Chemical Engineering Magazine, March 2015

March 2015

www.chemengonline.com

Improving Rotating Machinery Operations

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M A N A G I N G S T E A M S Y S T E M S

Interphex Show Preview

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P R E V E N T I N G C O M B U S T I B L E D U S T E X P L O S I O N S

Preventing Combustible Dust Explosions

Facts at Your Fingertips: Steel Corrosion

Carbon Capture Technologies

Process Control: Integrating Instruments and Systems

Targeting Metha Methane ne Emissions

Managing Steam Systems page 50

V O L . 1 2 2 N O . 3

M A R C H 2 0 1 5 •

We create create chemistry that lets individual needs love lov e global innovation.

As the global leader in catalysis, BASF draws on the talent and expertise of more than 1,100 researchers working in close partnership with our customers. This collaboration results in innovations that drive new levels of performance and achievement, today and over the long term. When global catalyst innovations help our customers become more successful, it’s because at BASF BASF,, we create chemistry. www.catalysts.basf.com Circle 4 on p. 82 or go to adlinks.che.com/56195-04


March 2015

Volume 122 | no. 3

Cover Story 50

Part 1: Why Bad Things Happen to Good Steam crucial Equipment Accounting for an entire steam trap population is crucial to avoiding safety incidents and sub-optimal production — high-priority consideration must be given to steam-system management

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Part 2: Mitigate Corrosion in CondensateReturn Systems Understanding the chemistry behind corrosion in condensate-return systems can aid in selecting and properly employing the best mitigation technique

In the News 7

Chementator Catalytic filter bags can slash investment cost for offgas treatment; This proces process s enables enables Mg alloy alloy to be cast economic economically; ally; ‘Anode‘Anodeless’ lithium battery prototype doubles energy density; Scaleup for modular H2 production via PEM electrolysis; Carbon fibers enhance swine wastewater treatment; CO2 capture with permeable polymer microcapsules; and more

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Business News Prayon to build food-grade hexametaphosphate plant in Georgia; Showa Denko JV starts up alumina plant in Indonesia; Kuraray boosts production capacity for ethylene vinyl alcohol; Arkema starts up thiochemicals plant in Malaysia; Methanex starts up relocated Geismar methanol plant; and more

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Newsfront T Target argeting ing Methane Methane Emiss Emissions ions New sensor, sealing and vapor-recovery technologies aim to reduce methane (CH4 ) emissions

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Newsfront Process Control Provides A Holistic View Integration between instruments and systems allows manufacturers to align process parameters with business performance

Technical T echnical and Practical Practical 46

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Facts at your Fingertips Steel Corrosion This one-page reference provides provides descriptions of corrosion corrosion mechanisms and corrosion resistance of various types of steel

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Technology Technol ogy Profil Profile e Propane Dehydrogenation to Make Propylene: the Oxydehydrogenation Approach

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A process to manufacture on-purpose on-purpose propylene by dehydrogenation dehydrogenation of propane is described

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Feature Report Prevent Combustible Dust Explosions With Nitrogen Inerting Targeted use of blanketing with inert gas offers an effective strategy for Targeted preventing combustible dust explosions in CPI facilities

CHEMICAL ENGINEERING

WWW.CHEMENGONLINE.COM

MARCH 2015

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Environmental Manager Post-Combustion Carbon Capture Technologies Several carbon-capture processes hold much promise, but there are challenges yet to be met

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Engineering Practice Rotating Machinery: What You Should Know About Operational Problems Follow this guidance to improve the operation, safety and reliability of rotating machinery in CPI plants

Equipment and Services 33

Focus Bulk Solids Handling A high-level detector has a mercury-free tilt switch; Magnetic pulleys help belt belt conveyors to separate metals; This firm offers flow-properties testing services; This radar level-detection probe is undaunted undaunted by uneven surfaces; Protect powder-handling powder-han dling systems from explosion risk; and more

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New Products Tank-cleaning nozzles that can handle lower flowrates; A fully temperature Tank-cleaning compensated handheld pressure calibrator; These industrial-gas pressure regulators have three outlet ports; A sealless thermoplastic pump for open tanks and sumps; and more

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Show Preview Interphex 2015 The Interphex conference and tradeshow will take place April April 21–23 in New York Y ork City. City. Here are a few of the many products products and services to be showcased

Departments 5

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Editor’s Page A ‘most-w ‘most-wanted’ anted’ safety impr improvem ovement ent Combustible dust is too often cited as the cause of serious accidents. The U.S. Chemical Safety Board recommends a comprehensive standard

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Economic Indicators

Advertisers

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36I-1European Special Advertising Section 79

Product Showcase

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Classified

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Reader Service

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Ad Index

Chemical Connections Follow @ChemEng @ChemEngMag Mag on Twitter Join the Chemical Engineering Magazine Magazine LinkedIn Group Visit us on www www.chemengonline.com .chemengonline.com for Latest News, Web-exclusive Web-exc lusive artic articles, les, Inform Information ation on the Nichol Nicholas as Chopey Scholarship, Test your Knowledge Quizzes, Bookshelf and more

Coming in April Look for: Feature Reports on Distillation; and Vacuum Dryers; A Focus on Compressors, Fans and Blowers; A Facts at your Fingertips on Biotechnology; a Solids Processing article on Size Reduction; an Engineering Practice article on Rectangular Tanks; News Articles on Metals Recovery; and Analyzers; and more Cover: Rob Hudgins, photo courtesy of TLV Corp. 2



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A ‘most wanted’ safety improvement improvement

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n the chemical process industries (CPI), dust can present an issue far more menacing than a housekeeping nuisance. Combustible dust is in fact, much too often listed as a cause of serious, and even fatal accidents.

Incidents In January of this year, the U.S. Chemical Safety Board (CSB; Washington, D.C., www.csb.gov) issued its report on the U.S. Ink plant flash fire that burned seven workers. This incident, which occurred in October 2012 in East Rutherford, N.J., was found to have resulted from the accumulation of combustible dust inside a dust-collection system that had been put into operation four days prior to the accident. One of the key findings in the report is that while the dustcollection system was designed for dust collection, it was modified to include a housekeeping function, which caused insufficient flowrates. The CSB report notes that the volume of air flow and the air velocity were below industry recommendations. In 2006, the CSB issued a comprehensive report on combustible dust hazards that was based on investigations of three major industrial explosions that occurred in the U.S. in 2003 alone. The three incidents, in North Carolina, Kentucky and Indiana, cost 14 lives and numerous injuries. In that 2006 study, the CSB identified 281 combustible-dust incidents that occurred in the previous 25 years and claimed 119 lives with over 700 injuries. Since 2006, the CSB documented 50 combustible-dust incidents that resulted in 29 fatalities and 161 injuries. These include the 2008 Imperial Sugar disaster near Savannah, Ga., and three incidents over a six-month period in 2011 at a powdered-metal plant in Gallatin, Tenn.

Standards and regulations What is striking in the reports about dust explosions is that at least in some cases, known engineering controls may have been preventative. In its 2006 investigation report “Combustible Dust Hazard Study,” the CSB recommended that the Occupational Safety and Health Admin. (OSHA; Wash Washington, ington, D.C.; www.os www.osha.gov) ha.gov) issue a standard to prevent combustible-dust fires and explosions based on standards already available from the National Fire Protection Agency (NFPA; Quincy, Mass.; www.nfpa.org). The CSB reiterates this recommendation in numerous subsequent reports including its most recent one issued in January. While standards exist, they are voluntary and not enforced through federal regulations. In 2013, the CSB designated a comprehensive general industry standard for combustible dust as its first “Most Wanted Chemical Safety Improvement.”

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Resources In the meantime, a wealth of information about combustible dust is available. The CSB website contains many lessons learned from incident investigations in both report and video format. The NFPA offers a number of relevant standards. OSHA offers various resources, including information on its Combustible Dust National Emphasis Program (NEP). And numerous articles, such as the Feature Report in this issue (Prevent Combustible Dust Explosions With Nitrogen Inerting, p. 64) help to share knowledge an d insight into ■ this important issue. Dorothy Lozowski, Editor in Chief


MARCH 2015

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Chementator Catalytic filter bags can slash investment costs for offgas treatment

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ast January, Haldor Clean gas side Topsø T opsøe e A/S (Ly (LynnClean gas side gby; www.topsoe. Raw gas side Three-layers woven glass com) and FLSmidth bags with embedded HAP* catalyst. One of the glass A/S (Copen (Copenhage hagen, n, both CO2 bags with e-PTFE membrane CO 2 Denmark; www.flsmidth. NH3 N2 com) began a joint, global N2 O2 Raw gas with effort to commercialize NOx dust and H2O pollutants a new catalytic filter-bag O2 technology, which the partCO Dust ners have developed over Three layers the past four years. Tradeglass bags named EnviroTex, these filand e-PTFE membranes ter bags are capable of reducing dust, volatile organic Dust is collected Pollutants removal Cleaned glass catalytic pass filter element compounds (VOCs) and on the surface by process oxides of nitrogen (NOx) in a *Organic HAP includes formadehyde, benzene, toluene, single, integrated process, styrene (m-, p-, o-) xylene, acetaldehyde and napt halene says Mikkel Nygaard Larsen, general manager, marketing and sales pollutants are catalytically decomposed into at Haldor Topsøe. Because EnviroTex treats harmless compounds (CO 2, N2, O2 and H2O). several pollutants in a single step, the physi- Even under “the highest” dust load, Envirocal footprint of the treatment process is re- T Tex ex will remove remove particu particulate late matter matter to below below 2 duced compared to alternative technologies parts per million, says Nygaard Larsen. VOC that require separate, standalone systems and NOx removal is typically more than 90% to handle a specific pollutant, says Nygaard of the incoming concentration, he says. Larsen, and capital expenditures (capex) are The new filte filters rs are said to be suita suitable ble for significantly reduced — “by as much as 80% a wide range of industries, including cement, for some applications.” glass and steel production; power genera The paten patent-pen t-pending ding Envir EnviroT oTex ex filte filterr bags tion; waste incineration; and coffee and grain consist of three layers of filter fabric, each of roasting. The new filters will be manufactured which contains a tailored catalyst that has at FLSmidth’s bag-production facilities in been optimized for removing specific pollut- Evans, Ga. The bags will then be “catalyzed” ants from offgases (diagram). The three-layer and assembled at Topsøe’s production site in fabric has a porous, woven structure and the Houston. Topsøe’s production site will be excatalyst is a mixture of active base and pre- panded to include a new production line dedcious metals. As the offgas passes through icated to producing EnviroTex. Construction the filter, dust is filtered on the first layer, and on this facility is slated for the end of 2015.

Edited by: Gerald Ondrey COMPOSITE COATING A new composite material that prevents metal corrosion, even under extreme conditions, has been developed by researchers from the INM – Leibniz Institute for New Materials GmbH (Germany; www www.inm-gmbh. .inm-gmbh. de). The patented composite consists of layers of particles placed on top of each other in a staggered fashion, creating a self-organized, highly structured barrier, says Carsten Becker-Willinger, head of the Nanomers Program Division. The protective layer is just a few micrometers thick and prevents penetration by gases and electrolytes. It provides protection against corrosion caused by aggressive aqueous solutions, including salt and acids, as well as corrosive gases under pressure. After thermal curing, the composite adheres to the metal substrate, is abrasionstable and impact-resistant. It can be applied by spraying or other commonly used wet-chemistry processes, and cures at 150–200°C. It is suitable for steels, metal alloys and metals such as aluminum, magnesium and copper, and can be used to coat (Continues on p. 8)

This process enables Mg alloy to be cast economically

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he New Energy and Industrial Technology T echnology Development Organization (NEDO; Kawasaki; www.nedo.go.jp) and Sankyo Tateyama T ateyama Inc. (T (Takaoka, akaoka, both Japan; www.st-grp.co.jp) have developed technology that enables the casting of small-diameter (500–100-mm dia.) magnesium-alloy billets, which are suitable for direct, compact forging. The production costs are said to be half those of existing technology, which involves an expensive and inefficient extrusion and forging process. The breakthr breakthrough ough is expected to en-

able a wider application of magnesium in automotive, consumer electronics and robotic products as an alternative to aluminum and iron. The new castin casting g procedu procedure re uses an adiabatic, structured template, which suppresses the coagulation of the melted materials within the template and enhances the rapid quenching and coagulation by means of cooling water injected at the bottom of the template. This procedure enables the structural refinement and formation of a dense solid texture, with average crystal-

grain size of 50 μm, and a dendrite arm spacing (DAS; a measure of the metal’s microstructure) of less than 15 μm. These parameters are about half those generated by existing billet-formation technology, and thus show that the magnesium-alloy billet has a significantly finer and homogeneous coagulation texture. Sankyo Tateyama has begun shipping samples of the cast billets. The partners have also started to develop multi-face, concurrent continuous casting technology, which will enable mass production.

Note: For more information, circle the 56-digit number on p. 82, or use the website designation. CHEMICAL ENGINEERING


MARCH 2015

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any shape of plates, pipes, gear wheels, tools or machine parts. The composite does not contain chromium VI or other heavy metals.

SELECTIVE MEMBRANE New selective hollow-fiber membranes that could enable water purification in a single step have been developed by researchers from the University of Twente’ T wente’s s (www (www.utwente.nl) .utwente.nl) MESA+ Research Institute, in collaboration with Pentair (Enschede, both the Netherlands; www.pentair.com). The membranes make it possible to purify water in a single process step (eliminating pretreatment required in existing water-treatment plants) while removing micropollutants, such as pharmaceutical residues (medicine residues, hormones and pesticides). The selective selective membrane is applied to thin porous straws (5-nm pore sizes). Multiple thin layers of polymer coating (of about 2-nm thick) are applied over the holes by means of a relatively simple chemical process that avoids solvents. Creation of the polymer layers can be controlled very accurately, so the number of layers, the density and the charge of the layers, and so on, can be chosen to suit the desired application. Modules containing more than 10,000 of the fibers (1-m long) can be numbered up for an industrial water-tr water-treatment eatment plant. Pentair is taking over the further product development of the membrane.

‘GREEN’ TIRES At last month’ month’s s Tire Technology Expo (February 10–12; Cologne, Germany), Solvay S.A.’s Silica business unit unveiled Efficium, which the company says is a breakthrough highly dispersible silica (HDS). Used as a reinforcing filler, Efficium allows for higher productivity and greater flexibility in producing “green” tire compounds for cars and trucks.

