate yield. Another lead- residual oil. In one of its first applications, ing to aBB. The upgrade ing topic was pollution control for FCCs, in a North American refinery, the catalyst adapter allows full usage of which are a major source of refinery emis- has led to a 6% increase in feed throughput. an instrument’s capabilities sions. Rossi noted that complex refineries This increases profitability by $10 million/ and transmits this informa- with FCC and hydrocracking units have sig- yr, according to Kenneth Bruno, Albemarle’s tion wirelessly. it works on all nificant potential to shift toward diesel fuel global applications technology manager for makes of harT instruments. while other wireless adapt- production, with attractive economics and FCC, who spoke at the NPRA meeting. ers exist, the advantages of minimal investment. In a separate, commercial trial in a re- this one, according to aBB, An increase in the ratio of light cycle oil sidual FCCU, an Upgrader MD (maximum are its small size and the fact (LCO) to gasoline in an FCC can be read- distillate) catalyst increased LCO yield by that it does not run on batter- ily achieved by adjusting the unit’s operat- nearly 3 wt.% and decreased the bottoms ies. Battery life can be an area ing conditions and reducing the catalyst yield by 1 wt.%. of concern for wireless trans- activity, noted David Hunt, technical ser- BASF Catalysts LLC (Iselin, N.J.; basf. mitter users. aBB is planning vice manager for Grace Davison (Houston, com) has also commercialized a new FCC to launch this product later this Tex.; www.grace.com). The drawback is an catalyst, HDXtra. In its initial installations year, and is currently looking increase in bottoms yield, said Hunt, so the catalyst has increased LCO yield from for testers to ensure full in- teroperability of this adapter. “maximizing LCO in the FCCU at reduced 10 vol% to as much as 30 vol%, says Joe conversion without producing incremental McLean, global marketing manager for re- bottoms oil is the true challenge.” fining catalysts. Corrosion protection a coating with comparable or even superior corrosion . . . knock out NOx . . . resistance than those based on chromium has been A relatively inexpensive way to treat oxides of nitrogen (NOx) emissions from an FCC is to use an additive, which is mixed with the Praxair, Inc. (Tonawanda, N.Y.; www. praxair.com) have joined forces to develop a novel NOx-control system for FCCs called developed by scientists at Brookhaven national labora- tory (Upton, n.y.; www.bnl. catalyst and minimizes NOx formation by CONOx. The system combines Shell’s NOx- gov). The patented technology manipulating N2 oxidation/reduction reac- control process with a Praxair oxygen-in- can be applied to aluminum, tions in the regenerator. Additives can reduce jection technique. steel, nickel, copper, bronze NOx by up to 70–75%, says, Martin Evans, Shell’s process redirects the airflow in the and brass, making it promis- vice-president engineering for Intercat Inc. catalyst regenerator to reduce NOx output ing for protecting components (Sea Girt, N.J.; www.intercatinc.com), which to below 40 ppm (CE June 2008, p. 15). In of valves, pumps and other makes additives that are a mix of catalyti- CONOx, a jet of hot oxygen is subsequently equipment. The technology is available for licensing. cally active metals. Higher removal levels re- injected through a lance into the fluegas. The The coating can be applied quire additional technology, such as selective O2 oxidizes CO and destroys NOx precursors. by a variety of ways, including catalytic reduction, he says. In pilot tests CONOx has reduced NOx emis- spraying or dipping compo- Shell Global Solutions (Houston, Tex.; sions by 70–80%, says Ye-Mon Chen, Shell www.shell.com/globalsolutions) and (Continues on p. 12) (Continues on p. 12) Note: For more information, circle the 3-digit number on p. 70, or use the website designation. ChemiCal engineering www.Che.Com may 2009 11
- 14. C hementato R (Continued from p. 11) nents to be treated into a solu- tion of the components. Cross linking of the components is NOx (Continued from p. 11) U.S. refinery later this year. Chen says the then induced by subsequent Global’s FCC regional manager. capital cost is approximately $10 million, treatment steps, such as heat- Praxair and Shell have licensed their first around one-tenth the cost of selective cata- ing, to form corrosion-inhibit- system, which is scheduled to start up in a lytic reduction (SCR). ing metal oxide nanoparticles, such as cerium-based oxides. The resulting coating is water . . and control SOx repellent and strongly bound M ost of the sulfur emanating from FCCs FCC is operated in partial-burn mode. to the metal, making it espe- is either contained in the products or Albemarle’s newest additive, SOxMaster, cially resistant to brine. and because an ultra-thin (10-nm released as hydrogen sulfide in the fluegas, overcomes this disadvantage by combining thick) film is formed, Bnl says from which it is scrubbed by amines. How- the hydrotalcite technology with novel mate- the coating is “highly” eco- ever, about 10% is emitted as sulfur oxides rials, says Kramer. In an initial commercial nomical and efficient. (SOx). Aside from hydrotreating the feed, the installation, SOxMaster has achieved 90% two popular ways to reduce SOx emissions from the FCC catalyst regenerator are to use sulfur reduction in a deep partial-burn unit, versus a maximum of 40% for a conventional Heavy gems rubicon Technology, inc. an SOx-reduction additive or treat the fluegas additive. Kramer adds that SOxMaster has (Franklin Park, ill.; www.rubi- by wet scrubbing, says Alan Kramer, global a half-life of about 30 days, against 5–7 days con-es2.com) has grown what FCC additives specialist for Albemarle. for a conventional additive. it believes to be the world’s An advantage of additives over wet scrub- A catchall emissions control system for largest sapphire crystal. at 200 bers is that there is practically no capital FCCs is offered by Intercat and Pall Corp. kg, the super boule will enable cost, he says, but the competitiveness of (Port Washington, N.Y.; www.pall.com). The the company to offer large-size additives in terms of cost and effectiveness system combines Intercat’s NOx and SOx optical windows and next-gen- depends on the cost of scrubber caustic and (magnesium hydrotalcite) additives with eration wafer products with di- the nature of the FCC operation. Albemarle Pall’s self-cleaning blowback filter for par- mensions over 12 in. rubicon’s makes additives of hydrotalcite, a magne- ticles. The filter consists of porous metal or proprietary eS2 crystal-growth technology — routinely pro- sium-aluminum hydrate compound, which ceramic tubular elements, and captures fine, ducing bulk sapphire crystals is added to the FCC regenerator along with dry catalyst particles emitted by the regener- up to 85 kg for 8-in.-dia. wafers the catalyst. The additive absorbs SO3 and ator. Evans, of Intercat, says the total capital and optical windows with 10-in. releases the sulfur into the reactor product cost could be as low as half that of a conven- dimensions — can be scaled stream as H2S. However, Kramer notes that tional system that uses a wet scrubber for up to produce even larger- additives tend to be less effective when an SOx, NOx and particulate-matter control. sized sapphire products in the future, says the firm. Reducing foundry emissions C ast parts, such as engine blocks, are typically made by pouring molten metal into so-called cores — sand-based Technik GmbH (Fuldabrück, Germany), for the production of casting cores using the Inotec process. Developed and pat- pected to begin series production of a package consisting of various cores, in- cluding those to be used for the casting molds that have internal passages for ented by Ashland-Südchemie-Kernfest of cylinder blocks for a new, six-cylinder the component to be cast. Such casting GmbH — a joint venture between Süd- diesel engine of BMW AG (Munich, Ger- cores are typically made by reacting Chemie and Ashland, Inc. (Covington, many; www.bmw.com). BMW is said to sand with organic binders in a curing Ky.; www.ashland.com) — the Inotec be the first OEM in automotives to grad- process. In recent years, industry has binding system combines a liquid com- ually reduce the use of organic binding been seeking alternatives to organic ponent (a modified silicate solution) agents, and use only inorganic-bound binders to avoid releasing toxic emis- with promoters that contain high con- cores from 2010 onwards. sions during curing. centrations of minerals. Because the Inotec was first demonstrated in 2005 Last month, Süd-Chemie AG (Munich, binding system is inorganic, virtually in the production of light-metal cast- Germany; www.sud-chemie.com) inau- no emissions are emitted in the process, ings, when BMW’s foundry in Landshut, gurated in Moosburg a new production says the company. Germany, decided to use the inorganic plant of its subsidiary, WD-Giesserei- From May, the Moosburg plant is ex- binding system. Cold-war cleanup posal of waste, and cleaning and demol- ishing former weapons complex facilities. to demolish nuclear and other facilities, remediate waste sites, remediate con- O n March 31, U.S. Dept. of Energy (DOE; Washington, D.C.) Secretary Steven Chu announced $6 billion in new These projects and the new funding are managed by the DOE’s Office of Environ- mental Management, which is responsi- taminated groundwater and retrieve solid waste from burial grounds. Also, the funding will accelerate cleanup of funding under the American Recovery ble for the risk reduction and cleanup of facilities, waste sites and groundwater and Reinvestment Act to accelerate envi- the environmental legacy from the U.S.’s along the Columbia River to support ronmental cleanup work and create jobs nuclear weapons program. shrinking the active area of cleanup at across 12 states. Projects identified for Among the 12 states and DOE sites the 586-sq. mi. Hanford Site to 75 sq. funding involve the cleanup of soil and that will receive funding is the Rich- mi. or less by 2015. More information groundwater, transportation and dis- land Operations (Wash.; $1.961 billion) can be obtained at www.em.doe.gov 12 ChemiCal engineering www.Che.Com may 2009
- 15. Ideas that tailor the broadest line to move your product. Performanteed ™ Hapman’s MiniVac™ pneumatic conveyor: maximize your ROI, minimize your time Maximize ROI with the Hapman MiniVac™ pneumatic conveyor. Eliminate the need for an expensive air supply and reduce energy costs by up to 30% with the MiniVac™’s integral blower. Reduce labor and time with tool-less, side-door access for filter changes 3 ways to convey. convey and cleaning. Eliminate the need for separate dust collection One Performanteed™ solution. with the MiniVac™’s internal filter. Keep filter operating at top Only Hapman offers three types of conveyor systems— efficiency with the standard reverse-pulse filter cleaner. Only with and the 60+ years expertise to determine which is best the Hapman MiniVac™ pneumatic conveyor. for your specific application. Our tailor-made solutions and broadest material handling line carry the industry’s only true performance guarantee. Tubular drag Helix™ flexible screw Bag dump PosiPortion™ Bulk bag Bulk bag conveyors conveyors stations feeders fillers unloaders “Only Hapman offers Performantee™, the first and only true performance guarantee in the industry. We guarantee that our equipment will achieve USA · Kalamazoo, Michigan the specific results for which it was designed and manufactured. If it www.ideasthatmove.net doesn’t, we’ll revise, repair, or make whatever UK · Bristol, England Europe · Bratislava, Slovakia www.hapman.co.uk www.hapman.eu changes are necessary. Performanteed.” India · Vadodara, Gujarat Ned Thompson, president, Hapman www.hapman.in Circle 13 on p. 70 or go to adlinks.che.com/23014-13
- 16. C hementato R Syngas clean-up Biomass & heat recovery feeder Harvest gas Ammonia from biomass Air Fluidized Water gas shift S ynGest, Inc. (San Francisco, Calif.; www. separation bed & plant gasifier pressure swing syngest.com) plans to commercialize a Oxygen adsorption process for the production of ammonia from biomass by the fall of 2011. The first plant, Hydrogen to be located in Menlo, Iowa, will convert Ammonia Ammonia 150,000 ton/yr of corncobs into 50,000 ton/ synthesis storage Nitrogen yr of ammonia, enough to fertilize 500,000 acres of nearby farmland. Chopped corncobs will be gasified in a wald, chief executive officer, is confident bubbling bed gasifier at 1,700°F and 100 psi, that it will be competitive for two reasons: it The threat of GHGs using oxygen from a cryogenic air-separation will use a cheap feedstock instead of natural After a thorough scientific review plant (flowsheet). The resultant syngas, pri- gas, and distribution costs will be low be- ordered by the U.S. Supreme marily hydrogen and carbon monoxide, will cause the product will be used locally. “With Court, the U.S. Environmental be subjected to a water-gas shift reaction, a conventional plant, distribution accounts Protection Agency (EPA; Wash- followed by pressure-swing adsorption, to for half the cost of bringing ammonia to the ington, D.C.) issued a proposed obtain 99.9%-pure H2. The H2 will be com- market,” he says. “Our long-term plan is to finding that “greenhouse gases (GHGs) contribute to air pollu- bined with N2 from the air-separation unit build small plants, located near sources of tion that may endanger public to produce ammonia. biomass and local markets. Each plant will health or welfare.” The pro- Although the plant will be miniscule by cost approximately $80 million and will gen- posed finding, which now moves world scale ammonia standards, Jack Os- erate revenues of about $30 million/yr.” to a public comment period, identified six GHGs that pose a Solid catalyst simplifies turning algae into biodiesel potential threat: CO2, CH4, N2O, hexafluorocarbons, perfluoro- R esearchers at United Environment & Energy (UE&E; Horseheads, N.Y.) have developed a catalyst for the efficient con- traditional methanol-and-lye process. Fur- thermore, it eliminates the need for a purifi- cation step, since there is no liquid catalyst carbons and sulfur hexafluoride. According to the EPA, “science clearly shows that concentra- tions of these gases are at version of algae to biodiesel. The mixed- mixed into the resulting fuel. UE&E has unprecedented levels as a result metal oxide catalyst (comprised of metals produced 10 gal. of algae biodiesel by this of human emissions, and these that are resistant to corrosion yet reac- method and plans to sell the technology for high levels are very likely the tive) facilitates the transesterification of commercialization by other companies. One cause of the increase in average algae oil and methanol. The mechanism for company has produced over 100 gal. of fuel temperature and other changes the reaction over the solid catalyst is still by this method, and has certified the process in our climate.” under study, but preliminary results indi- to ASTM standards. cate that fine methanol/oil drops contact While algae is easy to grow, extraction of Hydrocracking the catalyst surface, and the active sites its oil is a challenge. UE&E has established UOP (see p. 11) now offers an of the catalyst prompt reaction along the a relationship with a non-U.S. supplier of enhanced, two-stage hydroc- methanol/oil interface. algae oil, because U.S. environmental regu- racking process that uses two The conversion process is 40% less expen- lations limit use of the toxic solvents needed new catalysts to increase distil- sive than an industrial-scale version of the to extract oil from algae. late yield by 5–6%. The com- pany has licensed the process to several companies, says Rossi, A better way to make efficient catalysts of UOP, and the first commercial units will start up in 3–4 years. A new procedure for making uniform, me- tallic nanoparticles has been developed by the research group of Kousuke Mori, The resulting nanoparticles exhibit en- hanced catalytic properties; for example, a palladium catalyst with uniform diameters Keep computers cool an associate professor at Osaka University of 2 nm are found to be twice as active as As electronics products con- (www.mat.eng.osaka-u.ac.jp), with support those prepared by impregnation for the pro- tinue to get smaller while at the from New Energy and Industrial Technol- duction of hydrogen peroxide from H2 and same time incorporating more components, new ways to take ogy Development Organization (NEDO; O2 in water. The catalytic activity is further away the heat is an important Kawasaki, both Japan). The photo-assisted enhanced by adding gold during the UV quest. Researchers at the process, which uses ultraviolet (UV) light to deposition, which leads to the formation of Fraunhofer Institute for Manu- deposit precursor metals onto active sites nanoparticles of Pd-Au alloy. The technique facturing Engineering and Ap- of a titanium substrate, is said to be less is applicable to precious metals, such as Pt, plied Materials Research (IFAM; expensive and simpler than conventional Pd and Au, and shows promise for reducing Dresden, Germany; www.ifam. impregnation methods, while producing the environmental burden of solvent-based fraunhofer.de) may have a smaller (1–3-nm dia.) particles with a con- reactions, such as the anthraquinone route (Continues on p. 17) trolled, narrow size distribution. to H2O2. 14 CHEMICAl ENGINEERING WWW.CHE.COM MAy 2009
- 17. Visit us at ACHEMA, Frankfurt, Germany HALL 8 - Booths B5-B10 & M27-M29 T R A N S F E R R I N G C O N F I D E N C E PSG (Pump Solutions Group) delivers cohesion, synergies and relevant value to our customers with superior products, world class operations and a tireless commitment to excellence. PSG offers you a broad array of quality and innovative pump technologies that you’ve come to expect from premiere pump brands like Wilden, Blackmer, Mouvex, Neptune, Almatec and Griswold. PSG features world class facilities in the U.S., Germany, China, India, and France. We consider ourselves global citizens and, as a collective, are passionately committed to innovative technologies that will positively impact the world for the better. It is this ferocious pursuit of excellence and accountability that drives us to deliver unequaled customer satisfaction, state of the art technologies and market knowledge. PSG believes in its people and the intellectual capital that delivers tomorrow’s fluid transfer solutions today. Visit us today at www.PumpSG.com. Circle 14 on p. 70 or go to adlinks.che.com/23014-14 1401 Ford Street, Redlands, CA 92373 • Suite 205 • USA Telephone 909-422-1730 • Fax 909-783-3440 www.pumpsg.com • achema@pumpsg.com
- 18. C hementato R Spinning yarns of CNTs T he exceptional properties of carbon nanotubes (CNTs), such as high ten- sile strength and high thermal and Texas at Dallas (http://nan- otech.utdallas.edu), developed a way to make have electrical conductivities, have sug- pure, CNT yarns and webs, gested a number of applications, in- avoiding the problems asso- cluding lightweight materials for bal- ciated with the presence of listics protection, actuators for muscles a binder. or artificial muscles, filaments for light The technology under de- sources, electrodes, super-capacitors, velopment involves growing and flow sensors. So, many research- “drawable” forests, which ers have tried to prepare macroscopic means that CNTs taken off CNT materials that exhibit at least the wall of the forest cause some of the properties of individual the drawing off of CNTs CNTs. This has so far proved elusive. from the next layer. Continuous ap- C2H2 in He at 670ºC and atmospheric One method of assembling CNTs into plication of this process leads to the pressure. The yarn is spun using a macroscopic structures is to disperse formation of a continuous web of CNTs spinner adapted from a conventional them into a binder. However, a rapid that may be used directly or twisted spinning method. increase of viscosity with concentration into a yarn (photo). The resulting yarns have a range of limits the final concentrations to about The team has grown drawable for- useful properties. Single yarns have 7 wt.%. Researchers from CSIRO Tex- ests on a silicon wafer with a 5-nm a breaking strength of 600 MPa and tile and Fibre Technology (Belmont, film of an iron catalyst. Aligned forests electrical conductivities of about 300 Victoria, Australia; www.csiro.au), and of multi-wall CNTs are grown on the S/cm. Young’s moduli of 25 to 50 GPa the NanoTech Institute and Depart- wafer in a 45-mm dia. quartz tube by were measured and the typical break- ment of Chemistry at the University of chemical vapor deposition of 5 mol% ing strain was found to be about 5%. Helping you keep your cool under any circumstances 24/7/365. Aggreko Cooling Tower Services (ACTS) ACTS provides proven rental cooling is the world’s largest provider of rental tower solutions to: cooling tower solutions. For over • Maintain cooling capacity during 20 years, we have successfully helped partial or complete tower repair customers solve their cooling water limitations - under any circumstances. • Reduce cooling water temperatures during peak summer conditions From the planning stages to the turnkey • Minimize post-disaster downtime installation of convenient modular cooling towers, ACTS has the solutions to help • Add cooling water capacity with no you keep your cool, 24/7/365. capital commitment Contact Aggreko today for all your rental cooling tower needs. Performance Certified by Cooling Technology Institute 866.310.0870 www.coolingtowers.com Circle 15 on p. 70 or go to adlinks.che.com/23014-15 16 ChemiCal engineering www.Che.Com may 2009
- 19. (Continued from p. 14) C hementato R solution. Together with indus- trial partners in the ExtraMat project, scientists have devel- oped a material (a mixture of Alkaline-earth-based catalysts diamond powder and copper bonded together with chrome) for C–C bond formation that has a thermal conductivity 1.5 times higher than that of copper, yet expands no more S alts of alkaline-earth metals have been shown to catalyze reactions for the se- lective formation of carbon-carbon bonds, performed with 10 mol% Mg(OtBu)2, in di- methyl formaldehyde solvent at room tem- perature (OtBu = tert-butoxy). Switching to than ceramics when heated. by chemistry professor Shu Kobayashi 10 mol% of Sr(HMDS)2 (with 11 % ligand) H2-generating tablets and colleagues at the University of Tokyo and THF (tetrahydrofuran) solvent (HMDS The Energy and Environmen- (www.chem.s.u-tokyo.ac.jp). The research, = hexamethyldisilazide), the Mannich reac- tal Research Laboratories supported by the Japan Science and Tech- tion leads to a 92% yield after 24 h, with of the Industrial Technology Research Institute (ITRI) of nology Agency (Tokyo), promises to deliver syn-to-anti ratio of 93-to-7. Taiwan (www.itri.org.tw) has alternatives to conventional catalysts that The group has confirmed that it can se- developed a pill that stores contain toxic, scarce and expensive metals. lect anti- or syn-type products for various H2 gas in a solid substance, The researchers found that alkaline-earth- imines substrates derived from aromatic instead of a large and hazard- metal salts can activate, with an atomic compounds, aliphatic compounds, and aro- ous pressurized bottle. Called efficiency of 100%, the nucleating agent matic compounds containing oxygen and the Power-gra, the pill is com- sulfonyl imidate, which enables them to sulfur atoms. The reaction procedure has posed of hydrides (primarily selectively form C–C bonds. Futhermore, also been extended to asymmetric synthe- NaBH4), a catalyst and other Kobayashi’s group has shown that the ste- sis, achieving enantio-selective Mannich re- patented ingredients. When reoselectivity can be adjusted by using dif- action with 85% yield after 48 h, syn-to-anti water is added, the pill re- leases H2, which can be used ferent solvents. ratio of 83-to-17 and 57% enantiomeric ex- to power a fuel cell to generate For example, the Mannich reaction of cess when using using 10 mol% of Sr(OiPr)2 electricity. In the near future, 1 benzaldehyde-derived imine and sulfonyl (12 mol% of asymmetric ligand) and 10 g of Power-gra will be sufficient imidate results in a 94% yield with a syn- mol% of Et3N in THF (OiPr = isopropoxy; to fully charge a cell phone. ❏ to-anti ratio of 4-to-96 after 17 h, when Et3N = triethylamine). ■ Circle XXX or go to www.info.ims.ca/34xx-xx Circle 16 on p. 70 or go to adlinks.che.com/23014-16
- 20. Circle 17 on p. 70 or go to adlinks.che.com/23014-17
- 21. Newsfront RefineRs face unceRtain futuRe Source: EIA Gasoline and crude oil prices Short-term energy outlook, March 2009 480 440 Retail regular gasoline* Forecast 400 Wholesale gasoline 360 Crude oil Cents per gallon 320 Declining product demand, 280 240 volatile margins, and a 200 160 global recession are forcing 120 80 40 many refiners to rethink 0 * Retail price includes state and federal taxes Jan 2005 Jan 2006 Jan 2007 Jan 2008 Jan 2009 Jan 2010 investment decisions Figure 1. Gasoline and crude prices will exhibit a slow recovery after falling from record highs in mid 2008 P etroleum refiners throughout the cially in the U.S. A global economy in Wood Mackenzie believes that in- world are faced with increasing recession, improvements in fuel effi- dustry dynamics have fundamentally uncertainty regarding future re- ciency standards, and the replacement changed from a U.S. “demand pull” fining margins, crude prices and of petroleum-based fuels by renewable environment to a European “supply project costs. These factors, along with fuels are factors that combined to push.” This is because Europe is treat- falling demand for refined products, place downward pressure on demand. ing gasoline as a byproduct in its at- a global recession, and tighter credit In 2008, price of West Texas Inter- tempt to satisfy its diesel deficit. U.S. markets, are forcing global refiners to mediate (WTI) crude oil averaged refining utilizations, therefore, fell reconsider, postpone, or cancel expan- $100/bbl according to the U.S. Dept.of further than those of Europe, with the sion projects. Energy’s (DOE; Washington, D.C.) En- U.S. East Coast especially suffering. At the same time, mandated reduc- ergy Information Admin. (EIA; www. According to EIA, total consump- tion of sulfur levels in refined products eia.doe.gov). EIA predicts that the tion of refined products in 2008 fell — both gasoline and diesel fuel — are global economic slowdown will cut the nearly 1.3-million bbl/d, or 6.1%, from significant factors affecting refiners’ 2008 average price by more than half, consumption levels in 2007 (Figure 2). spending plans for the next few years. to an average of $42/bbl in 2009 and Major factors contributing to declining Changing fuel regulations in the U.S., $53/bbl in 2010. demand were a rise in retail gasoline Europe, Asia, and Latin America will During early 2009, however, gaso- and diesel prices to record levels dur- force petroleum refiners that import line prices have been slowly increas- ing the first half of 2008 and a dete- gasoline and diesel fuel into those re- ing while crude oil prices have stabi- riorating economy in the second half gions to invest additional capital. lized; refiner margins have recovered of the year. In addition to satisfying the more- from their recent lows. After averag- EIA is projecting that total prod- stringent fuel specifications, refiners ing $1.69/gal in December 2008, the uct consumption in 2009 will decline must produce fuels from lower qual- retail gasoline price in February rose another 420,000 bbl/d, or 2.2%, due ity crude oils. If crude oil prices rise in to $1.92/gal, according to EIA. Retail to continued economic weakness. The the next few years, as they did in 2008, gasoline prices are expected to aver- expected economic recovery in 2010 petroleum refiners are more likely to age $1.96/gal in 2009 and $2.18/gal in should boost total refined-product con- process less expensive crudes, which 2010 (Figure 1). sumption by 210,000 bbl/d, or 1.1%, are heavier and contain more sulfur. U.S. demand for oil fell by about with all of the major fuels registering Meanwhile, refiners in the U.S. are 1.3-million bbl/d in 2008, according increases in consumption (Figure 3). also faced with uncertainty regard- to Alan Gelder, head of Downstream In the long term, EIA is predicting ing future regulations for greenhouse Consulting Americas for Wood Mack- that total U.S. demand for liquid fuels gas emissions and the potential for enzie (Houston, Tex.; www.woodmac- will grow only about 1-million bbl/d higher requirements of biofuels in- research.com). “However, rather than between 2007 and 2030. cluding ethanol. this resulting in a drop in imports,” EIA expects a peak in gasoline prices Gelder says, “U.S. refinery utilization of slightly more than $2/gal in 2009. It Falling demand actually fell to accommodate contin- is possible, however, that weekly prices Demand for refined petroleum prod- ued exports from other regions, nota- could rise significantly higher at some ucts is declining worldwide, and espe- bly gasoline from Europe.” point this spring or summer. ChemiCal engineering www.Che.Com may 2009 19
- 22. World liquid fuels consumption Source: EIA Short-term energy outlook, March 2009 95 Newsfront 90 Total consumption Forecast Total consumption, 106 bbl/d Total consumption, 106 bbl/d 85 80 75 2.0 70 Figure 2. For on-highway diesel fuel prices, 1.5 Demand for 1.0 EIA is projecting an average of $2.19/ 0.5 refined prod- gal in 2009 and $2.51/gal in 2010. A 0.0 ucts will re- continuing decline in diesel fuel con- -0.5 cover in 2010 China -1.0 after declining sumption in the U.S. in 2009, com- United States -1.5 in 2008–2009 bined with growing weakness in dis- Other countries Annual growth -2.0 tillate fuel demand outside the U.S. 2002 2003 2004 2005 2006 2007 2008 2009 2010 will reduce refining margins for distil- Annual growth, 106 bbl/d late. Because of the global weakness in industrial output, it is possible that diesel prices will fall below gasoline prices this summer. High inventory levels of gasoline and diesel are also placing downward pressure on prices. Figure 4 shows that EIA expects inventories to remain at the top of their historical bands in 2009 and 2010. Refining margins Although crude prices were at record highs in 2008, gasoline and diesel fuel prices kept pace, which allowed U.S. refiners to enjoy healthy profit mar- gins initially. The high prices, however, ultimately caused most consumers to reduce consumption, which has now lead to a severe decline in margins. Worldwide-refining margins in 2008 were weaker than in 2007, with the U.S. suffering the greatest de- cline. This decline in refining margins reflected lower refinery utilization, which was a response to the fall in de- mand in Europe and North America, according to Gelder. In 2009, refinery utilization in the U.S. has averaged about 82%. In Janu- ary 2008, utilization hit a peak of 91%, and as recently as the summer of 2005, refiners were running full out, reach- ing utilization rates of 97–98%. Because of lower motor-gasoline consumption, EIA expects refining margins for gasoline to remain de- pressed for much of 2009 but to in- crease slightly in 2010 as consump- tion begins to recover. One indicator of a recovery in U.S. refining margins is surplus capacity, which is determined by changes in oil product demand and new projects, ac- cording to Gelder. Wood Mackenzie is expecting a significant reduction in oil demand in 2009, with a further fall of 700,000 bbl/d in the U.S. “Recovery in U.S. economic growth is projected for 2010, but we now be- lieve that U.S. gasoline demand has Circle 18 on p. 70 or go to adlinks.che.com/23014-18 20 ChemiCal engineering www.Che.Com may 2009
- 23. U.S. liquid fuels consumption growth Source: EIA (Change from previous year) 400 Forecast Thousands of barrels per day 200 -6.1% -2.2% 1.1% 0 -200 Figure 3. completion date of its $2-billion project Demand for -400 all fuels in to expand its Detroit, Mich., refinery. -600 The $2.2-billion project would add the US will Total increase in -800 Motor gasoline 100,000 bbl/d in order to process addi- 2010 -1,100 Jet fuel tional volumes of Canadian crude oil. -1,200 Distillate fuel Construction on Marathon’s Heavy Other Oil Upgrading Project started at the -1,400 2008 2009 2010 end of the second quarter of 2008. The company says it is delaying the project already peaked and will continue to decline from now on,” says Gelder. “This is due to the combination of the recession in the near term and improving vehicle fuel efficiency over the medium term.” Since P K Saunders invented the original Gelder projects that U.S. petroleum diaphragm valve in 1928, and founded Saunders Valve Co. five years later, refining mid-cycle margins will be Saunders has led the way in providing lower than the recent past. In particu- the highest standards of reliability, lar, U.S. East Coast refiners will be in engineering and safety. The range has been continually expanded over 75 a weak competitive position that could years through innovation in both design challenge their economic sustainabil- and new materials technology. As a ity. And given declining gasoline de- result the Saunders diaphragm valve has gained a widespread reputation for its mand, it is essential for refiners with a versatility and established a presence in strong location advantage to manage diverse process industry sectors. local supply in order to not undermine a key driver of their earnings. Immediate opportunities for U.S. re- finers are to shift away from gasoline to diesel fuel and then consider inno- vative approaches to either protect or SEE OUR NEW PRODUCTS AT enhance their current competitive po- sition, according to Gelder. STAND Q2R6 Project cancellations HALL 8 Recent announcements are proving that refiners are moving forward more cautiously and reconsidering their Celebrate with us plans to expand their refining capac- 75 years of science inside! at ACHEMA 2009! ity. In mid March, for example, Motiva Enterprises LLC (Houston, Tex.; www. motivaenterprises.com) announced that it was delaying its $7-billion ex- pansion project at its Port Arthur, Tex., refinery. The project would expand the 285,000-bbl/d refinery to a capacity of more than 600,000 bbl/d. Motiva, a joint venture of Royal Dutch Shell (The Hague, Netherlands; www.shell.com) and Saudi Refining Inc. (Houston, Tex.), was planning to complete the project in late 2010. The project, which would make the Port Arthur refinery the largest in the U.S., is now slated to start up in the first quarter of 2012. In early February, in conjunction with its annual report, Marathon Oil www.cranechempharma.com Co. (Houston; www.marathon.com) an- nounced that it was delaying the final Circle 19 on p. 70 or go to adlinks.che.com/23014-19 ChemiCal engineering www.Che.Com may 2009 21