‘Anode-less’ lithium battery prototype doubles energy density

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new prototype Carbon anode lithium battery with a very thin metal anode achieves an energy Separator density of 1,200 W-h/L at room temperature — Cathode double that of conventional Li-ion batteries Carbon anode cell using graphite anodes. 600 Wh/L The prototype battery battery,, developed by Massachusetts Institute of Technology’s (MIT; Cambridge, Mass.; www.mit.edu) spin-off SolidEnergy (Waltham, Mass.; www.solidenergysystems.com), uses a standard lithiumcobalt oxide (LCO) cathode with an ultrathin, two-layer, lithium-on-copper anode that allows larger energy density. SolidEnergy has developed a specialized electrolyte that allows the system to work. “The key know-how is really in the electrolyte,” says Qichao Hu, “because conventional electrolytes do not work with this kind of battery system.” SolidEnergy’s electrolyte has two parts: a liquid around the cathode and a solid polymer composite electrolyte on the anode of the battery. To make it work at

Silicon-composite anode

Ultra-thin metal anode Solid polymer ionic liquid

Separator

Cathode

Cathode

Silicon anode cell 800 Wh/L

Near “anode-less” cell 1200 Wh/L

room temperature, SolidEnergy developed a proprietary mixture of ionic liquids, a new salt species and other new materials with high conductivity and efficiency. SolidEnergy partnered with fellow MIT product A123 Venture Technologies (Waltham, Mass.; www.a123systems.com) to fabricate the prototype. Going forward, SolidEnergy will focus on supplying the new electrolytes and anode materials to large manufacturers of Li-ion batteries used in consumer electronics and other applications. The company plans a pilot facility, to be completed in late 2016, that will be able to produce the materials for the equivalent of 30 million cell phone batteries per year, says Hu.

Scaleup for modular H2 production via PEM electrolysis

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wo new proton-exchange-membrane (PEM) electrolysis systems have debuted, targeting applications that require large volumes of hydrogen. Prior to the launch of Proton OnSite’s (Wallingford, Conn.; www. protononsite.com) M1 and M2 modular H 2generation systems, the largest capacity commercially available from PEM modules was just 30 m 3 /h H2, says the company. The M1 and M2 system systems s can produc produce e 200 3 3 m /h and 400 m /h of H2, respectively, representing an intensive scaleup effort. Multiple units can be connected to achieve even greater production capabilities for huge-scale projects. In order to reach these higher capacities while ensuring safe operation, the M1 and M2 were designed with a specific emphasis on the differential pressure (DP) between the H 2 and O2 sides of the membrane. Maintaining a DP of 30 bars across the membrane minimizes gas crossover problems, and also allows the system to produce a very high-quality H2 stream. Furthermore, this DP approach

enables a simplified, low-pressure watercirculation loop that removes any hazards due to pressurized O 2, and allows for a passive system shutdown. Another safety advantage of employing onsite H 2 generation is that the safety risks associated with longterm H 2 storage (in the case of purchased hydrogen) are eliminated. This is especially important for remote manufacturing locations. Applications for the M1 and M2 include pharmaceuticals and semiconductor manufacturing, as well as large-scale industrial heat-treating. In semiconductor applications, the generated H 2 can be used for oxygen scavenging or as a carrier gas. Potentially, the most promising outlet for large-scale H 2 generation lies in the fields of energy storage and fuel cells, where the modules can be installed into existing infrastructure. The generated H 2 can also be injected into methanation processes and integrated into the natural-gas grid or used for upgrading biogas.

(Continues on p. 14)

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Carbon fibers enhance swine wastewater treatment

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akahiro Yamashita and colleagues at the Institute of Livestock and Grassland Science, National Agriculture and Food Research Organization (NARO, Tsukuba, Japan; www. naro.affrc.go.jp) have developed an aerobic bioreactor that can reduce nitrous oxide emissions by nearly 90% in the treatment of swine wastewater. The reactor uses an array of horizontal carbon fibers (CF) within the reactor column to support microorganisms. A CF rea reacto ctorr with an eff effect ective ive volume of 10 L was tested against a conventional activated-sludge (AS) reactor (diagram), and was shown to achieve a 90% reduction in the released N 2O — a greenhouse gas with a global warming potential that is 300-times higher than that of carbon dioxide. The CF react reactor or also also showed showed a “dras“drastic” reduction in dissolved nitrogen. The researchers evaluated the water quality of influent and effluent during 73 to 176 days operation

Mesh cylinder to after 72 days acclimation support carrier A period. The removal effiTop view ciencies of the CF reactor Effluent were 96% for biochemical oxygen demand (BOD), 5 cm 94% for suspended solids Air Carbon fibers fixed at a 90-deg angle (SS), 93% for total organic Pump Blower carbon (TOC) and 90% for Influent total nitrogen (TN). In the Side view 55 cm CF reactor, 156 mg/L of the B dissolved inorganic nitroDistance: 5 cm gen (DIN) was removed as 11 units Effluent 5 cm NH4-N, which left 14 mg/L Plastic mesh cylinder DIN as NO3-N; the DIN as NO2-N was almost undetectable. In comparison, Swine Pump Blower wastewater the removal efficiencies of (A) Aerobic bioreactor packed with carbon fibers (CF reactor) the AS reactor were 94% (B) Aerobic bioreactor mixed with activated sludge (AS reactor) for BOD, 76% for SS, 82% for TOC, and 26% for TN. In the AS reactor, 144 mg/L of the tor were 725 g-CO2 eq/m3 /d. DIN was removed as NH 4-N, leaving NARO has now started to conduct behind 183 mg/L DIN as NO 3-N; the tests with a demonstration-scale reDIN as NO2-N was also undetect- actor with an effective working volable. N2O and CH4 emissions from ume of 700 L, and the researchers the CF reactor were w ere 42 g-CO2 eq/ are optimizing the reaction condi3 m /d, while those from the AS reactions for further scaleup.

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Frankfurt am Main · 15 – 19 June 2015

Scaleup for a test facility to grow algae for biofuels

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he New Energy and Industrial Technology Development Organization (NEDO, Kawasaki; www. nedo.go.jp) and partners IHI Corp. (Tokyo; www. ihi.co.jp), Kobe University (www.ko (www.kobe-u.ac.jp) be-u.ac.jp) and Neo-Morgan Laboratory Inc. (NML; Kawasaki, all Japan; www.neo-morgan.com) have completed construction on an outdoor test site with 1,500-m 2 of pond surface area for further development work on the production of biofuels (including jet fuel) from algae. Located at Nanatsu Island, Kagoshima Prefecture Prefecture in Japan, the facility will start up next month, and be used for developing a complete process for biofuel production, including the extraction process, working to lower production costs and enable stable mass-production. The facility is part of the NEDO project, “Development of the application technology of the strategic next-generation bio-mass energy.” The project will be looking at further developing the algae, Botryococcus braunii , which has a good potential for algaculture because of the type of hydrocarbons (HCs) it produces, and the fact that up to 86 wt.% (dry) can be long-chain HCs, which can be hydrocracked into fuels. The main drawback for this promising algae had been its slow growth rate. But in 2013, IHI NeoG Algae LLC (a joint venture of IHI, Gene & Gene Technology (G> Suita, Japan) and NML operated a 100-m 2 outdoor facility in IHI’s Yokohama site. With NEDO support, the company demonstrated the world’s fasted growth rate for a Botryococcus braunii strain — 1,000 times faster than ordinary Botryococcus braunii . This fast-growing strain was first discovered by professor Taira Enomoto at Kobe University, further refined by G>, and improved by NML. The collaborations led to new strains with notable characteristics, such as larger algae bodies with improved floating performance.

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new type of CO2-capture media based on permeable polymer microcapsules has been developed by teams of scientists at Lawrence Livermore National Laboratory (Livermore, Calif.; www.llnl.gov), Harvard University (Cambridge, Mass.; www.harvard.edu) and the University of Illinois-UrbanaChampaign (www.illinois.edu). The materials have several advantages over amine-based approaches to absorbing CO2 from power-plant fluegas.



MARCH 2015

Using microfluidics techniques, the scientists produced microcapsules (photo, p. 12) that contain a liquid sorbent — sodium carbonate solution combined with a catalyst — that can absorb CO2 quickly. The microcapsules are made from a highly permeable silicone polymer material that allows CO 2 molecules to pass through, but prevents the sorbent material from escaping. By forcing the sorbent to remain in small droplets, the microcapsules can maximize the surface area that contacts CO 2. The permeable microbea microbeads ds are inexpensive to make, easy to handle and produce minimal waste, the researchers say, and with encapsulated fluids inside, they allow users to combine the advantages of solid and liquid CO 2capture media in the same system, while avoiding many of the environmental and corrosion issues posed by aminebased CO2 capture. Microcapsules have been used in a variety of products previously, including pharmaceuticals, cosmetics and food, but the scientists say their work is the first demonstration of the use of microcapsules in CO 2 capture. The project was detailed in a research paper published in a recent issue of Nature Communications. The researchers are working on enhancements that will allow scaleup of the technology. t echnology.

Perfluorinated compounds may pose a risk to firefighters

P

erfluorinated compounds — firefighting foams — such as perfluorooctane sulfonates (PFOS) have been used as fire suppressants, but some of them, such as perfluoroalkyl acids have been associated with serious environmental contamination. Also, several new fluorinated surfactants have been developed lately, and there has been concern over the effect of those substances on wildlife and on firefighters who are most exposed to them. However, several of those new compounds have not yet been identified and it may be very difficult to identify them. Now,, a team from the University Now Univer sity of Queensland (Brisbane, Australia; www.uq.edu.au), Örebro University (Örebro, Sweden; www.oru.se), and Queensland University of Technology (Brisbane, Australia; www.qut. edu.au) has developed a method borrowed from medicine for identifying those substances in the blood of firefighters. The team compared the fluorinated surfactants found in the blood of 20 firefighters with compounds in the blood of 20 people who had not been exposed to firefighting foams. The team ran the blood sample sampless through the tradi tradi-tional quadrupole time-of-flight tandem mass spectrometry (QTOF-MS/MS) and has identified more than 3,000 organic and fluorinated compounds. However, when the team applied a statistical analysis to the data, a clear distinction appeared between the firefighters and the controls. The team found nine flu orinated compounds in the firefighters’ blood, either exclusively or at much higher levels. Only five of those compounds appeared in online chemical databases or in the literature interpreting the MS data. The team has tentatively identified the other four four,, unknown unknown compounds as sulfonic acids analogous to PFOS.

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Efficium allows allows for increased productivity (by up to 30% for truck tires) due to its impact on mixing and extrusion throughput, says the company. An additional benefit is added flexibility for compounders due to its silanization control and reformulation opportunities, without compromising on rolling resistance, wear and grip, the company adds.

NON-STICK POL POLYMERS YMERS Researchers at Harvard University’s Wyss Institute (Boston, Mass.; www.wyss. harvard.edu) have developed a surface technique that can prevent the formation of biofilms on medical surfaces. The approach, called liquid-infused polymers, enables polymers to soak up and store lubricating liquids that can move to the surface and prohibit bacteria from forming films. The the effect was studied using a solid silicone.

An electrochemica electrochemicall process to mimic photosynthesis

P

hotosynthesis is one of the best ways to convert carbon dioxide into renewable energy and at the same time, reduce the concentration of CO2 in the atmosphere. In plants, there are two main steps in photosynthesis: First, water is split (via solar energy), generating a proton and releasing oxygen. The second step (Calvin cycle) is a dark reaction where CO2 absorbed from the atmosphere is reduced to glucose. A proton is carried via NADPH (nicotinamide adenine dinucleotide phosphate-oxidase) and transferred to the Calvin cycle as a source of hydrogen and energy. A key step in the process is the hydrogenation drogenatio n of CO2 to organic compounds. Professor Jeffrey Chi-Sheng Wu, of the Dept. of Chemical Engineering, National Taiwan University (Taipei; ntu.edu.tw), has studied the photocatalytic hydrogenation of CO 2 by a novel twin reactor to mimic photosynthesis under light irradiation. His process is said to have a higher photoconversion yield of CO2 than that achieved in a single reactor. reactor. The twin reactor divides the hydrogen photocatalyst and the oxygen photocata-

lyst into two compartments using a membrane, which separates the H + ions and O2 molecules, preventing a reverse reaction. Wu used Pt/SrTiO 3:Rh as the hydrogen photocatalyst and BiVO 4 as the O2 photocatalyst. Iron is used as an electron mediator. Oxygen is released at one side of the reactor, while H+ ions diffuse through the membrane to the other side. There, CO 2 molecules are reduced to hydrocarbons by the photocatalyst. Wu investigated the diffusion of the Fe 2+ / Fe3+ through a Nafion 117 membrane. The transfer rate of mediator ions was significantly larger than the photoreaction rate, indicating that the membrane did not delay the water-splitting reaction in the twin reactor.. The H2 generation rate reached 0.65 actor µmol/g .h and matched the H 2 /O2 stoichiometric ratio of water splitting. Wu found that the hydrogen-generation in the twin reactor system was the rate-limiting side. By using a twin reactor, the deactivation of Pt/ SrTiO3:Rh could be minimized due to the suppression of Fe(OH) 3 formation on the photocatalyst surface. ■

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Business News LINEUP ANELLOTECH ARKEMA BASF BENTLEY DAIKIN FMC JOHNSON MATTHEY KURARAY

Plant Watch

Prayon to build food-grade sodium hexametaphosphate plant in Georgia February 11, 2015 — Prayon S.A. (Engis, Belgium; www.prayon.com) plans to build a manufacturing plant for food-grade sodium hexametaphosphate (SHMP) in Augusta, Ga. Projected capacity of the new SHMP unit is 10,000 metric tons per year (m.t./yr). Supplementing an existing SHMP production site in Roches de Condrieu, France, the Augusta plant will double the company’s global SHMP production capacity.