- 24. U.S. gasoline and distillate inventories Short-term energy outlook, March 2009 Source: EIA 260 Newsfront 240 Total motor gasoline inventory Forecast 220 Millions of barrels 200 due to delays in the projected produc- 180 Figure 4. U.S. Total distillate fuel inventory inventories of tion of Canadian oil sands and current 160 gasoline and die- market conditions. 140 sel will remain The company now forecasts the 120 high during the project will cost about 15% more than 100 next two years its original $1.9-billion estimate, due “Normal” range published in EIA Weekly Petroleum Status Report, Appendix A primarily to additional costs associ- 0 ated with the project deferral from the Jan Jan Jan Jan Jan Jan 2005 2006 2007 2008 2009 2010 original fourth-quarter 2010 startup, as well as increased project scope. The project delays, however, are not confined to U.S. refiners. Refiners outside the U.S. are also reevaluating Mission: Immersion. their expansion plans. In late March, Kuwait National Immersion Engineering™ ™ Petroleum Co. (Safat; www.knpc.com. kw) announced that it had cancelled goes deep to solve your plans to build a 615,000 bbl/d refin- ery at Al-Zour. The refinery, if built, heat transfer problems. would be the largest facility in the Middle East. The petroleum refiner had an initial estimate of $10 bil- lion, but this was later increased to $15 billion. Construction on the re- finery was halted after a council-of- ministers meeting, at which time the contractors were notified that their contracts were cancelled. The project is reportedly not com- pletely dead, however. The Kuwait oil minister said that the next Kuwaiti cabinet would review the project and decide whether or not to proceed. A global shift Although many refiners are postpon- ing or cancelling project plans, many projects in certain areas of the world are going forward. The oil companies that own these projects are most often supported by government subsidies; Even though you may call us on the performance and applications of heat phone miles away, we're so deep into therefore, the refineries are less sensi- transfer fluids than we do. your stuff--your fluid, your equipment, So pick a service and call one of our tive to low margins. your system--we can virtually touch it, technical specialists. Or, check out our In one of the largest refinery expan- see it. web site for case histories, data sheets, sions, India’s Reliance Industries Ltd. Immersion Engineering is a bundle of comparisons, user’s guide, tip sheets (Mumbai; www.ril.com) is in the pro- very specialized services that you can and technical reports. It’s all there, it’s cess of starting up its 580,000-bbl/d cherry pick. Some are free, some you deep, it’s Immersion Engineering. project in Jamnagar. The expan- pay for. We’re the only company offering sion, combined with the existing them all. 660,000-bbl/d refinery, will comprise a One thing is for sure; when you need total capacity of 1.24-million bbl/d of HTF help you need it now. Nobody knows more about the chemistry, HEAT TRANSFER FLUIDS crude, which will make the complex the largest in the world. 4 Portland Road West Conshohocken PA 19428 USA The refinery, which exports all of its Eyeball this selection of services. refined products, was commissioned in 800-222-3611 ® � Fluid Analysis � Troubleshooting late December 2008. By the following 610-941-4900 • Fax: 610-941-9191 � Fluid Maintenance � System Layout March, the company was commission- info@paratherm.com � Training ing all of the secondary units at the new www.paratherm.com refinery, and expects to be at full capac- Circle 20 on p. 70 or go to adlinks.che.com/23014-20 22 ChemiCal engineering www.Che.Com may 2009 P2008A 1/2 Page
- 25. ity by September 2009 at the latest. Coast will have to cut production runs grow 3.3%/yr — much faster than the In February 2009, the Dung Quat the most, followed by the Gulf Coast, 0.5%/yr growth in total energy use. refinery in Vietnam officially became where refiners will have to cut runs This strong growth is due mainly to operational. This 140,000 bbl/d petro- more than those in Europe. The Euro- the renewable fuel standard in the leum refinery — the first in Vietnam pean industry will suffer less than its Energy Independence and Security — will be at full capacity by the end of U.S. counterparts. Act of 2007 (EISA2007), which will June 2009. EIA predicts, in its Annual Energy require 36-billion gal of biofuels to be Other significant refinery additions Outlook 2009, that overall consump- produced by 2022. ■ Crane_Ball_Valve_2009.pdf 1 3/16/09 1:56 PM are occurring in China. Projects that tion of marketed renewable fuels will David Nakamura should start up in the next six months include two PetroChina Co. (Beijing; www.petrochina.com.cn) refineries with a combined crude processing capacity of 250,000 bbl/d, China Pe- troleum & Chemical Corp.’s (Beijing; www.sinopec.com) 160,000 bbl/d refin- ery in Quanzhou, and China National Offshore Oil Corp.’s (Beijing; www. STAND Q2R6 cnooc.com.cn) 240,000-bbl/d refinery HALL 8 in Huizhou. Upgrading capacity In the past few years, refiners have installed significant hydrotreating ca- NEW! the science inside pacity to comply with more stringent diesel requirements. The solutions for reducing diesel sulfur are much more complex than those for gasoline. The primary process for convert- ing hard-to-remove sulfur species in diesel is high-pressure hydrotreating. These units, both new and revamped, are expensive. The additional required hydrotreat- ing capacity is also affecting other process units in refineries. Additional hydrogen-generation capacity will have to be installed to meet the higher hydrotreating demands. In addition, to process heavier crudes, many refiners are opting to in- stall coking units, which convert heavy Lined Ball Valve residual streams to higher-value gaso- line and diesel, and a byproduct petro- leum coke. Renewable fuels Increasing requirements for ethanol in the gasoline pool further weakens demand for refinery-based gasoline. This demand decline will have a nega- tive effect on U.S. refinery utilization, due to its gasoline orientation, accord- ing to Gelder. The short-term addition of 1.9-mil- lion bbl/d of new refining capacity in the Atlantic Basin only increases the www.cranechempharma.com problems of oversupply. Gelder ex- pects that refiners on the U.S. East Circle 21 on p. 70 or go to adlinks.che.com/23014-21 ChemiCal engineering www.Che.Com may 2009 23
- 26. Circle 22 on p. 70 or go to adlinks.che.com/23014-22
- 27. Honeywell Newsfront Staying alive Repeatability, flexibility and visibility via automated control systems can help batch processors make it Figure 1. Many batch automation vendors through the recession are enabling batch functionality at the controller level A s it is with all chemical proces- Increase flexibility. Flexibility, too, www.yokogawa.com) and chairman of sors, the current economic cli- is crucial at this time as processors are the World Batch Forum (Research Tri- mate is forcing batch processors being asked to produce a wider range angle Park, N.C.; www.wbf.org). “But to produce more saleable product of products from the same equipment now unit supervision can be done in at a better profit margin from the same with very little setup-related down- the controller as well.” assets. Increasing flexibility, reliability time between batches This means that the unit can stand and visibility while decreasing batch Track and trace. In this sagging alone inside the controller, where be- cycle times via integrated automation economy, many batch processors are fore a server was needed to manage systems can help increase throughput cutting back on documentation and the operation. “Controllers are be- and the chance of survival. quality procedures. Experts warn that coming more powerful, which lets you this is only laying a trap for the future run more inside the controllers them- Staying afloat as regulations regarding record keep- selves. This is where batch processing Undoubtedly it’s difficult to get more ing are becoming more stringent. His- is headed because you can do more product from a process, especially in torical batch information can also be with less equipment,” says Wilkins. the wake of staff reductions and fa- used to improve a process. For these Chris Morse, product marketing cility shutdowns. However it is pos- reasons, batch processors must begin manager for batch with Honeywell sible to improve batches in an effort to step up their game in this area (Morris Township, N.J.; www.honey- to ensure longevity even during an well.com), agrees that this is the ticket economic crisis. To do so, experts rec- True batch control to more successful batch operations. ommend the following: While taking these actions may seem “Moving the procedural levels of batch Increase reliability. Since the prod- difficult, automation vendors do pro- control into the controller provides a ro- uct from many batch processes is im- vide solutions that can help. Increas- bust environment and reliability,” says mensely valuable and any loss of a ing reliability, they say, lies in moving Morse. “We call it ‘bumpless redun- batch due to failure will result in a sophisticated and intelligent batch dancy,’ meaning that if one controller large financial setback, ensuring reli- automation down the automation hi- fails, the system automatically moves ability is especially important during erarchy and into the controller. “In the to the back up with no single point of the current economic downturn past there were hierarchical systems hardware or software failure that will Reduce batch cycle time. Like other where recipe management and other cause the batch to hold, which could be chemical processors, batch processors aspects of batch processing and unit dangerous or involve economic loss.” need to get more from less. Getting control were run in a server and the In addition, this recent move helps a batch cycle down from 12 h to 11 h actual phases and individual building with cycle time reduction. In previ- and 45 min translates into additional blocks were done in the controller,” ous generations of batch automation, revenue from the same assets, so it is says Maurice Wilkins, vice president there was a server involved, which prudent to find ways to reduce batch of the Global Strategic Marketing left dead time in communication be- cycle times Center with Yokogawa (Newnan, Ga.; tween that server and the control- ChemiCal engineering www.Che.Com may 2009 25
- 28. The human Touch Newsfront W hile automation obviously plays a starring role in successful batch processing, both processors and automation system suppliers realize there will always be a certain de- gree of human intervention involved. From that revelation came the advent of several solutions designed to embrace and enhance the human touch. ler. “We have customers who have “Along with the economic woes faced by chemical and batch processors comes the problem calculated that by reducing dead with reduced engineering staffs and the graying workforce,” says Fred Ungerer, chief operat- time, they can increase their an- ing officer with Performix, Inc. (Houston, Tex.; www.performixinc.com). “This leaves proces- nual throughput by up to 3%,” notes sors with knowledge management and transfer issues. While some say the problem further Morse. “They can sell that additional justifies automation, there will still be a human touch at certain points during the process, so product, which means they have suc- the issue really becomes how do you make the most of the combination of automation and cessfully reduced cycle time and im- human touch and how do you make the human touch more effective and more consistent?” proved productivity.” He says the idea of consistency in automated processes is especially relevant during this time when facilities are moving overseas and becoming global. “As you move from one facility Using advanced process control as across the world to another, you need to have as much consistency in the process as is possible part of the batch process can also help because there may be differences in materials due to different sources in various areas around improve yield by allowing users to the globe,” explains Ungerer. “In these situations, how to take knowledge and move it from one make more informed decisions about part of the world to another becomes a key issue.” equipment and processes, says Todd As a result, Performix began offering Manufacturing Execution System solutions, which are Stauffer, PCS 7 marketing manager built on the SAP framework. The three core components to the solution include xRecipe for with Siemens Energy & Automation recipe editing and management, xMES, a recipe executing engine that includes plant floor (Alpharetta, Ga.; www.siemens.com). user interfaces and xBatch, the execution historian. “Advanced process control is a way The components work together to keep a master document of what needs to be done, which to understand how you’re currently is housed in SAP, yet allows data to be viewed and/or collected on the plant floor. “The solu- tion may include operators with handhelds that allow them to view checklists of the proper running so you can make fine adjust- ments to the process with ease,” he says. “With the distributed control Integrating information interface and concept across all the systems of the past, it was difficult Providing integration at a variety of systems, not just the batch or auto- and costly to make small changes levels can also help processors boost mation system. Further up the au- unless you were knowledgeable in their batch. At the operator level, it’s tomation pyramid, integration with the vendor’s programming.” important to provide a common user ERP (enterprise resource planning) Circle 23 on p. 70 or go to adlinks.che.com/23014-23
- 29. Performix, Inc. steps to follow, such as what protective equipment Performix’s xMES Next Generation User Interface (UI), displayed on a Panasonic is necessary or the steps necessary for startup,” Toughbook Wireless Handheld, is used says Ungerer. “Laying out step-by-step instructions by plant operators to help facilitate for a process goes a long way toward increasing batch manufacturing processes during consistency and reliability and is an ideal way to execution. This particular UI view shows transfer knowledge from one location to another just a few of Performix’s capabilities or from retiring to next-generation workers.” including Electronic Work Instruction, Performix’s solutions can be automated so users plant floor device integration with a Bar don’t have to confirm each step or can be set up Code scanner and seamless connectiv- so they must confirm everything. “It becomes a ity back to ERP for realtime visibility of the manufacturing enterprise simple stepped process,” says Ungerer. “Rules and electronic work instructions are developed and then put in the tomated and available to operators helps ensure that the startups and hands of the operators so they can execute them. Not only does it shutdowns are done the same way from shift to shift.” improve safety, consistency and reliability of a process, but it can For this reason, he says, Yokogawa recently enhanced the functions also be used to do analysis of a batch.” of the Human Interface Station for Centum VP, a new DCS system. Information such as how long a batch took and what steps were The Centum VP HMI (human machine interface) introduces a unified taken can provide insight into how to cut cycle time and expand and intuitive operating environment, while facilitating easy access to capacity. “If you know there are variations from batch to batch, but information. The visualization of operational know how and consid- know the manual aspects of operations are handled the same each eration of information users’ mental models enable everyone to work run, you can begin to zero in on the other variables that may be af- more consistently. The unified and intuitive HMI helps harness the fecting cycle times,” says Ungerer. power of an integrated production control system by ensuring that Yokogawa (Newnan, Ga.; www.yokogawa.com), too, is offering a information gets prioritized and providing actionable information. means to automate procedures for newer members of the workforce. While Centum VP works in conjunction with Yokogawa’s current “In industry it’s a big deal to be able to do the same thing the same batch system to ensure repeatability, the company is working on a way every time,” says Maurice Wilkins, vice president of Yokogawa’s batch solution that will better take advantage of the HMI features, Global Strategic Marketing Center. “And having the procedures au- says Wilkins. ❏ systems allows processors to seam- Vendors are tackling this in a vari- being an installed application on lessly move from order to order input, ety of ways. Honeywell is more deeply top of the automation system,” says to planning and inventory manage- integrating the batch automation Morse. “This provides the user consis- ment and then into kicking off the functions into the system, so “it does tency in look and feel, which reduces batch process. batch right out of the box rather than the training requirements for main- Psst ... Raymond® & Bartlett-Snow™ Thermal Equipment & Systems Raymond® and Bartlett-Snow™ products have been success- fully providing solutions for thermal process applications involving chemical, petro- chemical, ceramic, magnetic, metals, food, fertilizer, plastic, industrial solid waste and nuclear industries. For over a century, we have provided innovative and dependable equipment and systems for SoundPLAN is recognized around the globe as the the changing needs of these industries worldwide. leader in noise evaluation and mapping software. We give you cutting edge noise-control innovations with fast Rotary Calciners calculations and striking graphics that are easy to understand. Rotary Dryers It’s all designed to help you manage potential noise problems Rotary Coolers before they arise, keeping your project on budget and on time. Rotary Kilns Software is available in English, Asian & European languages. And we are proud to offer expert, local Flash Dryers support for your technical and sales needs. Let us introduce you to SoundPLAN— 4525 Weaver Pkwy, Warrenville, IL 60555 CONTACT US FOR A FREE DEMO CD Toll free: 877.661.5509 Air Preheater Company Tel: 630.393.1000 • Fax: 630.393.1001 Call today +1 360 432 9840 TM Raymond Operations Email: info@airpreheatercompany.com www.soundplan.com www.airpreheatercompany.com Circle 10 on p. 70 or go to adlinks.che.com/23014-10 Circle 30 on p. 70 or go to adlinks.che.com/23014-30 ChemiCal engineering www.Che.Com may 2009 27
- 30. Newsfront taining and operating a system.” tem,” explains Morse. “We’re taking change between orders and batches. One of the newest developments in measures to be able to manage large Siemens is handling the integra- the area of integration is with Hon- numbers of recipes and integrate tion challenge through its Simatic IT eywell’s Experion Process Knowledge with ERP systems. A batch can be product, which bridges the gap be- System (PKS), which offers new in- kicked off by an external system, tween its PCS 7 control system and tegrated batch functionality through usually an ERP, without paper or Simatic Batch. While Simatic Batch the new Experion Batch Manager. manual handling between the ERP is a graphical tool that allows users “Every item of batch automation and automation system.” He says to make recipe changes in a drag-and- can be changed online with this sys- this provides flexibility and ease of drop environment, there was still dif- ficulty in getting the information for those changes from the IT people to the process control folks. “We are pro- viding Simatic IT to make those two worlds talk in an effort to increase flexibility,” says Robert Purvy, PCS 7 technical consultant with Siemens. “Typically there are IT guys and process control guys, but batch pro- cessors need to make that line blur if they want to increase productivity via flexibility,” he says. “The information and data regarding scheduling, ware- housing and material management that is normally in the scope of IT has got to make it to the process control people so they have information on the quality of the raw materials if it differs from the information in the ERP system.” “Having integration between these normally disparate entities will also enable batch processors to quickly change from one product to another if something comes up,” says Purvy. “Quite simply, integration provides batch processors with information in real time, which enables them to pro- duce more products with the same equipment, make changes on the fly, optimize production runs and keep track of it all.” Track and trace And keeping track of it all is espe- cially important as regulations re- garding documentation and record keeping grow tougher every day. Not only does tracking and tracing keep batch processors in compliance, it also helps them understand the process, enabling process improvements. Most suppliers of automation solu- tions provide some sort of track-and- trace, documentation and historical analysis functionality in their offer- ings. Rockwell Automation (Milwau- kee, Wis.; www.rockwellautomation. com), for example, offers its Plant PAx Process System and, within that, a Circle 25 on p. 70 or go to adlinks.che.com/23014-25 28 ChemiCal engineering www.Che.Com may 2009
- 31. Honeywell ing, which offers a range of stan- using modern and reliable batch con- dard out-of-the-box reports for track trol systems to gather and study the and trace, material usage, electronic information collected by track and batch reporting and exception re- trace functions. This enables the user porting. “The system takes all that to make informed decisions to achieve data, collects it and gives the user a the levels of flexibility and increased report that can be used to fine tune productivity necessary to stay alive the process,” he says. What it boils during the economic downturn. ■ down to is that batch processors are Joy LePree www.woodgroup-esp.com Low tolerance for pump problems? Figure 2. Honeywell introduced the No problem. Experion LS control system as part of it’s Experion PKS line to provide the power and reliability of a distributed control system in a small and flexible Pressure to lower ever-increasing maintenance solution. Experion LS manages all con- costs and reduce environmental impact has paved tinuous process control applications the way to better surface pumping solutions. SPS APPLICATIONS: and optimizes batch and sequence- � Booster Our multi-stage centrifugal SPS™ Surface Pump- Transfer oriented applications typically found in � ing Systems provide versatile, low-maintenance � Circulation smaller batch processing sites alternatives to many split-case centrifugal, � Injection positive-displacement and vertical-turbine pump batch management and control func- applications. The SPS is a cost-effective solution tion focused on batch and sequence for processing, petroleum, mining, water and other management, which leverages Inte- industries that require high-pressure movement SP1000: rated 50 to 1000 HP grated Architecture and Factory Talk. of fluids. Proven benefits include: (SP2000: rated 1000 to 2500 HP also available) Factory-Talk Batch software provides modules for batch management, man- ual work instructions, materials man- agement and material usage tracking, forward/backward track and trace, regulatory compliance, validation and Call this number: 281.492.5160. other tracking activities. Or e-mail sps @woodgroup.com. “Not only does this help with regu- latory compliance and product recalls, it also turns data into usable infor- mation, which helps batch processors truly understand and optimize the Wood Group process,” says Andy Stump, segment Surface Pumps manager for Rockwell Automation’s Manufactured by Wood Group ESP, Inc. Process Systems Team. He says the Factory-Talk Batch product provides web-based report- Circle 26 on p. 70 or go to adlinks.che.com/23014-26 ChemiCal engineering www.Che.Com may 2009 29 SPS problem ad_CE_half_2-09.indd 1 2/19/09 3:04 PM
- 32. Solids Processing Focus Focus on Heat Transfer New line of blown film coolers est air possible to the are designed for warm climates air ring. Units are The BFC Series of Blown Film Air available in 600–7500 Chemineer Coolers offer an increase in blown film ft/min sizes. — Mokon, ventional empty productivity, especially in warmer cli- Buffalo, N.Y. tubes, says the firm. mates or other environments where www.mokon.com The product offers design ambient air temperature rises during pressures to 10,000 psi. The unit, con- the summer. The Series boosts produc- These heat exchangers offer high structed from all metals and alloys and tivity by eliminating production vari- heat transfer coefficients offered with special connections and ables in air ring supply, including air Equipped with streamlined Kenics fittings, is ASME/TEMA compliant. — temperature, pressure and volume. A Static Mixer elements, Kenics heat ex- Chemineer, Inc., Dayton, Ohio modulated chilled-water supply pro- changers (photo) offer maximum trans- chemineer.com vides a constant exit-air temperature fer rates, even with highly viscous, to the process, and the air inlet dif- difficult-to-process materials. Ken- Withstand harsh outdoor condi- fuser ensures that the air stream cov- ics Static Mixer technology offers the tions with this heat exchanger ers the full face of the cooling coil. The highest available heat-transfer coeffi- The Climaguard Outdoor Heat Ex- exit-air chamber is insulated to reduce cients, providing heat-transfer rates of changer removes up to 3,000 W of condensation while providing the cold- three to seven times greater than con- enclosure heat and features a double- Building Solutions That Minimize Your Risk Pre-engineered, prefabricated buildings deliver innovative, code-compliant fire protection, safe storage and workspace solutions. • Reduce risk and liability • Custom-built units fit the way you work • Meets supply-chain value goals • Fast turnaround • Efficient on-site set-up GSA Contract No. GS-28F-1099C DLA Contract No. SPM500-01-D-0108 Safety. Efficiency. Value. Hazardous material containment systems designed for the way you work™. Safety Storage Inc. 1-800-344-6539 www.SafetyStorage.com Circle 27 on p. 70 or go to adlinks.che.com/23014-27 Circle 29 on p. 70 or go to adlinks.che.com/23014-29 30 ChemiCal engineering www.Che.Com may 2009
- 33. Unifin International durable three-part system is available for marine environments. — Unifin International, London, Ont., Canada www.unifin.com This Series of thermal fluid crimped and dip- Mobile coolers designed heaters includes new sizes sealed core, for for demanding oil applications With the addition of the ASME Code efficient thermal The ForZair line of mobile coolers 16-mil. and 20-mil. Btu/h thermal- transfer in harsh (photo) feature this firm’s Mono- fluid heaters, these Btu fuel-fired outdoor environments. Units can eas- Aluminum Extruded Fin-Tubes and horizontal heaters are now available ily be surface- or recess-mounted to plate fin technology for optimal heat- from 2.4-mil. to 20-mil. Btu/h out- an enclosure. Climaguard units are transfer efficiency and exceptional put. In addition, the firm offer fuel- designed to seal out harsh environ- durability. ForZair mobile coolers fired vertical heaters from 0.2-mil. ments, including temperature ex- are designed to work with Cardinal to 14-mil. Btu/h output and electric tremes, corrosive environments and transformer oil pumps, which utilize heaters to 1.7-mil. Btu/h output. wind-driven rain. Robust Climaguard a glandless design to prevent leaks. Thermal-fluid heaters are available Heat Exchangers are compatible with ForZair units are available with a per- as stand-alone products, or they can 48 Vd.c. and 115 Va.c. power supplies. formance range of 125–750 kW for oil be skid mounted with circulation A maximum 2,000-W heater option is flows of 200–650 gal/min and a top oil pumps and expansion tanks. Heaters available on d.c. and a.c. volt heaters, rise (TOR) of 35–63ºC. A galvanized can be customized upon request, and and variable-speed blowers come stan- finish is standard, with other surface can reach 750ºF. — Fulton Thermal dard on d.c.-powered units for quiet treatments optional. A two-part epoxy Corp., Pulaski, N.Y. running. — Hoffman, Anoka, Minn. paint option is available for chemi- www.hoffmanonline.com ■ www.hoffmanonline.com cally-aggressive environments, and a Kate Torzewski Circle 24 on p. 70 or go to adlinks.che.com/23014-24 ChemiCal engineering www.Che.Com may 2009 31
- 34. People WHO’S WHO Clements Murray Davidson McCarty Rummel John Paterson becomes vice-president Harvard's John A. and Elizabeth S. president of research, development of Ross Mixing, Inc. (Port St. Lucie, Armstrong Professor of Engineering and engineering. Fla.), a division of Charles Ross and and Applied Science. Son Co. (Hauppauge, N.Y.). Malek Jalel is appointed president of KBC Advanced Technologies plc the biodiesel company Innovation Paratherm Corp. (West Consho- (Houston) names John Dosher senior Fuels (Albany, N.Y.). hocken, Pa.) promotes Rich Clements vice-president of strategic consulting. to COO and vice-president of Patrick McCarty becomes president operations. Heidi Davidson is named techni- of separations company KMPT USA cal development engineer for the (Florence, Ky.). Cherry Murray of Lawrence Liver- SOLVAir Products Group of Solvay more Laboratory is named dean of Chemicals (Houston). Ric Rummel is now director of global the School of Engineering and Ap- sales at Hardy Instruments (San plied Science at Harvard Univer- ITT Corp. (Seneca Falls, N.Y.) pro- Diego, Calif.). ■ sity (Cambridge, Mass.), and becomes motes Charles Cappellino to vice- Suzanne Shelley Circle 31 on p. 70 or go to adlinks.che.com/23014-31
- 35. Brooks Instrument Anachem Splice detection system for paper and packaging Sentinel Splice (Joint) De- tection Technology (photo) is designed to monitor 1–16 webs of material and will de- Splice Detection tect any splice or joint that Technologies may exist within the web- based process. It is applica- ble to manufacturing processes that require the culling out of splices or joints prior to shipment. Unaffected by printed surfaces, material color, grade changes and process speeds, the Sentinel is a self-calibrating system that is powered by 24 Vd.c. It provides an opto-isolated, digital electronic out- put with a pulse width selectable for 1, 10 or 100 ms. The Sentinel can be connected directly to PLC control devices or interfaced into existing marking systems or di- rectly control devices. — Splice Detec- tion Technologies, Syracuse, N.Y. www.splicedetector.net Flow calibrator with extended range dual manifold capability Exact Flow Utilizing a two-meter manifold control system, the portable, automated Flow Gator calibrator (photo) operates in create calibration data files, which can dispensing of samples and identical single viscosity fluids from 0.1 to 310 be up loaded to a PC for storing his- performance across the pipette. Pi- gal/min. Calibrations in multiple vis- torical calibration data. — Exact Flow, petman Neo Multi is available with cosities can be achieved from 0.35 to Scottsdale, Ariz. nominal volumes of 20 µL or 200 µL. 310 gal/min. Instead of removing flow- www.exactflow.com Accuracy and precision specifications meters from service for recalibration, are more stringent than ISO 8655-2 the Flow Gator flow-transfer standard Achieve consistent dispensing recommendations. — Anachem, Bed- allows users to bring the calibrator over 8 or 12 pipette channels fordshire, U.K. to the flowmeter. This flow calibrator The Pipetman Neo Multi 8- and 12- www.anachem.co.uk is intended for inline calibration and channel pipettes have recent design validation of meters using the actual changes, including a reengineered This flow controller is unaffected process liquid. Rugged, lightweight spring that reduces pipetting forces. by temperature and pressure and compact, the Flow Gator incor- The unique design of the tip-holder, The family of B-Series mass flow con- porates handheld electronics. Two with successive sealing rings, offers trollers (photo) is designed to be insen- dual-rotor turbine flowmeters, which the widest compatibility with a full sitive to fluctuations in pressure and provide exceptional repeatability of range of the most commonly used temperature. Each flow controller is ±0.02%, enable the Flow Transfer tips. A dispenser spacer distributes built on a standard 1.125-in.-wide plat- Standard system uncertainty to be dispensing forces equally. Plus, a form with a powerful user interface and <±0.25% of reading. The Flow Gator patented mechanism distributes the local digital display. The mass flow con- system’s intuitive, menu-driven cali- pipetting forces equally over each troller actively measures line pressure bration software enables end users to channel, for consistent aspiration and and adjusts the control valve to virtu- Note: For more information, circle the 3-digit number ChemiCal engineering www.Che.Com may 2009 32D-1 on p. 70, or use the website designation.