LUBRIZOL METHENEX PPG PRAYON SHOWA DENKO SOLVAY STYROLUTION TECHNIP THERMO FISHER SCIENTIFIC W.R. GRACE

Showa Denko JV starts up alumina plant in Indonesia February 9, 2015 — P.T. Indonesia Chemical Alumina, a joint venture (JV) owned by Showa Denko K.K. (SDK; Tokyo, Japan; www.sdk.co.jp) and PT Antam (Persero) Tbk., of Indonesia, has started commercial operations at its new alumina plant in West Kalimantan, Indonesia. The plant’s production capacity for alumina is 300,000 m.t./yr. Kuraray boosts production capacity for ethylene vinyl alcohol in Belgium February 6, 2015 — Kuraray Co. (Tokyo, Japan; www.kuraray.co.jp) will increase the production capacity for ethylene vinyl alcohol copolymer (EVOH) resin at the Antwerp, Belgium site of EVAL Europe N.V., a wholly owned Kuraray subsidiary. The capacity increase will add 11,000 m.t./yr of EVOH production capability capabili ty.. The expanded facilities facilitie s are expected to begin operations in late 2016.

benzene styrene monomer (EBSM) plant to be located in Qingdao City, China. The plant’s planned EBSM production capacity is 500,000 m.t./yr. PPG plans capacity expansion for precipitated precipitate d silica at Netherlands site February 3, 2015 — PPG Industries, Inc. (Pittsburgh, Pa.; www.ppg.com) is increasing production capacity for precipitated silica at its manufacturing location in Delfzijl, the Netherlands, by more than 15,000 m.t./yr. The capacity capacity expansion expansion is expected expected to to come online in 2016. Arkema starts up thiochemicals plant in Malaysia January 30, 2015 — Arkema (Colombes, France; www.arkema.com) has started up a new thiochemicals-production facility. Located in Kerteh, Malaysia, the new site produces methyl mercaptan for use us e as a synthesis intermediate in animal feed and dimethyl disulfide. Arkema’s investment in the construction of this facility totaled €200 million. Methanex starts up relocated Geismar methanol plant January 26, 2015 Methanex Corp. (Vancouver, B.C., Canada; www.methanex.com) started up its methanol plant in Geismar, La. The plant’s capacity is 1 million m.t./yr of methanol. The plant was relocated from the company’s site in Punta Arenas, Chile. BASF plans worldwide expansion of PVP production January 22, 2015 — BASF SE (Ludwigshafen, Germany; www.basf.com) plans to invest up to €56 million in the expansion of its polyvinylpyrrolidone (PVP) value chain over the next four years. Through revamping existing plants in Ludwigshafen and Geismar, and introducing PVP technology at a site in Shanghai, the company will increase its global PVP production capacities by up to 6,000 m.t./yr.

Styrolution opens styrene-butadiene copolymer pilot plant in Antwerp February 5, 2015 — Styrolution Group GmbH (Frankfurt am Main, Germany; www. styrolution.com) launched a styrene-butadiene copolymer (SBC) pilot plant in Antwerp, Belgium. An identical but scaled-down version of Styrolution’s larger production SBC plant pl ant in Antwerp, which which has a production production capacity capacity of 65,000 m.t./yr, the pilot plant will be used to conduct research, and to enhance specialty Solvay building new hydrogen peroxide plant in the Netherlands styrenics products. January 22, 2015 — Solvay S.A. (Brussels, Technip awarded contract contra ct for Qingdao Belgium; www.solvay.com) plans to build ethylbenzene ethylbenzen e styrene monomer plant a new manufacturing and filling facility to February 3, 2015 — Technip (Paris, France; produce hydrogen peroxide grades for the www.technip.com) was awarded a contract pharmaceutical industry. The new facility is by Qingdao Soda Ash Industrial New Mate- located at Solvay’s peroxide-production site Look for more rial & Technology Co. to provide the technol- in Linne-Herten, the Netherlands, and is exlatest news on chemengonline.com ogy, engineering and services for an ethyl- pected to be completed in July 2015. 16



MARCH 2015

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Mergers & Acquisitions Bentley acquires modeling software company Acute3D February 10, 2015 — Bentley Systems, Inc. (Exton, Pa.; www.bentley. com) has acquired Acute3D (Valbonne; France; www.acute3d.com), a provider of software for reality modeling. Acute3D’s software automates the generation of high-resolution, three-dimensional representations from digital photographs.

Thermo Fisher Scientific acquires Advanced Scientifics February 5, 2015 — Thermo Fisher Scientific Inc. (Waltham, Mass.; www. thermofisher.com) has acquired Advanced Scientifics, Inc. (ASI; Millersburg, Pa.; www.asius.com) for $300 million. ASI designs, manufactures and delivers single-use systems and equipment for the preparation, processing, storage and transportation of biopharmaceuticals.

W.R. Grace to split into two separate companies February 5, 2015 — W.R. Grace & Co. (Columbia, Md.; www.grace. com) has announced a plan to separate into two independent companies. The two companies, to be named prior to closing, will be “New Grace,” comprised of Grace’s Grace’s Catalysts Technologies and Materials Technologies business segments, and “New GCP,” comprised of Grace’s Construction Products business segment and the Darex packaging business.

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Johnson Matthey and Anellotech to jointly develop catalytic systems February 4, 2015 — Anellotech Inc. (Pearl River, N.Y.; www.anellotech. com) and Johnson Matthey plc (London; www.matthey.com) will co-develop advanced catalyst systems for Anellotech’ Anellot ech’ss Catalyt Catalytic ic Fast Pyroly Pyrolysis sis Process for producing bio-based benzene, toluene and para-xylene. FMC sells Alkali Chemicals business to Tronox Tronox for $1.64 billion February 4, 2015 — Tronox Ltd. (Stamford, Conn.; www.tronox.com) has signed a definitive agreement to acquire FMC Corp.’s (Philadelphia, Pa.; www.fmc.com) Alkali Chemicals business for $1.64 billion. Lubrizol acquires Brazilian coatings company EcoQuimica February 2, 2015 — The Lubrizol Corp. (Wickliffe, Ohio; www.lubrizol. com) has acquired São Paulo-based EcoQuimica Industria e Comercio Produtos Quimica Ltda., a manufacturer and supplier of coatings technology. EcoQuimica is now part of Lubrizol Advanced Materials, reporting to the Performance Coatings business.

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Solvay to divest Frankfurt-based refrigerant business to Daikin January 30, 2015 — Solvay S.A. will sell its refrigerant and pharma propellants business based in Frankfurt, am Main Germany, to Daikin Industries, Ltd. (Osaka, Japan; www.daikin.com). The divestiture ture comes as Solvay increases focus on fluorine specialties and high-purity chemicals. ■ Mary Page Bailey WWW.CHEMENGONLINE.COM

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Newsfront

Ta T argeting Methane Emissions New sensor, sensor, sealing and vapor-recovery technologies aim to reduce methane emissions Source: Hy-Bon

IN BRIEF

Vapor combustor unit (VCU)

SOURCES OF METHANE EMISSIONS

Compressor building

INEXPENSIVE MONITORING SEALING TECHNOLOGY

Vapor recovery tower (VRT)

Tank battery

Vapor recovery unit (VRU)

Instead of being released to the the atmosphere, associated associated gas from oil wells can be recovered at various stages of the production process, and then be either compressed and fed to gas pipelines or used as fuel, or burned with heat recovery FIGURE 1.

To well heads

Low pressure separator

O

n January 14, the Obama Admin- from the production, transmission and disistration announced a new goal tribution of NG. Although emissions from the to cut methane emissions from O&G sector are down 16% from 1990 levels, the oil-and-gas (O&G) sector by the emissions are projected to rise more than 40–45% from 2012 levels by 2025. The an- 25% by 2025 without additional steps to nouncement builds on the foundation for fur- lower them, according to The White House ther action laid out by the U.S. Environmen- Office of the Press Secretary. Achieving the tal Protection Agency (EPA; Washington, Administration’ Administration’s s target target would save up to 180 180 D.C.; www.epa.gov), which in 2012 issued billion cubic feet of NG. The initiative would standards for volatile organic compounds also support businesses that manufacture (VOCs) from the O&G industry. Last April, and sell cost-effective technologies to idenEPA published five technical white papers* tify, quantify and reduce emissions. that focus on technical issues of compresOne of the largest sources of methane sors; “completions” (the process of getting emissions in the O&G industry is the flaring a well ready to produce gas after it is drilled and venting of associated gas from oil-proand fractured) and ongoing production of duction facilities. The two main contributors hydraulically-fractured hydraulically-fra ctured oil wells; leaks; liquids are storage-tank vent gas (26.6 billion ft 3 /yr) unloading; and pneumatic devices. and well venting and flaring (18 billion ft 3 /yr), Based on peer reviews and public input according to Hy-Bon Engineering Company, received, EPA will initiate a rule-making ef- Inc. (Midland, Tex.; www.hy-bon.com) — a fort to set up standards for CH 4 and VOC major supplier of vapor-recovery technology emissions from new and modified O&G pro- (Figure 1). In the past, this associated gas has duction sources, as well as natural gas (NG) simply been vented at various places during processes and transmission sources. The the path from the well to the storage tank, rule is expected to be issued this summer, says Inayat Virani, vice president, sales at Hywith a final rule ready by 2016. Bon. This includes the gas released from the separator, as well as the vapors that accumulate in the headspace of the storage tank. In Sources of methane emissons Methane emissions accounted for nearly the U.S. alone, CH4 vent-gas emissions are 10% of U.S. greenhouse gas (GHG) emis- lost from storage tanks at the rate of 26.6 bilsions in 2012, of which nearly 30% came lion ft3 /yr /yr,, he says. says. Vapor V apor recove recovery ry units (VRUs) (VRUs) are one one of the Best Management Mana gement Practices Pra ctices of the EPA’ EPA’s Nat* www.epa.gov/airquality/oilandgas/whitepapers 20



MARCH 2015


ural Gas STAR program,* and they capture 95% or more of hydrocarbon (HC) vapors being vented from storage tanks. These recovered vapors have a higher energy (Btu)content than pipeline-quality NG. Recovered vapors are thus more valuable than NG, and have multiple uses, including condensate recovery. “In a ma jority of cases, VRUs have a return on investment of about six months,” says Virani.

Honeywell’s RAE Systems (San use a variety of modified carbon nanJose, Calif.; raesystems.com) for otube (CNT) sensors to build (print) a a leak detection system that inte- sensor array that can identify, identify, quantify grates continuous sampling and and locate CH4 leaks. And GE Global a non-dispersive IR sensor for low Research (Niskayuna, N.Y.; www.geparts-per-million methane detection globalresearch.com) will use a novel The University of Colorado (Boul- microstructured optical fiber as part der; www.ucolorado.edu) for a of an IR spectroscopy system. The metal-oxide sensor network on a design will allow detection along the single integrated circuit board length of hollow optical fibers. Dalian Actech, Inc. (Dalian, Liaoning, China; www.dlactech.com) Sealing technology and Foller & Associates (San Fran- As work on lower-cos lower-costt leak detectio detection n cisco, Calif.; www.foller.net) for an progresses, another group of compaIR laser-based system for continu- nies has been developing new sealing ous monitoring systems and gaskets that last longer Quanta3 LLC (Longmont, Colo.; and have reduced leakage. Some of www.quanta3.com) for a CH4-spe- these technologies have already been cific diode laser detection system proven in other sectors of the chemiNext month, round two of the com- cal process industries (CPI), such as petition begins, in which these sys- the chemical industry, where even tems will undergo independent testing miniscule leaks can lead to hazards by the Southwest Research Institute or lost revenue. And others are being (SWRI; San Antonio, Tex.; www.swri. specifically developed to handle comorg). By the end of this year, round mon leak sources in the O&G sector. three will begin, which involves dem The Fluid Sealing Association onstrations at industry pilot sites. (FSA; Wayne, Pa.; www.f www.fluidsealing. luidsealing. Meanwhile,, last December, the U.S. com) has endorsed the EPA’s goals Meanwhile Dept. of Energy (DOE; Washington, for reducing CH4 emissions, and •

•

Inexpensive monitoring Although CH4 is easily detected using infrared (IR) absorption spectroscopy and other techniques, the high costs of sensing technology have prevented routine applications for identifying and quantifying leaks — especially in remote, outdoor locations involving large numbers of wells and pipelines. Today there is a diverse group of leak detectors available, with IR cameras being state-of-the-art, says Ben Ratner, senior manager, Environmental Defense Fund (EDF; Washington, D.C.; www.edf.org). The problem is, such devices are very expensive (costing $80,000–100,000). Also, they tend “The problem is, everyone wants to see a return on to be less selective and are only able to find large leaks, he says. Because investment within three months instead of two to three of this, the number of detectors being years,” says FSA s ’ s Henri Azibert used in the field is limited, and then, only for periodic spot-checks. As a D.C.; www.energy.gov) announced has offered its support to help the result, a leak could go undetected the funding of 11 new projects to Obama Administration reach its CH4for many months. The challenge is enable CH4-emissions reductions reduction target. Normally, nobody to develop CH4 monitors that are through its Advanced Research Proj- thinks about seals unless they leak inexpensive, have good quality and ects Agency-Energy (ARPA-E; www. and a fire or explosion ensues, says ultimately can lead to reduced emis- arpa-e.energy.gov). As a part of FSA’s technical director Henri Azibsions, says Ratner Ratner.. ARPA-E’ss newest program, ARPA-E’ program, Methane ert. For example, nobody is going to With this in mind, EDF and seven Observation Networks with Innova- dedicate a $10,000 VOC analyzer to O&G companies began the Methane tive Technology to Obtain Reduc- monitor for leaks for a joint that uses Detectors Challenge in order to en- tions (MONITOR), $30 million has a $10–50 gasket. One can look at courage the development of the next been distributed among 11 projects any gasketed joint, and it might only generation of sensors. “We want involving U.S. companies for devel- be releasing a few parts-per-million cheap, distributed sensors that can oping new detector technologies. of CH4. However, because there find leaks in realtime, thus changing For example, IBM (Yorktown are such large numbers of gasketed the detection of leaks from months Heights, N.Y.; www.research.ibm. joints at a production facility, facility, the acto minutes,” says Ratner Ratner.. com) has received $4.5 million to cumulated emissions can become From the 22 teams submitting pro- develop new, low-cost optical sen- very significant, he says. “Aside from posals in 2014, the following four most sors and integrate them in a distrib- the environmental issues, that is promising were selected by a team uted sensor network. The sensors lost product,” says Azibert. Reducfrom EDF, industry and independent will use on-chip, tunable diode laser ing these fugitive emissions can be advisors to advance to round two: absorption spectroscopy enabled by achieved through the proper selecSensAir AB (Delsbo, Sweden) and shortwave IR silicon photonics tech- tion and installation of gaskets. In the nology. In another project, Palo Alto end, such good practice is not only * For more information on the EPA's STAR proResearch Center (PARC; a Xerox good for the environment, but it will gram, see the longer version of this article at company; Calif.; www.parc.com) will save money, he says. www.chemengonline.com •

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MARCH 2015

The sad part is, the O&G indu industry stry can actually benefit by being more conscientious. Good sealing solutions can save money in the long run, says Azibert. The problem is, everyone wants to see a return on investment within three months instead of 2–3 years. “That is being too short-sighted.” FSA has developed a calculator to help users determine the lifecycle costs for sealing systems. In some cases, a user can save millions of dollars over the lifetime of the system by using a $600 seal versus a $200 seal, says Azibert. One area prone to fugitive emissions is compressors, which are widely used throughout the O&G sector, sector, as well as across the CPI. Recent developments in sealing technology can greatly reduce — and even eliminate — CH4 leakage from compressors. The O&G sector uses two types of compressors, centrifugal and reciprocating. For centrifugal compressors, there are two sealing options. One uses oil as a barrier to seal the system. Because of the high rota-

tional speeds involved, this type of to that used in car engines, instead of seal needs to leak oil, otherwise the a rotating shaft. The piston rod-sealing system will burn up due to frictional system is one of the key factors deheat, explains Azibert. Although the termining the efficiency and reliability oil is recycled, it is full of gas, and this of the reciprocating compressor. With gas has typically been vented in the conventional packing, no matter how past. The alternative is to use a dry elaborate the design, there will always seal, which uses gas for the seal- be a certain amount of leakage — as ing. FSA is working on an economic much as 500 to 1,000 L/h from a single analysis of changing from wet to dry packing, and a compressor can have seals. The idea is that not only is the up to eight packings, says Christian gas contained, but in doing so, it will Hold, global product manager, Rings save money over time, says Azibert. & Packing at Hoerbiger Ventilwerke In recent years — in part due to GmbH & Co. KG (Vienna, Austria). the efforts of EPA’s STAR program In 2008, Hoerbiger introduced — wet seals have actually become its BCD packing technology, which obsolete for centrifugal compres- incorporated a new seal ring. The sors, says Chris Kapp, head of packing features a split design that Compression Technology Sys- enables it to compensate for wear. tems at Hoerbiger (Houston; www. As a result, leakage rates from this hoerbiger.com). But because older design are reduced by 2–3 times, and machines are still in operation, some wear occurs uniformly. The lifetime of still need to be convinced to make the packing has also been extended the switch, he says. significantlyy — by 50% to even 800% significantl For reciprocating compressors, the in some cases. But it is still impossituation is totally different, because sible to predict the integrity of such these machines use a system of valves packing, so leakage rates are also and pistons to compress gas, similar impossible to predict, says Hold.