- 36. LumaSense Technologies New Products ally eliminate actual flow and flow- ture data (from –20–350°C) to be signal changes as caused by pressure displayed directly on the visible fluctuations. In addition, the output image. The pocket-sized Mikro- of every B-Series mass flow controller SHOT is lightweight (10.5 oz.) and is characterized over the full operat- uses off-the-shelf batteries (an a.c. ing temperature range. The B-Series adapter is also included). Its large incorporates internal self-diagnostic 2.7-in. display and 160 X 120 pixel routines that continuously check the image resolution allow easy view- health of the device. In the event of a ing of images. The SD card, USB and diagnostic fault, an alarm code flashes video output capability allow for anal- automation and control solution that on the user interface. An easy-to-use ysis of the data on a laptop. MikroSpec can also be used in heterogeneous service port provides additional diag- 4.0 software is included for image system landscapes. This facilitates nostic capability, minimizing the need analysis and reporting. — LumaSense the gradual and therefore inexpen- to remove the mass flow controller Technologies, Santa Clara, Calif. sive expansion or modernization of from process service. — Brooks Instru- www.lumasenseinc.com existing plants and equipment. All ment, LLC, Hatfield, Penn. the subsystems are interconnected www.brooksinstrument.com Communication blocks for field by means of Industrial Ethernet. devices into control systems The new “PCS7 to IEC 61850” com- This thermal-imaging The PCS7 to IEC 61850 TCP/IP com- munication blocks are intended not camera is portable munication blocks have enabled only for use in process-engineering The Mikron MikroSHOT (photo) is the problem-free integration of IEC- installations, where a connection is latest offering from this firms’ Mikron 61850-capable field devices into in- to be established between the process Infrared thermal imaging product line. strumentation and control systems control system and the power system The MikroSHOT’s Thermal-on-Visible based on Simatic PCS7 or S7. The control equipment, but also for small mode allows for radiometric tempera- plant operator thus has an integral to medium switchgear, which are au- Circle 42 on p. 70 or go to adlinks.che.com/23014-42 Circle 35 on p. 70 or go to adlinks.che.com/23014-35 32D-2 ChemiCal engineering www.Che.Com may 2009
- 37. PS/2 and USB interfaces; and stripper Modbus Interface Tool allows users sensor for strip-and-peel or tear-off to select, sort and group register data applications. In addition, the H-Series by Coriolis device, Modbus address, contains internal memory for storing datatype or keyword. Control systems downloaded label formats, graphics based on digital protocols, such as Mod- and fonts, allowing the printers to be bus, are typically more accurate and operated without being connected to provide faster response than analog a computer. The units come with this control systems. The Modbus digital Tharo Systems firm’s Easylabel Start software for interface provides a complete window custom designing and printing bar into the Coriolis device, including con- code labels. — Tharo Systems, Inc., figuration, operations, maintenance tomated with Simatic PCS7 or S7. — Brunswick, Ohio and troubleshooting. — Emerson Pro- Siemens AG, Erlangen, Germany www.tharo.com cess Management, Boulder, Colo. www.siemens.com www.emerson.com An interface tool is now offered These thermal-transfer printers to all Micro Motion customers This microphone measures feature internal memory A complimentary support utility is now sound based on light variations H-427 and H-436 Series Thermal offered for all Micro Motion customers The MO 2000 optical microphone Transfer Label Printers (photo), who use Modbus protocol to interact (photo, p. 28D-4) utilizes a new type of suited for high-volume printing, are with their Coriolis meters. The Modbus transducer that processes acoustic sig- available in 203 or 300 dpi resolution. Interface Tool is a PC-based data-de- nals on the basis of variations in light These all-metal printers feature a full livery system that replaces more than intensity. In the optical microphone, backlit LCD display; standard real- fifty pages of Modbus register data in light from an LED is directed onto a time clock; ink-in or ink-out ribbon tabular form with a simple point-and- reflective diaphragm via a transmit- use, 450-m capacity; serial, parallel, click spreadsheet presentation. The ter fiber-optic cable. The diaphragm Circle 37 on p. 70 or go to adlinks.che.com/23014-37 Circle 36 on p. 70 or go to adlinks.che.com/23014-36 ChemiCal engineering www.Che.Com may 2009 32D-3
- 38. New Products HF Inverting Filter Centrifuge Sennheiser Electronic Cutting edge centrifuge technology for reflects part of the light into a receiver filtration, washing and drying of fiber-optic cable. If the diaphragm is solid/liquid suspensions moved by sound signals, the reflected • Increase production light beam is deflected, with the result • Improve productivity - Thin Cake that more or less light is coupled into Processing • Eliminate Operator Exposure - Full the receiver fiber-optic cable, and then Containment converted into electrical signals. The • Effective Automated CIP current- and metal-free design allows • Widest Range of Applications - Hardest the microphone to be uninfluenced by to Easiest Filtering Products magnetic fields. — Sennheiser Elec- • Lowest Possible Moistures - PAC ™ Technology tronic Corp., Old Lyme, Conn. • Dry Product Inside the Centrifuge - www.sennheiserusa.com PAC™ Technology A viable alternative Hilscher North America to control VOC emissions Conical Vacuum The design of this new wet electro- Dryer - Mixer static precipitator for sulfuric-acid- Advanced technology emissions control makes it easier to for simultaneous fabricate and significantly less expen- multi-function drying and mixing sive to install. Economical alloys are used to make the system significantly more cost effective while exceeding pro- change. A standard USB port is used • Full Containment Operation cess requirements. The system’s alloy for configuration along with loading • Largest Heat Transfer Surface Area construction allows shop fabrication to network firmware and diagnostics. — • Automatic CIP • Handles the Widest Range of Materials a much greater degree, which means Hilscher North America, Inc. Lisle, Ill. • Variable Volume Batch Sizes significantly less field labor. The result- www.hilscher.com • Gentle Low Shear Drying & Mixing ing project cost savings can be signifi- • Quick & Trouble Free Product cant, says the firm. — A. H. Lundberg This laboratory-scale centrifuge Discharging Associates, Inc., Bellevue, Wash. is designed for clean processes www.lundbergassociates.com The sanitary design of this laboratory Pennwalt filtering centrifuge is ideal for solid/ Super-D-Canter Use this gateway for industrial liquid separation, washing and ex- Cutting edge continuous communication connectivity tractions of food ingredients, polysac- centrifuge technology The netTAP 100 (photo) is a flexible charides, crystals, botanical extracts for separation of and cost-effective gateway designed to and pharmaceuticals. The unit is rug- slurries into liquid or bridge the gaps between traditional ged enough to handle dense products, solid phases. fieldbus, realtime Ethernet-based sys- including powdered metals. Separate • Only (1) drive motor • High Abrasion Points are fitted with tems and serial protocols. Based on feed and wash lines allows approxima- replaceable parts this firm’s netX chip, up to 1,000 proto- tion of a production-scale centrifuga- • Advanced Polymer injection system col combinations are made possible in tion process. The basket, machined • Most economical cost a modular compact DIN-rail mounted from a solid block of 316 stainless Ideal for: housing. The netTAP 100 is capable of steel, has a 6-in. dia. and is 3.6-in. • Ethanol Stillage Dewatering linking any of the major fieldbus, real- high with a 1-in. cap. It has a solids- • Sludge Thickening & Dewatering • Chemical Intermediates & Fine Chemical time Industrial Ethernet’s and serial holding capacity of 0.68 L, and is able • Production of Plastics (PVC Dewatering) protocols used in the market today. to reach speeds of 4,000 rpm. The unit • Clarification of Liquids master and slave protocols for CANo- features a NEMA-4X electrical enclo- • Distillery Stillage pen, DeviceNet, Profibus, CCLink, Eth- sure and base frame, a 1/2 h.p., totally erCAT, Ethernet/IP, Modbus TCP, Pow- enclosed, non-ventilated motor and a erlink, Profinet, Sercos III, MB/RTU, 110-V power supply. — The Western MB ASCII RS232-, RS422, and RS485 States machine Co., Hamilton, Ohio are included for realtime I/O data ex- www.westernstates.com Circle 38 on p. 70 or go to adlinks.che.com/23014-38 32D-4 ChemiCal engineering www.Che.Com may 2009
- 39. patterns of all processes and pin- ronments where high levels of CO2 are point areas for improvement. — ABB, generated. The CO200 features a main- Baden, Switzerland tenance-free NDIR (non-dispersive in- www.abb.com frared) CO2 sensor, as well as a visible and audible CO2 warning alarm with This indoor air-quality monitor relay output for ventilation control. In- senses carbon dioxide door air quality is displayed in ppm as The Model CO200 checks for carbon Good (380–420 ppm), Normal (≤1,000 dioxide concentrations in indoor envi- ppm) or Poor (≥ 1,000 ppm). The unit Omega Engineering Build this paperless data acquisi- tion system into a network The RD8300 paperless recording sys- tem (photo) has features a high con- trast 142 mm color Active Matrix TFT LCD with a rugged touch screen that can be operated by a finger or the on- board stylus. It has a built-in OPC server and email client, 6 to 12 univer- sal and relay outputs, multiple media drives, and locking media access door. This CE-compliant product needs no additional equipment for harsh envi- ronments and is NEMA 4 rated. The unit can be used in a range of idnus- tries that require rugged equipment, as well as food processing and chemi- cal laboratory applications. — Omega Engineering Inc., Stamford, Conn. www.omega.com Manage energy use with this software The IndustrialIT cpmPlus Energy Manager software is offered to help users monitor, manage and optimize energy usage for maximum efficiency and cost savings. Energy Manager in- cludes tools for planning and sched- uling, energy-balance management, and reporting for overall electricity cost savings of 2–5%, says the firm. Energy Manager clearly indicates the cost of electricity and provides sup- port to schedule electricity consump- tion for off-peak hours. It coordinates electricity purchases and sales with its own generation capacity, then schedules this generation during on- peak hours, when purchased electric- ity is most expensive, to provide addi- tional cost savings. Energy Manager also includes reporting and analysis tools that evaluate the energy use Circle 39 on p. 70 or go to adlinks.che.com/23014-39 ChemiCal engineering www.Che.Com may 2009 32D-5
- 40. Parker Hannifin New Products Eriez contains an Automatic Baseline Cali- bration (minimum CO2 level over 7. 5 d) or a manual calibration in fresh air, and features a Max/Min CO2 value recall function. Extech’s CO200 has a temperature range of –4–140ºF, a hu- midity range of 0.1–99.9% RH, and a tube magnets CO2 range of 0 to 9,999 ppm. — Extech remove medium-to- Instruments, Waltham, Mass. large tramp metal such www.prestolifts.com as bolts, nuts and hand tools. Rare-earth powered tube magnets Magnets separate contaminants remove small ferrous contaminants to 72 ft/min. The filter regulators are from dry and liquid products such as pins, staples and clips. Xtreme designed with a rolling diaphragm for The 1-in. dia. ProGrade Tube Mag- Rare Earth powered tube magnets are extended life with quick response and nets are available in lengths of 4–24- best at separating out weakly mag- accurate pressure regulation regard- in. and are primarily used to remove netic fine ferrous contaminants. — less of changing flow or inlet pressure. ferrous contaminants from liquids in Eriez, Erie, Pa. Four mini filters, offered with high-effi- tanks, as a quality control check of dry www.eriez.com ciency coalescing filter media, are ideal bulk materials, or in various other ap- for harsh-environment applications, plication settings where a powerful, For pneumatic instrumentation such as chemical washdown areas. portable magnet is needed. ProGrade requiring special air preparation Five regulator models are offered in Tube Magnets are offered in three This firm now offers a new line of fil- ¼ to 1 ½-in. ports with a maximum strengths, enabling customers to select ter regulators, regulators and mini pressure capacity of up to 300 psig and the right degree of magnetic strength filters (photo). The four filter regula- flowrates to 300 ft/min. These products for their application. Ceramic powered tors are offered with flowrates from 16 are ideal for pneumatic equipment and Circle 40 on p. 70 or go to adlinks.che.com/23014-40 32D-6 ChemiCal engineering www.Che.Com may 2009
- 41. reverse-acting rupture disc complies altime viscometry measurement of with ASME BPE criteria. — Continen- fluids at up to 450°C without special tal Disc Corp., Liberty, Mo. cooling. The device has no moving www.contdisc.com parts, and the sensor is an all-welded construction that can be mounted at Realtime viscosity monitoring, any location and in any orientation even at high pressure using any process fittings. Calibra- The new XL7-HT2 high-temperature tion is unaffected by installation or viscometer provides continuous re- environment. The standard sensor instrumentation requiring special air L preparation. — Parker Hannifin Corp, Exp a ca ooki ww elor ree ng f Haverhill, Mass. r w.m opp cha or www.parker.com ust ortu nge? an nit ge ies ng Alternative flurosurfactants that .co at m are environmentally preferred The anionic, short perfluoroalkyl chain PolyFox fluorosurfactants are formulated to meet the goals of the U.S. Environmental Protection Agen- cy’s (EPA) Design for the Environment (DfE) program. The new products are formulated using dipropylene glycol monomethyl ether (DPM) solvent in- stead of diethylene glycol monobutyl ether (butyl carbitol), the solvent used previously. Some consider DPM to be an environmentally preferred formu- lating agent. The PolyFox technology platform is based on an oligomeric poly (oxetane) backbone with short perfluo- Chemicals and Polymers – Think Mustang. roalkyl groups. PolyFox materials are neither prepared from PFOA, PFOS or telomer-based fluorochemicals of We get below the surface. concern, nor can they degrade into Mustang has vast experience in conceptual design, front end such materials. Consequently, PolyFox loading, project planning and execution. Our veteran process fluorosurfactants and fluorochemicals design team is experienced in all areas of technology and design. by regulatory agencies globally, in- We have developed tools for conceptual planning that analyze the cluding the EPA and the EU’s REACH program. — Omnova Solutions, Inc., whole picture for chemical and polymer integration/modernization Fairlawn, Ohio projects. Our goal is to provide you with options, tradeoffs and www.omnova.com relative costs during the front end planning process. At Mustang, our strong front end capability provides accurate Use this rupture disc in project scope definition, cost estimating and fit-for purpose engi- clean applications neering from concept through commissioning. Designed specifically for the phar- maceutical, biotech and food and When you are planning your next revamp, upgrade or expansion, beverage industries, the Sanitrx MP contact Mustang. We get below the surface with great teams to rupture disc features severe service guide you through your project with no surprises. application capabilities. This rupture disc offers reliable performance from People Oriented...Project Driven® full vacuum to the recommended op- erating pressure in excess of 100,000 16001 Park Ten Place, Houston, Texas 77084 USA cycles. Precision scoring on the vent Tel: +713/215-8000 • Fax: +713/215-8506 Web: www.mustangeng.com side of the dome assures optimum E-Mail: robert.stodghill@mustangeng.com cleanability and improves rupture disc performance. The Sanitrx MP scored Circle 41 on p. 70 or go to adlinks.che.com/23014-41
- 42. New Products is made of 316 stainless steel, but if necessary, other materials of con- struction can be used. High-pressure models are rated at 20,000 psi (1,380 bars) or greater. Viscosities of up to R. Stahl Schaltgeräte 1,000,000,000 cP can be measured. — Hydramotion Ltd., York, England (photo) has now been extended to fea- www.hydramotion.com ture its first operational communica- tion interface for Foundation Fieldbus For light duty, use this High Speed Ethernet (FF HSE). The power-driven stacker system has already supported the This line of fully powered stackers has Modbus TCP protocol for basic Eth- a lifting height of 62 in. and a capacity Presto Lifts ernet performance. This new FF HSE of 1,500 lb. The Power Stak Lite line of version now provides users with a light-duty stackers (photo) features a ters. Units are available in fork-over more advanced and considerably more narrow mast design and an offset con- design for use with open-bottom pallets powerful Industrial Ethernet protocol trol handle to improve ease of use and or adjustable straddle design for use implementation. Remote I/O technol- comfort, while eliminate blind spots. with closed-bottom pallets. — Presto ogy allows users to deploy consistent An auto-reversing belly switch protects Lifts, Inc., Attleboro, Mass. plant communication networks inte- operators when walking the unit back- www.prestolifts.com grating conventional HART-capable wards, while an automatic brake imme- and Foundation Fieldbus H1 devices. diately halts travel when reversed. The The IS1 remote I/O interface — R. Stahl Schaltgeräte GmbH, Power Stacker is built on an stable, yet now comes in a FF HSE version Waldenburg, Germany short wheel base to provide maximum A market-leading remote I/O system www.stahl.de ■ maneuverability, even in tight quar- for Zone 1, Div. 1 applications, the IS1 Kate Torzewski and Gerald Ondrey Harness the power of positive press. Custom reprints from Chemical Engineering could be one of the smartest marketing decisions you make. Contact The YGS Group at 717.399.1900 x100 or learn more online at www.theYGSgroup.com/reprints The YGS Group is the authorized provider of custom reprints from Chemical Engineering. Circle 43 on p. 70 or go to adlinks.che.com/23014-43 32D-8 ChemiCal engineering www.Che.Com may 2009 Chem Eng_Quarter Vert.indd 1 3/10/09 3:10:03 PM
- 43. Hydramotion Siemens Realtime viscosity monitor- ing, even at high pressure The new XL7-HT2 high-tem- perature viscometer (photo) provides continuous realtime viscometry measurement of fluids at up to 450°C without special cooling. The device has no moving parts, and the sen- sor is an all-welded construc- Krüss tion that can be mounted at any R. Stahl Schaltgeräte location and in any orientation using ing point level switches any process fittings. Calibration is for high, low or demand unaffected by installation or environ- levels of dry bulk solids ment. The standard sensor is made of in bins, silos or hoppers. 316 stainless steel, but if necessary, The new device detects other materials of construction can be the presence of mate- used. High-pressure models are rated rial with bulk densities at 20,000 psi (1,380 bars) or greater. starting at 60 g/L (3.8 Viscosities of up to 1,000,000,000 cP lb/ft3) in mining, food, can be measured. — Hydramotion plastics, chemical and Ltd., York, England pharmaceutical indus- www.hydramotion.com tries, even in hazardous Samson applications. The device is used pri- weather or environmental influence, The IS1 remote I/O interface marily for high- or low-level indication, or the exhaust air can be routed now comes in a FF HSE version and for redundancy of continuous level through a pipeline. When combined A market-leading remote I/O system systems as overfill or dry-run protec- with a positioner, the booster allows for Zone 1, Div. 1 applications, the IS1 tion. Sitrans LVS100 is impervious to control valves with large pneumatic (photo) has now been extended to fea- external vibrations, and the vibrating actuators to be controlled quickly ture its first operational communica- fork design ensures the sensing tines and precisely, even with high flow- tion interface for Foundation Fieldbus are kept clean for reduced mainte- rates or pressure drops. — Samson High Speed Ethernet (FF HSE). The nance. — Siemens Industry Automa- AG, Frankfurt, Germany system has already supported the tion Division, Nuremberg, Germany www.samson.de Modbus TCP protocol for basic Eth- www.siemens.com ernet performance. This new FF HSE Analyze molten liquids version now provides users with a This booster allows fast control, at very high temperatures more advanced and considerably more even with high flowrates The Drop Shape Analysis System powerful Industrial Ethernet protocol Thanks to its precisely manufactured with Tube Furnace (DSAHT; photo) implementation. Remote I/O technol- bypass restriction, the new Type 3755 can perform optical drop studies at ogy allows users to deploy consistent Booster (photo) can be adjusted ex- temperatures up to 1,750°C, making plant communication networks inte- actly and lead-sealed in this setup. it suitable for studying liquid metals grating conventional HART-capable Because the Booster is completely and slag, molten glass and ceramics and Foundation Fieldbus H1 devices. pressure balanced, it provides a sta- at their firing temperature. The clear — R. Stahl Schaltgeräte GmbH, ble output, even under changing pres- shadow image of the sample provides Waldenburg, Germany sure conditions. The signal pressure is information about the melting behav- www.stahl.de transmitted with defined hysteresis, ior (for example, flyash fusibility ac- without loss and emitting little noise. cording to ASTM D1857). The shape of A versatile level switch for moni- The Booster is designed so that the a molten drop on a solid sample makes toring bins, silos and hoppers functional parts only come into con- wetting visible. Versions up to 1,200, The Sitrans LVS100 (photo) is the lat- tact with instrument air. Its exhaust- 1,500 or 1,750°C, for oxidizing, reduc- est addition to this firm’s line of vibrat- air port can be protected against ing or inert atmospheres, or for mea- Note: For more information, circle the 3-digit number ChemiCal engineering www.Che.Com may 2009 32I-1 on p. 70, or use the website designation.
- 44. Dresser Masoneilan New Products surement under vacuum cover a wide range of ap- plications. — Krüss GmbH, Hamburg, Germany www.kruss.de Process pumps for FDS units KSB KWPKC-Monobloc (photo) is a new pump series designed for use in secondary circuits of fluegas desul- nents (such as casing and discharge Free (EF) Seal and many other inno- furization (FDS) plants. The main ap- cover) are lined with wear-resistant vative design characteristics, the Cam- plication of these pumps is to transport CeramikPolySiC — a specially devel- flex II valve reduces equipment emis- limestone slurry and circulating water, oped composite material of ceramic sions that can occur at the valve shaft to remove gypsum and to thicken solu- and polymer that is proven to be abra- sealing or packing, particularly after tions. The pump series covers flowrates sion and corrosion resistant. — KSB long-term operation. The EF combines up to 3,000 m3/h and discharge heads AG, Frankenthal, Germany a double O-ring sealed packing fol- up to 120 m. The pumps feature a pull- www.ksb.com lower with low-friction tetrafluoroeth- out design for the radially split casing ylene- (TFE) based packing materials to make maintenance quick and easy. This valves seal keeps emissions for long-term service that complies An adjustable clearance gap is pro- at bay without excessive friction with low-emissions standards. In ad- vided on the suction side to keep the The Camflex II rotary globe valve dition, the small-range rotary motion pump’s efficiency high. The impellers (photo) can help users meet environ- of the Camflex II valve shaft provides are made of this firm’s wear-resistant mental emissions standards. Featur- benefits, such as preventing contami- Noridur Das, and the wetted compo- ing a specially developed Emissions nants from entering the packing sys- Process safety redefined! h at t launc Produc 09 MA 20 ACHE 19 D17-D 09 , Stand 0 Hall 8 11.– 15.05.2 rt, Frankfu With four new model ranges of piston dia- phragm pumps sera is setting new standards Seybert & Rahier in the dosing of aggressive and toxic chemicals. GmbH + Co. Betriebs-KG Optimal process safety and reduced life cycle sera-Straße 1 costs due to: 34376 Immenhausen Germany Modern multi-layer diaphragm technology Tel.: +49 (0)5673 999-0 Integrated diaphragm rupture signalisation Fax +49 (0)5673 999-150 Efficient control electronic www.sera-web.de Circle 44 on p. 70 or go to adlinks.che.com/23014-44 Circle 37 on p. 70 or go to adlinks.che.com/23014-37 32I-2 ChemiCal engineering www.Che.Com may 2009
- 45. You’re going to upgrade your process instrumentation loops. But how reliable will your measurements be? The accuracy of your results is reliant on the quality of your input. That’s why from the process interface valve to the transmitter you can’t afford any weak links. Swagelok provides only the highest quality, fluid handling solutions for your instrumentation loops. Plus we’ve streamlined e-business applications and offer CAD templates to simplify system configuration. If accuracy is important, choose Swagelok and get the most from your instrumentation loop. Contact your authorized Swagelok sales and service center or visit www.swagelok.com. Circle 45 on p. 70 or go to adlinks.che.com/23014-45
- 46. New Products tem from atmospheric exposure, which can accelerate corrosion. Another feature of the Camflex II valve is an integrated extension Heinen Drying bonnet that enables the standard and recycling the fine dust particles TFE packing material to with- that are produced during the process. stand its full temperature range No material is lost with the exhaust — up to 400°C. — Dresser Maso- air, nor pollutes the ambient air. The OSMO neilan, Courbevoie, France Membrane Systems filters are directly cleaned via clean- www.dresser.com ing nozzles integrated in the dryer’s the capacity of an existing evapo- hood. The filter types (stainless steel, These membranes enable higher ration plant can be increased “enor- PTFE or PP) are selected according to pressure operation of RO plants mously” by an upstream, high-pres- the process (drying, cooling, agglom- This firm has modified its spiral- sure RO plant. Pilot and test plants eration and so on) and product (coarse wound membrane elements in a way (photo) are also available. — OSMO and fine-grained powders; granules, that enables reverse osmosis (RO) Membrane Systems GmbH, Korntal- pellets or extrudates; suspensions, so- desalination plants to operate at pres- Münchingen, Germany lutions or slurries). — Heinen Drying sures of up to 120 bars — consider- www.osmo-membrane.de GmbH, Varel, Germany ably higher than the 80 bars used in www.heinen.biz conventionally driven, high-pressure This FB dryer incorporates RO plants. As a result, a significantly a filter for fines Ceramic bearings enable dry run- higher concentration of salts can be One feature of the Heinen fluidized- ning without lubrication achieved, thereby reducing the invest- bed (FB) systems is the high-perfor- This manufacturer provides differ- ment and operating costs needed for mance filter cartridges integrated in ent kinds of bearing solutions for the downstream evaporation. In addition, the dryer’s hood (photo), chemical_eng_177X123-GB_2009 30-03-2009 10:30 Pagina 1 separating chemical process industries (CPI). Over 40,000 PIERALISI centrifuge systems in operation worldwide. And THE WINNING RANGE IN now highly-successful solutions for numerous processing applications. THE PROCESSING INDUSTRY The PIERALISI Decanter is an ideal choice for chemical applications including Polyolefins, HDPE and PVC, as well as for the Biotech-Pharmaceutical sector (fermentation broth), for minerals incl. ceramics, for 2- and 3-phase Bio- Diesel and Spent Grain/Stillage applications, to list just a few of its uses. The PIERALISI Disc Stack Separator is the winning solution for hygienic applications in the Biotech- Pharma-ceutical sector. Compact in design for aerosol-free operations, the Separator is available as a complete unit. Moreover it is also the perfect choice for Fine Chemicals, for soot and for a wide range of Bio-Diesel applications, not forgetting all kinds of Food processing applications, as well as for a host of other jobs. ACHEMA 2009 Frankfurt, May 11 to 15, 2009 Hall: 5.0-B40-C41 Ochsenfurter Strasse 2 - 97246 Eibelstadt - Tel.: +49 93 03 / 90 82-0 - Fax: -20 E-mail: pieralisi@pieralisi.de - Internet: www.pieralisi.de Circle 46 on p. 70 or go to adlinks.che.com/23014-46 32I-4 ChemiCal engineering www.Che.Com may 2009
- 47. *e. mission. one of the four members of the e.q.p.e.c. (enemies of quality, production, environment and costs). wreaks havoc on the environment. Jamesbury Emission-Pak® valves keep your emissions under control Many process streams encourage fugitive losses. Metso Automation’s Emission-Pak provides a quick, easy way of assuring compliance with emissions standards. Mounted on Jamesbury® valves, Emission-Pak combines a PTFE/graphite body seal and gasket, which maintains a leak-free joint at the valve bonnet, with a double-packed, live-loaded V-ring steam seal mechanism that maintains a constant packing force without over-compression. Emission-Pak is available in a wide range of corrosion resistant trim materials, and is suitable for use in extreme pressure and temperature situations. www.metso.com/automation Circle 47 on p. 70 or go to adlinks.che.com/23014-47
- 48. Cerobear New Products Full ceramic bearings con- sist of rings and balls made of ceramic, whereas the rings E. Begerow of a hybrid bearing system A new, mineral-free depth are made of high-value bear- filter medium ing steel (photo). Both bearing types centrifuge or filter press. The system This firm has developed the bepure have a variety of advantages over consists of a fixed cylindrical chamber process, in which different types of standard bearings. In particular, seiz- with an eccentric agitator inside that high-purity cellulose are crosslinked ing — one of the main failure modes undergoes two independent move- to form a structure that does not re- in standard steel bearings due to poor ments; it can rotate on its own axis quire the addition of any inorganic lubrication — is virtually impossible as well as tangential to the cylinder. material, even for sterile filtration in full ceramic and hybrid bearings, This combined double rotation allows duties. BecoPad P (photo) is charac- says the manufacturer. This makes it optimal mixing of the product, con- terized by unparalleled purity, with possible to use these bearings without tinuously renewing the surface of the ion and endotoxin contents hardly lubricants, and dry-running bearings mass exposed to evaporation, covering detectible, says the manufacturer. The drastically reduce friction and particle the entire volume of the vessel. As a new range is available as a low or high emissions. — Cerobear GmbH, Herzo- result, solvent release is facilitated cationic version. The filters are said to genrath, Germany and drying times are significantly have a lifetime up to 20% longer than www.cerobear.de reduced, says the manufacturer. The conventional sheets. Rinse volume is Planex System is available with vol- reduced by 50%, which results in sig- This multimotion dryer offers umes from 300 to 4,800 L, with load- nificant cost and time savings, says a number of advantages ing capacities from 15 to 80% of the the firm. — E. Begerow GmbH & Co., The Planex System is a patented, vessel volumes. — Italvacuum S.r.l., Langenlonsheim, Germany multi-product dryer for vacuum dry- Borgaro (Turin), Italy www.begerow.com ■ ing of wet powders obtained from a www.italvacuum.it Gerald Ondrey Harness the power of positive press. Custom reprints from Chemical Engineering could be one of the smartest marketing decisions you make. Contact The YGS Group at 717.399.1900 x100 or learn more online at www.theYGSgroup.com/reprints The YGS Group is the authorized provider of custom reprints from Chemical Engineering. Circle 43 on p. 70 or go to adlinks.che.com/23014-43 32I-6 ChemiCal engineering www.Che.Com may 2009 Chem Eng_Quarter Vert.indd 1 3/10/09 3:10:03 PM
- 49. plics®plus – Modularity in a new dimension Simpler and more standardised – with plics®plus, VEGA takes level, switching and pressure instrumentation into a new dimension. This tried-and-true instrument concept now impresses again with even greater housing variety and additional measuring principles. And its further simplified, uniform adjustment as well as optimised connection technology create additional synergies that save time and costs. Circle 48 on p. 70 or go to adlinks.che.com/23014-48 www.vega.com
- 50. There is the World, and then there is the World of Pompetravaini. Different, Unique for Reliability and Service The Pompetravaini pump ethic was born in a far distant 1929. For Pompetravaini, eighty years are not simply a great achievement, but also a starting point for the future. Long experience, many years of history, technology, strategy, and marketing have consolidated the Pompetravaini brand - not only in our national territory, but with our continued leadership, with more than eighty presences worldwide, also in the international market. Seven new Pompetravaini operations have been opened throughout the world: U.S.A., Canada, France, The Netherlands, Germany, United Kingdom, Poland and these, together with more than twenty exclusive distributors, complete our current international presence. Our commitment is always to stay ahead pompetravaini spa I-20022 Castano Primo (Mi) • Via per Turbigo, 44 • Ph. +39.0331.889000 • Fax +39.0331.889057 • sales@pompetravaini.it • www.pompetravaini.it Circle 49 on p. 70 or go to adlinks.che.com/23014-49