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Source: Hoerbiger

Main packing Oil seals Oil

Gas

Piston rod

Pressurized oil barrier FIGURE 2.

The XperSEAL (left) completely eliminates leakage from the piston rod of reciprocating compressors. It does this by means of a pressurized oil bar-

rier (right)

Now, Hoerbiger offers a completely Now, new system tradenamed XperSEAL (Figure 2). Whereas leakage rates with BCD are cut in half, XperSEAL is inherently leak-free — true zero leakage — under both dynamic and static operations, says Hold. The sealing system also has the advantage that it does not require a packing cooling system, and it allows packing condition to be monitored continuously. In XperSEAL, a pressurized volume of oil surrounds the reciprocating rod and is sealed by specially designed oil seal rings. This oil barrier prevents pressurized process gas from leaking along the rod. Another effect that oc-

curs with using oil (as opposed to gas seals) is that the reciprocating motion of the rod makes it possible to “pump” oil after it has leaked out of the barrier, back into the barrier against the counteracting pressure gradient. The first first XperSEAL XperSEAL system system was installed in the field in February 2012 at a CNG (compressed natural gas) refilling station operated by Öresundskraft AB (Helsingborg, Sweden). In this case, NG is compressed in four stages from 4 to 250 bars. Measurement showed that indeed CH4 emissions were below the detection limit. Other applications include a gascompression unit at a NG gather-

ing and treatment operated at NAM (Nederlandse Aardolie Maatschappij) B.V. — a JV of Shell Nederland B.V. and ExxonMobileNAM — in Assen, the Netherlands, where the new seal was specifically tested for its ability to prevent gas leakage. In another application — a compressor for a propane refrigeration unit in Egypt, the user was able to reduce operating costs by more than $100,000/ yr by preventing loss of the valuable propane through leakage. All three of these field trials were presented at the 9th EFRC Conference (Sept. 11–12, 2014; Vienna, Austria). ■ Gerald Ondrey

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Process Control Provides A Holistic View Integration between instruments and systems allows manufacturers to align process parameters with business performance Source: Rockwell Automation

IN BRIEF TRANSPARENT TRANSPARENT INTEGRATION SIMPLIFIED CONNECTIONS INTERNET OF THINGS

FIGURE 1.

Modern DCS systems have plantwide capabilities, such as the PlantPAx modern DCS system installed at BASF in Ludwigshafen, Germany

A

s technological advances in instru- formation than we’ve traditionally collected,” mentation and control continue to explains Clark. “At the same time, processors progress, processors are beginning are realizing that the plant process isn’t just to realize that not only can their pro- about making a product, but also about makcess control system keep a watchful eye on ing a profit. In other words, there’s more to the process, but with the addition of some examine than temperatures and pressures. newer technology, it can also be used to de- There’ There’s s a busin business ess here and they want to termine the effect the process has on the en- make sure that not only are the pressure and tire enterprise. However, properly integrating other process parameters under control, but the various instruments and systems, and dis- that they are also making money via the contributing the data and information that would trolled process. As a result, more demands allow this holistic view can be a challenge. For from both the operational and business segthis reason, more and more processors are ments are being placed on control systems.” asking for intelligent instruments and smart And, when you begin to extend process add-on systems that integrate flawlessly and control into the business domain, he says, securely with their distributed control systems you can obtain business information in real(DCS), as well as a simple way for separate time. “Processors can’t afford to wait until the departments to view, analyze, interpret and end of the month for these critical numbers. use the collected information and data. They want to know right now now how much enen“Processors want more capabilities in their ergy the process is consuming, how much instruments, which can be addressed through product they are making and if they are on hardware, software and technology that can target to meet production and profitability be put inside protective envelopes and de- goals,” says Clark. ployed in the chemical process industries (CPI),” says Donald Clark, vice president of Transparent integration integ ration of systems global application consulting with Schneider In order to achieve this view of the business Electric (Palatine, Ill.; www.schne ww w.schneider-e ider-electric. lectric. domain without departing from process com). “This practice has generated more in- control, it becomes necessary to integrate,



MARCH 2015

27

nearly transparently, a large number of foreign instruments and systems under one larger infrastructure. So, providers of control systems are attempting to make this not only possible, but also seamless and simple. As such, Schneider Electric offers its Foxboro Evo product. “It’s like an integrating umbrella and hanging off it are controllers, maintenance systems, laboratory systems and the like,” explains Clark. “And Foxboro EVO brings all these systems under one common infrastructure while providing a single human interface with schematics and diagrams and the ability to fetch information from any of these sources and integrate it into the ERP [enterprise resource planning], where it can be viewed, managed and administrate administrated.” d.” Foxboro Evo is referred to as an “enterprise control system” (ECS) that provides users with the opportunity to expand from process control into enterprise control with a single system through the available capabilities including a scalable network, cybersecurity hardening, unified control and safety, engineering tools, human/ machine interface, enterprise historian and a maintenance dashboard. Gordon Bordelon, industry solutions principal, chemicals, with Rockwell Automation (Milwaukee, Wisc.; ww.rockwellautomation.com) agrees that tighter integration between process and business networks is indeed a trend. “This allows information to be shared between the plant floor and the enterprise,” he says. “This is not traditional chemical process control. Instead, it’s blurring the line between process control and information technology (IT). Modern DCS and information systems now provide realtime process analytics to operations to empower process manufacturers to make more informed decisions resulting in improved profitability of production assets.” Bordelon says the DCS can no longer be an isolated operation. As organizations move toward gaining greater visibility into their operations, their need to establish a seamless flow of information from device to enterprise has become a requirement of a modern DCS. For this reason, the PlantPAx system from Rockwell Automation (Figure 1) is based on 28

Source: Emerson Process Management

Source: Phoenix Contact

MACX signal conditioners conditioners meet the standards for functional safety in all phases of the product lifecycle, while also making integration and wiring easy FIGURE 3.

FIGURE 2.

Improved integration integration efficiency with smart device connections is simplified by the DeltaV S-Series Ethernet I/O Card

open communication standards, leveraging EtherNet/IP as its backbone. As a result, secure, realtime information can be made available throughout the enterprise for better business decisions. In addition, it allows the use of commercial, offthe-shelf products, smart field instruments and supports the adoption of the latest IT technology for automa-

tion infrastructure, such as virtualization and industrial data centers. At the same time, he says, many CPI processors are looking to standardize controls across the enterprise. “This means they would employ the same control system infrastructure, consistent applications and the same implementation methods across multiple plants,” explains Bordelon. “As technology evolves, the technologies become easier to standardize, allowing processors to have common controls, standards, practices and management across many plants.” The PlantP PlantPAx Ax modern DCS platform with open and common building blocks, sample code and

Source:Endress+Hauser

The Promass Coriolis density and mass flow family of flowmeters, as well as other flow and analytical instruments from this manufacturer manufacturer,, implement the OD VA EtherNet/IP Standard FIGURE 4.



MARCH 2015

configuration tools provides the groundwork for creating standards across an organization, says Bordelon. “We’ve created standard reference architectures for how networks are deployed. Our controller and I/O platform, which is the core of our modern DCS platform, has the ability to span multiple levels of a company’s enterprise.”

Simplified connections While the sharing between operations and enterprise or between multiple plants opens up a host of businessoptimization opportunities, getting the data from the instruments to the control system to facilitate such sharing can be a problem. For this reason, Emerson Process Management’s (Austin, Tex.; www.emersonprocess.com) DeltaV digital control system offers I/O on Demand. Regardless of I/O type — traditionally wired I/O, Foundation Fieldbus, Profibus DP, DP, DeviceNet, DeviceNet , AS-ibus or even ev en redundant wireless wireless — users can add and begin using the information, natively and with far less engineering, design and fieldwork. Most recently, says Dave Imming, vice president of product and services and marketing with the Process Systems and Solutions business unit of Emerson Process Management, the company has added Ethernet I/O cards (EIOC) to provide a platform to access data from intelligent field devices within the DeltaV system (Figure 2). Field devices capable of Modbus TCP, TCP, EtherNet/IP EtherNet/ IP and EIC 61850 MMS protocols are all supported. The EIOC provides access to and control over the data of the device network by running control modules inside. In this way, PLCs, whole motor control or centers of single drives or switchgears can be controlled directly by the EIOC. The EIOC can be used to monitor or control directly any Ethernet protocol-based intelligent field devices. All the data coming into the EIOC can be used in control modules running inside the EIOC, allowing them to generate alarms when needed and be monitored by the operator. Each EIOC is capable of handling large amounts of data in up to 2,000 control modules received from a maximum of 256 physical and 256 logical devices. Up to 60 CHEMICAL ENGINEERING

EIOCs can be added to the DeltaV I/O network, allowing freedom when it comes to segregation of networks. And, user user-configurable -configurable IP addressing allows the EIOC to be used in almost any plant environment. The EIOC and the intelligent field devices must simply be on the same IP subnet to communicate. “We see a lot of devices with Ethernet capability and this allows us to bring in a large amount of data via Ethernet ports and then bring things

together, keep data relevant and get it to the right people,” says Emerson’s son’ s Imming. Imm ing. Similarly, Emerson also offers DeltaV Virtual Ethernet I/O Card (vEIOC) for realtime, smart-device control and data integration. The vEIOC card resides in the I/O network in the DeltaV hierarchy. The card can be used with both online and offline systems. Modules needed to process the data from the field devices are configured, assigned and run in the vEIOC. In this

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Circle 45 on p. 82 or go to adlinks.che.com/56195-45 MARCH 2015

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Winner is selected by a Board of Judges comprised of current chairs of chemical-engineering departments at accredited a ccredited U.S. U.S. and E.U. universities. It is this unbiased selection process, combined with a more than 80-year tradition that makes the Kirkpatrick Chemical Engineering Achievement Award one one of the most prestigious honors that a CPI company can receive. The Kirkpatrick Chemical Engineering Achievement Award will will be bestowed in November at the Chem Show in New York.

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Industrial IoT

Cloud

Remote Corporate Outbound connection Two-way data flow Plant FIGURE 5.

Source: Skkynet

Device

A cloud-based server will likely be the center of the the industrial Internet of Things

way, the vEIOC is self-contained and does not need an external controller to process the data. Values can be read from another controller’s control strategy via external references. Access to interface graphics, as well as alarming and history collection, is the same as any other module in the DeltaV DCS. In addition to making it easier to get data from the devices into the system, the devices themselves are becoming easier to integrate. The ability to easily integrate is especially

important when it comes to safety integrity level (SIL)-rated equipment. “Easy connection helps ensure that everything is working properly and meeting the safety regulations, as well as safety-related business goals,” says Zachary Stank, product marketing specialist with Phoenix Contact (Harrisburg, Pa; www. phoenixcontact.com). “Processors don’t need or want to spend a lot of time putting safety products into the DCS, so they want something that

THE INTERNET OF THINGS MEETS PROCESS CONTROL

T

he Internet of Things (IoT) is defined as the interconnection of devices within the existing Internet infrastructure. It is suggested that it will offer connectivity of devices, systems and services operating on a multitude of protocols. How this may translate into the future of process control is still up in the air. However, However, experts in control and computing have some ideas. “Automation will look different in the future because we can push the intelligence of devices further into the process, because smart devices are getting smaller and cheaper,” says Donald Clark with Schneider Electric. “In the past, automation was stuck on, like an appendage outside of the process, but with wireless and smart devices becoming smaller, we are able to take a sensor or controller and put it inside a reactor, pipe or pump and allow the equipment to not only report on temperature or pressure, but also provide diagnostics on itself, too. This means a pump could report on and control the process, but also administrate itself and send this information where someone can see it and act upon it. “Putting automation directly inside pieces of equipment and collecting those data is where the Internet of Things is taking us,” says Clark. Already,, some companies are taking steps that they say may redefine the future of process Already control. Skkynet Cloud Systems (Mississauga, Ontario, Canada; skkynet.com) has partnered with B+B SmartWorx (Ottawa, Ill.; www.bb-smartworx.com) www.bb-smartworx.com) to create intelligent networks that can collect, manage and analyze data generated by billions of sensors, transforming those data into actionable intelligence that lets companies make predictions and prescribe actions to cut costs, increase productivity or increase revenue. The partnership is being launched with a focus on the IoT IoT.. B+B SmartWorx will provide a cellular router that collects raw data from devices and protocols and emits the data to Skkynet’s net’ s Secure Cloud Service via the cellular n etwork. From the Cloud, users — from operators to plant engineers to managers, analysts and customers — can access the information in a secure manner (Figure 5). “This is a more secure option than a VPN because the central plant is not attached, so there’ there’s s no opportunity to attack,” says Andrew Thomas, CEO with Skkynet. The service is capable of handling over 50,000 50,000 data changes per second per client, at speeds speeds just a few milliseconds over Internet latency latency.. Secure by design, it requires no VPN, no open firewall ports, no special programming, and no additional hardware. CHEMICAL ENGINEERING