- 51. Choosing a Control System Department Editor: Kate Torzewski TECHNOLOGY REQUIREMENTS [1] an outdated HMI platform or abandon it 6. Asset management entirely, control-system suppliers should pro- Does the solution focus on the entire process? 1. Control architecture vide the means to leverage existing invest- A supplier’s asset-management solution Does the solution provide an integrated ments and intellectual property, and at the should be “process centric.” Users have an automation platform? same time migrate plant control rooms and enterprise-wide view of the relationships New systems should manage process knowl- engineering stations to newer, more robust between all installed assets, and as such, edge through a combination of advanced technology. This can include field upgrade can make informed decisions affecting plant technologies, industrial domain expertise, “kits” allowing users to retain their existing availability. This approach allows the user and Six Sigma methodologies. hardware and industrial-class furniture, to determine: 1) the impact of equipment Choose an open, scalable control system while expediting the transition to the latest problems on the process; 2) the association that is fully redundant, includes robust operator environment. between these problems and the business; control algorithms and provides on-process and 3) the priority of needed repairs. upgrades to minimize plant downtime. The 4. Networks system should be embedded with best-in- Does the solution employ open CHOOSING a dCS OR a PLC [2] class applications for advanced control, asset or proprietary protocols? management and control monitoring, and Control systems employing open network When choosing a control system for a par- include a human interface integrating plant- protocols provide process plants with ticular process application, there are many wide information and delivering realtime new levels of connectivity. Users have considerations that can help influence the process data. Additionally, the system should the freedom to select the best control and decision. Remember that a DCS is optimally comply with open industry standards. instrumentation solutions for a given task. Be designed for process control with refinery sure the control system you choose makes control origins and a PLC is optimally 2. Field instrumentation full use of recognized open standards, and designed for machine or motion control Does the solution integrate “smart” devices? is equipped to integrate the industry-leading with car factory relay panel origins. While Control solutions should support digital field network protocols. These include Foun- PLCs are sometimes used for process-control integration of field instruments, allowing dation Fieldbus, Profibus, HART, DeviceNet applications, there are some trade-offs in processes to be linked with monitoring and ControlNet, among others. terms of degree of programming, robust- and control equipment, and providing the ness and operational suitability. This is most platform needed to operate plants more 5. Optimization often attempted with small or non-hazardous profitably. An automation provider should Does the solution support processes where the loss of benefits is less offer a maintenance-management program redesigned work processes? visible. Below, each type of system and incorporating all of field assets — tradi- When selecting a new control system, it is those areas where it typically performs best tional and fieldbus alike — and providing important that the vendor offer a solution are listed. tools for integrating all device information in tightly integrating optimization, multivari- a single database. able control and advanced process control References (APC). Moreover, these tools should be 1. Gregg, J., Control System Selection, Chem. 3. User interface embedded in a system architecture that Eng., August 2002, pp. 62–66. Does the solution support complex human- captures and leverages process knowledge 2. Bohan, J., Industry Solutions Manager, machine interface (HMI) requirements? over time. A methodology will also be in Honeywell Process Solutions (Phoenix, Ariz.), Instead of requiring customers to support place for continuous improvement. personal communication, Apr. 6, 2009. DistributeD control system (Dcs) Programmable logic controller (Plc) Should be used when: Should be used when/for: • fair amount of continuous control is required — DCS A • igh speed processing (faster than 1 ms). This is the hallmark of PLC H systems typically have more built-in capability in this systems area, such as selectors, calculators, stepped outputs and • 0%+ discrete application (digital inputs/outputs). PLCs are optimized 9 initialization for discrete applications, due to their packing line heritage • he application will be changing frequently (several times a T • our application is predominantly machine/motion control. The nature of Y year or more — adding new feed lines, tanks, and so on). ladder-logic processing is ideal for machine/motion control applications Tools in the DCS are fool-proof and make changes quickly • he application will not change frequently, or if so, the changes are T • ou have a batch process — sequence capability and Y small. PLCs are very flexible for making small changes, but lack integ- handling is built into the DCS rity checks and built-in functionality for making large-scale changes to • ou want to assign specific areas of the process to opera- Y an automation strategy tors. Again, this is built-in • ou need to control single pieces of equipment or single workstations Y • he system must be integrated with other applications T that are loosely integrated at a higher level. Many end users deploy and/or systems. DCS systems have a number of open SCADA architectures with PLCs that are effective for capturing data protocols built-in for integration across the systems, while preserving autonomy for each controller • oss of control or operational view during production L • perators of the application have responsibility over a piece of O is unacceptable. DCS systems are robust due to their equipment only. PLCs offer many options for closely coupled operator refinery heritage, and robustness is built-in because it is touch panels expected • ou anticipate that the controllers for various pieces of equipment have Y • ou anticipate having multiple controllers that need to Y minimal communication between them, and the communication will not “talk” to each other in a peer-to-peer fashion (sharing a change much. Building messaging in the PLC system is costly and must lot of data throughout the application). This is built-in to a be maintained DCS system • ou will require valve line-up logic for numerous (close to 100), multi- Y • ou need a highly available production system (control- Y position valves. Ladder logic is a very clean, effective way to handle ler, HMI, server, network, etc). A DCS system is pre-built this requirement ready to go out of the box • our application has many areas, separated by distance, that each Y • istorical data about your application is important to your H require only a small amount of I/O (less than 100). PLCs can be scaled company. History collection is built-in and very robust to cost-effectively handle tens of I/O at multiple locations
- 52. Solids in Cover Story Feature Report Gas out Designing and Operating Gravity Dryers Cylinder section Gas distributor Gas in Properly designed, bulk solids bins or silos offer numerous advantages in slow, Hopper section diffusion-limited drying operations Greg J. Mehos, Jenike & Johanson Solids out E vaporation of moisture or volatile 4. Gravity dryers also provide storage Figure 1. In a gravity dryer, gas organic compounds (VOCs) from or surge capacity, which is desirable (usually air or nitrogen) is injected via a distributor typically located near the bulk solids usually takes place in when interruptions in production cylinder-hopper junction. The gas passes two stages: one in which the dry- take place. upward, stripping volatile components ing rate is constant, and the second in A schematic of a gravity dryer is from the solids, which flow downward which the rate decreases over time. shown in Figure 1. Gas, usually air or Devolatilization during the first stage nitrogen, is injected via a distributor is properly designed, the local solids is rapid and can be readily accom- typically located near the cylinder- stress can approach zero. In other plished in flash, spray, or fluidized bed hopper junction. When polyolefins are words, the solid particles in the vicin- dryers. In the second stage, however, processed, steam is also introduced to ity of the gas distributor may become the VOC or moisture removal rate is neutralize the catalyst. The gas passes fluidized due to high gas velocities. diffusion limited, and several hours upward, stripping volatile components As a consequence, instabilities can of residence time are often necessary. from the solids, which flow downward. occur throughout much of the vessel To meet low moisture or VOC targets, A rotary valve or other feeding device • Sufficient gas injection rate. two unit operations may be required. at the hopper outlet modulates the The composition of the gas stream An economical way to provide the solids discharge rate. inside the dryer will vary with po- extended residence time required for The keys to successful design and sition inside the vessel. As volatiles slow, diffusion-limited drying is to use operation of a gravity dryer include are stripped from the solids stream, a bin or silo that has been modified the following: the concentration of volatile compo- to allow injection of a sweeping gas • Uniform solids flow. A non-uni- nents in the gas stream will increase and, in some cases, to provide heating. form solids-velocity profile will im- as it travels upstream in the vessel. These unit operations have a variety pact the quality of the final product If the gas injection rate is too low, of names, including gravity dryers, since exposure time of the solids to the driving force for devolatilization purge or conditioning columns, mov- the gas will be variable. In the worst may vanish in the upper portion of ing bed columns, and silo or bin dry- case, there may be no motion along the vessel ers. Relative to other methods — such the walls, and the solids will only • Adequate residence time. The as heated screws, paddles or disks, flow in a channel above the vessel’s volume of the gravity dryer must fluidized bed processors and tray dry- outlet. The residence time of the sol- be large enough to provide the resi- ers — modified bins or silos offer the ids will be dramatically less than dence time necessary for the vola- following advantages: intended and may not allow the de- tiles or moisture targets to be met. A 1. The capital cost of a gravity dryer sired degree of volatiles removal residence time on the order of hours is generally much lower than that • Uniform gas flow. The distribution may be required when drying is dif- of a fluid-bed processing unit or of system used to inject the gas must fusion limited heated screws. result in a constant gas velocity Gravity dryers that function as desired 2. Gravity dryers have no mechani- throughout the cross-section of the are those whose designs are based on cal agitators or other moving parts, dryer. Channeling of the gas will not the fundamental flow properties of eliminating the maintenance costs only cause the gas to bypass an ap- bulk solids and the diffusional and associated with such devices. preciable portion of the solids, but it phase-equilibrium properties of the 3. Gravity dryers provide a longer may cause flow instabilities volatile species. Obtaining purposeful residence time than most other • Non-zero solids stress. Unless the data is critical. At a minimum, the fol- technologies do. region where the gas is introduced lowing properties should be obtained: 34 ChemiCal engineering www.Che.Com may 2009
- 53. 50 Mass flow Funnel flow 40 Wall friction angle, ’ Uncertain region Shear stress 30 Funnel flow 20 Mass flow 10 Stagnant ’ 0 material 0 10 20 30 40 50 Normal pressure Hopper angle, C Figure 2. In general, there are two Figure 3. The angle of wall friction is Figure 4. Design charts are useful types of flow patterns in a vessel: funnel the angle that is formed when a line is in determining combinations of wall flow and mass flow. The preferred flow drawn from the origin to a point on the friction angle and hopper angle that pattern in a gravity dryer is mass flow wall yield locus provide mass flow • Cohesive strength. Used to deter- of the moving solids. Funnel flow oc- are on the vertical axis. Any combina- mine outlet dimensions that prevent curs when the walls of the hopper sec- tion of ϕ' and Θc that falls within the a cohesive arch from developing tion of the vessel are not steep enough mass flow region of the chart will pro- • Wall friction. Needed to calculate or its friction is not low enough for the vide mass flow. hopper angles that ensure flow of bulk material to flow along them. Designing right to the limit of the the bulk material along the vessel The preferred flow pattern in a grav- mass flow region is not recommended walls at an appropriate velocity to ity dryer is mass flow. In mass flow, the for conical hoppers. Figure 4 shows a maintain overall residence-time- entire bed of solids is in motion when region of uncertainty where the flow distribution goals material is discharged from the outlet. pattern cannot be predicted with con- • Compressibility. Provides the re- This behavior eliminates stagnant re- fidence. In actuality, this region rep- lationship between solids pressure gions in the vessel, which provides a resents a margin of safety to account and bulk density more uniform velocity profile. In addi- for slight differences in material flow • Permeability. Used to specify op- tion, mass flow minimizes the transi- properties and wall surfaces. If the erating conditions that circumvent tion time during grade changes when combination of wall friction angle and flooding, to determine outlet dimen- more than one product is processed hopper angle lies too close to the fun- sions that allow the desired solids in the vessel [1]. Hence, in order for nel-flow line, a switch to funnel flow discharge rate, and to determine the a gravity dryer to operate properly, can occur. Hence, a 4–5-deg. margin of gas pressure profile in the column mass flow is vital. safety is used with respect to the mass • Phase equilibria. Used to calculate The first step in designing vessels flow boundary. the minimum gas-injection rate for mass flow is to measure the wall The uniformity of the solids velocity • Kinetic information. Used to cal- friction between the bulk material and in a vessel depends on how close the culate the required solids residence the wall material. Wall friction is mea- hopper angle is to the mass flow bound- time. sured by a method described in ASTM ary. As the hopper angle is steepened, Modified bins or silos can also be used D-6128 [2]. A sample of bulk material the velocity profile in the hopper sec- to remove undesirable components of is placed inside a retaining ring on a tion becomes more uniform. In a mass a gas stream. Here, a zeolite or other coupon of wall material, and various flow hopper, the velocity differences di- suitable bulk material flows down- normal loads are applied. Material minish in the cylinder section and the ward in the vessel and selectively ad- in the ring is forced to slide on the solids velocity becomes nearly uniform sorbs unwanted species from a coun- stationary coupon, and the resulting unless the solids level is very low. tercurrent gas stream. Although the shear force is measured as a function focus of this paper is devolatilization, of the applied normal force. The wall Outlet size the same concepts can be applied to yield locus is constructed by plotting The outlet of the dryer must be large moving bed adsorbers. shear force against normal force. enough to prevent a flow obstruc- Design charts originally developed tion from developing. If the cohesive Achieving mass flow by Jenike [3] provide allowable hop- strength of the bulk material that de- In general, there are two types of flow per angles for mass flow given val- velops as a result of its consolidation patterns in a vessel: funnel flow and ues of the wall friction angle (ϕ'). The in a vessel is greater than the stresses mass flow. These flow patterns are il- angle of wall friction is the angle that imparted onto it at the outlet, a cohe- lustrated in Figure 2. In funnel flow, is formed when a line is drawn from sive arch will develop. an active flow channel forms above the origin to a point on the wall yield The cohesive strength of a bulk solid the outlet, with stagnant material re- locus. A representative wall yield locus is a function of consolidation pressure maining at the periphery. This pattern is shown in Figure 3. and is determined by the method de- leads to a non-uniform velocity profile An example design chart is shown scribed in ASTM D-6128 [2], where a inside the vessel, a dramatic reduction in Figure 4. Values of the allowable direct shear tester is used to measure in solids residence time, and gas flow- hopper angle (Θc, measured from ver- the shear strength of a material under ing preferentially in the central chan- tical) are on the horizontal axis, and varying consolidation pressures. A nel due to the decreased permeability values of the wall friction angle (ϕ') sample of powder is placed in a split ChemiCal engineering www.Che.Com may 2009 35
- 54. Yield strength or arch stress Cover Story Slope = 1/ff cell and then pre-sheared (consoli- 1. The flow function lies below the dated by exerting a normal compact- flow factor and the two curves do ing load and then shearing it until not intersect. When this is the case, Flow function the measured shear stress is steady). the stress imparted on the arch is Next, the shear step is conducted, in always greater than the material’s critical which the vertical load is replaced cohesive strength, and there is no Consolidation pressure with a smaller load, and the sample is minimum outlet dimension. again sheared until it fails. The pre- 2. The flow function lies above the flow Figure 5. The relationship between shear and shear steps are repeated factor and the curves do not inter- strength and pressure is known as the flow function for a number of normal stresses, and a sect. The bulk solid will not flow due yield locus is then determined by plot- to gravity alone. Gas distribution ting the failure shear stress against 3. The flow function and flow factor Uniform distribution of the stripping normal stress. From the yield locus, intersect, as shown in Figure 5. At gas is essential. Otherwise, the bulk the major consolidation pressure and the point where the two lines inter- solid’s exposure time to the gas can be cohesive strength are determined [3]. sect, the arch stress is equal to the non-uniform, severely impacting uni- By conducting the test over a range strength of the bulk solid. The value formity of purging. If the distributor of consolidations, the relationship be- of the stress or strength is equal to is not properly designed, the gas may tween consolidation pressure and the the critical stress σcritical. The mini- bypass a significant portion of the cohesive strength of the bulk mate- mum outlet diameter to prevent a solids. If introduced at a point where rial can be determined. The relation- cohesive arch from developing in a the solid’s stresses are low, the gas is ship between strength and pressure is cone, Bmin, can then be calculated likely to cause localized fluidization of called the flow function. An example from Equation (1): the solids. flow function is given in Figure 5. Localized fluidization frequently oc- The greater the material’s cohesive H( ) curs when gas is introduced at high Bmin C critical (1) strength, the greater will be the ten- velocities via nozzles or perforated dency for the formation of a stable plates, which can lead to flow instabili- obstruction, such as an arch or dome Where the function H(Θc) is approxi- ties propagating throughout the dryer. at the vessel outlet. A stable cohesive mately equal to 2 and is given by Je- If gas is introduced through screens in arch is formed when the strength nike [3], and γ is the material’s weight the converging section of the vessel, of the bulk solid is greater than the bulk density. only a relatively small amount of gas stresses acting upon it. Jenike [3] While an outlet diameter greater can be injected in the lower portion showed that the magnitude of these than the minimum will prevent cohe- of the cone, since at higher injection stresses depends on a material’s bulk sive arching, it may not necessarily rates, the minimum fluidization veloc- density, the outlet dimension, and the be large enough to allow the desired ity will be readily exceeded due to its geometry of the hopper. The stresses discharge rate when fine powders are small cross-sectional area. acting to overcome a cohesive arch and processed. The maximum flowrate of a To avoid fluidization, a gas dis- cause flow are described by a hopper’s fine powder can in fact be several or- tributor may be accompanied by an flow factor (ff), which is a function of ders of magnitude lower than that of inverted conical insert. Gas is intro- the internal friction of the bulk solid, coarser materials. Two-phase flow ef- duced underneath the inverted cone, the hopper angle, and the wall friction. fects are significant due to the move- directly into the material through The flow factor can be obtained from ment of interstitial gas as the powder the free surface that forms. Gas may design charts given by Jenike [3] or compresses or expands during flow. also be introduced through screens formulas given by Arnold and McLean A limiting condition occurs when the around the perimeter of the inverted [4, 5]. By comparing the flow factor and compaction in the cylinder section cone or through the outer hopper sec- flow function and ensuring that the forces too much gas out through the tion or both. If properly designed, an stresses at the outlet are greater than material top surface. When the bulk insert will expand the flow channel a critical value, the minimum open- material dilates in the converging and eliminate stagnant regions of ing size required to prevent a cohesive section of the vessel, a slight vacuum bulk solids in the vessel. arch from forming can be calculated. forms, resulting in gas counter flow An improperly designed gas distrib- Since the flow factor is a constant through the outlet. At a critical solids utor, however, can cause non-uniformi- for a given material and bin, a plot of discharge rate, the solids contact pres- ties to occur in gas or solids flow or to the arch stress against consolidation sure drops to zero, and efforts to exceed result in unstable flow. An insert that pressure is a straight line through the this limiting discharge rate will result is too small or too large, or is placed too origin. Superimposing the material’s in erratic flow [6]. For fine powders, high or too low relative to some critical flow function on the same graph al- permeability testing is recommended size and position, will expand the flow lows the cohesive strength and arch to determine the outlet size required channel very little, if at all. Even if stress to be compared (see Figure 5). to achieve the desired discharge rate. optimally located, an inverted conical There are three possible results of Calculation of limiting flowrates is de- insert is unlikely to convert a funnel such a comparison: scribed by Johanson [7]. flow pattern to mass flow, since simple 36 ChemiCal engineering www.Che.Com may 2009
- 55. volatile component, gas phase Minimum gas injection rate Concentration of Equilibrium line Gas injection rate decreases Operating lines Solids outlet Solids feed Figure 6. Notable improvements in gas uniformity can be achieved by injecting Concentration of volatile component, gas via an annulus and a set of crossbeams located at the intersection of the cone solid phase and cylinder [9] inverted cones have little effect on the tion can be placed in a sealed container, Figure 7. The minimum gas-injection flow pattern below their base [8]. and the vapor phase composition can rate is such that the concentration of the volatile component in the gas leaving the Notable improvements in gas unifor- be determined by gas chromatography column is in equilibrium with the solids mity can be achieved by injecting gas or other analytical methods. feedstream. The gas injection rate should via an annulus and a set of crossbeams The minimum required gas injec- be set safely above the minimum, and the located at the intersection of the cone tion rate is determined by plotting the column diameter must be sized to ensure and cylinder [9]. By properly sizing the equilibrium line and an operating line stable operation of the dryer annulus and crossbeam components on the same graph. The operating line quired, since otherwise, unacceptably of the distributor, high gas injection is determined as follows. First, the high gas velocities will result, causing rates can be achieved with gas veloci- target volatiles level of the solids and fluidization and unstable operation. ties low enough to prevent localized the concentration of volatile species in The cross sectional area of the col- fluidization. The crossbeams can also the inlet gas are located on the graph. umn must be large enough to prevent be used to support a conical insert. By Next, a gas injection rate is assumed, the solids stresses from approaching properly choosing the dimensions and and points on the operating line are too close to zero. Solids stress and gas material of construction of the inner calculated using a material balance. If pressure profiles can be determined cone, mass flow can be achieved with the gas and solids streams are lean in by an analysis given by Johanson [7]. a hopper angle that is twice as large volatiles, the solids and gas rates are Expected gas-interstitial pressure as would be required if an inner cone nearly constant throughout the cylin- and solids stresses in a 3-m dia. dryer were not present. This results in a sub- der, and the slope of the operating line having a 20-m tall cylinder are shown stantial saving of headroom compared is constant and equal to the ratio of in Figure 8 and 9, respectively. (See to mass flow designs without inserts. the solids-to-gas, mass flowrates. Table 1 for other parameters used in Distributor designs that employ cross- Example equilibrium and operat- the calculations.) Note that there is beams are shown in Figure 6. ing lines are given in Figure 7. The a significant increase in the solids horizontal axis represents the solids stress at the cylinder-hopper junction, Minimum gas-injection rate volatiles content; the vertical axis de- and therefore, a load analysis should As the solids travel countercurrent to notes the volatiles content of the gas be performed during the structural the stripping gas inside the dryer, the stream. Note that for a constant sol- design of the dryer. The interstitial driving force for mass transfer of the ids feedrate, the slope of the operating gas pressure increases and solids volatile species is not constant, since line increases as the gas injection rate stress decreases with increasing injec- the compositions of both the solids is reduced. The minimum gas-injection tion rate. The gas-pressure and solids- and gas streams vary along the vessel rate is such that the concentration of stress profiles depend on the bulk height. For a specified solids feedrate, the volatile component in the gas leav- solid’s permeability and compressibil- a minimum required gas injection rate ing the column is in equilibrium with ity and the feedrates of the solids and exists. If an injection rate less than the the solids feedstream (see Figure 7). sweeping gas. minimum is used, the driving force The gas injection rate should be set As the gas injection rate is in- will vanish in a portion of the column, safely above the minimum, and the creased, the particle-to-particle con- and the desired level of devolatiliza- column diameter must be sized to en- tact stresses decrease. The reduction tion cannot be reached. sure stable operation of the dryer. in solids stress is most severe where To determine the minimum gas re- the gas is injected into the vessel. In quirements, a relationship is needed Cylinder diameter Figure 10, the minimum solids stress to describe the phase equilibrium be- There is a trade-off between gas injec- is plotted against gas injection rate. tween the solids and gas phases. In tion rate and required solids-residence The analysis illustrates the impor- the case of polymers, the equilibrium time. Higher gas rates allow a shorter tance of properly sizing the vessel, as relationship can be determined from residence time, since at high rates, the the solids stress decreases with in- Flory-Huggins theory. Flory-Huggins volatiles in the gas phase are more di- creasing gas rate. If solids stress is low parameters are tabulated for several lute, the driving force for mass trans- enough, the solids may become fluid- solvents and polymers [10]. In the ab- fer is greater, and hence drying rates ized, resulting in severe flow instabili- sence of published data, a bulk mate- are higher. At high gas flows, however, ties throughout the vessel. rial with a known volatiles concentra- vessels with greater diameters are re- Note that the gas rate in the purg- ChemiCal engineering www.Che.Com may 2009 37
- 56. 25 25 Cover Story Distance from outlet, m Distance from outlet, m 20 20 Gas rate = 5 kg/min 7.5 kg/min 10 kg/min 15 15 12.5 kg/min ing section of the vessel (the cylinder) does not necessarily 10 10 12.5 equal the gas injection rate. kg/min Usually, the outlet of the dryer 5 Gas rate = 5 is equipped with a rotary valve 5 kg/min 10 7.5 kg/min or other feeding device. De- kg/min pending on the pressure down- 0 0 50 60 70 80 90 100 110 120 130 0 10 20 30 40 50 60 70 80 stream of the feeder and the Intersticial gas pressure, kPa Solids stress, kPa pressure buildup that results from injecting gas into the col- Figures 8 and 9. Expected gas interstitial pressure (left) and solids stresses (right) are umn, additional gas may leak illustrated for a 3-m-dia. dryer having a 20-m-tall cylinder through the vessel outlet or a fraction of the injected gas may flow For batch stripping, where the con- required bed height is made, and the cocurrently with the solids stream out ditions at the particle surface are con- diffusion and mass-balance equations the outlet. This addition or reduction stant, the diffusion equation has an are solved to determine the volatiles of gas flow in the cylinder must be analytical solution, which can be inte- content of the solids leaving the dryer. taken into account when determining grated to give the average concentra- Adjustments in the bed height are gas injection rate and solids residence tion of the volatile component, –, as a then made until solving the system of x time requirements. function of time [11]: equations gives the target solids-vol- 2 2 n Deff t atiles content at the outlet. Usually, x xs 6 1 Required residence time exp (3) additional height is specified to allow The required residence time, which di- x0 xs 2 n 1n 2 RP2 surge capability. rectly determines the cylinder height, In the analysis, the Sauter mean depends on the relative rates of the In the case of a gravity dryer, how- radius is used. Sauter mean radius is bulk solid and gas streams, the phase ever, where the gas passes countercur- defined as the radius of a sphere that behavior of the volatile species, and rently to the solids stream, the surface has the same volume-to-surface-area the local rate of mass transfer of the volatiles content is not constant. The ratio as a particle of interest. Because species. To describe the transport of a concentration of volatiles in the vapor the average volatiles concentration of trace volatile species in a particle, the stream, and hence the equilibrium con- a solid particle is based on its volume diffusion equation written in spherical centration at the particle surface, var- while devolatilization takes place at coordinates is used: ies with axial position in the column. its surface, the Sauter mean is appro- x 1 x Hence, Equation (3) cannot be applied priate for tackling transport phenom- Deff r 2 (2) to moving beds unless the volatiles ena problems. t r2 r r content of the gas stream is negligible, The temperature of the solids is Where x is the concentration (wt.%) such as when large amounts of purge usually set by upstream process volatile species in the solid, r is the gas are used. In most cases, having a conditions, such as the temperature radial coordinate, t denotes time, and low volatiles level in the gas stream of the bulk solids leaving the flash Deff is the effective diffusivity. The ini- exiting the dryer is undesirable, since dryer, fluidized dryer or other process tial and boundary conditions are: recovering volatiles from a lean gas unit. The gas may be preheated, but stream can be difficult. The diffusion considering its small thermal mass t 0, x x0 equation must therefore be solved nu- compared to that of the bulk solids x merically, using an overall mass bal- stream, the gas and solids tempera- r 0, 0 ance to track the volatiles level in the tures are usually approximately r gas stream. equal in most of the cylinder [12]. If r RP , x xS One should note that not all particles temperatures are expected to vary are spherical or can be approximated greatly inside the dryer, the solids- where RP is the Sauter mean-particle as spheres. Powders have many shapes, and gas-phase temperature profiles radius, x0 is the initial concentration and engineering judgment must be can be estimated using a procedure of the volatile component and xs is the used to assess the results of analyses described by Munjal and Kao [13]. surface concentration. The first bound- that assume a spherical symmetry. When specifying the height of the ary condition signifies symmetry of the To determine the required residence cylinder section, the designer should intraparticle volatile-component con- time, the diffusion and mass-balance account for the length required for centration profile. The second bound- equations are solved iteratively. The the injected gas to become uniform. ary condition describes equilibrium at gas injection rate is specified, one that The height at which the gas velocity is the interface of the solid and gas and is safely greater than the minimum, considered uniform is typically on the assumes that the devolatilization pro- and a dryer diameter that ensures order of either one vessel diameter, if cess is diffusion limited (that is, there that the superficial gas velocity is gas is injected through or near the cyl- is negligible resistance to mass trans- low enough to prevent fluidization is inder walls, or one half the diameter, fer in the gas phase). determined. Next, an estimate of the if the gas injected near the centerline 38 ChemiCal engineering www.Che.Com may 2009
- 57. Table 1. SimulaTion inpuTS 1.50 1 Mass fraction volatiles remaining Gas rate = Column Diameter, m 3 Minimum solids stress, kPa 1.25 5 kg/min Height of solids above 20 gas distributor, m 1.00 7.5 kg/min Height of solids above 20 cylinder-cone junction, m 0.75 0.1 10 kg/min Hopper angle from verti- 20 cal, deg. 0.50 Outlet dia., m 3.0 0.25 Angle of wall friction, 15 deg. 0.00 0.01 2.5 5.0 7.5 10.0 12.5 0 5 10 15 20 Bulk density, kg/m3 450–525 Gas injection rate, kg/min Distance from top surface, m Permeability, m/s 0.05–0.17 Figure 10. Solids stress decreases Figure 11. In this case, if 25 m.t./h of Design pressure (gauge), 50 with increasing gas rate and can become solids are fed to a gravity dryer having a kPa too low, causing solids to become fluid- 3-m-dia., 20-m-tall cylinder, a 10 kg/min Design temperature, °C 80 ized and resulting in severe flow insta- gas injection rate is necessary to achieve bilities throughout the vessel a 99% reduction in volatile components Solids feed rate, metric 25 ton/h and the volatiles concentration of the flow instabilities do not occur due to Gas (air) rate, kg/min 10 solids is measured over time. A least- high gas velocities. Gas must be in- Effective diffusivity, m2/s 1.9E–11 squares fit of the data to the analytical jected at a rate high enough to provide Particle Sauter mean 1.0 solution to the diffusion equation pro- a driving force for purging throughout dia., mm vides the diffusion coefficient used in the vessel, and the volume of the ves- Volatile component- 316 the design of continuous dryers [14]. sel must be large enough to afford the vapor pressure, kPa Figure 11 shows the effect of gas necessary residence time. Obtaining injection rate on the performance of a fundamental, bulk-solid flow proper- Flory-Huggins interaction 1.5 coefficient gravity dryer. (See Table 1 for design ties — including cohesive strength, parameters.) In this case, if 25 metric wall friction, compressibility, and per- Initial solids volatiles 0.001 content, mass fraction tons per hour (m.t./h) solids are fed meability, along with phase equilib- into a gravity dryer having a 3-m-dia., rium and kinetic data — is necessary 20-m-tall cylinder, a 10 kg/min gas in- to ensure that the gravity dryer will and near the cylinder walls. If cross- jection rate is necessary to achieve a operate as desired. ■ beams are used, most of the cylinder 99% reduction in volatile component Edited by Rebekkah Marshall section is available for solids purging. level. If a greater degree of devolatil- Finding an appropriate value for ization is desired, a dryer with a larger Author Greg J. Mehos is a project the effective diffusivity may be chal- diameter may be required to keep gas engineer at Jenike & Jo- lenging. Using published values of velocities low enough to prevent fluid- hanson, Inc. (400 Business Park Drive, Tyngsboro, MA diffusion coefficients and adjusting ization and to provide additional resi- 01879; Phone: (978-649-3300; them by accounting for porosity and dence time. The height of the cylinder Email: gmehos@jenike.com), an engineering consulting tortuosity will not necessarily give may also need to be increased to pro- firm specializing in the stor- results that predict reality. Although vide the required residence time. age, flow, and processing of powder and bulk solids. He the analytical solution to the diffusion has been involved in a wide range of bulk solids handling equation in most cases cannot be used Summary projects including flow property testing, hopper to calculate the required residence Silos or bins used to handle bulk sol- and feeder design, and the design and analy- sis of purge and conditioning columns. Mehos time in a continuous purge vessel, it ids can also be used for devolatiliza- is a member of AIChE and currently serves on can be used to determine the effective tion provided that they are properly the executive committee of AIChE’s Particle Technology Forum. He received B.S. and Ph.D. diffusivity from batch stripping data. designed. The vessel must allow uni- degrees in chemical engineering from the Uni- Gas is passed through a fluidized bed form flow of the solids and gas, and versity of Colorado and a masters degree from the University of Delaware. He is a registered or a thin, fixed layer of bulk material, the vessel dimensions must ensure professional engineer. References 1. Buchelli, A., Golden J.R., and Beran, D.L., pers, Powder Technol., 15, 279 (1976). 10. Bartan, A.F.M., CRC Handbook of Polymer- Determination of Polyolefins Powder Flow 6. Royal, T.A. and Carson, J.W. Fine Powder Liquid Interaction Parameters and Solu- Characteristics during Product Transitions, Flow Phenomena in Bins, Hoppers, and bility Parameters, CRC Press, Boca Raton, Ind. Eng. Chem. Res., 46, 24, 8120 (2007). Processing Vessels, presented at Bulk 2000: Florida, 1990. 2. ASTM D-6128, “Standard Test Method Bulk Material Handling Towards the Year 11. Bird, R.B., Stewart, W.E. and Lightfoot, E.N., for Shear Testing of Bulk Solids Using the 2000, London, 1991. “Transport Phenomena,” John Wiley & Sons, Jenike Shear Cell”, ASTM International 7. Johanson, R., Two-phase-flow Effects in Sol- New York, 1960. (2006). ids Processing and Handling, Chem. Eng., 72, 12. Mehos, G.J. and Pittenger, B.P. Using Bins 3. Jenike, A.W., Storage and Flow of Solids, Bul- 1, 77 (1979). and Silos to Heat or Cool Bulk Solids, Chem. letin 123, University of Utah Engineering 8. Pittenger, B.H., others, “Uniform Purging Eng., 114, 8, 57, August 2007. Station, 1964 (revised, 1976). of Resins in Contact Purge Vessels”, Polym. 13. Munjal, S. and Kao, C., Mathematical Model 4. Arnold, P.C. and McLean, A.G., An Analytical Eng. Sci., 39, 9, 1802 (September 1999). and Experimental Investigation of Polycar- Solution for the Stress Function at the Wall 9. Dick, D.S., and Hossfeld, R.J., Versatile bonate Pellet Drying, Polym. Eng. Sci., 30, 21, of a Converging Channel, Powder Technol., BINSERT System Solves Wide Range of 1352 (1990). 13, 255 (1976). Flow Problems, Proceedings of the 12th An- 14. Colaykyan, M. and Eisinger, R.S., Removal of 5. Arnold, P.C. and McLean, A.G., Improved nual Powder & Bulk Solids Conference, 302 Residual Monomers from Polymers in Fluidized Analytical Flow Factors for Mass-Flow Hop- (1987). Beds, Ind. Eng. Chem. Res., 42, 2654 (2003). ChemiCal engineering www.Che.Com may 2009 39
- 58. Feature Report Fire & Gas in Safety Systems Switchgear MCC Fire detection Notification LOGIC SOLVER Fire and gas point Fire or Gas detection Integrating fire-and-gas Safety detectors and mitigation systems into overall process safety control can help ensure Figure 1. A typical F&G safety system comprises detection, logic control, and alarm and mitigation functions. The logic solver is the fast responses to emergencies central control unit of the overall F&G detection and control system. The controller receives alarm and status or analog signals from field monitoring devices required for fire and gas detection. The controller Scott Hillman handles the required actions to initiate alarms and mitigate the hazard Honeywell B y continuously monitoring for of fuel. Water and land quality were of this issue is the state of the global abnormal situations, such as a adversely affected across southern economy; manufacturers simply can- fire, and combustible or toxic England, resulting in a clean-up ef- not afford the monetary losses com- gas releases, fire and gas (F&G) fort that cost hundreds of millions of monly associated with plant safety detection and mitigation systems are pounds. Such incidents illustrate the incidents. the linchpins to maintaining overall potential threats to the world’s oil- Amid this backdrop, integrated safety and operation of industrial fa- and-gas supply chain and other vital process control and safety systems cilities. The premise of these systems process industry resources. They also have emerged over the last few years is to protect processes and the envi- serve as a critical reminder that, due as effective solutions for providing ronment by providing early warning to the very nature of the business and safer working conditions in plants. In of incidents and enabling actions that the products associated with it, the providing operators better visibility prevent them from escalating. Also, CPI is inherently fraught with risks. across process and safety, CPI compa- implementing an integrated F&G These risks range from raw mate- nies are realizing that integrated sys- strategy based on the latest automa- rial and intermediate toxicity and tems can reduce costs by minimizing tion technology, the chemical process reactivity, to energy release from equipment damage and incidents that industries (CPI) not only meet pro- chemical reactions, high tempera- impact people and the environment. tection requirements, but also have tures and high pressures. With all At the same time, the reflection on potential to enhance business success. too frequent news reports of cata- corporate image is positive. strophic incidents occurring at man- F&G safety awareness ufacturing facilities across the globe, Elements and integration In December 2005, an explosion at the safety has never been a more scru- International standards organize Buncefield fuel terminal in Hertford- tinized issue than it is today. Com- safety implementation under a series shire, U.K. ignited millions of gallons pounding the already high visibility of six protection layers: 40 ChemiCal engineering www.Che.Com may 2009
- 59. Plant evaluation system/ Plant security center, (normally not in F&G scope) F&G operator DCS/SIS operator station station F&G mimic Plant wide panel historian Fault-tolerant Ethernet ethernet Serial interface Digital Battery video server backup DCS Addressable F&G logic solver ESD safety fire alarm panel safety manager manager Digital video cameras Addressable fire detectors, F&G modules, manual call points F&G detectors, manual call points Sounders, beacons mimic panel Non-process manned buildings Process unit areas Figure 2. A good F&G system combines state-of-the-art fire and gas detectors, conventional and analog addressable fire panels, clean-agent and inert-gas fire suppression systems, and an SIL 3 certified fire-and-gas logic solver into a consistently designed and executed solution. An integrated system provides common tools, operating interface and networking, resulting in a common platform with independent systems • Inherently safe plant design The logic solver acts as the central warnings of explosive and health haz- • rocess control systems that are P control unit (Figure 1), which receives ards, including combustible and toxic safe and secure alarm and status or analog signals gas releases, thermal radiation from • utomatic safety, security and A from field monitoring devices such as fires and minute traces of smoke mitigation systems detectors or manual pull stations, ini- in sensitive equipment enclosures. • Work procedures tiates alarms and mitigates the haz- They also provide audible and visual • Alarm systems ard. Correct and proven connection alarm indications to ensure that op- • Mechanical protection systems of detectors to plant safety systems erators and personnel are informed Acting as the prevention safety layer, is an important factor in reliable per- of hazardous situations. With these the safety shutdown system takes formance of the F&G system and for improved detection capabilities, F&G automatic and independent action to establishing the desired SIL. systems automatically initiate execu- prevent a hazardous incident from oc- In the past, a proprietary F&G sys- tive actions, such as deluge systems curring and to protect personnel and tem was standalone or a hardwired and evacuation procedures. This plant equipment against serious harm. mimic overview panel that was linked minimizes the escalation of safety in- Still, in reality, incidents unfortunately to a control system. With these older cidents and protects personnel, prop- escalate far beyond this layer. systems, fire-control measures had to erty and the environment. This problem is the main reason be manually activated, which was far Further value can be realized an that F&G systems should remain at from an ideal practice. Today, however, F&G solution is plugged into an inte- the core of any integrated solution. F&G detection systems are gener- grated system that provides common Used for automating emergency ac- ally programmable electronic systems tools, operating interface and network- tions with high-integrity safety and (PES) with high safety availability and ing, resulting in independent systems control solutions, F&G systems act as mitigation effectiveness. As modern that are tied together on a common the mitigation safety layer that takes F&G systems are tightly integrated platform. A recommended approach action to lessen the consequences of with the overall process safety strategy, is integration at the controller level, hazardous events. They are also criti- mitigation is either enacted through which provides: plant-wide safety in- cal to resuming full production when an emergency shutdown (ESD) system strumented system (SIS) point data; recovering from these incidents. or directly by the F&G system itself. diagnostics and system information; A good F&G system combines state- Using these new techniques and add- alarms and events, operator displays; of-the-art detectors, conventional and ing intelligence to instruments to re- and sequence of event information to analog addressable fire panels, clean- duce the number of spurious alarms any station. This minimizes manual agent and inert-gas fire suppression has greatly improved detection rates. intervention and drastic plant shut- systems, and a safety integrity level Thanks to these advances in F&G downs, reduces hardware costs, and (SIL) certified logic solver (Figure 2). detectors, the systems can detect early allows plants to recover more quickly ChemiCal engineering www.Che.Com may 2009 41
- 60. Feature Report Secure process control Asset management and protection and easily from process upsets and ab- Abnormal situation management normal situations. Effective operating environment Modern safety systems, when seam- Boundary management lessly integrated with the plant au- tomation system through a secure Emergency shutdown system communication network, will transfer Physical protection alarm signals, fault and trip signals and system diagnostics. Information Emergency response from all related systems can be man- aged from the same location, enabling that additional layer to monitor the Figure 3. Industrial operations benefit from a holistic approach to safety that status and operability of the total supports a secure process control network to the perimeter of the plant to protect F&G detection and control system. people, assets and profitability. A layered safety strategy encompasses process and Overall SIS technology integrates system technology — and the people who interact with that technology — to help safety measures dispersed throughout plants achieve their safety objectives a plant to reduce risk to employees and assets, increase process availabil- lated layers of protection (Figure 3) many cases, reduce overall wall-to- ity, and improve regulatory compli- plays an important role in improving wall project costs by 25%. Seamless ance. SIS solutions can be integrated safety and efficiency. integration with the ESD and DCS with F&G detectors for increased pro- The F&G system should have com- through a common network proto- tection, and unified with third-party munications integration with the col provides a safe landing in case of systems to reduce validation and ac- plant distributed control system emergencies and eliminates the need ceptance testing costs. (DCS) in order to have F&G graphics for additional equipment or engineer- Combined with the new generation and alarms displayed to the operator. ing. Integration of fire detection and of F&G solutions, an integrated sys- However, there also should be inde- security systems for offsites and utili- tem provides alerts of abnormal situ- pendent displays, such as independent ties with the plant automation infra- ations in a fast, accurate and struc- human-machine interfaces (HMIs), structure further improves operator tured way, giving personnel time to for plant operators to respond to F&G efficiency, through single-window ac- decide upon the correct course of ac- excursions when the DCS HMIs are cess for alarm visualization, diagnos- tion. These solutions, which include not available. The plant F&G system, tics, and events and historians. new integration capabilities with with a fire system for occupied build- These truly integrated safety sys- process-simulation tools, F&G detec- ings, should also be integrated with tems deliver several benefits, includ- tors and control communication pro- the plant evacuation and site security ing the following. tocols, enable safety engineers to de- center for efficient plant-evacuation • Integrated operational interface sign large integrated and distributed procedures. This enables plant man- • Integrated peer control plant-wide safety strategies. With in- agers to keep better tabs on personnel • Integrated diagnostics novative simulation solutions, safety and efficiently coordinate with first • Integrated postmortem analysis engineers can easily test the impact responders during emergencies. • Integrated F&G system of safety strategies on the overall As part of an overall plant-safety • Integrated power supplies plant design and operations before strategy, end users need a unified • Integrated modifications implementation. This reduces overall platform for emergency shutdown and • Integrated simulation and risk and the impact of system modifi- F&G detection. A single window for optimization cations and ultimately increases prof- operators and a common tool for engi- Operational integration provides itability by bringing new plants into neering and maintenance drives down a seamless interface to the process full production much faster. operational risk and costs. under control, and at the same time, In addition, new field-device con- Integrated control and safety sys- maintains safe separation. From an figuration tools allow plant personnel tems (ICSS) provide multiple benefits operational perspective, it makes no to automatically configure intelligent to process plants. They help opera- difference where the application is safety devices and integrate them tors minimize intervention and shut- running. All required information is into the control system database. downs, and recover more easily from available to the operator. This allows Facilities subsequently save money process upsets. They also allow facili- applications ranging from rotating by using a single tool to manage all ties to reduce hardware and installa- equipment and compressor-protective equipment assets. tion costs, and ensure easier system systems, to emergency shutdown sys- configuration with preconfigured tems and large plant-wide F&G ap- Toward integrated systems function block selections. plications to be monitored from any As more plant owners move toward Plants implementing an ICSS plat- operator console. highly integrated plant-production form for F&G, ESD and DCS systems Additionally, industrial operations systems, appropriate integration with can significantly lower their opera- benefit from a holistic approach to multiple interdependent yet interre- tion and maintenance costs, and in safety that supports everything from a 42 ChemiCal engineering www.Che.Com may 2009
- 61. Review potential F&G incidents as Integrated safety In oIl and gas L part of risk assessment ike other process industry operations, oil and gas terminals present difficult challenges for automation and safety technology. Tank farms, storage areas, and loading and un- Define loading operations all require F&G and safety systems to protect personnel, assets and role required of F&G the environment. The consequences of incidents at oil and gas terminals, as illustrated at the system in risk reduction Buncefield fuel terminal, can be enormous (Figure 5). In oil and gas terminal applications, operators not only need overfill protection but also an Select integrated fire and life safety system allowing proactive response to alarms and events and a single realtime view to any potential threat. Industrial plants have procedures and safety appropriate system type systems designed to bring operations to a safe state in the event of equipment malfunctions and other operational problems. In the case of a significant security incident, an integrated system can activate these same procedures and systems. An integrated system also leads to Set less expensive implementation and maintenance, since all components work together. performance standard An integrated fire-and-life safety solution for terminals typically includes high-high tank alarms and loading system interlocks (compliant with IEC 61511) that prevent overflow through shutdown of pumps. Likewise, it incorporates the latest-technology gas and vapor Develop detectors, integrated with the overfill shutdown system, to detect incidents before they esca- specification test, mainten- late. The system will mitigate safety incidents by ensuring that all personnel are informed of ance, inspection procedure hazardous situations in a clear and unambiguous manner, and providing fast and efficient response to associated risks. An effective terminal automation safety and security solution will not only include overfill Implement protection, but will also integrate security access control, personnel mustering systems and performance standard video monitoring to reduce the possibility of unauthorized access or intrusion. Integration of technologies such as security biometrics and wireless mesh networks enhance the operation and the lower cost of implementation of these systems. ❏ Figure 4. An effective project strategy starts with an assessment of future or existing fire and gas per- formance according to functional safety tools and procedures for managing safety lifecycle as outlined in safety standards. Based on this assessment, abnormal situations and reducing standards such as IEC 61511. An in- end users have a detailed roadmap for incidents. When an abnormal situa- tegrated main automation contractor installing new equipment or updating obsolete infrastructure to an optimal tion occurs, alarm management, early (I-MAC) can help identify F&G haz- level of safety. The main automation con- event detection, and abnormal situa- ard points and possible risks, and then tractor can help to identify F&G hazard tion management (ASM)-designed develop basic design packages and re- points and possible risks, and develop displays ensure operators have the lated acceptance test criteria to meet basic design packages and related ac- information available in the context safety requirements. This results in ceptance test criteria to meet safety requirements they need it. This enables faster reac- optimized risk reduction and opera- tion to hazardous situations. tional performance, better compliance secure process control network (PCN) Next, properly designed emergency- with safety standards, and increased to the perimeter of the plant. This lay- shutdown systems and automated lifecycle sustainability. ered safety strategy encompasses pro- procedures can move a plant to a safe Supplier assistance can extend cess and system technology — and the state in the event that an incident es- to implementing SIS solutions; live people who interact with that tech- calates beyond the inner sphere of pro- hot cutover, implementation and ex- nology — to help plants achieve their tection. Should an incident occur, F&G ecution of revamps; and installation, safety objectives. detection solutions, coupled with rapid commissioning and safety validation. A layered safety strategy unifies location of individuals and a carefully To sustain the end user’s F&G sys- all plant protection layers (including designed emergency response proce- tem performance, leading automa- basic control, prevention and mitiga- dure, will help contain the impact. tion contractors also provide lifecycle tion, as outlined in IEC 61511 stan- Finally, a layered approach to safety support services that include periodic dard) required for achieving optimum protects the perimeter of the plant proof testing; system maintenance; functional safety. It also provides the using physical security that safe- training programs on safety, code and required functional safety with a high guards access to structures and moni- standard compliance; and spare parts SIL. This includes superior visualiza- tors traffic approaching the facility. management. tion and logging facilities enabling op- When designing a truly integrated timal operator response and accurate system, an effective project strategy Challenges and the road ahead evaluations. By integrating basic con- starts with an assessment of future Industrial standards such as IEC trol, prevention and mitigation com- or existing F&G performance accord- 61511 (ANSI/ISA S84.01 in the U.S.) ponents, a CPI company can vastly ing to functional safety standards play a large role in developing, imple- reduce its overall project costs and (Figure 4). Based on this assessment, menting and installing F&G systems. ongoing maintenance expenses. end users have a detailed roadmap for The overall safety lifecycle model de- At the core of a layered safety strat- installing new equipment or updating scribed in the IEC standard lists all of egy is process design — the embodi- obsolete infrastructure to an optimal the necessary project activities, from ment of the business, safety and pro- level of safety. This process begins the concept (definition) phase to the duction considerations necessary for with a hazard and risk assessment decommissioning phase, necessary to effective operations. At the next layer, (such as HAZOP) and then contin- ensure the functional safety of equip- the layered approach implements ues through the various steps of the ment under control (EUC). These ac- ChemiCal engineering www.Che.Com may 2009 43
- 62. Feature Report tivities can be divided over a wide range of categories, such as proce- dures, documentation, testing and validation, planning, hardware and software development, and risk assessment. The IEC 61511 standard con- cerns the determination and devel- opment of risk-reduction measures (RRMs) required as the outcome of an EUC risk assessment. The basic principle of risk assessment is that all potential risks to the EUC are identified and analyzed. This in- cludes calculating the probability of each potential EUC hazard and determining the risk reduction Figure 5. Like other process industry op- erations, oil & gas terminals present difficult measures required to achieve an challenges for automation and safety tech- acceptable SIL. This is defined by nology. Tank farms, storage areas, and load- the following expression. ing/unloading operations all require fire and Risk = Probability x Consequences gas and safety systems to protect personnel, The prescribed reduction mea- assets and the environment. The conse- quences of incidents at oil and gas terminals sures either decrease the risk can be enormous probability (for example, ESD sys- tems), or mitigate their consequences engineers to design and build stand- (for example, F&G systems). The risk alone safety applications and distrib- of EUC hazards can be reduced by a uted plant-wide safety topologies. combination of several RRMs, where Plants must find ways to improve each measure handles one part of the F&G system effectiveness through total required risk reduction factor optimization of F&G detector cover- (RRF). age, system safety availability and Recently, there have been discus- mitigation effectiveness. At the same sions regarding whether F&G detec- time, they must reduce the cost of tion systems should contribute to risk ownership for safety equipment. reduction, or be considered only as a Many facilities are also dealing with protection for the installation. The the cost of upgrading and refurbish- ISA technical report TR84.00.07, pro- ing existing, non-integrated F&G viding guidance on the evaluation of systems. Compounding this issue is fire-and-gas system effectiveness, is the fact that plants must meet their currently in draft review. safety needs while ensuring opera- Additionally, a growing number of tional and business readiness at proj- regulations have drawn more atten- ect startup. Faced with this reality, tion to process safety and the role they seek the lowest risk and high- played by F&G systems. Manufactur- est value protection from their safety ing plants must cope with business system and F&G technology. ■ challenges ranging from increased ac- Edited by Kate Torzewski cident, incident and insurance costs, to compliance with strict standards and codes, such as NFPA, API and OSHA Author in the U.S., and BS EN and SEVESO Scott Hillman is the global solutions director for Honey- II in Europe. Also, issues related to well’s New Construction Solu- corporate image and environmental tions (2500 West Union Hills Drive, Phoenix, AZ 85027 stewardship have growing implica- Phone: 602-313-4138; Fax: tions in the global market. 602-313-4040; Email: scott. hillman@honeywell.com). In To help address these issues, indus- his 20 years with Honeywell, trial plants need effective solutions Hillman has held project en- gineering, training, consult- for improving a wide range of process- ing and a variety of product manager positions. He also is a Certified Safety safeguarding practices. This requires a Functional Safety Expert (CFSE) and a member control-system architecture that allows of the CFSE Governance Board. Circle 32 on p. 70 or go to adlinks.che.com/23014-32 44 ChemiCal engineering www.Che.Com may 2009
- 63. Engineering Practice Feature Report Optimal Cooling Systems For Coastal Plants When all economic and environmental Process factors are considered, Sea Hot seawater Cold a cooling tower may be the best option outlet Hot DM water DM water Seawater inlet Mahdi Gougol and Jamshid Pouresfandiary Cham Research Institute of Petroleum Industry Plate and frame Hassan Dezvareh Resnani heat exchanger Kaviyan Petrochemical Co. Figure 1. In the once-through cooling system, B ecause temperature control is is not sufficient for cooling, so seawater makes a single pass through the system important in any process, a wa- a continuous flow of water is before returning to the sea ter-cooling system is a common used as a cooling medium. Wa- Evaporation component in chemical process- ter-cooling systems can be clas- ing plants. For facilities located near sified as two main types: once coastal areas, the tendency is toward through, and recirculating [1]. Process the use of seawater instead of river Once-through cooling sys- Makeup Cooling Hot tower water for cooling purposes. Seawater tems. This type of cooling sys- seawater Sea outlet has the advantage of having nearly a tem is usually available near constant quality (chemical analysis), large, natural sources of cold Hot Cold Inhibitor DM DM nearly a constant temperature and is water. In once-through cooling, Blow water water available in large amounts. This option there is no equipment or facil- down is not without its challenges, though. ity for recirculating, cooling Presented here is an economic- and reusing the cooling water. NaOCl Plate and frame heat exchanger environmental approach for selecting The water is entirely supplied the best cooling system for operation from the sea, and after flow- at the sea shore. An actual facility, lo- ing through the heat exchang- Figure 2. In the recirculating cooling-water system, a cooling tower is used to recycle the cated in the Persian Gulf, is used as ers it leaves the system and seawater. Such systems have significantly smaller an example. is discharged back to the sea investment costs than once-through systems, and (Figure 1). a smaller environmental impact Cooling system options When seawater is used, the Air and water are the least expensive, most important problems in the pro- in which the construction material is most available and accessible fluids cess heat exchangers are corrosion, resistant to corrosive seawater. for removing heat from equipment and scaling, deposition, and microbiologi- For this reason, plate-and-frame processes. When cooling is achieved cal growth. Because the equipment is type heat exchangers are typically directly with ambient air (air-cooled in direct contact with seawater, these used. This type has some advantages systems), the minimum temperature problems are more severe than in sys- over shell-and-tube heat exchangers, difference between the ambient air tems that use other sources of water such as high turbulent streams, high and the warm outlet media — the (rivers, lakes or groundwater). velocity, low approach temperature, so-called approach temperature — is To prevent the above-mentioned low scale deposition, and so on. about 10–15°C. problems and reduce the damages, an Microbiological growth in heat ex- Air cooling is typically used in indirect method of heat transfer is ap- changers and associated equipment in processes such as condensation of plied. That means desalinated or de- contact with seawater is controlled by low-pressure steam, where the tem- mineralized (DM) water is used to cool injection of sodium hypochlorite solu- perature of condensation does not nec- hot process fluids. Then, the warm DM tion or other chlorine solutions. essarily need to be low. But in many, water is collected and sent to a num- Recirculating cooling systems. In if not most, processes, the air supply ber of seawater/DM heat exchangers this type, water after the heat adsorp- ChemiCal engineering www.Che.Com may 2009 45
- 64. Engineering Practice tion is sent directly to a cooling tower where it is cooled through simultane- ous heat and mass transfer to the air (Figure 2). The hot water is sprayed at the top, then trickles through the cooling fills while the air is drawn or forced through the cooling fill from the bot- tom. The unsaturated air absorbs hu- midity and will saturate to the equi- librium state (namely, the wet bulb temperature). The energy required for water evaporation is supplied by the remaining bulk of warm water. When seawater is the cooling source, the cooling system is called Figure 3. Seawater cooling towers can use natural draught (left), induced draught a seawater-cooling tower. Apart from (middle) and forced draught (right) sources of makeup water, there are significant differences between sea- As mentioned before, the major cool- 40, 45 and 50°C. The verticle lines water cooling towers and other types ing effect of a cooling tower is due to at these four temperatures have the of cooling towers. water evaporation. When designing a same length (same absolute humidity), As with once-through systems, in- cooling-tower system, the question to but cross different constant enthalpy direct heat transfer is preferred in ask is, will the tower operate properly lines. To determine the corresponding recirculating systems to prevent the in the local ambient conditions? The wet bulb temperature, the constant corrosion, scaling, deposition, and mi- most important parameter in the de- enthalpy line for each temperature is crobiological growth problems. sign and selection of a cooling tower followed to where it crosses the 100% is ambient wet-bulb temperature. In relative humidity curve, and a verticle Cooling tower types theory, this is the lowest water tem- line extended downwards. So, for dry Cooling towers are categorized accord- perature that can be reached in a bulb temperatures for 35°C and 50°C, ing to the flow directions of air and cooling tower. However, due to very the corresponding wet bulb tempera- water — that is, either counter cur- high investment costs, achieving such tures derived from Figure 4 are 27.4°C rent or cross flow types. Airflow in the temperatures is usually not practical. and 30.6°C, respectively. This shows tower is supplied through two main Instead, the minimum water tem- that for a 15°C difference in dry bulb mechanisms: mechanical draft and perature that is normally reached temperature, a nearly 3°C difference natural draft. Mechanical draft can be in a cooling tower is 3 to 5°C higher in wet bulb temperature is observed. either forced or induced. than the ambient wet-bulb tempera- However, the assumption of con- In the forced-draft type, motor ture [1, 2]. As a consequence, an en- stant absolute humidity in Scenario 1 driven fans located at bottom periph- gineer should decide on the operation is not realistic, because an increase in ery of the tower cause the air to flow of a cooling tower, after analyzing dry-bulb temperature will cause some through the tower. This type of cool- the wet-bulb temperature variation. seawater to evaporate. In this case, the ing tower is used for capacities ex- Up to dew-point temperature, the water content of air does not remain ceeding 30,000 m3/h. For capacities water content of air is not changed constant. Therefore, the relative hu- below 30,000 m3/h, the induced-draft although the relative humidity varies. midity as well as wet bulb tempera- type is used [1, 2]. In this case, the During daytime, the dry-bulb tem- ture increases so slightly that it does fans are installed at the top of the perature is going to increase. In this not have an effect on the operation of tower (Figure 3). condition, if water content of air re- the cooling tower. This can be observed mains constant, the relative humidity in Scenario 2 of Figure 4. Seawater cooling towers reduces [Equation (1)]. At the same During nighttime, both the dry-bulb Throughout most of the year, coastal time, the wet-bulb temperature is and the wet-bulb temperature are areas have high relative humidity going to increase, although its rate of going to decrease though relative hu- (RH), which is defined by Equation (1). variation is less than that of the dry- midity increases. In this condition the bulb temperature. This difference can cooling tower operates through the fol- be observed by examining Scenario 1 lowing mechanism. (1) on the psychrometric chart shown in When the hot water comes in con- where Figure 4. tact with cold/saturated air, the air is ˆ Pwater = Partial pressure of water at Consider a situation where air with getting a little warm due to the trans- air in ambient temperature a constant absolute humidity of 0.02 fer of sensible heat from hot water to sat Pwater = Saturation pressure of water kg water per kilogram of dry air, and the air. Thereafter, the air is not satu- at air in ambient temperature the four dry bulb temperatures of 35, rated and it can take up some water 46 ChemiCal engineering www.Che.Com may 2009