MARCH 2015

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integrates easily.” For this reason, Phoenix Contact developed MACX signal conditioners (Figure 3) with functional safety for processors who want to do analog signal conditioning but need to maintain an SIL rating. The signal conditioners have been developed and produced according to the standards for functional safety. In addition, they are available with maximum explosion protection and, with MACX Safety, users can integrate

analog signals easily into the safety application, for intrinsically safe circuits in hazardous areas. Another example of simplified integration of devices includes Endress+Hauser’s (E+H; Greenwood, Ind.; www.us.endress.com) Promass Coriolis density/massflow family of flowmeters, as well as other E+H flow and analytical instruments, which implement the ODVA EtherNet/IP Standard (Figure 4). “Intelligent devices continue to

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flourish by moving from supplying self-diagnostic information to providing operators/technicians with actionable problem-solving guidance,” says Craig McIntyre, industry manager, chemical, with E+H. The benefits of employing a Webbased device like the Promass Coriolis flowmeter are many, according to McIntyre, including inclu ding a direct, two-way, high-speed digital communication of density, flow, volume flow, temperature and diagnostics/configuration information into an EtherNet/IP architecture environment in place of a traditional one-way analog/frequency/ pulse I/O and associated controller scaling/integration programming. The server server-based -based Promass has an embedded Electronic Data Sheet and associated add-on profile, which are installed on the controller side, supporting rapid pre-configured integration for control and visualization. Pre-engineered faceplates for Promass are provided for rapid HMI visualization development. development. And addon instruction exchanges data between each process variable located in the Promass and the faceplate installed on the display. The name of the specific add-on instruction becomes the link from the Promass to the faceplate on the graphic. Further, says McIntyre, additional cost and risk reductions can be gained during the integration, field implementation and field service phases through the associated lifecycle-management system. Integrated application-engineering tools, factory-maintained device documentation and maintenance tools, and information-integrated support of engineering software implementations can bring increased information value and access to associated stakeholders. “The use of server-based devices integrated into secure local and WAN implementations to reduce integration costs and facilitate remote management is increasing,” says McIntyre. And, An d, this typ type e of int intel ellig ligen entt dev devic ice, e, with its ability to seamlessly deliver data and information to a control system that ties process information to enterprise information in realtime, may mark the arrival of the Internet of Things in the process control industry industr y. ■ Joy LePree




MARCH 2015

Focus

Handling Bulk Solids High-level detector has mercury-free mercury-fr ee tilt switch

signed to promote the flow of any dry material. Capacities range from 3 to 100 ft 3 of storage. The Live Bin (photo) is designed to provide positive discharge of fine particles and fibrous or flaky materials, on a firstin, first-out basis, ensuring mass flow and eliminating material segregation. These hoppers can be used to discharge to any feeder or process line, or in applications where a surge bin is required. They are suitable for use in sanitary applications, says the company.— Vibra-Screw, Totowa, N.J. N .J. www.vibrascrew.com

The patent-pending BM-TSM tilt switch (photo) used for high-level detection of powders and bulk solids mounts on the top of bins and activates an alarm when material rises and tilts the switching mechanism by 15 deg. The shaft of the tilt switch can be custom made in lengths from 1 to 8 ft, to accommodate site-specific needs. It is available with either a paddle or sphere mount at the end of the shaft, and can be used with materials that have a bulk density of at least 15 lb/ft 3. Its simple mechanical design can be used as an alternative to a top-mounted rotary level indica- This firm offers flow-properties tor, and it is suitable for a wide range testing services of solid materials in many industries, To To ensure sound, predictable opsays the manufacturer. It can be in- eration of processes involving bulk stalled through a 1.24-in. NPT pro- solids, operators must have a thorcess connection on the roof of the ough understanding of the bulk bin and sends an alert status to a material’s flow properties. Such inhorn, light or control panel.— Bin- sight is essential when designing Master, Div. of Garner Industries, silos, bins, hoppers, feeding sysLincoln, Neb. tems, chutes, conveyors and more, and can help to identify the cause www.binmaster.com of poor flow, powder flooding and rate limitations, segregation issues Magnetic pulleys help belt and product non-uniformity. This conveyors to separate metals When used with conveyor belt sys- company provides a wide array of tems, these permanent and elec- testing services, to assess a matetric magnetic pulleys (photo) auto- rial’s cohesive strength, wall friction, matically separate heavy tramp iron internal friction, compressibility, percontaminants from the transported meability, angle of repose, density materials. Facilities can convert their and more.— Jenike & Johanson, belt conveyor into a self-cleaning Tyngsboro, Mass. magnetic separators by adding the www.jenike.com pulley. These pulleys are constructed of steel center tubes with welded This level-measuring device dividers to securely hold magnet is undaunted by dust stacks. Standard pulley models use Pulse radar is a proven technique powerful ceramic magnets in an axial for sensing bulk-materials level in interpole circuit. These magnetic pul- silos and tanks, and is reliable and leys are available in a wide range of accurate when the space has a high diameters, and larger sizes and cus- level of suspended particles. The MP tomization options are available. — Series microwave-based, pulseEriez, Erie, Pa. radar devices are used to determine the level of bulk solids in silos or www.eriez.com tanks. The MP70 model has a measuring distance of up to 230 ft (70 Ensure proper material flow m). Transmitting at a frequency of with these vibrating hoppers These fully assembled, self-con- 26 GHz with a narrow beam angle tained vibrating hoppers are de- of 8 deg, the MP Series radar de-

BinMaster

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Note: For more information, circle the 3-digit number on p. 82, or use the website designation. CHEMICAL ENGINEERING


MARCH 2015

33

Buss-SMS-Canzler Your partner in developing new products and processes

vices provide consistent, accurate measurements even in dusty environments, says the firm. — Bindicator, Spartanburg, S.C. www.bindicator.com

These devices provide the full range of level detection Automation Products

Thermoformed belt makes this conveyor ideal for sanitary use

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Kaiserstraße 13-15 • 35510 Butzbach • Germany Tel: Te l: +49 60 33 - 85 - 0 • Fax: +49 60 33 - 85 - 249 E-Mail: info@ [email protected] Circle 8 on p. 82 or go to adlinks.che.com/56195-08

The full family of Dynatrol bulk-solids level indicators (photo) provide probes that are well-suited for a diverse array of bulk solids materials. The DJ Series handles products ranging from lowdensity flakes and powders to heavy granules and pellets. The GJ Detector is constructed to handle problem Symetix applications that have a tendency to pack or bridge. The GSS sensor operates successfully with consistent results on difficult product applica The Sanitary Belt Conveyor (photo, tions (such as precipitated powders, top left) is designed for bulk tablets, fines, low-density powders and macapsules, softgels and powders, as terials as light as 0.5 lb/ft 3. Side-wallwell as ingredients handled on regu- mount and suspended models are lated and over-the-counter pharma- available. These rugged probes have ceutical and nutritional-supplement no moving parts, ensuring long life in manufacturing and packaging lines. service. — Automation — Automation Products, DyFeaturing a positive-drive, urethane natrol Div., Div., Houston belt, stainless-steel frame and com- www.dynatrolusa.com ponents, open construction and other sanitary features, this belt con- Bulk-bag filling station has a veyor eases cleaning, which reduces variety of design features labor, speeds product changeover Flexicon and increases uptime while improving equipment and product hygiene. Designed for conveying ingredients to blending and mixing operations, and finished products to packaging operations, the versatile conveyor comes in cantilever, flat and inclined configurations that can be mounted to the floor, mounted on casters or suspended. The belts can be designed with a flat surface or with a variety of shaped flights or flexible side walls to contain the product in the pockets during operation. The FDAcompliant belting is thermoformed to ensure a homogeneous and seamless belt, which reduces the risk of bacterial contamination and fouling. It can accommodate throughput The stainless steel, sanitary Bulk Bag from less than 2,000 lb/h to more Filler (photo) fills bags by weight. It than 60,000 lb/h. — — Symetix, Walla includes an integral metal detector/ Walla, Wash. separator that removes tramp metals as the material enters the filler, filler, www.symetix.com CHEMICAL ENGINEERING


MARCH 2015

and then ejects the collected metals through a chute. The filler frame uses a patented “twin centerpost” design, which is said to maximize strength and improve accessibility to bag hooks. The height of the fill head is adjustable, to allow for bags of many sizes to be used, and an inflatable cuff forms a highintegrity seal to the bag inlet spout. An automated vibratory deaeration and densification system maximizes capacity and stabilizes the bag for storage and shipment. This bulkbag filler has received USDA acceptance, is constructed of Type 316 stainless steel and finished to sanitary standards, and is configured with full-length forklift tubes, allowing it to be easily moved throughout the facility.— Flexicon Corp., Bethlehem, Pa. www.flexicon.com

Radar level-detection probe is undaunted by uneven surfaces

Norres Schlauchtechnik

making them well-suited to handle high flowrates of extremely abrasive solids, such as sand gravel, grain, refuse glass and chips. The abrasion resistance of this hose is 2.5 to 5 times higher than comparably sized hoses of most rubber materials, and is about 3 to 4 times higher than those constructed from most soft polyvinylchlorides (PVC), says the company. The smooth interior helps to optimize flow. A sister product — the Norplast PUR-CU 387 AS — features metallic grounding wire and a permanently antistatic polyurethane inside liner, liner, which extends the scope of applications by making the hose suitable for use in areas exposed to potential explosion hazards.— Norres Schlauchtechnik GmbH, Gelsenirchen-Schalke, GelsenirchenSchalke, Germany

The Optiwave 6300 C radar instrument provides accurate measurement of solids level in silos, hoppers, bulk storage containers, and on conveyor belts, and is said to be www.norres.com especially well-suited for measuring the uneven surface of silo contents. Protect powder-handling The patent-pending patent-pending drop drop form of the systems from explosion risk plastic antenna generates a smaller A full line of explosion-protect explosion-protection ion sobeam angle (2 deg) compared to lutions offers protection for facilities conventional antennas, eliminating handling potentially explosive bulk the need for an antenna-aim antenna-aiming ing kit to solids. This company offers a wide amplify the reflected signal. The drop array of ATEX-certified explosion form also helps to minimize crusting vents, flameless explosion-venting or dust buildup on the antenna, mak- systems, explosion-suppression ing it ideal for applications involving systems, explosion-isolation sysmaterials with high dust potential, tems, and explosion detectors. The such as mineral powders, granulates company also offers state-of-the-art and wood chips. Users can choose explosion-testing services to evalufrom a 3-in.-dia. antenna made from ate materials in accordance with polypropylene or polytetrafluoro- ASTM and ISO procedur procedures. es. — Fike ethylene, or a 6-in.-dia. (DN150) Corp., Blue Springs, Mo. antenna made from polypropylene. www.fike.com Conventional stainless steel horn antennas up to 6 in. (DN150) are also Particulate-monitoring device available. An installation wizard and is approved for hazardous duty comprehensive help capabilities, available in nine languages, ease setup and startup. — Khrone, Inc., Peabody, Mass. www.us.krohne.com Auburn Systems

Lightweight, flexible conveying hose resists abrasion Norplast PUR 387 hoses (figure) provide good abrasion resistance,

The Auburn U3400H is a two-wire, loop-powered, dynamic-range par-

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MARCH 2015

35

ticulate monitor for both high- and low-temperature applications using HART protocol (photo). It is designed for use in particulate-matter monitoring applications that require hazardous location certification. It is designed for emission monitoring and process flow applications (such as bag-leak detection, or monitoring flow increases or decreases) for which a continuous 4-20-mA signal is needed. The HART protocol allows for bi-directional communication with the unit for remote access and control. The U3400H is designed to be wired directly to a PLC, DCS, data logger or any control device capable of providing the 24-V loop power while simultaneously receiving the continuous 4-20-mA signal. — Auburn Systems, Systems, Danvers, Mass. www.auburnsys.com

Piab

Best Process Solutions

powders in a range of applications. This firm offers offers a family of vacuum pumps and vacuum generators, based on patented, multistage Coax technology. The vacuum can be arranged for base mount- pump (photo) uses compressed air ing or overhead suspension (photo). as the input, and through a venturi Feeders come in a range of vibrating effect, is able to generate 22-in.-Hg trough lengths and special designs vacuum, while driving air volumes are available. The company’s op- (std. ft3 /min) that are are three times times tional BPS Inertial Isolation System the volume of the compressed air is designed to eliminate the transfer inlet. Through the use of multiple of vibratory energy to support struc- stages, high vacuum is generated tures and buildings.— Best Process as the air flow is ramped up. This Solutions, Brunswick, Ohio pump has no electric parts, which reduces maintenance and ensures www.pbsvibes.com long life and inherent safety in dusty Vibratory feeders feeders convey or hazardous environments. — Piab bulk solids smoothly This vacuum technology uses Available in electric or air air-operated -operated the venturi effect USA, Hingham, Mass. models, these heavy-duty vibratory Va Vacuum cuum conveying technology www.piab.com feeders are designed with above-, is widely used to provide gentle below- or side-mounted drives and transport of dry bulk solids and This vibratory separator can

handle wet or dry materials The Finex Separator vibratory separator is designed for accurate grading, scalping or sizing of wet or dry materials, and can produce up to five different size fractions in a single operation. Compared with traditional spring-suspension spring-suspe nsion separators, these systems are said to have improved accuracy, capacity, noise levels and flexibility in terms of system upgrades. Four sizes are available: 30-, 40-, 48- and 60-in. dia. — Russell Finex, Inc., Pineville, N.C. www.russellfinex.com

ENSURE YOUR PIPING INTEGRITY

In today’s operating environment, it’s more important than ever that the piping within your Mechanical Integrity Program complies

•

with standards such as API-570 and API-574. •

Quest Integrity offers a comprehen comprehensive sive solution for piping circuits using our proprietary, ultrasonic-based intelligent pigging technology ultrasonic-based combined with LifeQuest™ Fitness-for-Service Fitness-for-Service software.

•

100% inspection of internal and external pipe surfaces Inspection results tailored to comply with API-570 and API-574 LifeQuest Fitnessfor-Service results tailored to comply with API-579

Ensure your piping integrity by identifying degradation before loss of containment occurs. www.QuestIntegrity.com A TEAM Industrial Services Company

Seal designs and more for powder handling are offered Maintaining a proper seal against dry particulates particulat es or chemicals can present challenges. This company offers a variety of seal designs and materials, such as quick connect and disconnect seals for hoppers, bulk-bag filler systems and transfer cars, inflatable follower plate and drum-filling seals, FDA-compliant thermoplastic elastomer compression gaskets to seal doors and other machine closures, and more. — Pawling Engineered Products, Pawling, NY. www.pawlingep.com ■ Suzanne Shelley




MARCH 2015

Europe 2015 Special Advertising Section Germany’s 2015 2015 trade fair season celebrates European success

CHEMICAL ENGINEERING ESSENTIALS FOR CPI PROFESSIONALS

Inside the Europe Special Advertising Section 2015

Giant ACHEMA event in June is a world forum for the CPI

T

his 2015 Europe Special Advertising Section celebrates European equipment manufacturers and service providers across the chemical process industries (CPI). In the next 16 pages you will find entries from Germany, Austria and Italy – the heartland of Europe’s success in process equipment, engineering services and complete plants. Germany is also the undisputed leader in international trade shows, and this year

brings several events of interest to engineers and managers in the CPI. Anuga FoodTec (www.anugafoodtec.com), showcasing food and drink technology, takes place in Cologne, 24–27 March. The previous event in 2012 attracted nearly 1,300 exhibitors and around 43,000 visitors. The European Coatings Show (www. european-coatings-show.com) will be held in Nurember Nuremberg, g, > page 36I-2

AUMA Berndorf Band BEUMER Maschinenfabrik Bürkert Fluid Control Systems Buss-SMS-Canzler Dec Group Finder Pompe GEA Process Engineering GEA Wiegand Italvacuum LIST Müller Pfeiffer Vacuum Phoenix Contact Pompetravaini A M E H C E D : O T O H P

Sandvik Process Systems ThyssenKrupp Industrial VEGA

Trade Trad e fairs such as ACHEMA are meeting places for vendors, customers and researchers

Brilliant technology

Planex System: multi-patented paddle vacuum dryer with ZeroFrict ZeroFriction ion® planetary movement eccentric agitator

Criox System: patented rotary vacuum dryer/pulverizer

Italian quality

Multispray Cabinet Dryer: tray vacuum dryer with extractable shelves

Saurus939: low maintenance LubriZero® vacuum pump

Frankfurt (Germany), 15 - 19 June Stand B44, Hall 4.0

Your vacuum dr ying specialist

[email protected] | italvacuum.com

Circle 21 on p. 82 or go to adlinks.che.com/56195-21 adlinks.che.com/56195-21 CHEMICAL ENGINEERING


MARCH 2015

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Europe 2015 Special Advertising Section

Simulation proves control systems GEA Wiegand highlights the advantages advant ages of test testing ing

L A M E h C E D : o t o h p

Discussions in front of real equipment items are a traditional part of the ACHEMA formula: here, a screw screw compressor on show show at ACHEMA ACHEMA 2012

21–23 April, covering paints, coatings, sealants, adhesives, printing inks, and construction chemicals. Chemspec Europe (www.chemspecev ents.com/europe/), ents.com/eur ope/), held 24–25 June in Cologne, targets manufacturers and suppliers of fine and specialty chemicals, formulators, and custom processors. For the CPI as a whole, the most important event of the year is ACHEMA (www. (www. achema.de), which takes place 15–19 June in Frankfurt. This three-ye three-yearly arly exhibition and congress is a world forum for process engineering and biotechnology. Around 3,800 exhibitors and 170,000 visitors are expected, says organizer DECHEMA eV (Frankfurt, Germany; www.dechema.de). In terms of exhibition groups, the leaders in terms of numbers are the traditionally strong areas of instrumentation, control and automation; mechanical processes; and laboratory and analytical techniques. High demand has also brought additional space for pharmaceuticals, packaging and storage. These strengths reflect overall trends in ACHEMA’s core sectors: machinery, plant engineering, and the chemical industry. Despite the turbulent international business environment, these sectors are proving surprisingly resilient, DECHEMA points out. Particularly at international level, they are “hard-wired” for growth, and exhibitor numbers reflect trends such as the shale gas bonanza in the US and continuing industrial growth in India and China. The three focal themes of ACHEMA 2015 are BiobasedWorld, Innovative Process Analytical Technology (PAT), and Industrial Water Management. Visitors should not expect to see separate exhibition areas for > page 36I-1

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these, however. “What distinguishes focal themes is that they impact and shake up the process industry as a whole,” explains Dr. Thomas Thomas Scheuring, CEO of DECHEMA Ausstellungs-GmbH. “The developme development nt of new technologies and solutions thrives on the interplay of different sectors and disciplines.” As a result, exhibitors involved in these themes can be found in diverse areas of the exhibition. BiobasedWorld, for instance, celebrates the bio-based economy through a spectrum ranging from process development to sensors, and from suppliers of stainless steel fermenters to processors of bio-based packaging materials. The soon-to-be-published ACHEMA congress program will be more streamlined than before, DECHEMA says, and will avoid parallel scheduling of thematically related sessions. Hot topics include energy efficiency,, materials and materials testing, and ciency safety technology. On four days a panel discussion or plenary lecture will tackle key themes like the implications of the shale gas boom for the bioeconomy, trends in chemical production, Germany’s energy turnaround, and developments in industrial water use. There will also be many guest and partner events. New this year will be the ACHEMA PRAXISforums: short presentations held near the relevant exhibition halls. This will help to promote the exchange of views by shortening the distance between lecture areas and exhibition stands. Topics include Single-Use Technologies, Pharmaceutical Production, Components and Equipment, Mixing and Separation, and Safety and www.achema.de Plant Control. ■


ike any other plant asset, automation systems can benefit from simulation at the design and construction stage, says thermal processing and separations specialist GEA Wiegand. Automation systems for large process plants combine supervisory control and data acquisition (SCADA), long-term data storage, and associated engineering systems, allowing investment and operating costs to be optimized on the basis of real plant data. Simulations before the plant is commissioned reveal reveal any weak points in both the system itself and the underlying processes, so problems can be corrected in time. GEA Wiegand uses its own programs based on WinMOD software to model complex plants. Customized program modules simulate the process itself, and this system connects to the real automation system via field As the the real real plant plant is is bus. This “virtual being built, a virtual plant” allows enmodel allows checks gineers to check of the control system the performance to avoid any surprises of the automation when the time comes system in real for commissioning time and to simulate incidents. Simulation facilitates: • communication checks between the plant’s measurement and power devices and the control system; • verification of control program steps; • safe testing of critical process steps; • accurate setting of control parameters; • testing of complex control algorithms such as predictive and state-space control; • operator training before the physical plant is complete; • testing unusual or time-consuming plant conditions; • rapid checks on the feasibility of requests from demanding customers. www.gea-wiegand.com


MARCH 2015

We know what makes a

GOOD POWDER

To make superior powders, look for a GEA Niro drying system. We specialise in supplying industrial drying systems designed to match your exact product and plant specifications, and with more than 10,000 references worldwide our expertise is unsurpassed. Our comprehensive product range includes GEA Niro spray dryers, fluid bed systems, spray congealers and the SWIRL FLUIDIZER™. At our extensive test facilities, the most experienced test engineers and process technologists in the business will help you move m ove rapidly from idea to product development and profitable production.

GEA Process Engineering A/S Gladsaxevej 305, DK-2860 Soeborg, Denmark Tel: +45 39 54 54 54, Fax: +45 39 54 58 00 [email protected], www.gea.com Circle 17 on p. 82 or go to adlinks.che.com/56195-17

engineering for a better world

GEA Process Engineering


Lobe blowers feature the finest f inest Italian It alian engineering engineering Pompetravaini has added a range of blowers and vacuum boosters manufactured in Modena, a city with a long tradition of high-quality mechanical engineering

W

Fit for the race track: BORA blowers will become more widely known now that they are owned and distributed by Pompetravaini

ith the acquisition of BORA Blowers, Italian manufacturer Pompetravaini has again extended its offer in the world of rotating equipment. BORA, now Pompetravaini-BORA, Pompetravaini-BORA, started two decades ago in Modena, a city famous for the production of “dream cars” – including Ferrari, Lamborghini, Lamborghini, and Maserati – and for fine mechanics in general. BORA lobe blowers and vacuum boosters have always been technology leaders in terms of their design, materials, casting and machining quality, and the care taken during assembly. As a result, the performance and reliability of these machines are well known to users all over the world, Pompetravaini Pompetravaini says. The acquisition will contribute to the wider distribution of BORA products, which from now on can take advantage of Pompetravaini’s worldwide network of skilled distributors and service centers. The range comprises four main product families: blowers, exhausters (including air-cooled versions), vacuum boosters, and the FP (Food Packaging) range of accelerator boosters. Together, the Pompetravaini-BORA range covers pressures of 0.01–2800 mbar (a) and flowrates up to 3000 m3/h. Blowers and exhausters can be supplied completed with filters, silencers, valves, and sound cabins. Boosters can be fitted with the DVD2 PLC control system, which protects the machine from misuse while pushing it safely to the best efficiency limit. Pompetravaini also offers integrated packaged solutions in the form of customized skids for boosters, ejectors, and www.pompetravaini.com liquid-ring vacuum pumps.

Amalgamation Amalgam ation create createss Engi Engineeri neering ng Excell Excellence ence3 ThyssenKrupp Industrial Solutions offers the combined capacity of three established ThyssenKrupp engineering companies within the ThyssenKrupp group

T

hyssenKrupp Industrial Solutions is the amalgamation of ThyssenKrupp Resource Technologies (itself created by the merger of ThyssenKrupp Fördertechnik and ThyssenKrupp Polysius) and ThyssenKrupp Uhde. Each of these companies in itself is a global player; by combining its plant engineering and construction expertise in the Process Technologies and Resource Technologies business units, the group is now able to offer its customers “Engineering Excellence3”. With numerous subsidiaries on every continent, ThyssenKrupp Industrial Solutions is a world leader in international heavy plant engineering, helping customers to realize their projects through innovative technology and comprehensive know-how. ThyssenKrupp Industrial Solutions always strives for solutions that are “outside the box” and consequently able to provide better value to customers. The group is also committed to better use of natural resources. When environmental and climate protection concerns have to be taken into account, and with raw materials prices rising, ThyssenKrupp’s ThyssenKrupp’s engineering expertise enables its customers to achieve considerable competitive advantages. Innovation means not standing still, so the organization adapts continually to optimize its processes and structures. The Process Technologies business unit is one of the world’s leading engineering experts in planning and constructing chemical works, refineries, and plants for coke and other products. It offers the full range of services of an EPC contractor, contractor, with cost-efficient

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For the Egyptian Propylene & Polypropylene Company (EPPC) ThyssenKrupp Industrial Solutions built a turnkey petrochemical complex in Port Said, some 170 km north-east of Cairo. The complex consists of a propylene plant and a polypropylene plant with respective annual production capacities of 350,000 tonnes high-tech solutions covering the entire life cycle of the plant. www.thyssenkrupp-industrial-solutions.com



MARCH 2015

The radar senso s ensorr for fo r bulk bu lk solid s olids s VEGAPULS VEGA PULS 69 Level measurement with bulk solids radar, making the impossible possible: The most modern radar level technology and a frequency range of 79 GHz has made the new VEGAPULS 69 radar the sensor of choice for bulk solids industries. This sensor is capable of measuring poorly reecting bulk solids over long ranges, in narrow, or even segmented vessels. 

Measuring range: up to 120 m





Encapsulated antennas:



reliable results even with buildup

Very good good focusing: simplies simplies the setup setup One device for all bulk solids: Standardization Standardiz ation of sensors

Link to website: www.vega.com/vegapuls69 Circle 47 on p. 82 or go to adlinks.che.com/56195-47 adlinks.che.com/56195-47


Long-term Long-ter m value in solids handling and packaging A new bag filling syst system em is the lates latestt addition to BEUMER’ BEUMER’s s range of sustain sustainable able syst systems ems for conveying, loading, palletiz palletizing ing and packaging granular products

BEUMER’s new stretch hood machine in action

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he Beckum-based BEUMER Group (Germany), with its affiliations around the globe, is a leading international manufacturer of intralogistics systems. BEUMER specializes in conveying, loading, palletizing and packaging technology, technology, as well as in systems for

sorting and distribution. Together Together with Crisplant a/s and Enexco Teknologies India Limited, the Group employs about 3,900 people and achieves an annual turnover of about EUR 627 million (2014). A new addition to the product range is the BEUMER fillpac, which fills bulk materials in bags. This allows BEUME R to offer its customers a full line of packaging machinery from a single source. A built-in electronic weighing system ensures that each bag has the correct weight. Another recent development development is an addition to BEUMER’s stretch hood range (photo). The company’s specialists designed the new model from scratch, optimizing the components in terms of function, arrangement and ergonomics. The layer palletizers in the BEUMER paletpac series, meanwhile, meanwhile, palletize bags with geometric accuracy and high stability. This enables easy storage and ensures secure conveyance to the packaging system downstream. BEUMER also provides extensive extensive customer support, ensuring that all of the user’s systems have a high level of availability. Highly capable experts located all over the world provide professional professional repair and maintenance services, deliver spare parts and carry out customer training. The BEUMER Group is committed to a “total value of ownership” (TVO) approach based on ecological and social considerations – such as ergonomic ergonomic human-machine human-machine interfaces – as well well as economics. This allows customers to maximize the total value of their www.beumergroup.com investments over the long term.