- 65. If the temperature difference between Percent: 100 80 60 40 hot-water inlet (43°C) and cold-water Humidity ratio, kg H2O per kg dry air 0.028 outlet (35°C) of the cooling tower is 8ºC, and if it is assumed that all of the h = 90 kJ/kg 30 heat load is removed by evaporation, 0.024 2 the process heat balance is: Relative humidity, % 0.020 h = 70 kJ/kg 1 (5) 0.016 20 where h = 50 kJ/kg 0.012 QR.R = Recirculating rate of cooling water 0.008 10 lEV = Latent heat of evaporation DT = Range (difference between 0.004 hot inlet water and cold outlet water from the cooling tower) 0.000 0 5 10 15 20 25 30 35 40 45 50 CP = Specific heat capacity of sea- Dry bulb temperature, °C water Figure 4. A psychrometric chart is a graph of the physical properties of moist air Substitution of lEV and CP for an av- at constant pressure erage recirculating seawater tempera- ture of 39°C and DT = 8°C results in: vapor. As the cold air rises upward temperature of the seawater and the through the tower, its temperature high turbulent flow in the plate-and- (6) increases more and more because of frame heat exchangers) [2]. From Equations (4–6) it is seen that its long contact time with warmer According to material balance of the blow-down and makeup water are water moving downward. cooling tower, 3.2% and 4.6% of QR.R, respectively. In contrast, hot water that moves Comparing these two flowrates downward becomes colder and colder (2) with a once-through cooling system in due to simultaneous heat and mass And for salts, which QMU = QBD = QR.R reveals that transfer to the air. As a result, the a once-through system, with the same cooling tower maintains its water- heat load as a forced-draft type cool- cooling ability, not only during the ing tower, has a flowrate of hot water day but also at night. (3) discharged to the sea that is 31 times higher than that of the recirculating Environmental impact Where system, and the makeup water is 21 In a cooling system, hot water dis- CC = concentration cycle. times higher. charged to the sea has the most im- CBD = TDS of recirculating seawater This means that, for the example portant environmental impact. The in the cooling tower that is the above, the flowrate of discharged hot temperature of discharged seawater same as blow down water to the sea is 100,000 m3/h for should be controlled, and limited to CMU = TDS of fresh seawater that is a once-through cooling system and an acceptable value that usually is used as makeup water 3,200 m3/h for a cooling tower. Besides specified by environmental protection QMU = flowrate of makeup the problems caused by local heating organizations and regulatory bodies. QBD = flowrate of blow down due to the larger volume of water dis- As an example, let us consider an In the Persian Gulf, the TDS of water charged, other problems associated olefins plant located in Assaluyeh near is 38,000 ppm. From Equation (3) we with the once through system are the the Persian Gulf. Two cooling systems find that the concentration cycle of larger amount of chemicals present in are compared: a forced-draft, round seawater cooling tower is 1.45 [3]. the discharged water, such as chlorine, cooling tower, and a once-through We want to know how much makeup dispersants, anti-corrosion additives system. The cooling water flowrate is water and blow-down water is needed and non-oxidizing biocides. 100,000 m3/h with an inlet (outlet) to maintain the concentration cycle at Accordingly, the environmental im- temperature of 35°C (43°C). The wet- 1.45. Therefore: pact of a once through cooling system bulb temperature of the Assaluyeh is so extensive that it can affect irre- region is 31°C and the maximum dry- versibly the seawater ecology and de- bulb temperature is 48°C. stroys the seawater eco-system. Assume that the maximum-admis- sible, total-dissolve solid (TDS) of the Economic comparison recirculating cooling water is 55,000 (4) For the economical assessment of the ppm to prevent scaling (with this TDS, same example, three main param- scaling cannot occur due to the low eters are considered, the benefits and ChemiCal engineering www.Che.Com may 2009 47
- 66. Engineering Practice the operating and investment costs. TABLE 1. A COMPARISON BETWEEN The investment costs include all three ECONOMIC PARAMETERS IN THE STUDIED CASE phases of engineering, procurement and construction. Seawater cooling tower Once through (million $) (million $) All equipment considered under procurement (water pumps and drives, 3.9 4 Engineering cost filters, chlorinator, piping, electrical 32.5 53.6 Procurement cost work, instrumentation, spare parts 13 33.8 Construction cost and steel structure), and the corre- sponding construction phase for the 49.4 91.4 Investment cost seawater cooling tower are also used 0.61 0.57 Commissioning cost in the once-through system. However, the equipment sizes, and amount of 14.72 14.02 Operating cost per year time and labor required for construc- tion are mostly different. same, the investment cost for a once- Reference If the required temperature of sup- through system is 45% more than that 1. Hensley, J.C., “Cooling Tower Fundamen- plied water in the once-through sys- of the seawater cooling-tower system, tals,” 2nd ed., Marley, 1985. tem is lower than the surface water or $42 million more. Therefore, all the 2. Kessel, F., “Seawater Cooling Towers” SPX near the coastline, especially in the economical factors are considered, Cooling Technologies Lecture, 2006. hot seasons, the user should install such as payback period and net pres- 3. Gougol, M., Feasibility study of cooling systems, RIPI Final Report, NO.31480542 a pipeline on the seabed and proceed ent value, the seawater cooling tower Aug., 2007. through the sea to achieve required is the better option. 4. Eftekharzadeh, S., Baasiri, M. M., and water temperature. Lindahl, P. “Feasibility of Seawater Cool- ing Towers for Large-scale Petrochemical As the seawater is transferred from Salt emissions Development,” proceedings of The Cooling the seabed by gravity, the onshore For seawater applications, today’s cool- Technology Institute Annual Conference, Tex., TP03-17 (2003). basin shall be constructed in a depth ing technologies are now able to guar- lower than the point of seabed water antee a maximum drift of 0.0005% of intake. It is these parts of the once- the total cooling water flowrate — a through system (that is, offshore pip- rate that is the measurement limit Authors ing and basin) that dominate the cost of existing test equipment. This salt Mahdi Gougol is a senior process engineer with the of a project. In cases where the intake becomes mixed with the fan air flow Research Institute of Pe- point to reach water with sufficiently released from the selected seawater troleum Industry (P. O. Box 14665-1998, Tehran, Iran. low temperature is far from the coast, cooling tower. Therefore, the maxi- Phone: +98-21-4473-9768; Fax:+98-21-4473-9779; Email: the investment cost of a system could mum concentration of salts (in the gougolm@ripi.ir), where he is drastically increase. drift) traveling with the plume is sev- responsible for water optimi- zation and cooling tower mod- Operating costs include operating eral times lower than the concentra- eling projects. His key projects materials, labor (to operate the sys- tion of salts in the air that originates include: water optimization in Kahngiran gas refining co., Razi Petrochemical tem), maintenance, and electricity. from seawater spray and aerosol [4]. Co., Tehran Oil Refining Co., Ilam Petrochemi- (For this example, one of the chemicals cal Co., and Bidboland Gas Refining Co. Gougol has a M.S.ChE from the Mazandaran University produced in the plant is NaOCl, so it Final remarks of Science and Technology, Babol, Iran. He is currently responsible for preparation of cooling is not included in the calculation for From both economical and environ- tower simulation and optimization software. the operating costs.) The maintenance mental points of view, a seawater cool- Hassan Dezvareh Resnani cost associated with a once-through ing tower has noteworthy advantages is utility project manager at Kaviyan Petrochemical Co. system is higher than that of seawa- compared to a once-through system. (4th floor, Engineering Depart- ter cooling tower, while the cost for in- The once-through option should only ment, No.54, Karimkhan St., 7'th Tir Square, Tehran, Iran; hibitors is lower for the once-through be considered in the case where the Phone: +98-21-8884-6125; Email: hdezvareh@bpc.co.ir). system. Because fans are used in the yearly average wet-bulb temperature He has over 15 years experi- forced-draft, round-type cooling tower, is so high that the required cooled ence in operation and design of utility units. Dezvareh has electricity demand is almost the same water temperature cannot be provided a B.S.ChE from Sharif Uni- as for a once-through system. When by a cooling tower. versity of Technology, and a M.S.ChE from Teh- ran Polytechnic University, Iran. all these different factors are consid- If the process designer does not Jamshid Pouresfandiary ered, the total operating cost is almost consider all aspects in the design of Cham is the CFD special- ist at the Research Institute equal for both systems. Also, the total a cooling system, he or she might of petroleum industry (same amount of supplied cooling water is select the once-through system sim- address as Gougol; Phone: +98-21-4473-9554; Email: the same for both systems. ply on the basis of high air humidity. pouresfandiarij@ripi.ir). His The results of the cost-comparison This can waste millions of dollars and current research interests in- clude CDM and energy man- calculation is presented in Table 1. One cause extensive damage to the ma- agement. Pouresfandiary has can see that, although commissioning rine environment. ■ a Ph.D. degree in mechanical engineering from the Shinshu and operating costs are almost the Edited by Gerald Ondrey University, Japan. 48 ChemiCal engineering www.Che.Com may 2009
- 67. Engineering Practice Feature Report EPC ContraCtors Selecting an ERP Package The goal of any Engineer-Procure-Construct Figure 1. Successful completion of complex (EPC) arrangement is to manage risk, prevent projects at petrochemical complexes, oil refiner- ies and other CPI facilities requires close col- cost overruns, and deliver the project on time. laboration between engineering, fabrication and construction disciplines. Under an EPC contract, such collaboration must be optimized to avoid The right enterprise resource planning waste and errors that can result when the design attributes change after fabrication has already (ERP) system can help begun. Properly structured ERP systems can help streamline and automate the data- and project- management needs of these complex projects Magne Halvorsen, IFS AB I n recent years, a growing number arises whenever design changes are time-consuming litigation, whereby of projects throughout the chemical needed, especially after the project the various contract participants — process industries (CPI) have been has already commenced, and these engineering firms, fabricators and sub- carried out using Engineer-Pro- changes must be managed not only contractors — may find themselves in cure-Construct (EPC) contracts. Be- across the EPC’s internal processes, civil court, trying to sort out the rami- cause such contracts typically involve but across the entire network of sub- fications of cost overruns and claims of the work of numerous subcontractor contractors and suppliers, as well. inadequate project execution. parties, they tend to be complex. As Imagine the cascading series of This article provides guidance for such, specialized tools are required to events that result when flow line pres- the evaluation and selection of ERP manage their information- and proj- sure requirements are changed on a systems, for both EPC contractors and ect-management needs. project. First, the project engineers the project owners throughout the CPI In general, operating companies must change the design accordingly. who engage them. It also reviews how throughout the CPI enjoy working Such changes will affect not only the different the EPC model is from the with EPC contractors because they purchasing of pipes, valves, pumps traditional Design-Bid-Build model, can expect a greater degree of predict- and other items associated with the and discusses how existing business ability on the costs associated with line, but the work of many subcontrac- technology must change to accommo- the finished project; this predictabil- tors, as well. For instance, EPC con- date EPC work, from the perspective ity comes from the fact that EPC con- tractors need to ensure that the con- of both the EPC contractor and proj- tracts typically put much of the risk of tractual responsibilities for how these ect owner. The article reviews how discipline integration on the contrac- changes are to be handled are honored. both integrated, point source software tor’s side. Such centralization gives an In this way, EPC contractors are one products and traditional ERP software owner a single point of responsibility part engineer, one part fabricator, one often fail to deliver all of the capabili- — as the saying goes, “one throat to part contractor, one part construction ties that an EPC contractor needs to choke” — which can help to avoid the manager and one part insurance bro- turnkey a complex project, and pro- finger-pointing and buck-passing that ker. The risk that the EPC contractor vides recommendations for EPC con- often results when engineering, fabri- must assume to ensure firm contract tractors to consider when evaluating cation and construction activities are terms must be monetized during con- ERP packages. handled by separate entities. tract negotiation. While such a setup often sounds Lacking an adequate enterprise re- Centralizing risk management ideal, in real life, EPC contractors rou- source planning (ERP) system to han- Perhaps the single most important tinely face significant challenges when dle the information- and project-man- word that can be used to describe the it comes to ensuring that the project agement, EPC contractors will have world of the EPC contractor is “risk.” will be completed at the agreed-upon a hard time delivering the project as With each contract, the EPC contrac- price — despite any contingencies that promised. When this occurs, project tor must manage numerous variables, may or may not arise. Uncertainty owners may be forced into costly and confronting a variety of unknowns, all ChemiCal engineering www.Che.Com may 2009 49
- 68. Engineering Practice EPC Contractors Business ENGINEERING PROCUREMENT CONSTRUCTION INSTALLATION COMMISSIONING Process CORPORATE PERFORMANCE MANAGEMENT CONTRACT MANAGEMENT Estimating Scope Sales Contract Variation Orders Retentions Payment Applications PROJECT MANAGEMENT WBS Project Budget & Forecast Risk Management Change Management Reporting Control ENGINEERING PROCUREMENT/ CONSTRUCTION INSTALLATION/ MATERIAL COMMISSIONING MANAGEMENT Multi Discipline Material Catalogues Job Setting MC/Commissioning Engineering Register BOM/Availability Packages MTO, RFQ, Business Class Management Purchasing Welding/QA Documentation Solutions Expediting Schemas & Reports Component Specification Project Inventory CAD Integration SUB-CONTRACTING Sub-contracts Agreements Inquiries Work Instructions Retentions Payment & Certificates FINANCE MANAGEMENT Common Business Model General Accounting Automatic Workflow Project Accounting Revenue Recognition Human Resources, T & A, and Payroll Connect/Data Migration Business Document Management Business Models Enablers Collaboration with Suppliers and Customers Quality Management KEY: MC = Mechanical Contracting WBS = Work Breakdown Structure CAD = Computer Aided Design MTO = Make To Order RFQ = Request for Quotations QA = Quality Assurance Figure 2. The key elements of an ERP solution for EPC contractors are shown here the while remaining fiscally respon- ful outcome, project managers must ERP packages are too limited or seg- sible for delivering a fixed outcome to ensure successful communication in mented in their functionality to give the customer, in accordance with the real time with both different internal the EPC contractors the true project predetermined contract price. Manag- departments, and with subcontractors lifecycle management capabilities ing risk must remain a top priority as and clients, as well. they need. A truly functional enter- the project is being bid, planned and This very demanding business en- prise software tool for EPC contractors executed, and comes to what is hope- vironment is a key reason why ERP must not only provide functionality for fully a successful conclusion. software should be appealing to EPC engineering, procurement, construc- Unfortunately, on any EPC con- contractors. When project and corpo- tion, installation and commissioning, tract, risk is not a static factor that rate managers are able to bring the but must also allow all information can simply be determined during the entire project lifecycle into a single to flow easily back and forth between design process. Rather, the risk profile enterprise-wide information- and these different disciplines, so that risk of any project changes as information project-management application, they can be managed dynamically as the about design changes filters through are able to gain visibility into the sup- project progresses. the purchasing and fabrication de- ply chain, streamline communication ERP systems are also useful in this partments and beyond the company’s among all parties, and keep closer era of mergers and acquisitions, con- four walls to become disseminated to tabs on the live costs of all aspects of solidation, and increasing globaliza- the EPC contractors and their various the project, as it unfolds. tion in the CPI. As various fabrication subcontractors. To achieve a success- Unfortunately, most commercial and engineering shops merge to form 50 ChemiCal engineering www.Che.Com may 2009
- 69. Customer Sales Contract Invoices, valuations, Send Retentions applications for payment Variations Figure 3. The right ERP system can help Customer Revisions Value EPC contractors to manage aspects of the Certificates Order and payments Receive contract itself. Key aspects of these contract- management capabilities are shown here and actual counting systems. This means that Sub Contract substantial subcontractor fees can ac- cumulate without showing up in the project accounting system until it is too late to adjust the budget to accom- Activity Activity modate the added expenses. Sub Contractor Committed The ability to ensure that subcon- and actual tractor agreements are followed, to convey up-to-date information to the Sub Contract Invoices, valuations, Purchase subcontractor, and to reintroduce cost applications for payment Send Retentions Order and activity information from the sub- Variations Certificates contractor back into your main project and payments Revisions Value Receive accounting system are vital aspects for maintaining control of the project and capturing live costs as they are EPC contracting businesses, and as on that list. But well after that ini- incurred. A properly structured ERP EPC contractors purchase relevant tial data transfer, engineers are often system provides these capabilities. operations to build localized presence called upon to revise the design. Unfortunately, most commercial around the world, modern ERP sys- When this happens, the risk of an ERP products and other packaged tems can provide the continuity the information mismatch arises, be- enterprise software systems are ill- merged organizations need. cause as design revisions are made, equipped to deal with the complexi- Similarly, as the markets served by corresponding changes might not be ties that are particular to EPC con- today’s EPC contractors become less made to the part numbers released tracting. Because ERP has its roots geographically restricted, and compa- to the purchasing department. From in manufacturing, many of these tools nies extend themselves into more for- the standpoint of the procurement are better adapted to environments eign markets, the ability for the entire and fabrication departments, it might that have a sharper delineation be- project team to remain connected in then appear that the original design is tween the design and manufacturing real-time via a properly structured en- still active and money and resources processes. That is probably why so terprise application — one that can op- are still being spent executing it. Only many EPC contractors are still using erate in a number of languages, units later will they realize that the materi- a patchwork of point solutions to man- of measure and currencies — also be- als they have on hand no longer con- age their finances, human resources comes desirable. This globe-spanning form to the project’s requirements. and purchasing needs, and perhaps capability also helps to overcome The use of separate point solutions using in-house or self-developed solu- language and other communication for planning, engineering, procure- tions for materials management, fab- barriers in the supply chain as local ment, document management and rication, engineering and other core engineering and other disciplines are finance are often not well-equipped technical and business processes. sourced from around the world. to provide needed visibility between For instance, many ERP systems departments, and they are even less developed during the 1980s and 1990s The need for ERP well-suited to provide visibility be- were based on the concepts of Manu- As a general rule, EPC contractors yond the four walls of the company facturing Resources Planning (MRP) often run discrete software tools to into the operations of subcontractors and similar systems (called MRP2), carry out a number of point solutions in who are retained to execute portions which add capacity and product in ad- different parts of their business, each of the project. This presents a problem. dition to materials management. Both designed to manage specific elements For instance, as changes occur to the of these methodologies assume certain — related to, for instance, planning, design, there are implications for the standard business and manufacturing engineering, procurement, document subcontractors, as well. Oftentimes, structures. But EPC contractors often management and finance functions — EPC subcontractor agreements in- face a non-standard, project-driven within the overall project continuum. clude clauses that specify how changes structure — one that has less emphasis However, such a patchwork approach are to be handled — clauses that can on materials management and more to project and data management has have budgetary implications. emphasis on project management — its drawbacks. For instance, if a team of proj- and EPC contracts change with each Consider the process of transfer- ect engineers is working from Excel project, and change throughout the ring a bill of materials (BOM) from spreadsheets, they likely do not have course of the project, as well. the engineering application into the immediate access to information on production/procurement applications. how subcontractors are to be paid, and What to look for Essentially, you are exporting a parts changes made to their documentation Unfortunately, today’s EPC contrac- list from the CAD tool, to support ef- often are not communicated effectively tors have very few options in pack- forts related to purchasing the items into the project or general ledger ac- aged software that truly satisfies all of ChemiCal engineering www.Che.Com may 2009 51
- 70. Engineering register Purchasing portal Project portal Project information Engineering Practice Project ID: Status: NO1502 Started Project name: Company: Huldra The Project Enterprise Program: Manager: MAGNE Planned start: 2/17/05 Planned finish: 7/17/07 Actual start: 3/6/07 Actual finish: their requirements, from pre-bid to Project status design to project completion. Thus, ACTIVITY 013 DESCRIPTION Purchase package 013 BUDGET ESTIMATE 200,000 COMMITTED 1,190,000 USED 0 ACTUAL identifying a standardized IT plat- D1.1 Documentation SMDL 70,000 18,750 18,750 F11 Fabrication 790,000 form that will meet all these needs F12 Fabrication PA section 3,200,000 can be a challenge. But when such F13 Pre-fabricated pipes 225,000 H1-01 Installation of pump 200,000 a solution can be found, it can de- O12 Purchasing 50,000 55,000 37,500 liver better results and be a lot less SC0001 T1-01 Sub contract material SC0001 Invoicing 140,000 expensive compared to the need for 9 rows, 0 skipped heavy customization of a standard Project performance Project reports manufacturing ERP package or ef- forts to integrate a number of dis- Project documentations - You have 0 released document(s). crete point solutions. Document packages Perhaps the single most difficult Project Sub project Package Available for aspect of the EPC contractor’s re- quirements is the need for tight in- Figure 4. Enterprise applications designed for the EPC environment need to include a tegration between the CAD solution "project portal" that shows both project budget details and actual costs from the general used in the design phase, and the ledger on an activity-by-activity level. This will provide realtime visibility into costs as the project evolves rest of the project support systems. As noted earlier, any changes made • nsure visibility of project fi- and identify cost over-runs early- E to the design will affect the budget, nancials. When it comes to project enough to make adjustments, a well- purchasing and fabrication require- accounting, reliance on the general equipped EPC contractor will then ments, and thus must be communi- ledger is similar to “reading it in the avoid the unpleasant fiscal surprises cated efficiently to all subcontractors newspaper” — by the time you’ve that can crop up toward the project’s (Figure 2). seen it, you learn what has hap- conclusion. The ability to tender a Other crucial elements to look for in pened, but it is certainly too late more competitive bid and to prevent an EPC software package include the to do anything about it. In order to budgetary overruns will translate into ability to do the following: change any activities that will im- a greater number of projects that can • andle collaboration in engi- H pact project financials in the gen- be completed profitably. neering and procurement with eral ledger, you need to see where external fabrication contractors. the project is going — not where it What to look for Project participants need to dynami- has been. That’s why a system that Today, the number of packaged soft- cally share design and other project ensures visibility with regard to ware options that are available to data in real time; proper integration project cost and progress is so im- meet the unique needs of the EPC allows these subcontractors to work portant. After all, if your enterprise contractor is limited, and vendors may more like an integral part of the software allows you to see devia- attempt to sell suboptimal products project team tions from the budget as they occur, to EPC contractors. Thus, a certain • ee beyond a materials list. His- S you can then look forward and make amount of due diligence is required torically, ERP systems transfer a alterations or manage the project to ensure that any multi-faceted en- materials list, consisting of simple in such a way as to remain within terprise software tool will do what the quantitative data (such as part budget parameters and constraints. vendor says it will do. numbers and quantities), from the As software-based tools continue to There is no substitute for asking a engineering department into a pur- advance, more and more EPC con- lot of questions of a vendor, and requir- chasing module. However, as noted tractors will be making this move ing the vendor to show you how your earlier, while changes that take from general ledger to project man- business processes would be executed place in an EPC project might not agement and control within the software environment it- affect the purchase part numbers at EPC contractors should also realize self — rather than trying to demon- all, they are likely to affect descrip- that the ability to implement the right strate the system capabilities through tive information about the parts and enterprise application can provide a more generalized PowerPoint the relationships between the parts an important upside — competitive sales presentation. and other documentation. Such advantage — by helping them to get Do your best to look beyond the out- changes are common when design the technology side of their business ward appearance of the solution, to and fabrication processes overlap, in order. A contractor with better cost see how the application is able to cope and must be easily visible to other controls — for instance, one who can with changes and risks. Make a vendor project team members in procure- anticipate real costs and avoid hidden run the solution with actual project ment and construction functions ones by correctly allocating expenses data, ask them to change something and to all subcontractors. This high- to specific contract tasks — can confi- in engineering or in the project struc- lights the need for tight, transpar- dently submit a more-competitive bid. ture and see how the technology deals ent integration between engineering With the right measures in place to with the changes and disseminates and procurement both avoid unbudgeted expenditures the information accordingly through 52 ChemiCal engineering www.Che.Com may 2009
- 71. Contract No: Contract Name: Contract type: Type description: EP1000MH EPC Huldra process module upgrade 2 EPCI contract Customer ID: Customer name: Contract status: Currency: Company: Site: NO1002 Exxon Mobile Estimated USD 30D NO1 Contract reference: Prospect name: Contract manager: Contract manager name: NO_MAGNE MAGNE General Items Defaults Win/Loss Revision Customer Project Tasks Deduction Contacts Summary Change history Status Contract rev: Status: Submit Tender. . . Tender Baseline: Create Application. . . 1 Planned Frozen Award. . . Contract Baseline: Set Tender Baseline: Review Set Contract Baseline Lines/items Activities Deleted items Activate Line No Line Line Sales value Cost value Application For Payments. . . Complete name description Contract current Contract current Bid Status Close 1 S1 Studies 130,000,00 Notes. . . Lost Contract. . . 2 C1 Concept development 1,300,000,00 Cancel Copy Contract. . . 3 E1 Engineering 3,400,000,00 4 C2 Commissioning 1,250,000,00 Populate Query. . . Create Shortcut. . . Add to Favorites. . . Copy Object Paste Object Item No Item Item Calculation Calculation Status Sales Sales Sales part Cost Cost rate Cost Item Se name description method type part site part description Properties rate factor value com current 1 Hours Per unit Sales value Planned NO1 500,00 h NOK 1,00 USD Figure 5. The "contract management" functionality of any ERP system must allow an EPC contractor to manage contracts throughout the entire lifecycle of a project, from bid to application for payment, to commissioning the enterprise-wide application. • anage and control complex M understand all risks — related to, Similarly, in the application and contracts. An application should for instance, unpredictable materi- product documentation, watch for ver- let you record all invitations to ten- als supply, weather, exposure to risk biage that indicates that the product der, respond to tenders, monitor ne- by subcontractors — and then miti- is actually an EPC solution and not gotiation processes, and track the gate or avoid any impact a just repackaged manufacturing so- conversion from tender to contract. • upport engineering and design S lution. Terms like project, contract, It should also allow you to record activities. An ERP package for EPC subcontract, engineering and fabrica- work progression, and allow for re- contractors must include a compre- tion should be present in abundance visions of contract baselines at the hensive multidisciplinary engineer- in the sales and training documenta- same time as you manage cash-col- ing register for process-, electrical-, tion provided from the vendor. If those lection activities like application for phrases are not there, it might be best payment (Figure 3) to consider another vendor. • Provide project-driven capabili- Similarly, the flexibility of any solu- ties. Make sure that the project plan tion is important, in terms of how it can is the central engine that drives be reconfigured to meet your changing progress, procurement, off-site man- needs. Such adjustments might take ufacturing, construction and instal- place on an individual project and re- lation. When all business processes quire on-the-fly changes in the work are working within the same plan- breakdown structure as represented ning document, team members can in the application. As noted above, it easily drill down into details or view is important to consider how the ap- information and progress on aggre- plication adjusts to all changes that gated levels. The application should transpire in the course of a project. also support two-way integration Certain types of project changes have with leading planning tools such as implications for the way the company Primavera, Microsoft Project and does business in general. For instance, Safran. This means that informa- as regulations and customer require- tion should not only be exportable ments change, and as you enter new to these project-management tools, markets, add new disciplines, identify but that changes made in the third- new competitors, how easy is it to con- party program should flow back into figure the application or add function- the enterprise application ality to meet your needs? Some appli- • esignate risk-management ca- D cations can handle change over time pabilities. An ERP package that is more easily than others, while others designed explicitly for EPC contrac- may require a complete reconfigura- tors should be able to create a list of tion, which could bring a heavy pen- potential problems and constraints alty, in terms of financial implications that could add risk to a project, and and potential business disruptions. lets users review and correct for During the selection of any ERP any incidents that occur during a system, contractors should consider project. The information should be whether the system provides the func- structured and presented in such a tionality needed to do the following: way as to help an EPC contractor Circle 33 on p. 70 or go to adlinks.che.com/23014-33 ChemiCal engineering www.Che.Com may 2009 53
- 72. Engineering Practice instrumentation-, and AEC/piping for all materials issued to different • nsure dynamic connection be- E engineering — in short, a central fabrication processes. These progress tween projects and the general repository for all design data acces- details should be rolled back to the ledger. An appropriate ERP pack- sible to all project participants in overall project to ensure total control age will automatically allow finan- real time. The system should also • nsure visibility of work done E cial transactions to be created auto- include integrated document man- by suppliers. Specific aspects of matically at the source event within agement and support both the de- the fabrication operations and the the project, and updated to the com- sign of new projects, as well as the cost of the work that has been out- pany’s central financial records, to modification of projects that involve sourced to suppliers should also ensure that cost and revenue are assets in operation be visible within the ERP applica- correctly posted on the work break- • rovide support for material, in- P tion. This helps project managers down structure and entered into the ventory and supplier catalogs, to to verify whether suppliers are de- general ledger (Figure 5) streamline the material manage- livering their aspects of the project ment process. All drawings of parts according to plan — from within the Closing thoughts should belong to a specific aspect of enterprise application — and evalu- For any EPC contractor, the pressure the project, and all parts should have ate the consequences of any specific is on to manage risk and prevent neg- a scheduled (required) date. When delays or failures. Ideally, the ERP ative outcomes, such as cost overruns you calculate the material take-off package should allow for a number or failure to deliver project elements (MTO), the application should gener- of types of arrangements with sub- on time and as specified by the proj- ate a complete overview of the total contractors. One approach would ect owner. The ability to manage engi- material requirements and work ef- be a contract that allows the EPC neering and construction, along with fort for your EPC project, including contractor to control payments by any subcontracted construction, in the required dates. Planners should percentage of work completed. This order to deliver a project within time be able to monitor the progress of approach can offer greater control and budget parameters requires an fabrication efforts and track details over systems and prices (Figure 4) ongoing process of managing risk as project variables continue to change over the life of the project. Contractors who take on EPC work must have the tools in place to de- liver on the project, not only within the time and budget allowed, but in a way that ensures their profitability. The ability to identify and mitigate risk in complex turnkey projects, and the ability to identify deviations from the timeline and budget early enough to make corrections, are key criteria EPC contractors should look for when evaluating competing ERP options. ■ Edited by Suzanne Shelley Author Magne Halvorsen is senior business analyst with IFS AB, the global enterprise software company (200 S. Executive Dr., Suite 100, Brookfield, WI 53005; Phone: 262-317-7419; Email: Magne Halvorsen@ifs. no; www.ifsworld.com). In this capacity, he helps companies involved in engineer, procure, construct (EPC) activities and other complex business models to meet their enterprise software needs. Halvorsen has career experience in the petro- chemical and offshore industries, and has held multiple technology advisory positions with IFS’ global and Scandinavian operations. Halvorsen holds an M.S. degree in production engineering from Narvik University College, Norway. Prior to joining IFS, he worked as manager of IT Planning for Kongsberg Maritime, a supplier of electronics to the shipping, offshore, oil & gas, subsea, navy, coastal marine and fisheries, maritime training, port and harbor surveillance industries. Circle 34 on p. 70 or go to adlinks.che.com/23014-34 54 ChemiCal engineering www.Che.Com may 2009