High-performance safe couplin coupling g relays just 6 mm mm wide The world’s narrowest solution for SIL-cer SIL-certified tified safe coupling relays re lays saves space, cuts energy use, and simplifies simpli fies testing, says Phoenix Contact

E

lectrical isolation and power amplification are the primary goals of safe coupling relays. Although the relays are vital and necessary in many applications, for the user they involve additional space and effort for the integration. With its PSRmini product family, Phoenix Contact now provides the world’s narrowest solution for SIL-certified coupling relays. Though they are just 6 mm wide they ensure a high level of functional safety, thanks to proven EN 50205-certified, force-guided contacts. The compact design is made possible through Phoenix Contact’s newly developed relay technology. The design is based on a slim but powerful elementary relay characterized by minimal space requirements, low energy consumption, and high system availability. Comprehensive tests and approvals ensure that the safe coupling modules can also be flexibly used in applications and environments that exceed the norm. For example, the relays are G3-compliant in accordance with ISA S71.04 for use in especially corrosive atmospheres, and are

36I-6

IECEx-certified to facilitate the decentralized design of an application in Ex Zone 2. The proof test prescribed by the standards can easily be performed via a simple visual check of the device. Complex and timeconsuming manual measurements that are mandatory when using standard relays that do not comply with EN 50205 are, therefore, no longer required. In addition, the coupling modules feature built-in diagnostics that change the line input signal to A1 in the event of an internal fault. This is registered as an alarm by the control system, and reduces to a minimum the effort required for a proof test. The use of the existing control system infrastructure eliminates the requirement for additional alarm inputs and wiring installation, minimizing downtime and significantly increasing system efficiency. Corresponding termination carriers are also available for the PSRmini product family, which provide the option of using system cabling solutions for quick, error-free commissioning and connection in the field. www.phoenixcontact.com


Safety at 6 mm: The new safe coupling relays from Phoenix Contact


MARCH 2015

INGENIOUS INDUSTRIAL PUMP SOLUTIONS. CREATED FROM HEART POWER

We work with wi th HEART, MIND and BODY, because we are PEOPLE PEOPLE serving PEOPLE , with PASSION , INTELLIGENCE and COMMITTMENT that’ss why we are able that’ a ble to offer SOLUTION PACKAGES , NOT JUST PUMPS

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Design for excellence

 Personalized guidance in the pump selection process 

Fast response response and delivery delivery

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Long term after market market support

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Trained service and spare parts parts available worldwide worldwide

Pompetravaini has been manufacturing industrial pump since 1929. 85 years of passionate service!

www.pompetravaini.it

Pompetravaini Spa Via per Turbigo, 44 • 20022 Castano Primo (Mi) • Tel. +39.0331.889000 • Fax +39.0331.889057 [email protected] • www.pompetravaini.it Circle 35 on p. 82 or go to adlinks.che.com/56195-35


A wide range of pum pumps ps for hea heavy-duty vy-duty tasks Finder Pompe’s Pompe’s ability to supply both centrifugal and positive-displac positive-displacement ement pumps in large sizes has helped the company win two large orders in Saudi Arabia

R

ecent investment by Finder Pompe to rationalize and simplify the design of its API 676 positive-displacement positive-displacement (PD) twin-screw pumps, as well as a new oil test loop specifically designed for screw pumps, have already brought interesting results, the company says. Finder supplies large twin-screw pumps like the one above to handle heavy fuel oil in Saudi power stations

In fact Finder has recently delivered delivered its biggest-ever order. Besides ISO 5199 vertical turbine and sump pumps and API 610 vertical sump pumps, this also included a significant number of API 676 twin-screw PD pumps. The pumps will be installed at SEC’s Jeddah South Thermal Power Plant, Saudi Arabia, to handle heavy fuel oil/crude oil, boiler water, seawater, and process water, depending on the various applications. The pumps had to meet challenging specifications, including high flowrate ( >2,000 m3/h) and 380 CSt CSt viscosity for the steam-jacketed screw pumps, with double API Plan 53B sealing system serving four mechanical seals; and high-capacity ( >1800 m3/h) vertical turbine pumps made from duplex steel for seawater service. Besides its ability to meet the difficult technical requirements, Finder won the order from lead contractor Hyundai Heavy Industries (HHI) thanks to its good previous performance, excellent excellent customer support, and competitive pricing and delivery times. Finder was considered a crucial vendor because of its wide range of approved API and non-API centrifugal pumps, as well as API 676 screw pumps. Finder is now working on a second project for HH I, for delivery in mid-2015. This is the Shuqaiq power plant, also owned by SEC and a twin of the Jeddah South plant. Finder plans to further develop its range of twin-screw pumps, improving their performance in terms of differential pressure and www.finderpompe.com the fluid viscosities they can handle.

Turnkey systems for efficient effi cient solidification solidification Pastillation specialist SBS Steel Belt Systems and steel belt expert Pastillation exper t Berndorf Band work together to provide dust-free dust-free handling handli ng of a wide range of products

S

BS Steel Belt Systems Srl is an Italian company, founded in 1984, which produces steel belt machinery and turnkey plants for a wide range of industries: chemical, petrochemical, food, rubber and powder coatings. SBS is a partner par tner of the multinational Berndorf Band Group, whose headquarters are in Austria. SBS itself is located in Venegono Inferiore (Varese), a small town close to Milan’s Malpensa airport. SBS Steel Belt Systems Srl (Italy) and its partner SBS Steel Belt Systems Inc. (USA) have pioneered the developme development nt of pastillating units for a wide range of products. In recent years SBS Group has moved into sulfur solidification technology, technology, providing several oil refineries and gas fields with turnkey solutions complete with: • liquid sulfur pumps and piping • water cooling systems • sulfur solidification units equipped with continuous Berndorf steel belts • solid sulfur belt collectors and silos

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Leaders in pastillation for sulfur and other products: SBS and Berndorf Band

• bagging equipment and truck loaders. The SBS pastillation head, known as ACCUDROP, has recently been upgraded through the use of a very effective rotating outer shell. With its high pipe wall thickness and innovative drilling pattern, ACCUDROP now has the ability to produce pastilles with a diameter of around 4 mm, better spherical shape, and higher mechanical strength.


These characteristics characteristics help to reduce a well-known problem in the pastillation industry: dust. Caused by abrasion during handling (for instance in packing, unpacking, loading, and unloading), dust formation is influenced by the properties of the product. Small, smooth and strong pastilles produce only a negligible amount of dust, thus resulting in an eco-friendly product. The combination of an ACCUDROP pastillation head and a Berndorf steel belt provides an efficient and secure process. Excellent flatness of the belt and regular service from both SBS Steel Belt Systems Group and Berndorf Band ensure long operating life and lower maintenance costs. In recent years SBS Group has collaborated with some of the largest engineering and construction companies to supply refineries in southern Italy, Spain, Serbia, Turkey, Russia, Indonesia, Saudi Arabia, Qatar, Jordan and many other countries all ACHEMA Hall 5.1, D61 over the world. www.berndorf-band.at www.steelbeltsystems.it


MARCH 2015

Nobody manufactures 6 mm safety relays.

Until now.

Maximum SIL3 performance in hazardous areas

Relay Technology Designed by PHOENIX CONTACT

PSRmini are the world’s narrowest SIL-certified coupling relays. They are just 6 mm and 12 mm wide and ensure optimum functional safety thanks to force-guided contacts. The highly compact design saves up to 70 % installation space made possible by Phoenix Contact’s newly developed relay technology. The safe coupling relays enable simple diagnostics directly on the device or the controller and can be used for applications in Ex zone 2.

For additional information call +49 52 35 3-00 or visit phoenixcontact.com

ION04-15.001.L1

© PH PHOENIX CO CONTACT 20 2015

Circle 32 on p. 82 or go to adlinks.che.com/56195-32


Energy-efficient processes for polymers Roland Kunkel of LIST AG AG explains how equipment equip ment designed to operate with little or no solvent can simplify process design, improv improve e product quality and cut emissions Conventional technology Reactants Solvent

Reactants

Vapor

Dry Processing

LIST KneaderReactor To s olvent separation and recovery

Final product

New KneaderReactor technology

Excellent heat transfer allows LIST ’s KneaderReactor KneaderReactor to operate at polymer concentrations of 40–99%

P

rocess intensification – the reduction of processing steps and equipment – is a revolutiona revolutionary ry approach to process and plant

design that minimizes costs, increases flexibility and delivers higher yields. The gateway to process intensification for both living and LIST KneaderReactor. free-radical polymerization is the innovative LIST KneaderReactor. Conventionall stirred-tank reactor technology has many shortConventiona comings due to its requirement for solvents with a concentration of up to 90% to transfer heat and facilitate the mixing of the polymer solution during polymerizatio polymerization. n. Additionally, the likely occurrence of hotspots and thermal degradation make it difficult to reduce the solvent concentration. Once polymerization polymerization is complete, the solvents must then be remove removed d and treated – increasing cost, safety risks and environmenta environmentall impact. The LIST KneaderReactor is designed to operate in the concentrated phase with little to no solvent, reaching a polymer concentration of 40–99% during polymerization polymerization.. Its design provides constant surface renewal that improves heat transfer, allows excellent temperature control, and minimizes the diffusion and mass transfer limitations – particularly effective for exothermi exothermicc bulk polymerization polymerizationss with a polydispersity index less than 2. Due to this process intensification, several several process steps can be eliminated. As a result, the optimized process saves raw materials, reduces energy consumption, increases process efficiency, improves product quality, and lowers both CAPEX and OPEX. Processing in the concentrated phase also minimizes the environmental impact by eliminating solvents and toxic materials. www.listdryprocessing.com

Focusing on the essential in level measurement VEGA’s new radar sensor for bulk solids, the VEGAPULS VEGA’s VEG APULS 69, detects even the smallest reflected signals thanks to its 79 GHz operatin operating g frequency and high dynamic range

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adar level measuring instruments have created their own success story, largely superseding measurement principles such as electromechanical electromechanical sounding systems or ultrasonic devices in many sectors of industry. Yet although radar’s areas of application have gradually grown, experts agree that no single radar level instrument is currently able to cover every application. Thanks to its high operating frequency and other advances, however, the new VEGAPULS 69 from VEGA from VEGA comes comes very close to this ideal. The VEGAPULS 69 features a much wider range of application than previous radar instruments. With a measuring range of up to 120 m and an accuracy of ±5 mm, it has enough power reserves even for unusual assignments such as mine shafts and distance measurement in conveyor systems. The VEGAPULS 69 operates with a frequency of 79 GHz and an antenna size of 75 mm to achieves a beam angle of just 4°. The narrow beam avoids obstacles or deposits on vessel walls, and so makes measurements more accurate and reliable. A large dynamic range (120 dB) allows the VEGAPULS 69 to detect even the smallest reflections. For highly reflective media such as coal, ore, and rock, this guarantees even better certainty and reliability in measurements. For poorly reflective media such as plastic powders, fly ash and dry sawdust, it means measurem measurements ents of much higher quality, with reliable operation at distances up to 120 m. The VEGAPULS 69 can even measure substances such as polystyrene pellets and fumed silica powder that are traditionally

36I-10

beyond the reach of radar level measurement altogether. Inspired by the “spirit level” apps available for smartphones, VEGA engineers came up with a clever idea. They developed an app that can be used to set the angle of inclination when installing the VEGAPULS 69. To do this, the phone is simply placed on the instrument, allowing the sensor to be aligned quickly and optimally. www.vega.com/ vegapuls69

±5 mm at 120 m: The VEGAPULS 69 takes radar to new levels



MARCH 2015


Simulation Simula tion for better bet ter drying

Endless steel belt systems for the chemical & petrochemical industry

A new supercomput supercomputer er aids spray dryer design at GEA Process Engineering

A

new supercomputer – an HPC cluster with 512 cores, 90 TB of disk space and 2 TB of RAM – puts GEA Process Engineering in a league of its own for computational fluid dynamics (CFD) simulations of spray drying processes. The benefit for customers is even better and more efficient spray drying plants, the company says. Process simulations are the key to developing highperforming and cost-effectiv cost-effective e processing plants, and here GEA Process Engineering has been ahead of the game since the company introduced the DRYNETICS method in 2008. By using real drying properties established from singledroplet experiments, the CFD simulations provide far more precise results than they would otherwise. Compared to the previModern CFD simulation of spray dryers on powerful computers provides a high level of accuracy accuracy,, making it possible to optimize the design of entire plants as well as individual components

ous computer used for CFD, the new 512-core HPC cluster has more and faster CPUs, more RAM and larger storage capacity, making it more than six times as powerful. This allows GEA’s fluid mechanics specialists to push the boundaries of possibility even fur ther ther,, whether the job is to prove the performance of a given design, help with troubleshooting on an existing plant, or develop new dryer components. “With this computer we can process the smaller and less complicated simulations a lot faster, avoiding bottlenecks, and at the same time complete far larger and more complicated calculations within a reasonable amount of time,” says Mads Reck from the Fluid Mechanics R&D team in Copenhagen. “It allows us to do simulations so advanced that it puts us ahead of any and all competition. Had competitors started to catch up, this is a giant leap effectively leaving them behind,” Reck says. Extensive CFD simulations were key when GEA designed the world’s biggest dairy spray drying plant, Fonterra’s Darfield D2 in New Zealand. Every component was examined and optimized for operation as part of the complete process line. Advanced CFD modelling techniques were then used to further optimize and confirm the design of all critical parts. The plant was started up successfully last year and has continued to perform as designed throughout its first season. Another use of CFD simulation is in troubleshooting and optimizing existing spray dryers, where it is applied during reconfiguration of the dryer for new operating conditions or to remove any bottlenecks. GEA is using the new supercomputer to simulate not just spray www.gea.com dryers but also mixing equipment.

SBS Group designs and builds continuous process plants, equipped with steel belts from Berndorf Band, for a wide range of applications in the chemical, petrochemical, rubber and food industry. Having been pioneers in the development of pastillating units, SBS now supplies also complete packages for the solidication of liquid sulphur into pastilles. Rolldrop® and and Accudrop® are registered trademarks of SBS Group.

SBS Steel Belt Systems s.r.l. Phone: +39 0331 864841 [email protected]

www.steelbeltsystems.it www.berndorfband-group.com Circle 5 on p. 82 or go to adlinks.che.com/56195-05


The importance impor tance of correct correc t steam pipe and valve sizing sizing Efficient and reliable plant operation often depends on specialist steam equipment that is properly designed and maintained maintained,, says Bürkert Fluid Handling Syst Systems ems

Element steam valves from Bürkert

S

team is widely used in the process industries for heating and hygiene. Yet among all the specialisms required on a modern plant, steam equipment is some-

times overlooked, notes Ian Webster, Hygienic Processing Segment Manager at the UK subsidiary of fluids handling specialist Bürkert . “This can lead to breakdowns that could have been avoided if some basic principles were better understood,” he says. As a rule of thumb, engineers should use 25 m/s as the reference velocity when sizing pipes and valves. This is a crucial part of the design, since oversized pipework costs more in terms of materials and installation. Larger pipework also means greater heat loss, more condensate, and hence additional steam trapping to stop wet steam from reaching the point of use. On the other hand, undersized pipework results in reduced pressure at the point of use, which may impede the performance of the equipment. High steam velocities can also cause water hammer and erode pipework. Tables are available to help in sizing pipework, valves and fittings, including

steam traps. However, the designer needs accurate information on the system layout, the available steam pressure, and the flowrate of steam required. As a general rule, drain pockets should be of the same pipe diameter as the steam main, up to a size of DN100, and at least 100 mm deep. Condensate can skip over narrower pockets, and if these overflow they can also cause water hammer. Condensate pipework needs to be sized to account for the presence of flash steam, which can make up 95–99% of the total flow by volume. Control valve sizing is more complex, and here it may be advisable to seek expert assistance from a manufacturer such as Bürkert. Provided the basic design information is available, proper sizing tools can calculate valve sizes and orifice diameters, and warn of possible cavitation, flashing and choked flow. www.burkert.com

R E EC E C I E I V VE F U E t o UL L o A A L L LL o f L L f C h e e

A C C C CE S E SS S

F i m in g n e i c ca l g r a E e r t t i i p s p n s a r g i n e rt ti ee r i c l e i c l e s e n s i n g ’ ’s s F a n o n ac t ne e c o c t s s a t on nv t Y o u v e en i n ie ur n r e t n t l o oc ca t a ti i o n o . n

EACH INFORMATION PACKED PDF ARTICLE PDF ARTICLE includes graphs, charts, tables, equations and columns on the full chemical engineering processes you deal with on a daily basis. This is the t he tool you will come to rely on, referring back to the information again and again with just the click of a mouse.