- 73. Gulf Coast special advertising section Aggreko • Bryan Research & Engineering • Chemstations • Emerson Process Management Fike Corp. • Griswold Pump Co. • Haws Corp. • Honeywell Process Solutions Photo: tiger tower ServiceS Mustang Engineering • Petro-Canada • Solutia Therminol Tiger Tower Services • TLV Corp. • Wilden • Wood Group ESP
- 74. Gulf Coast Special Advertising Section Multistage centrifugal pumps are gaining ground Multistage centrifugal pumps originally developed for downhole applications find favor in the chemical and petrochemical industries, says Wood Group E lectric submers- ible pump (ESP) systems are now Issue Capital cost SPS Low PD Low SC High Whole life cost Low High Moderate providing specific Up time High % Low % High % solutions to a wide Down time Low % High % Low % range of surface Daily/weekly maintenance No Yes No fluid-movement Downtime per repair Low Moderate High applications, says Cost of repair Low Moderate High Wood Group Surface Noise level Low High Low Pumps, a unit of Vibration Low High Low Wood Group ESP. Pulsation Nil High Nil These systems fea- Mechanical Packing Mechanical Sealing (number of seals) ture a direct-drive, seal (1) (3 or 5) seal (2) multistage centrifu- Environmental leakage Virtually nil High Virtually nil Flexibility to changing flow/pressure High Moderate Low gal design ideally suited for most high- that is adaptable to changing flow conditions. They include API Long view: these multistage pumps pressure, low to 682 mechanical seal and API 610 flush/quench options. Multiple can replace other high-pressure types medium volume and units can be combined in parallel systems for higher capacities environmentally sen- and flexible operation. The pumps are available with short deliv- sitive applications. Building on rugged oilfield ESP technology and ery times. They can be electric, gas or diesel-powered; and can first used as produced water injection pumps, the versatile SPS typically handle up to 2000 gpm (64,000 BFPD) with discharge Surface Pumping System is the right choice to replace positive- pressures ranging up to 6,000 psi. displacement plunger, split-case and vertical-turbine centrifugal The table above compares the SPS to positive-displacement pumps in many applications. SPS systems feature a quiet, low- (PD) reciprocating and centrifugal split-case (SC) pumps. vibration, environmentally friendly and energy-efficient design www.woodgroup-esp.com/prodsurfpump.asp A customer enthuses over this heat transfer fluid Petro-Canada’s CALFLO HTF heat transfer fluid solved a serious and long-standing problem for a major Swedish plastics products manufacturer A s one of Europe’s leading in Europe and approximately 80% of the company’s products are exported from Sweden. Canada’s CALFLO HTF heat transfer fluid. “After we changed to Petro-Canada’s CALFLO HTF heat transfer fluid, we have suppliers “The problem we had in our machine been running for three years without prob- of extruded is that the oil degraded very quickly and lems,” says Christensen. “It solved a lot plastic sheets, got very black,” said Gerry Christensen, of problems, not just the short oil life. The Arla Plast AB Technical Chief responsible for maintaining pumps are working — we haven’t repaired constantly all the lines and equipment in the factory. any pumps since three years ago.” strives to “That hurt the pumps, and inside the roll- “Petro-Canada’s oil solved all of find effective ers we had a lot of black sludge from the the problems, so we are very happy,” solutions that oil, which led to many problems.” Christensen continues. “We changed all improve its When the oil broke down, it created of our lines, so now we are just running production and a chain reaction of consequences. “After CALFLO HTF.” ultimately its six months we had to put new bearings in After trying a variety of different prod- product offer- the pumps,” says Christensen. “We had ucts, Arla Plast found Petro-Canada’s ing. In operation to repair them and it costs a lot of money CALFLO HTF heat transfer fluid to be an since 1969, the to stop a line like this. We had one or two effective solution to its problems. By solv- Swedish company produces 12,000 t/y of days to repair the pumps, then we could ing the numerous operating issues, short high-quality transparent polycarbonate run for six months again.” oil life and equipment damage, CALFLO sheets. The sheets are used for machine Over the years Arla Plast experimented HTF dramatically decreased the costly protection, safety glazing and hockey with various heat transfer fluids to try downtime caused by previous oils. It rinks. Many of Arla Plast’s customers are and find a solution. “We tried at least allows the company to operate efficiently 10 different products and we had the and maintain its edge as one of Europe’s CALFLO HTF (above) means no more same problem with all of them,” explains leading suppliers of extruded plastic black sludge for Sweden’s Arla Plast Christensen. Then he came across Petro- sheets. lubricants.petro-canada.ca 56||||||CHEMICAL ENGINEERING||||WWW.CHE.COM||||MAy 2009
- 75. Gulf Coast Special Advertising Section Automation and information at every project stage From concept to commissioning, Emerson Process Management provides premier engineering, system integration and field services for process control and automation nal knowledge and skilled resources to can quickly locate and mobilize the talent offer turnkey project implementation, from needed for any project. No matter the size concept to commissioning and startup. and complexity, Emerson project manag- Industry-leading technologies like the ers can successfully deliver on schedule, PlantWeb digital plant architecture reduce budget, and quality. project costs substantially. Typical savings Managing large, multi-faceted projects have been documented at over 30% on requires a proven methodology to assure new installations. And the architecture’s success. With experience gained through built-in predictive intelligence can improve hundreds of thousands of project service plant efficiency by 2% or more. and engineering hours, Emerson’s meth- Emerson’s Main Automation Contractor odology helps customers manage projects (MAC) approach, with early involve- efficiently. Smooth performer: Emerson excels in ment, can identify and mitigate risk and Faster time-to-market and early posi- project management and technology establish alignment with project expecta- tive cash flow are often key measures of tions. Emerson minimizes change orders a project’s success. To help achieve these T hroughout its history, Emerson Process Management has remained focused on providing quality industrial automa- throughout the project by ensuring key decisions are made early in the process related to technology requirements, oper- outcomes, Emerson has developed a comprehensive library of standards and tools that can reduce implementation time tion and information systems that benefit ating objectives, and total life cycle costs. and minimize ongoing maintenance costs. process manufacturers. This has allowed Emerson project managers are trained, Emerson’s proven design basis provides a Emerson to develop into the premier auto- and kept current with the latest best prac- standard, modular core design that can be mation engineering, system integration tices in project management, working with customized to any specific needs, without and field services provider in the oil and the world-renowned Project Management additional project risk. gas industry. Unlike other automation Institute. Using a global resource and skills www.emersonprocess.com engineering firms, Emerson has the inter- database, Emerson’s project managers /solutions/projectservices A powerful simulation resource for refiners ProMax is powerful simulation software backed by excellent customer service from developer Bryan Research & Engineering F or over 30 years, Bryan Research & Engineering Inc. (BR&E) has been com- mitted to providing the energy industry • vessel sizing; and • parametric studies. The latest version of ProMax contains a with process simulation software that complete reactor suite for modeling kinetic accurately and efficiently predicts the per- (plug-flow and stirred-tank), equilibrium, formance of gas processing, refining and conversion, and Gibbs minimization petrochemical processes. Today, BR&E’s schemes. ProMax is also widely known for ProMax simulator is used by engineers its ability to model many aspects of a refin- around the world to design and optimize ery. For instance, ProMax may be used to: processing facilities. Totally integrated • model atmospheric and vacuum towers; with Microsoft Visio, Excel and Word, • investigate preheat exchange and ProMax is a comprehensive tool that offers fouling; incomparable flexibility. • study refinery changes on sour treating A few of the commonly used features of systems; ProMax include: • model FCC and coker main fractionators; • crude oil characterization; • define custom reactors; tomer support from a staff of knowledge- • gas and liquid sweetening; • define custom reports; able and experienced engineers, and sets • glycol dehydration / hydrate inhibition; • simulate caustic treaters; and up free initial plant models for operating • sulfur recovery; • predict optimal exchanger performance companies. • LPG recovery and fractionation; with active rating during simulation. ProMax’s advanced technology, includ- • sour water stripping; A ProMax license also includes much more ing over 2,500 pure components and 50 • exchanger rating/sizing; than just software. BR&E is committed thermodynamic package combinations, • exchanger network performance to providing unrivaled customer support. along with BR&E’s exceptional client monitoring; The company offers free training sessions services unite to make ProMax the “must • pipeline systems; around the world, provides timely cus- have” simulation resource. www.bre.com CHEMICAL ENGINEERING||||WWW.CHE.COM||||MAy 2009||||||57
- 76. Gulf Coast Special Advertising Section Lean times demand faster returns Honeywell’s plant optimization technology can cut plant operating costs significantly, increase productivity, and improve product quality W ith the current economic situation, it is more important than ever for refineries and petrochemical producers to up to multi-unit and multi-plant optimiza- tion. Profit Suite technologies are flexible and applicable to a wide range of industrial operate more efficiently. processes. They are also easier to imple- Honeywell can help manufacturers ment than competing products. reduce costs and increase efficiency As the foundation of Honeywell’s during these challenging times. The layered optimization approach, Profit company’s website at TheOptimizedPlant. Controller provides the base for improv- com shows how Honeywell solutions can ing the economic benefits of processes. reduce energy consumption (5–10%), raw Project payback periods of less than a year material usage (1–2%), quality variability are typical, with sustained benefits lasting (up to 50%), transition time (up to 30%), indefinitely. Honeywell’s applications: and maintenance costs. • increase profitability through increased Honeywell addresses all aspects of production, lower operating costs and process optimization, from improving higher product quality; regulatory loop control to optimizing • improve plant safety; entire processes. Under the name Profit • increase employee productivity through Suite, these technologies create a layered improved operator effectiveness and approach to optimization that Honeywell lower engineering requirements; and says is unique in the industry. • achieve high returns on investment. The layered approach is scalable and Other Honeywell solutions featured on benefits-driven. It creates solutions that TheOptimizedPlant.com include wireless, are sustainable in the long term, based on simulation tools, manufacturing execution Plant optimization can provide lasting a skill set that is common across projects systems, emissions monitoring and remote benefits, Honeywell says from basic advanced control, all the way services. TheOptimizedPlant.com Using rupture discs to safeguard your valves Fike rupture discs protect the environment, your equipment and your bottom line emission fines; and beyond the normal range, preserving the G lobal air qual- ity standards, • within the US, zero daily PRV emissions calculations allow you to sell emissions credits for increased profits. valve, reducing emissions, and reducing energy costs. The Axius, as well as other Fike rupture public health and Fike has several rupture discs to choose discs, are invaluable for protecting your environmental concerns from when protecting your PRVs, but the expensive pressure relief valves. are increasingly hot topics not only for the Axius offers clear advantages over any www.fike.com politicians, but also for business success. other disc on the market. It features a 95% In the US, the Clean Air Act is now requir- operating ratio (100% of minimum burst ing industries to implement a leak detec- pressure according to CEN ISO 4126–2) and tion and repair program (LDAR) to control a high tolerance to pressure pulsations. fugitive emissions. And while pressure The Axius is capable of cycling from full relief valves (PRVs) can be a vital part of vacuum to 95% operating ratio in excess of your process, they are expensive to main- 100,000 times—even at the lowest burst tain and a major source of process media pressures available. emissions. By installing Fike rupture discs Other discs can fatigue and fail much (bursting discs) upstream of your PRV, earlier, leaving the PRV exposed to you not only protect the valve, but greatly not only the system pressure, but also decrease emissions, and gain significant to—possibly corrosive—process media. In cost savings advantages: addition, if the valve is forced to operate, • possible exemption from PRV monitoring when it begins to return to normal or blow requirements; down, significant energy must be used to • zero emissions during normal operation build the pressure back up. With the effi- Protecting pressure relief valves: means no collection and disposal costs; ciency and high cyclic ability of the Axius, Fike’s Axius rupture disc • can significantly reduce possible fugitive you can count on the disc operating well 58||||||CHEMICAL ENGINEERING||||WWW.CHE.COM||||MAy 2009
- 77. Gulf Coast Special Advertising Section Stop wasting valuable MP steam for heating duties Back-pressure often restricts the use of cheap low-pressure steam—a problem solved by the PowerTrap combined steam trap and pump from TLV Corp. M any refineries and petrochemical plants use costly medium-pressure (MP) steam for low-temperature heating condensate to drain. TLV’s PowerTrap, a combined steam trap and pump, avoids both these problems by returning LP con- The typical way around this problem is either to use MP steam for heating, or to use LP steam and dump the condensate to duties, notes TLV Corp., when they could densate to the boiler house even against drain. Either way, energy is wasted. instead be using cheaper and more read- significant back-pressure. A much better way to use LP steam for ily available low-pressure (LP) steam. LP steam is a versatile heat source that heating when back-pressure is high is to Alternatively, plants may use LP steam for is so abundant on many process plants install a TLV PowerTrap, a combination of a heating, but waste energy by sending the that it is frequently vented to atmosphere, steam trap and a steam-powered conden- wasting its valuable energy content. MP sate pump. steam, on the other hand, is scarcer and The PowerTrap optimizes process heat- more expensive to produce, sometimes to ing equipment performance by ensuring the point where MP steam demand is made continuous drainage of condensate from up by letting down high-pressure steam—a equipment at steam pressures between very wasteful operation. vacuum and 200 psig. So why is MP steam often used for low- It reduces energy costs by allowing temperature heating duties in reboilers, plentiful LP steam to be used for process exchangers, jacketed vessels and preheat heating, avoiding the need to dump con- coils? A common reason is that if there is densate or use costly MP steam instead. significant back-pressure in the conden- The PowerTrap also improves the avail- sate return system, the pressure of the ability and reliability of process systems. LP steam is too low to drive condensate It reduces channel head gasket damage, through a steam trap and into the con- and eliminates cavitation or seal leakage Steam power: TLV’s PowerTrap works densate main. Instead, the system stalls: issues often experienced with electric at line pressures up to 200 psig condensate backs up in the equipment and pumps, says the manufacturer. impedes heat transfer. www.tlv.com Pumps are now even more reliable Griswold 811 Series feature enhanced power frames, resulting in increased performance and longer pump life G riswold Pump Company, a leading manufacturer of ANSI centrifugal pumps and an operating company within tually any fluid-processing application with flowrates up to, and including, 908 m3/h (4,000 gpm). Among the 811’s options Dover Corporation’s Pump Solutions Group are low-flow models, heavy-duty power (PSG), has given its 811 Series ANSI line of frames, fully open impellers with rear pumps enhanced power frames that not adjustment capability, and a wide variety only increase performance and longev- of mechanical-seal options. 811 Series ity, but also simplify maintenance. The pumps are available with ductile iron, 316 improved strength and rigidity of the 811 stainless steel, CD4MCu, and Alloy 20 Series power frames are an estimated 33% liquid paths, which make them viable in stronger than competing models, making temperatures as high as 260°C (500°F). All them better-equipped to withstand severe 811 Series pumps undergo extensive hydro conditions found in many process and testing before delivery. transfer applications. Knowing that its customers deal in 33% stronger: the Griswold 811 Series In addition, the large sight glasses and time-sensitive operations, Griswold has now features an uprated power frame magnetic drain plug provide longer bearing developed a manufacturing and inventory life for the 811 Series. Griswold also uses a system to suit the most critical needs. A performance, and engineering assistance fusion bonded epoxy coating on the inte- ready-to-ship inventory coupled with a in pump and component specification. rior surface of the power frame. This pro- worldwide network of stocking distributors Griswold Pump Company is a full-line vides a superior barrier between the iron means that when a customer orders an pump manufacturer with product lines frame and the lubricating oil, and keeps 811 ANSI Series pump from Griswold, it is dating back more than 70 years. Included the oil cleaner for longer. covered by a 36-hour emergency shipping among its industry-leading pump lines are The 811 Series offers a full range commitment. Griswold also offers value- ANSI, end-suction centrifugal pumps, self- of pump sizes, as well as options and added services like inventory-optimization priming pumps and submersible/vertical upgrades that can be tailored to meet vir- programs, technical support for equipment turbines. www.griswoldpump.com CHEMICAL ENGINEERING||||WWW.CHE.COM||||MAy 2009||||||59
- 78. Gulf Coast Special Advertising Section Energy solutions are not just for plant shutdowns Rental equipment and expertise from Aggreko can boost plant performance during hot weather, as well as covering plant shutdowns and cooling tower maintenance A ggreko’s proven experience and com- prehensive expertise has made it the premiere resource for rental energy solu- the industry, Aggreko can address emer- gencies, maximize production, and keep operations running smoothly when the tions for the petrochemical and refining heat is on. Aggreko’s experience and capa- industries. Drawing on a team of experts bilities have dramatically reduced the risks with vast industry-specific knowledge, the inherent in process cooling. ACTS can: company develops custom solutions to • maximize production during hot summer meet any challenge. months or peak demand times; This innovative approach goes beyond • maintain production while repairing or services for turnarounds, shutdowns and maintaining existing cooling tower; general maintenance. Aggreko Process • reduce costly downtimes after disaster Services (APS)—an experienced process strikes; and engineering team aimed at addressing • meet or exceed customers’ own environ- process, operational, and environmental mental and safety standards. constraints—was formed as a response to Whether providing rapid emergency customers’ growing needs for unique solu- response to equipment failure for a multi- tions to process enhancement. In hot weather, temporary cooling can national chemical organization, or vessel Aggreko Process Services can design keep plants running at full output cooling services to increase production, and install a project in a matter of weeks Aggreko is committed to delivering the instead of the months required for a typical Additionally, Aggreko Cooling Tower highest performance standards, 24/7/365. capital project, enabling customers to cap- Services (ACTS) was created to address Aggreko keeps production and profitability ture short-run market opportunities. APS demands for emergency or supplemental flowing while delivering valuable time and specifically targets process limitations cooling at refineries, factories and other cost savings, thanks to its experience, skill caused by high ambient temperatures and plants. With 24-hour availability and the and specialized equipment. fouled or under-performing equipment. largest fleet of modular cooling towers in www.aggreko.com/northamerica Preview the next version of this process simulator Version 6.2 of CHEMCAD from Chemstations will feature better report generation, easier heat exchanger design, and an updated software licensing system C hemstations is pleased to announce the upcoming release of its CHEMCAD suite of process simulation software, ver- gate the data input and review. We took a goal-directed approach to the process of generating thermal designs for exchang- throughout the development cycle, and to keep our development cycle times short. These techniques enable us to create sion 6.2. The highlights of this new ver- ers, and I think our customers will be very upgrade releases throughout the year, sion are an improved report generation happy with the improvements.” even while preparing larger yearly main- engine, an overhaul of the CC-THERM heat “The ideal licensing system for any tenance releases. Our releases are staged exchanger design and rating interface, and software would be totally transparent to such that each version is released as a an updated software licensing system. the user. The realities of modern comput- preview version first, and then as a release Aaron Herrick, the company’s Manager ing won’t let us get quite that far, but this version after it undergoes further testing.” of Development (aaronh@chemstations. latest update goes a long way to removing www.chemstations.com com), said: “We discovered that our cus- some of the headaches that licensing can tomers were spending quite a bit of time cause for our customers.” taking our stock reports and customizing “We try to be very aware of both the them in Microsoft Word and Excel. This engineering and IT constraints of our cus- new release will make it much simpler and tomer base, so we publish updates about faster to do that individualization from every six weeks. Those users needing the within the CHEMCAD interface, while main- latest and greatest features can get them taining the ease of export to Microsoft’s quickly. We also package a major, yearly tools.” update for those users with stricter IT “Our customer discussions turned requirements and/or tighter versioning up some significant opportunities to control for project work.” improve the interface for CC-THERM. We “Chemstations uses a blend of pro- had already made significant technical gramming techniques including goal- On display: improvements in the improvements, but the feedback indicated directed design, agile, and scrum, to forthcoming release of CHEMCAD that we could do more to help users navi- ensure that our customers remain in focus 60||||||CHEMICAL ENGINEERING||||WWW.CHE.COM||||MAy 2009
- 79. Gulf Coast Special Advertising Section These tigers specialize in tough tower jobs Working in 100-degree temperatures, Tiger Tower Services completes a problematic fractionation tower turnaround… just before the big storm A Louisiana refinery had a major turn- around planned and Tiger Tower Services was tapped to perform the frac- went into the column they found a cok- ing build-up so thick and dense that they needed pneumatic jackhammers to loosen tionation column project. It was a big job in the grid for removal. There were other hot weather. obstacles along the way but the Tigers’ When the Tiger Tower Services team experienced team found solutions to each surprise. They removed all the feed piping SOLT2641_Performance_120706 12/7/06 3:01 PM Page 1 and the trough distributor along with the structured packing and bed support. They cleaned the column walls and chimney tray for inspection. Then they re-installed the internals and replaced the packing. The bottom head had a lot of debris in addition to the heavy coke build-up, and required significant cleaning. Once The company handles all process the original stubborn grid was removed, column needs involving re-sections or a the new grid was installed, as were the major internals revamp, such as this one trough distributor and feed piping. The for a large process technology provider balance of the column required additional work including many tray and nozzle the job successfully and safely just before Tiger Tower Services provides all the replacements. hurricane Ike struck the coast, but they specialized skills needed for tray and The client was so pleased with Tiger rushed back to their homes to help their packing installation, tower maintenance Tower Services’ performance that they own community’s evacuation, relief and and plant turnaround projects have been invited back to perform other clean-up efforts. projects. And, not only did the Tigers finish www.tigertowerservices.com Heat transfer fluids for the oil and gas industry Therminol heat transfer fluids from Solutia are widely used in refining, gas processing, oil and gas pipeline operations, and reprocessing used lube oils T herminol heat transfer fluids from Solutia are commonly used in offshore and onshore oil and gas processing, Therminol fluids are frequently used to heat gases for regenerating solid desic- cants (such as molecular sieve) in gas operations such as low-sulfur gasoline production, solvent extraction, and sulfur recovery. WHEN THE HEAT IS ON, PUT THE fractionation, refining, transportation, and recycling operations. Therminol 55, dehydration beds; to reboil liquid des- iccants (such as glycols) used for gas Therminol heat transfer fluids have applications in transportation too. THERMINOL PERFORMANCE CREW Therminol 59, Therminol 62, Therminol dehydration; to regenerate liquid solvents Pumping stations along oil and gas pipe- ® 66 and Therminol VP1 have successfully (such as amines) used for gas sweetening; lines often require heating to control the TO WORK FOR YOU. demonstrated low-cost, reliable, and safe performance in these applications for to heat gas stabilization and NGL fraction- ation reboilers; and for other gas process- viscosity of oil streams, and to prevent condensation of components from gas In the heat transfer fluid race the competition caning operations. That’s why you need the Therminol Heat decades. Therminol fluids are selected get pretty heated. ® streams. Therminol heat transfer fluids becauseTransfer Fluid Performancecapital and for you. From In oil processing and refining,Lifecycle Care team they provide lower Crew working start to finish, the Therminol TLC Total ® have proven capable of meeting these operating costs, and better temperature you Therminol fluids areto win. For yourto enhance of seasoned professionals is ready to support with everything you need often used people, we provide requirements in virtually any environment. start-up assistance, operational training and a technical service hotline. For your facility, we offer system design, control, than other heat transfer options. flush fluid & refill and a fluid trade-in program*. We provide everything And the reprocessing of used lubri- quality Therminol products, sample analysis, oil/gas/ water/sediment/salt separation In gas processing and heat transfer system at peakand for other processing andSo join the winning team. you need to keep your fractionation, performance throughout it’s lifecycle. refining cating oils involves operations at very high temperatures and high vacuum, for which Therminol www.therminol.com heat transfer fluids are ideal. A variety of Therminol fluids are available with low vapor pressure, high thermal stabil- ity, and good heat transfer Therminol TLC Total Lifecycle Care is a complete program of products and services from Solutia performance, supporting designed to keep your heat transfer system in top operating condition through its entire lifecycle. process needs at virtually any ©Solutia Inc. 2006. Therminol, Therminol TLC Total Lifecycle Care and Solutia are trademarks of Solutia Inc. *Available only in North America. temperature. www.therminol.com CHEMICAL ENGINEERING||||WWW.CHE.COM||||MAy 2009||||||61 NOTE: Images are hires ready. Trim: 8 x 10.75 Live: 7.25 x 10 Bleed: 8.25 x 11 _Process Heating 4C
- 80. Gulf Coast Special Advertising Section Reliable and economical under extreme conditions The new Pro-Flo X air-operated diaphragm pump from Wilden can be adjusted easily to give either maximum throughput or minimum air consumption T he Advanced bolted Pro-Flo X pump from ensures product containment, while the Pro-Flo X air distribution system (ADS) with its Efficiency Management Systems needed in today’s energy-conscious and performance-driven applications. www.wildenpump.com Wilden is a (EMS) allows the pump user to control flow reliable and rates and air consumption with the simple economical turn of a dial. solution The Pro-Flo X technology makes the for empty- previously restrictive rules for air-operated ing ves- double-diaphragm pump use obsolete. sels, filling By adjusting the patent pending EMS dial tank cars, to your exact process requirements, the and trans- Pro-Flo X ADS will exceed your expecta- ferring bulk tions without breaking the bank. The pump chemicals performance can either be maximized to quickly and achieve a greater flow to get the job done safely. This fast, or you can maximize efficiency to new pump reduce the operating cost of the pump. is designed The Advanced Pro-Flo X pump provides to excel under reliability, flexibility and efficiencies extreme condi- tions. The bolted Powerful pumping: Wilden’s Pro-Flo X configuration 62||||||CHEMICAL ENGINEERING||||WWW.CHE.COM||||MAy 2009
- 81. Gulf Coast Special Advertising Section Project engineering for chemicals and polymers Mustang provides highly experienced process engineers and project managers for all types of process projects, including control and automation M ustang has wide-ranging experience on chemical and polymer projects, with a project management team whose mental program design, pilot plant pro- grams, and acquisition of physical and chemical property data. 1987 in Houston, Texas. Today the com- pany has more than 4,500 employees, offices throughout the US, and interna- members average more than 25 years Mustang Automation and Control (MAC) tional offices. Mustang has completed over in the process industries. Similarly, adds still another dimension to Mustang’s 4,700 projects for more than 350 clients. Mustang’s process engineers average total project capabilities on behalf of its www.mustangeng.com more than 20 years on these types of clients. An experienced team with exten- projects. Behind the scenes, the company sive process knowledge provides a vendor- boasts superior support teams and the independent approach with cost-effective latest 3D modeling techniques, including and workable solutions for complex IT, © iStockphoto.com/pattieS laser scanning, to streamline projects and automation and control projects. Front end reduce costs. definition is a forte of the team, combined Mustang can manage projects from with innovative tools and methodologies conception through to operations. With that allow MAC to be a full service provider its proven processes, it can also execute of automation integration services, includ- revamp projects that come in on budget, ing advanced process control and abnor- on time and without surprises. Mustang mal condition management. personnel have experience in most of Mustang supports its projects with the licensed petrochemical, chemical planning, established procedures and and polymer processes used today. The proven Best Practices. The company uses company’s experience allows Mustang its own stage gate process (Stage COACH) to assist clients with the introduction of and a robust proprietary project manage- “first of a kind” or licensed technologies. ment tool (PACESETTER) to make sure that Mustang has now completed more Mustang offers technical and economic projects are successful from start to finish. than 4,700 engineering projects studies, technology evaluation, experi- Mustang Engineering was founded in Plug-and-play for tempered water drench showers Emergency shower and eyewash specialist Haws Corp. ensures that its products match ANSI requirements under real plant operating conditions T oday’s industrial emergency show- ers and eyewashes water requirement, if the water fed into it is at 37°F? This is not going to happen, Hayes says, unless the entire system is designed able to maintain nominal flowrates and spray pattern heights in the widest vari- ety of circumstances. are mostly certified to accomplish the total task at hand. • Appropriate temperatures, flows and to exacting ANSI The idea of engineered solutions— pressures even if multiple victims are operational stan- designing a complete system to address using multiple emergency showers or dards, notes Casey the specific plant’s needs—is not new. It eyewashes at the same time. Hayes, Director has been done for years in circumstances The recent launch of an of Engineered where specifiers collaborated with equip- Engineered Solutions Solutions at ment manufacturers to optimize the design Division at Haws Corp. for- the Engineered of their entire system. Because manufac- malizes a service that the Solutions Division turers deal with drench showers and eye- company has provided infor- of Haws Corp. washes every day, they are most familiar mally for over 700 cli- However, he continues, the standards with installation and operating require- ents over the years. assume certain circumstances that may ments, as well as capabilities and limita- The group is staffed not apply to the plant in question. For tions. Importantly, they are often better with experienced instance, showers must deliver a flowrate equipped to logically match the various professionals who of 20 gpm. But, what happens if the inlet components that might go into a system understand clients’ line can’t supply 20 gpm? Is that a shower that could be called upon to provide: business as well as problem or a “system” problem? What • Real-time cooling or warming of inlet their own. The result about temperature requirements? How is water, to ensure that a victim can stand a is a unique oppor- a shower supposed to meet the tempered 15-min. drench or irrigation cycle without tunity for speci- suffering scalding or hypothermia. fiers to get it right Custom engineering (right) ensures • Recirculation and/or booster pumps to the first time, with- that showers (top) perform as designed ensure that sufficient pressure is avail- out “over-specing”. www.hawsco.com CHEMICAL ENGINEERING||||WWW.CHE.COM||||MAy 2009||||||63
- 82. SEALS/GUARDS 2C AD-07 8/15/07 8:59 AM Page 1 PRODUCT SHOWC ASE Particulate Monitors - HEAt Compare to Filter Sense Protect pressure or vacuum ExcHAngErs instruments from clogging, corrosion and damage. Compact and Economical, Plast-O-Matic Gauge Guards prevent dangerous leaks and allow dependable instrument readings from Shell & Tube •Deliveries are prompt full vacuum to 250 psi. T •StanDarD units are Sized and Selected by he most advanced continuous • PTFE or FKM Computer for greater accuracy measuring system for monitoring diaphragms. •Capabilities in sizes up to 80” diameter, 50 ton capacity. particulate emissions. Midwesco’s • PVC, Polypro or Standard or Custom Built black box is suitable for your bag PVDF bodies. to suit your requirements filter, cartridge filter, dust collector • Available with Quality Heat Exchangers and cyclone application(s). or without Economy Priced! gauges. Prompt Delivery! • AC Electrodynamic measurement Send for Data Book Catalogs principal. • Gauge and Capability Brochure • Measurement stability, velocity Shields for insensitivity and tolerance to harsh environments. DoylE & dust build up. rotH MFg. • Electronically records data directly into a PLC. • Midwesco’s on/off-site technical Phone: (212) 269-7840 support. Visit our site for more Fax: (212) 248-4780 info. E-mail Address: PLAST-O-MATIC VALVES, INC. CEDAR GROVE, NJ 07009 doyleroth@aol.com (973) 256-3000 • Fax: (973) 256-4745 www.plastomatic.com • info@plastomatic.com www.doyleroth.com www.midwescofilter.com Circle 201 on p. 70 or go to Circle 202 on p. 70 or go to Circle 203 on p. 70 or go to adlinks.che.com/23014-201 adlinks.che.com/23014-202 adlinks.che.com/23014-203 STALEY EQUIPMENT CORPORATION New & Used Equipment • Sales • Storage Engineering • Fabrication • Refurbishing (Pharmaceutical, Food, Chemical, Plastics) 100+ (in stock) Standard Features: Stainless Steel Ribbon Blenders • All contact surfaces polished stainless steel 400 Cu. Ft.. $ 119,007.00 • Split Seal 300 Cu. Ft. . . . 90,435.00 200 Cu. Ft. . . . 70,432.00 • Air Purge 150 Cu. Ft. . . . 60,674.00 • Heavy Duty Safety 100 Cu. Ft. . . . 50,352.00 Grating 75 Cu. Ft. . . . . 40,560.00 • Self-Supporting 50 Cu. Ft. . . . . 33,102.00 Hinged Cover 35 Cu. Ft. . . . . 29,047.00 • Heavy Duty Ribbon 25 Cu. Ft. . . . . 25,607.00 • 100% Wash Down 10 Cu. Ft. . . . . 16,230.00 • Pricing represents 5 Cu. Ft. . . . . . 12,436.00 all stainless steel 2.5 Cu. Ft. . . . . 8,603.00 construction 1.0 Cu. Ft. . . . . . 6,022.00 Rates subject to change. : FREEe On-Sit st Te BlendingUR of YO t Produc Adelanto, CA (760) 246-0041 www.staleyequipment.com Circle 204 on p. 70 or go to Circle 205 on p. 70 or go to Circle 206 on p. 70 or go to 64 adlinks.che.com/23014-204 adlinks.che.com/23014-205 adlinks.che.com/23014-206
- 83. Intelligen Suite The Market-Leading Engineering Suite for Modeling, Evaluation, Scheduling, and Debottlenecking of Single & Multi-Product Facilities SuperPro SchedulePro R e cipe D B Use SuperPro Designer to model, evaluate, and Switch to SchedulePro to schedule, model, debottleneck batch and continuous processes and debottleneck multi-product facilities Tracking of equipment occupancy Tracking demand for resources Inventory tracking for raw materials, in multi-product facilities (e.g., labor, materials, utilities, etc.) intermediates, products, and wastes SuperPro Designer is a comprehensive process simulator that facilitates modeling, cost analysis, debottlenecking, cycle time reduction, and environmental impact assessment of biochemical, specialty chemical, pharmaceutical (bulk & fine), food, consumer product, mineral processing, water purification, wastewater treatment, and related processes. Its development was initiated at the Massachusetts Institute of Technology (MIT). SuperPro is already in use at more than 400 companies and 500 universities around the world (including 18 of the top 20 pharmaceutical companies and 9 of the top 10 biopharmaceutical companies). SchedulePro is a versatile finite capacity scheduling tool that generates feasible production schedules for multi-product facilities that do not violate constraints related to the limited availability of facilities, equipment, resources and work areas. It can be used in conjunction with SuperPro (by importing its recipes) or independently (by creating recipes directly in SchedulePro). Any industry that manufactures multiple products by sharing production lines and resources can benefit from the use of SchedulePro. Engineering companies use it as a modeling tool to size utilities for batch plants, identify equipment requirements, reduce cycle times, and debottleneck facilities. Circle 240 on p. 70 or go to adlinks.che.com/23014-240 Visit our website to download detailed product literature and functional evaluation versions of our tools INTELLIGEN, INC. • 2326 Morse Avenue • Scotch Plains, NJ 07076 • USA Tel: (908) 654-0088 • Fax: (908) 654-3866 Email: info@intelligen.com • Website: www.intelligen.com Intelligen also has offices in Europe and representatives in countries around the world
- 84. software CA Co PE-O mp PE lian N t! Circle 242 on p. 70 or go to HTRI Xchanger Suite® – an integrated, easy-to-use suite of tools that adlinks.che.com/23014-242 delivers accurate design calculations for engineering e-material, e-solutions, e-courses • shell-and-tube heat exchangers • fired heaters and e-seminars for energy conversion systems: • jacketed-pipe heat exchangers • air coolers • Physical Properties • Steam Approximations • Power Cycles • Power Cycle Components/Processes • hairpin heat exchangers • economizers • Compressible Flow • plate-and-frame heat exchangers • tube layouts ENGINEERING SOFTWARE Phone/FaX: (301) 540-3605 • spiral plate heat exchangers • vibration analysis web Site: http://www.engineering-4e.com Visit the web site to check out free demos etc.! Interfaces with many process simulator and physical property Circle 243 on p. 70 or go to packages either directly or via CAPE-OPEN. adlinks.che.com/23014-243 Heat Transfer Research, Inc. HTRI@HTRI.net 150 Venture Drive www.HTRI.net Get CoNNeCted todaY College Station, Texas 77845, USA Circle 241 on p. 70 or go to adlinks.che.com/23014-241 www.che.com New & Used eqUipmeNt TOLL SCREENING by the screening specialists Wedge-Wire Screen Manufacturer: • reduced screening costs filtration screens, resin traps, strainer • maximized yield and efficiency baskets, hub and header laterals, media retention nozzels, and custom filtration • from 10 microns to 10 mesh products manufactured with stainless • from 100 to 1,000,000 pounds steel and special alloys. • receive the benefits of high-tech screening before you buy Contact: Jan or Steve Discover how much your product can be 18102 E. Hardy Rd., Houston, TX 77073 improved using our technologies!! Ph: (281) 233-0214; Fax: (281) 233-0487 Toll free: (800) 577-5068 www.alloyscreenworks.com 800–AT ELCAN sales@minox-elcan.com www. minox-elcan.com Circle 244 on p. 70 or go to Circle 246 on p. 70 or go to adlinks.che.com/23014-244 adlinks.che.com/23014-246 ASW Classified Ad_12-10-08.indd 1 12/10/08 5:05:26 PM PROCESS & MACHINERY Wabash sells & Rents boilers CONTROL 20,000 - 400,000 #/Hr. Diesel & turbine Generators ABB/BAILEY 50 - 25,000 KW INFI90TM/NETWORK90TM Gears & turbines 25 - 4000 HP SymphonyTM We stock large inventories of: Air Pre-Heaters • Economizers • Deaerators FOXBORO Pumps • Motors • Fuel Oil Heating and Pump Sets I/A SeriesTM Valves • Tubes • Controls • Compressors Pulverizers • Rental Boilers & Generators Cost-effective replacement, repair, and 24/7 Fast emergency service repair/exchange of hard-to-find DCS parts. 800-704-2002 ONE YEAR WARRANTY Phone: 847-541-5600 Fax: 847-541-1279 www.wabashpower.com We also purchase surplus or decommissioned DCS equipment. wabash POWER EquIPmENT CO. (770)271-9932 www.pmcx.com 444 Carpenter Ave., Wheeling, IL 60090 Circle 245 on p. 70 or go to Circle 247 on p. 70 or go to adlinks.che.com/23014-245 adlinks.che.com/23014-247 Circle 248 on p. 70 or go to adlinks.che.com/23014-248 66 ChemiCal engineering www.Che.Com maY 2009
- 85. New & Used eqUipmeNt KILO LAB CENTRIFUGE Filter Presses WAT E R W O R K S 800.232.9334 219.663.8210 • For R & D, and Small Scale Processing • Multiple capacities available • Basket filtration or solid / Clarifiers Sand Filters Tanks Pumps www.airtowater.com liquid sedimentation capability Filtration NEW USED SURPLUS • Hard- and Soft-sided Contain- ment for Potent Materials • Rental Equipment Available Accessories Filtration Equipment • Variable Speed up to 3000 Circle 250 on p. 70 or go to adlinks.che.com/23014-250 RPM • Ideal for Installation in a Fume Hood • Explosion-Proof API/Fine Chemical • Cart-Mounted Installation for Easy Portability • Available in 316L Stainless, 904L Stainless, and Facilities for Sale! Hastelloy 131481 - Complete API/ Fine Chemicals Processing Facility ROUSSELET Location: Turkey 141514 - Pilot Scale Manufacturing Process Plant ROBATEL Location: Belgium 703 West Housatonic Street – Ste L15, Pilot Scale & Production Equipment Available Pittsfield, Massachusetts 01201-6616 131940 - (5) Appx 10,000 L Glass Lined Horizontal Single Wall Tanks Phone: 413.499.4818 • Fax: 413.499.5648 83228 - 1991 Summix Bolz 980L Stainless Steel Nauta Style Dryer 83218 - Guedu 90 No/Po 90 L Stainless Steel Pressure Dryer email: sales@robatel.com 83224 - Franco-Montan 600 L Stainless Steel Vacuum Tray Dryer www.rousselet-robatel.com/che09 and many more ... Circle 249 on p. 70 or go to adlinks.che.com/23014-249 EquipNet.com/chemical +1.781.821-3482 Circle 251 on p. 70 or go to adlinks.che.com/23014-251 tOLL mANUFACtURiNG ADVERTISE IN THE ClASSIfIED NEW DUAL-SHAFT Contact Helene Hicks MIXERS! Tel: 212-621-4958 UNITS IN STOCK FOR Fax: 212-621-4976 RENT OR PURCHASE! Email: hhicks@che.com • Stainless Steel • Change Can Design CONsULtiNG • Vacuum Construction • Jacketed Mix Can • 50-Gallon Units Below $50,000 • 100-Gallon Units Below $70,000 1-800-243-ROSS USA Tel: 631-234-0500 • Fax: 631-234-0691 www.mixers.com sales@mixers.com Circle 254 on p. 70 or go to Circle 252 on p. 70 or go to adlinks.che.com/23014-254 adlinks.che.com/23014-252 CRYSTALLIZATION & PRECIPITATION Dr. Wayne J. Genck Genck International 3 Somonauk Court, Park Forest, IL. 60466 Tel (708) 748-7200 Fax (708) 748-7208 genckintl@aol.com – http://www.genckintl.com • Design/Scale-up • Troubleshooting • Particle Habit • Size Distribution • Purity • Product Micro-Analysis • Laboratory Investigations • Caking • Polymorphism • Filtration • Drying • Kinetics Studies ◆◆◆ Industrial Seminars ◆◆◆ Circle 253 on p. 70 or go to adlinks.che.com/23014-253 Circle 255 on p. 70 or go to adlinks.che.com/23014-255 ChemiCal engineering www.Che.Com maY 2009 67
- 86. New & Used eqUipmeNt FILTER PRESSES Shriver • JWI • Komline • Sperry HOCKMEYER Recessed and Plate & frame designs Equipment Corporation A leader in the grinding and PARTS SERVICE CENTER dispersion industries Plates: Poly • Alum & CI Filter cloth and paper Side bars • Hydraulic cylinders New & Used Equipment Avery Filter Company, Westwood, NJ Dispersers • Mills • Mixers • Phone: 201-666-9664 • Fax 201-666-3802 Tank & Tote Washers • E-mail: larry@averyfilter.com www.averyfilter.com Particle Size Analysis • Vessels Circle 256 on p. 70 or go to Visit us at www.hockmeyer.com adlinks.che.com/23014-256 or call us at 252-338-4705 Wanted to purchase: centrifuge geArBOXeS Used Dispersers & Mixers Circle 259 on p. 70 or go to adlinks.che.com/23014-259 Parts & Service for: • Bird • Alfa-Laval Circle 258 on p. 70 or go to adlinks.che.com/23014-258 • Sharples A Revolution in Gear Box Technologies Advertise in the Classified (515) 266-8225 fax (515) 266-5676 Interested? For more information on classified advertising, please contact: Helene Hicks • email: hhicks@che.com E-mail: sales@revtechlc.com Web Site: www.revtechlc.com Circle 257 on p. 70 or go to adlinks.che.com/23014-257 Tel: 212.621.4958 • Fax: 212.621.4976 Are you in it? Register (or update) your company listing today in Chemical Engineering’s Buyers’ Guide and ensure MAXIMUM exposure to thousands of key chemical process industry professionals. Go online now www.cebuyersguide.com Get Noticed! with enhanced listings and logos. Contact Helene Hicks at: hhicks@che.com Do it today ... the 2010 Buyers’ Guide print edition closes August 1, 2009 14060 68 ChemiCal engineering www.Che.Com maY 2009
- 87. Advertisers’ Index Advertiser Page number Advertiser Page number Advertiser Page number Advertiser Page number Phone number Reader Service # Phone number Reader Service # Phone number Reader Service # Phone number Reader Service # A Box 4 U 1 NPE2009 24 Rembe GmbH Safety 32D-8, SRI consulting 18 877-522-6948 adlinks.che.com/23014-22 + control 32I-6 adlinks.che.com/23014-17 adlinks.che.com/23014-04 • Nuova Maip 49 (0) 29 61 - 74 05 - 0 • Swagelok 32I-3 Aggreko, LLc 16 Pieralisi SPA 32I-4 adlinks.che.com/23014-43 adlinks.che.com/23014-45 866-310-0870 49 93 03/90 82-0 Rotex Inc 54 Tiger Tower Services 32 adlinks.che.com/23014-15 adlinks.che.com/23014-46 1-800-453-2321 281-951-2500 * Alstom Power Inc 27 Paratherm corp 22 adlinks.che.com/23014-34 adlinks.che.com/23014-31 877.661.5509 1-800-222-3611 Safety Storage 30 adlinks.che.com/23014-30 adlinks.che.com/23014-20 1-800-344-6539 * TLV corp 7 adlinks.che.com/23014-27 704-597-9070 Bryan Research Petro-canada Lubricants 28 adlinks.che.com/23014-08 & Engineering 10 adlinks.che.com/23014-25 * Samson AG 6 1-800-776-5220 adlinks.che.com/23014-07 Vega Grieshaber • Pompetravaini SPA 32I-8 adlinks.che.com/23014-12 • Seybert & Rahier GmbH Beteiligungs GmbH 32I-7 44-39.0331.889000 & co Betriebs-KG 32I-2 adlinks.che.com/23014-48 chemstations Inc 17 adlinks.che.com/23014-49 713-978-7700 49 (0)5673 999-0 Western States Prosim 26 adlinks.che.com/23014-44 adlinks.che.com/23014-16 adlinks.che.com/23014-23 Machine co 32D-2 comber SRL 30 Silverson Machines THIRD 513-863-4758 Pulsair System 8 Inc cOVER adlinks.che.com/23014-42 adlinks.che.com/23014-29 1-800-582-7797 800-204-6400 crane chempharma 21 adlinks.che.com/23014-28 adlinks.che.com/23014-02 Wilden Pumps & Eng LLc 20 adlinks.che.com/23014-19 Pump Solutions 909-422-1730 * Solex 9 adlinks.che.com/23014-18 crane chempharma 23 Group (PSG) 15 adlinks.che.com/23014-11 adlinks.che.com/23014-21 909-422-1730 Wood Group ESP 29 Solutia Therminol 2 Emerson Process FOURTH adlinks.che.com/23014-14 1-800-426-2463 281.492.5160 Mgmt cOVER • Rembe GmbH Safety 32D-3, adlinks.che.com/23014-05 adlinks.che.com/23014-26 adlinks.che.com/23014-03 + control 32I-2 Soundplan LLc 27 * Wyssmont co 32D-2 * Endress + Hauser 4 49 (0) 29 61 - 74 05 - 0 1-360-432-9840 201-947-4600 888-ENDRESS adlinks.che.com/23014-37 adlinks.che.com/23014-10 adlinks.che.com/23014-42 adlinks.che.com/23014-06 Fauske & Assoc 8 See bottom of next page for advertising sales representatives' contact information 877-FAUSKE1 adlinks.che.com/23014-09 classified Index - May 2009 (212) 621-4958 Fax: (212) 621-4976 Send Advertisements and Box replies to: Helene Hicks, Chemical Engineering, 110 William St., 11th Floor, New York, NY 10038 Fike corp 21 1-866-758-6004 Advertisers’ Advertiser Page number Advertiser Page number adlinks.che.com/23014-24 Product Showcase . . . . . . . . . . 64 Phone number Reader Service # Phone number Reader Service # Flottweg 44 Computer Software . . . . . . . . 65-66 Equipnet 67 Minox/Elcan 66 adlinks.che.com/23014-32 Consulting . . . . . . . . . . . . . . . . .67 781-821-3482 800-AT ELCAN Hapman 13 Equipment, Used or adlinks.che.com/23014-251 adlinks.che.com/23014-244 adlinks.che.com/23014-13 Surplus New for Sale . . . . . . .66-68 e-simulators 66 NATUREX 67 Haws corp 32D-5 Toll Manufacturing . . . . . . . . . . . .67 480-380-4738 201-440-5000 888-640-4297 adlinks.che.com/23014-242 adlinks.che.com/23014-253 adlinks.che.com/23014-39 Advertiser Page number Genck International 67 Plast-O-Matic Valves, Inc. 64 Phone number Reader Service # 708-748-7200 973-256-3000 Heinkel USA 32D-4 adlinks.che.com/23014-201 856-467-3399 adlinks.che.com/23014-255 Alloy Screen Works 66 Process Machinery 66 adlinks.che.com/23014-38 281-233-0214 Heat Transfer Reasearch, Inc. 66 770-271-9932 Honeywell Process SEcOND adlinks.che.com/23014-246 adlinks.che.com/23014-245 979-690-5050 Solutions cOVER Amadus Kahl 64 Rev Tech 68 adlinks.che.com/23014-241 1-877-466-3993 adlinks.che.com/23014-205 515-266-8225 adlinks.che.com/23014-01 HFP Acoustical Avery Filter company 68 adlinks.che.com/23014-257 Load controls Inc 32D-3 consultants 67 201-666-9664 888-789-9400 Robatel 67 888-600-3247 adlinks.che.com/23014-256 413-499-4818 adlinks.che.com/23014-254 adlinks.che.com/23014-36 adlinks.che.com/23014-249 charles Ross Hockmeyer 68 Membrana 32D-6 & Son company 67 Staley Equipment 64 252-338-4705 adlinks.che.com/23014-40 880-243-ROSS 760-246-0041 adlinks.che.com/23014-258 • Metso France 32I-5 adlinks.che.com/23014-252 adlinks.che.com/23014-204 adlinks.che.com/23014-47 Indeck 66 Wabash Power cU Services 64 847-541-8300 Mustang Engineering 32D-7 Equipment company 66 847-439-2303 adlinks.che.com/23014-248 713-215-8000 800-704-2002 adlinks.che.com/23014-206 adlinks.che.com/23014-41 Intelligen 65 adlinks.che.com/23014-247 Doyle & Roth 64 908-654-0088 Water Works 67 Noritake co Ltd 53 212-269-7840 adlinks.che.com/23014-240 800-232-9334 adlinks.che.com/23014-33 adlinks.che.com/23014-202 Midwesco Filter adlinks.che.com/23014-250 Engineering Software 66 Resources 64 Xchanger Inc. 68 • International Section 301-540-3605 952-933-2559 800-336-7300 * Additional information in adlinks.che.com/23014-243 adlinks.che.com/23014-203 adlinks.che.com/23014-259 2006 Buyers’ Guide ChemiCal engineering www.Che.Com maY 2009 69
- 88. New Product Information May 2009 JustFAXit! or go to www.che.com/adlinks Fill out the form and circle or write in the number(s) go on the web and fill out the ✁ below, cut it out, and fax it to 800-571-7730. online reader service card. name Title Company address City State/Province Zip/Postal Code Country Telephone Fax email | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | FREE PRODUCT INFO 14 engineering, Design & Construc- 29 10 to 49 employees 47 Pollution Control equipment (please answer all the questions) tion Firms 30 50 to 99 employees & Systems 15 engineering/environmental Ser- 31 100 to 249 employees 48 Pumps YOUR INDUSTRY vices 32 250 to 499 employees 49 Safety equipment & Services 01 Food & Beverages 16 equipment manufacturer 33 500 to 999 employees 50 Size reduction & agglomeration 02 wood, Pulp & Paper 17 energy incl. Co-generation 34 1,000 or more employees equipment 03 inorganic Chemicals 18 other———————————— YOU RECOMMEND, 51 Solids handling equipment 04 Plastics, Synthetic resins JOB FUNCTION SPECIFY, PURCHASE 52 Tanks, Vessels, reactors 05 Drugs & Cosmetics (please circle all that apply) 20 Corporate management 53 Valves 06 Soaps & Detergents 40 Drying equipment 21 Plant operations incl. mainte- 54 engineering Computers/Soft- 07 Paints & allied Products 41 Filtration/Separation equipment nance ware/Peripherals 08 organic Chemicals 42 heat Transfer/energy Conserva- 22 engineering 55 water Treatment Chemicals 09 agricultural Chemicals tion equipment 23 research & Development & equipment 10 Petroleum refining, 43 instrumentation & Control Sys- 24 Safety & environmental 56 hazardous waste management Coal Products tems 26 other———————————— Systems 11 rubber & misc. Plastics 44 mixing, Blending equipment 57 Chemicals & raw materials 12 Stone, Clay, glass, Ceramics EMPLOYEE SIZE 45 motors, motor Controls 58 materials of Construction 13 metallurgical & metal Products 28 less than 10 employees 46 Piping, Tubing, Fittings 59 Compressors 1 16 31 46 61 76 91 106 121 136 151 166 181 196 211 226 241 256 271 286 301 316 331 346 361 376 391 406 421 436 451 466 481 496 511 526 541 556 571 586 2 17 32 47 62 77 92 107 122 137 152 167 182 197 212 227 242 257 272 287 302 317 332 347 362 377 392 407 422 437 452 467 482 497 512 527 542 557 572 587 3 18 33 48 63 78 93 108 123 138 153 168 183 198 213 228 243 258 273 288 303 318 333 348 363 378 393 408 423 438 453 468 483 498 513 528 543 558 573 588 4 19 34 49 64 79 94 109 124 139 154 169 184 199 214 229 244 259 274 289 304 319 334 349 364 379 394 409 424 439 454 469 484 499 514 529 544 559 574 589 5 20 35 50 65 80 95 110 125 140 155 170 185 200 215 230 245 260 275 290 305 320 335 350 365 380 395 410 425 440 455 470 485 500 515 530 545 560 575 590 6 21 36 51 66 81 96 111 126 141 156 171 186 201 216 231 246 261 276 291 306 321 336 351 366 381 396 411 426 441 456 471 486 501 516 531 546 561 576 591 7 22 37 52 67 82 97 112 127 142 157 172 187 202 217 232 247 262 277 292 307 322 337 352 367 382 397 412 427 442 457 472 487 502 517 532 547 562 577 592 8 23 38 53 68 83 98 113 128 143 158 173 188 203 218 233 248 263 278 293 308 323 338 353 368 383 398 413 428 443 458 473 488 503 518 533 548 563 578 593 9 24 39 54 69 84 99 114 129 144 159 174 189 204 219 234 249 264 279 294 309 324 339 354 369 384 399 414 429 444 459 474 489 504 519 534 549 564 579 594 10 25 40 55 70 85 100 115 130 145 160 175 190 205 220 235 250 265 280 295 310 325 340 355 370 385 400 415 430 445 460 475 490 505 520 535 550 565 580 595 11 26 41 56 71 86 101 116 131 146 161 176 191 206 221 236 251 266 281 296 311 326 341 356 371 386 401 416 431 446 461 476 491 506 521 536 551 566 581 596 12 27 42 57 72 87 102 117 132 147 162 177 192 207 222 237 252 267 282 297 312 327 342 357 372 387 402 417 432 447 462 477 492 507 522 537 552 567 582 597 13 28 43 58 73 88 103 118 133 148 163 178 193 208 223 238 253 268 283 298 313 328 343 358 373 388 403 418 433 448 463 478 493 508 523 538 553 568 583 598 14 29 44 59 74 89 104 119 134 149 164 179 194 209 224 239 254 269 284 299 314 329 344 359 374 389 404 419 434 449 464 479 494 509 524 539 554 569 584 599 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360 375 390 405 420 435 450 465 480 495 510 525 540 555 570 585 600 if number(s) do not appear above, please write them here and circle: Fax this page back to 800-571-7730 Advertising sAles representAtives Mike O’rourke, Publisher North America george gortz, Helene Hicks, Chemical Engineering Jason Bullock, District Sales Manager Inside Sales Manager 5 lynbrook lane, Doylestown, Pa 18901 District Sales Manager Chemical Engineering Chemical Engineering; Tel: 215-340-1366; Fax: 609-482-4146 Chemical Engineering 2612 edgerton road 110 william St., new York, nY 10038-3901 E-mail: morourke@che.com 8325 Broadway, Ste. 202/PmB 261 University heights, oh 44118 Tel: 212-621-4958; Fax: 212-621-4976; Alabama, Canada, Connecticut, Delaware, Pearland, TX 77581 Tel: 216-932-2700; Fax 216-932-5810 E-mail: hhicks@che.com Florida, Maine, Maryland, Massachusetts, Tel: 281-485-4077; Fax: 281-485-1285 E-mail: ggortz@che.com Product Showcase, Literature Reviews, New Hampshire, New Jersey, New York (minus E-mail: jbullock@che.com; Indiana, Illinois, Iowa, Kentucky, Classified Display Advertising Western New York), North & South Carolina, Arkansas, Arizona, California, Michigan, Minnesota, Ohio, Western Alaska, Hawaii, Idaho, Mississippi, Pennsylvania (minus Western Pennsylvania), Colorado, Georgia, Kansas, New York, Western Pennsylvania, Montana, Nebraska, New Mexico, Rhode Island, Tennessee, Vermont, Virginia, Louisiana, Missouri, Nevada, Wisconsin North & South Dakota, Oregon, Utah, Washington, D.C., West Virginia, Latin America Oklahoma, Texas Washington, Wyoming International dipali dhar Ferruccio silvera rudy teng Chemical Engineering Chemical Engineering Chemical Engineering petra trautes 110 william St., new York, nY 10038-3901 Silvera Pubblicita Professional Publication agency Chemical Engineering Tel: 212-621-4919; Fax: 212-621-4990 Viale monza, 24 milano 20127, italy 6F-3 # 103 Fen liau St neihu Zeilweg 44 E-mail: ddhar@chemweek.com Tel: 39-02-284-6716; Fax: Taipei 114 Taiwan D-60439 Frankfurt am main India 39-02-289-3849 Tel: 886-2-2799-3110 ext 330; germany E-mail: ferruccio@silvera.it/www. Fax: 886-2-2799-5560 Phone: +49-69-2547-2073 Katshuhiro ishii silvera.it E-mail: rudy_teng@ppa.com.tw Fax: +49-69-5700-2484 Chemical Engineering Andorra, France, Gibraltar, Greece, or idpt808@seed.net.tw email: ptrautes@che.com ace media Service inc., 12-6, 4-chome Israel, Italy, Portugal, Spain Asia-Pacific, Hong Kong, People’s Austria, Czech Republic, Benelux, nishiiko, adachi-ku, Tokyo 121, Japan Republic of China, Taiwan Eastern Europe, Germany, Scandinavia, Tel: 81-3-5691-3335; Fax: 81-3-5691-3336 Switzerland, United Kingdom e-mail: amskatsu@dream.com Japan 70 ChemiCal engineering www.Che.Com maY 2009
- 89. Economic Indicators Business news plant watch on Dec. 1, 2009, the date of its official Dow completes its acquisition establishment. It will be located in Chuo-ku, of Rohm and Haas Bayer MaterialScience builds Osaka and capitalized at 450 million yen, April 1, 2009 – Dow has completed polyurethane raw materials facility with Suminoe Textile contributing 50.1% and its acquisition of Rohm and Haas. March 27, 2009 — Bayer MaterialScience Teijin Fibers 49.9%. Combining the two organizations creates (Leverkusen, Germany) is to invest 20 million a $14.0-billion diversified business portfolio, euros in a new aromatic and aliphatic which is called Dow’s Advanced Materials Kimberly-Clark acquires safety polyisocyanate manufacturing facility in division. The division is intended to achieve products company India.The new plant in Ankleshwar, in the $3.0 billion in additional value growth April 14, 2009 – Kimberly-Clark Corp. (Dallas, northwestern state of Gujurat, is scheduled opportunities, as well as annual cost Tex.) has acquired Jackson Products, Inc., to start operating in 2011. synergies of $1.3 billion. Rohm and Haas is a privately held, safety products company headquartered in Fenton, Mo. Jackson the key element in Dow’s new Advanced Polyethylene plant to be built in India Materials division. Pierre Brondeau has Products, Inc., more commonly known using Ineos technology been named president and CEO of this within the industry as Jackson Safety, March 25, 2009 — Ineos Technologies division, which includes: coatings, building is a leading provider of welding safety (Runcorn, U.K.) has reached an agreement and construction, specialty materials, products, personal protective equipment with Brahmaputra Cracker and Polymer Ltd. adhesives and functional polymers, and and work zone safety products. Terms of the (BCPL) to license the Innovene G process electronic materials. acquisition were not disclosed. for the manufacture of polyethylene (PE) in a plant to be built at Lepetkata in northeast BASF acquires Ciba and starts Taylor Chemical Co. rebrands India. With a production capacity of 220,000 integration process as Siovation metric tons (m.t.) per year in a single gas- April 9, 2009 – BASF has successfully April 1, 2009 — Taylor Chemical Co. phase reactor, the plant will be able to completed its acquisition of Ciba Holding (Lawrenceville, Ga.), a formulator and manufacture a wide range of LLDPE (linear AG. BASF now holds 95.8% of Ciba. BASF manufacturer of silicone-based technology low-density PE) and HDPE (high-density Board member, Dr. Hans-Ulrich Engel, has has announced a name change of PE) grades.This facility will form part of the become chairman of Ciba’s Board of the 29-yr-old company. The new name, Assam Gas Cracker Project, a grassroots Directors, the company’s senior supervisory Siovation is the culmination of a strategic integrated petrochemical complex being body. BASF intends to fully integrate Ciba transformation into a highly technical set up by BCPL. into the BASF Group.The integration process manufacturer and marketer of silicone- will start with a “discovery phase”, during based products. mergers and acquisitions which time joint teams consisting of BASF Sud-Chemie acquires BASF and Ciba employees will analyze the SOCMA becomes ‘Society of Chemical catalyst site in China acquired businesses in depth.The actual Manufacturers and Affiliates’ April 20, 2009 — Sud-Chemie AG (Munich) integration process will start in July 2009 on March 25, 2009 — In an effort to better serve and BASF SE (Ludwigshafen, both Germany) the basis of these results. the batch, custom and specialty chemical have come to an agreement about Sud- industry, SOCMA members have voted to Chemie’s acquisition of a production site for Emerson acquisition change the organization’s name from the synthesis gas (syngas) catalysts in Nanjing, expands expertise Synthetic Organic Chemical Manufacturers China.This site is independent from BASF’s April 7, 2009 — Emerson Process Association to the Society of Chemical main production facility in the same city.The Management (St. Louis, Mo.) has acquired Manufacturers and Affiliates. parties agreed not to disclose the purchase epro GmbH (Gronau, Germany).The deal price.Through this acquisition, Sud-Chemie expands Emerson’s online machinery- UOP and Ensyn offer second-generation becomes the largest manufacturer of monitoring capability and is expected to biomass technology syngas catalysts in China.The syngas speed availability of next generation solutions. March 24, 2009 — UOP LLC (Des Plaines, catalysts produced in Nanjing are used Terms of the deal were not announced. Ill.), a Honeywell company, has launched primarily in the conversion of coal or natural Envergent Technologies, LLC, a JV with Ensyn gas to ammonia for the fertilizer industry or Dow announces divestiture Corp., to offer technology and equipment the production of methanol. of Morton Salt to convert second-generation biomass into April 3, 2009 — The Dow Chemical Co. (Dow; pyrolysis oil for power generation, heating Textile companies form Midland, Mich.) has announced that Rohm fuel and for conversion into transportation a joint venture and Haas, a wholly owned subsidiary of fuels.The new company will offer Ensyn’s April 20, 2009 — Suminoe Textile Co., and Dow, has entered into an agreement to sell Rapid Thermal Processing technology Teijin Fibers Ltd. have agreed to establish the stock of Morton International, Inc., the to convert second-generation biomass a joint venture (JV) company that will salt business of Rohm and Haas, to K+S AG. to pyrolysis oil.The JV will also accelerate develop, manufacture and sell fabrics for The transaction values Morton International efforts to commercialize next-generation automotive seats and ceilings.The tentative at $1.675 billion and is subject to customary technology to refine the pyrolysis oil into name of the new firm is Suminoe Teijin closing conditions. The deal is expected to transportation fuels. ■ Techno Co., Ltd. , which will begin operating close in mid-2009. Dorothy Lozowski For additional news as it develops, please visit www.che.com May 2009; VOL. 116; NO. 5 Chemical Engineering copyright @ 2009 (ISSN 0009-2460) is published monthly, with an additional issue in October, by Access Intelligence, LLC, 4 Choke Cherry Road, 2nd Floor, Rockville, MD, 20850. Chemical Engineering Executive, Editorial, Advertising and Publication Offices: 110 William Street, 11th Floor, New York, NY 10038; Phone: 212-621-4674, Fax: 212-621-4694. Subscription rates: $59.00 U.S. and U.S. possessions, Canada, Mexico; $179 International. $20.00 Back issue & Single copy sales. Periodicals postage paid at Rockville, MD and additional mailing offices. Postmaster: Send address changes to Chemical Engineering, Fulfillment Manager, P.O. Box 3588, Northbrook, IL 60065-3588. Phone: 847-564-9290, Fax: 847-564-9453, email: clientservices@che.com. Change of address, two to eight week notice requested. For information regarding article reprints, please contact Angie Van Gorder at angie.vangorder@theygsgroup.com. Contents may not be reproduced in any form without written permission. Publica- tions Mail Product Sales Agreement No. PM40063731. Return undeliverable Canadian Addresses to: P.O. Box 1632, Windsor, ON N9A7C9. FOR MORE ECONOMIC INDICATORS, SEE NExT PAGE ChemiCal engineering www.Che.Com may 2009 71
- 90. Economic Indicators 2009 2008 download the cepci two weeks sooner at www.che.com/pci CHEMICAL ENGINEERING PLANT COST INDEX (CEPCI) 650 (1957-59 = 100) Feb. '09 Jan. '09 Feb. '08 Prelim. Final Final Annual Index: CE Index 532.3 539.6 539.8 2001 = 394.3 600 Equipment 631.9 642.4 645.8 2002 = 395.6 Heat exchangers & tanks 587.0 603.4 618.4 Process machinery 615.3 620.0 610.3 2003 = 402.0 550 Pipe, valves & fittings 770.6 781.8 768.2 2004 = 444.2 Process instruments 384.5 389.6 420.2 Pumps & compressors 897.0 902.1 850.5 2005 = 468.2 500 Electrical equipment 458.7 457.9 445.3 2006 = 499.6 Structural supports & misc 660.9 671.5 684.6 450 Construction labor 323.8 324.5 316.2 2007 = 525.4 Buildings 495.4 500.0 483.0 2008 = 575.4 Engineering & supervision 349.8 350.3 354.5 400 J F M A M J J A S O N D Starting with the April 2007 Final numbers, several of the data series for labor and compressors have been converted to accommodate series IDs that were discontinued by the U.S. Bureau of Labor Statistics CURRENT BUSINESS INDICATORS LATEST PREVIOUS YEAR AGO CPI output index (2000 = 100) Mar. '09 = 89.6 Feb. '09 = 91.2 Jan. '09 = 91.5 Mar. '08 = 107.3 CPI value of output, $ billions Feb. '09 = 1,438.0 Jan. '09 = 1,436.7 Dec. '08 = 1,422.1 Feb. '08 = 1,803.9 CPI operating rate, % Mar. '09 = 65.3 Feb. '09 = 66.3 Jan. '09 = 66.5 Mar. '08 = 78.8 Producer prices, industrial chemicals (1982 = 100) Mar. '09 = 224.0 Feb. '09 = 224.1 Jan. '09 = 226.2 Mar. '08 = 261.3 Industrial Production in Manufacturing (2002=100)* Mar. '09 = 95.8 Feb. '09 = 97.5 Jan. '09 = 98.1 Mar. '08 = 112.7 Hourly earnings index, chemical & allied products (1992 = 100) Mar. '09 = 144.2 Feb. '09 = 145.4 Jan. '09 = 145.2 Mar. '08 = 140.9 Productivity index, chemicals & allied products (1992 = 100) Mar. '09 127.2 Feb. '09 = 127.1 Jan. '09 = 125.1 Mar. '08 = 132.7 CPI OUTPUT INDEX (2000 = 100) CPI OUTPUT VALUE ($ Billions) CPI OPERATING RATE (%) 120 2500 85 110 2200 80 100 1900 75 90 1600 70 80 1300 65 70 1000 60 J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D *Due to discontinuance, the Index of Industrial Activity has been replaced by the Industrial Production in Manufacturing index from the U.S. Federal Reserve Board. Current business indicators provided by Global insight, Inc., Lexington, Mass. MARSHALL & SWIFT EQUIPMENT COST INDEX CURRENT TRENDS 1500 (1926 = 100) 1st Q 4th Q 3rd Q 2nd Q 1st Q While the decrease in the 2009 2008 2008 2008 2008 1485 CEPCI from February to M & s Index 1,477.7 1,487.2 1,469.5 1,431.7 1,408.6 March was slightly larger 1470 Process industries, average 1,553.2 1,561.2 1,538.2 1,491.7 1,463.2 than from January to Febru- Cement 1,551.1 1,553.4 1,522.2 1,473.5 1,448.1 1455 ary, the more notable trend Chemicals 1,523.8 1,533.7 1,511.5 1,464.8 1,438.5 1440 is the difference between Clay products 1,526.4 1,524.4 1,495.6 1,453.5 1,429.1 Glass 1,439.8 1,448.1 1,432.4 1,385.1 1,359.7 the February number and 1425 Paint 1,554.1 1,564.2 1,543.9 1,494.8 1,467.6 that of the previous year. As Paper 1,453.3 1,462.9 1,443.1 1,400.0 1,377.7 1410 expected, the preliminary Petroleum products 1,663.6 1,668.9 1,644.4 1,594.4 1,555.8 February CEPCI marks the 1395 Rubber 1,600.3 1,604.6 1,575.6 1,537.5 1,512.3 first time since the beginning Related industries 1380 of this particular economic Electrical power 1,425.0 1,454.2 1,454.4 1,412.8 1,380.4 1365 slowdown that the CEPCI has Mining, milling 1,573.0 1,567.5 1,546.2 1,498.9 1,473.3 dipped below its value at this Refrigeration 1,807.3 1,818.1 1,793.1 1,741.4 1,711.9 1350 time one year ago. Steam power 1,509.3 1,521.9 1,499.3 1,453.2 1,426.8 1335 Visit www.che.com/pci for Annual Index: 1320 more on capital cost trends 2001 = 1,093.9 2003 = 1,123.6 2005 = 1,244.5 2007 = 1,373.3 1st 2nd 3rd 4th and methodology. ■ 2002 = 1,104.2 2004 = 1,178.5 2006 = 1,302.3 2008 = 1,449.3 Quarter 72 ChemiCal engineering www.Che.Com may 2009
- 91. Silverson’s high shear Batch mixers don’t just mix; they emulsify, homogenize, solubilize, suspend, disperse and disintegrate solids. Every high shear Batch mixer in our range significantly outperforms conventional mixers by cutting processing times by up to 90% while improving quality, product consistency and process efficiency. Silverson High Shear Batch Mixers will: • Process from 1 to 8000 gallons • Eliminate agglomerates and fish eyes • Create stable emulsions and suspensions • Reduce particle size • Rapidly dissolve solids • Accelerate reactions For more information or a free trial give us a call @ 800.204.6400 Mixing at the speed of silverson.com Circle 02 on p. 70 or go to adlinks.che.com/23014-02
- 92. Circle 03 on p. 70 or go to adlinks.che.com/23014-03