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A new process for This mass spectrometer spect rometer adds value Pfeiffer Pfei ffer Vacuum’s Vacuum’s PrismaPlus is a compact, sensitive and recovering TDI Buss-SMS-Canzler explains Buss-SMS-Canzler Combi Fluidizatio Fluidization n Vacuum

Separation column Spray condenser Vapor dome

TDI cooler

Heating medium

Recovered TDI CFT Dryer Heating medium

Cooling medium

Cooler Vacuum

Cooling medium

Lock vessel Dry tar

Combi Fluidization Technology is a simple and economic way to treat TDI residue

P

roduction of toluene-2, 4-diisocyanate (TDI) yields a large amount of distillation residue containing 30–70% free TDI, notes Buss-SMS-Canzler , so overal overalll profitability depends on economic recovery of TDI from this residue. Thermal separation by evaporation and drying gives 100% TDI recovery, and is therefore accepted as state-of-the-art technology. However, in practice this recovery process is highly demanding, since the concentrated residue becomes highly viscous and sticky. It can solidify suddenly and may block the system with solids. Buss-SMS-Canzler’s Buss-SMS-Canzle r’s Combi Fluidization Technology (CFT) is excellently suited to overcome overco me these challenges. The unique CFT dryer combines contact and fluidized bed drying, and has its strengths in the economic treatment of sludges and pastes. A rotor within the horizontal dryer produces a mechanically fluidized bed. The wet product is evenly dispersed, so the dryer can handle materials that pass through viscous, pasty, sticky, crust-forming or crystallizing phases during drying. The CFT dryer thus offers a simple and economic way to www.sms-vt.com treat TDI residue.

intelligentt mass spectrom intelligen spectrometer eter

T

he PrismaPlus from Pfeiffer Vacuum is a mass spectrometer for qualitative and quantitative gas analysis and leak detection. Its key feature is a combination of high sensitivity,, stability and intelligent operasensitivity tion, while during routine operation users benefit from its robust, compact design and simple systems integration. The PrismaPlus delivers precise results over three different mass ranges (1–100, 1–200 and 1–300 amu) amu) down to a detection limit of 1 × 10 –14 mbar. With a choice of Faraday or electron multiplier detectors, even low-level contamination in vacuum systems can be quickly identified. In addition to displaying selectable partial pressures, direct attachment of a pressure gauge also enables the PrismaPlus to monitor total pressure accurately. The supplied Quadera software is easy to operate and offers an easy-to-read platform for capturing and visualizing both

Pfeiffer Vacuum’s PrismaPlus mass spectrometer

measured data and parameter records. Together with a wide selection of interfaces such as Ethernet, digital and analog inputs and outputs, this makes systems integration easy. A simple mouse click activates the pre-programmed functions, while the integrated VSTA editor lets advanced users write their own automated measurement measurement www.pfeiffer-vacuum.com routines.

The horizontal CFT dryer uses a rotor to fluidize and disperse material to be dried Circle 15 on p. 82 or go to adlinks.che.com/56195-15 adlinks.che.com/56195-15 CHEMICAL ENGINEERING


MARCH 2015

36I-13


Proven success for pastillation Sandvik marks 35 years of its i ts Rotoform process

Move products between bet ween pallets pallets Pallet transfer units from Müller Müll er makes light work of moving incoming goods from wooden to plastic pallets

U

niform, free-flowing pastilles are produced by controlled cooling of droplets deposited onto a water-cooled endless steel belt. It’s a simple principle but one that has endured: after 35 years of worldwide success, the Rotoform system remains the most effective process for the pastillation of many chemical products, says Sandvik . The Rotoform device itself consists of a heated, cylindrical stator and a perforated rotating shell that turns concentrically around the stator, depositing measured drops onto the steel belt. The speed of the Rotoform is synchronized with that of the belt cooler so the drops are placed without deformation. Cooling water sprayed onto the underside of the belt solidifies the droplets into consistently sized pastilles. The

A single single operator can transfer transfer a 1,000 kg load in just 30 seconds

I

n factories producing pharmaceutica pharmaceuticals ls and food products, wooden pallets are taboo for reasons of hygiene. This means that incoming materials must be repalletized between the delivery dock and the pro-

cessing area. To reduce the labor needed for this task to a minimum, Müller offers offers pallet transfer units that can also act as an up-todate and reliable clean zone interface. Since 1988 Müller pallet transfer units have been easing loads delivered on wooden pallets onto hygienic pallets. Pallet transfer units can be loaded for material flow in one or both directions, from the gray zone into the white zone or vice versa. Loads are transferred smoothly, and nothing gets damaged or tilted. Moving a 1,000 kg load takes only 30 seconds. This system is simple and can handle various types of loads – even asymmetrical ones. It is easy to operate, requiring just one person, and transfers the load from one pallet onto another without problems or the need for muscle power. In the same way loads ready for shipment can be transferre transferred d from the internal metal or plastic pallets back onto wooden pallets. Fully automated versions, with transfer in one or both directions, are availwww.mueller-gmbh.com able too.

The evolution of the species Rotoform yields free-flowing pastilles even from difficult subcooling melts indirect heat transfer avoids any danger of cross-contamination. Products handled include sulfur, resins, waxes, fatty chemicals, antioxidants, and fine chemicals. Sandvik has developed solutions for products of widely varying properties. Some, for instance, have a tendency to curl away from the steel belt; this can be overcome through carefully calculated temperature profiles and special heating of the drum that drives the steel belt cooler. Subcooling melts are another challenge associated with rubber chemicals, agrochemicals, photochemicals, stabilizers, and plastic additives. Here the product remains liquid even when the temperature falls below the melting point. Sandvik’s supercooling process overcomes this by introducing a homogeneous suspension of seeding crystals into the upstream melt. This remains the only viable way to produce highquality pastilles from subcooling melts. www.processsystems.sandvik.com

36I-14

The CosmoDry System from Italvacuum Italvacuum takes drying dr ying performance for grant granted; ed; ease of cleaning is the key

T

he CosmoDry System from Italvacuum is an innovative horizontal paddle vacuum dryer with a concentric agitator. agitator. Designed for maximum ease of cleaning, maintenance and internal inspection, it is ideal for multiproduct applications. The CosmoDry System targets the drying of wet powders from filters or centrifuges, especially pharmaceuticals, fine chemicals, and intermediates. Its mixing power power,, loading flexibility, drying speed, ease of unloading, and product quality are all givens. What sets the CosmoDry System apart from conventional paddle vacuum dryers, however, is the fact that the concentric agitator on its heated shaft can be dismounted in sections for easy cleaning and inspection. The agitator is designed for optimum mixing and heat transfer, while limiting mechanical and thermal stresses to aid the drying of temperatur temperature-sensitive e-sensitive products. Product deposition is kept to a minimum. The design facilitates both exterior and interior cleaning, the latter with the aid of an efficient CIP system.


The CosmoDry System features a dismountable agitator for ease of access The CosmoDry System is available in volumes of 150–4,400 l. Loading capacity is 30–80% of the chamber volume, depending on the product. The dryers are designed and manufactured to strict safety standards, and meet cGMP and ATEX regulations. www.italvacuum.com


MARCH 2015


Experts Exper ts in reactor charging charging Very few can match bulk handling expert exper t Dec when it comes to safely adding powders to reactor vessels

Dryer discharging and precise dosing into drums with Dec’s De c’s PTS, Dosivalve and Drum Containment System (DCS)

C

harging reactors with hazardous bulk materials is still a major cause of accidents, says Dec . Risks can be avoided by using Dec’s patented Powder Transfer System (PTS), which uses low-velocity dense-phase (plug-flow) conveying to avoid

electrostatic charges. All components are grounded, and the system keeps the reactor inert by separating the air from the powder. As well as reactor charging, the PTS can be combined with other powder handling equipment to boost production and reduce risks in filling, discharging, blending, and dosing applications. A recent advance is the Dosivalve, which works with the PTS to create a low-cost dosing system that is easily integrated to overcome problems when handling materials with poor flowability. The Dosivalve, which works with a pneumatic piston, eliminates the need for a buffer vessel between transferring and dosing. With a Continuous Liner System (CLS), the PTS/Dosivalve PTS/Dosiva lve also enables accurate dosing and packaging of powders into bags. Dec provides integrated solutions from a single source. The company is the North American representative of LUGAIA, a provider of packaging and transfer solutions, and now MAVAG, a specialist in filtration, drying and agitation. Interphex booth 1025 www.dec-group.net

Electric actuator specialist speciali st AUMA has a wide range of approved appro ved solution solutions s for safety safety-critical -critical applicat applications ions unctional safety, one of the most highprofile topics in the process industries, is especially important for chemical, oil and gas installations, where protection of people and the environment is essential and financial losses in event of accidents can be extremely high. As one of the world’s leading manufacturers of electric actuators, AUMA offers a broad range of devices providing cost-effective solutions for different SIL requireme requirements. nts. Internationally renowned test institutes have determined the safety parameters and SIL capabilities of AUMA products. A new TÜV certificate confirms that the company’s SA multi-turn actuators and SQ part-turn actuators with AC.2 SIL integral controls are suitable for applications up to SIL 3 (in redundant systems). These products comply with the second edition of IEC 61508. 61508. Design advantages of AUMA’s SIL actuators include configuration with different seating criteria, such as forced limit or torque seating, for example, to protect the mechanical integrity of the valve.

2

3

1

Evaporation and Rectification Recovering recyclables Treating solvents Producing alcohol Cleaning waste water

Safe actuation for SIL SI L applications applications

F

5 1 e 2 W G

AUMA SIL actuators in a typical safety safety instrumented system (SIS), including sensor (1), safety PLC (2) and actor (3), consisting of actuator and valve

AUMA can supply customers with safety parameters,, test reports, certificates, comparameters prehensive safety manuals, and checklists for commissioning and proof testing. Reinforcing its commitment to safety matters in actuation, AUMA is co-organizer of an international functional safety conference in October 2015 in Copenhagen www.auma.com (www.fscph.com).

This is just a small selection of applications for which we can offer the most economic plant concepts and equipment. Our experts will nd the optimum solution for your requirements.

ACHEMA 2015 15-19 June Hall 4.0, Stand F46

GEA Process Engineering

GEA Wiegand GmbH Phone: +49 7243 705-0 Internet: www.gea-wiegand.com

engineering for a better world




MARCH 2015

36I-15


New Products Tank-cleaning nozzles that can handle lower flowrates

0–30 to 0–225 psig. The regulators are equipped with 302 stainless-steel diaphragms, and nickel and stainless-steel housings are available on request. Each regulator comes with a four-seat valve-disc block, which can be rotated to provide a fresh valvedisc sealing surface, with spare valve discs provided. — Marsh Bellofram Corp., Newell, W. Va.

The expanded HydroWhirl Poseidon line of tank-washing nozzles (photo) now includes lower flowrates. The nozzles can now handle flowrates ranging from 4.45 to 26.3 gal/min. The smaller smaller-sized -sized nozzles are designed to fit through openings as small as 2 in., while maintaining a slow and controlled rotation speed. Complete www.marshbellofram.com 360-deg omnidirectional coverage allows for increased cleaning efficiency, Use this wireless device to and the nozzles’ slow-spinning spray remotely monitor storage tanks and longer spray dwell time on the The TankLink TankLink 95 (photo) is a wireless target surface increase impact when monitoring device for chemicals in compared to conventional rotating vented and unvented storage tanks designs. Fluid-driven and lubricated, in hazardous locations, providing acthese rotating tank-cleaning nozzles cess to tank data (such as critical level are constructed of corrosion-resistant and daily usage history) remotely. The polytetrafluoroethylene (PTFE) mate- T TankLink ankLink 95 utilizes 3G and 4G morial and are ideal for harsh chemical bile networks to monitor tank data, environments. — BETE Fog Nozzle, preventing personnel from having to Inc., Greenfield, Mass. enter hazardous areas (such as those where flammable vapor and gases www.bete.com or other ignition threats are present) A fully temperat temperature-co ure-compensate mpensated d to collect tank information. — Telular handheld pressure calibrator Corp., Chicago, Ill. The new HPC40 Serie Series s handh handheld eld pres pres-- www.tanklink.com sure calibrator (photo) is said to be the world’s first milliamp-loop calibrator This new SmartBob features that is fully temperature compensated horizontal mounting from –20 to 50ºC, enabling it to deliver The SmartBob SmartBob HM (horizontal (horizontal mount) the same accuracy whether measuring is a weight-and-cable-based level pressure, current, voltage or tempera- sensor that can be mounted on the ture. Suitable for calibrating pressures side of a bin, tank or silo. The Smartranging from vacuum to 15,000 psi, Bob HM features a rigid extension to with an accuracy of 0.035% of reading install on the side of the bin. Precise for all ranges, HPC40 instruments are level measurements are taken at predesigned for process-control applica- determined time intervals at a location tions, such as verification or calibration directly below the probe to continuof pressure gages, transducers, trans- ously monitor the inventory of material mitters, pressure switches and safety inside of the bin. b in. The device’s continuvalves. A single HPC40 Series device ous level sensor works like an autocan typically replace several gages or mated tape measure, but eliminates calibrators. — Crystal Engineering, the need to climb bins for manual San Luis Obispo, Calif. measurements. It is listed for Class II, Groups E, F, & G and enclosure www.crystalengineering.net types NEMA 4X, 5 and 12, ensuring These industrial-gas pressur pressure e the sensor is safe to use in locations regulators have three outlet ports where combustible dust may be The T39 Series of of industrial-gas industrial-gas prespres- present. — BinMaster, Lincoln, Neb. sure regulators (photo) incorporates www.binmaster.com three outlet ports within a single regulator, allowing for more versatility, as A pod system that eliminates well as potentially simplified piping the need for hand dosing layouts. T39 Series regulators are This modular modular “pod” system system (photo, (photo, p. available with a choice of seat materi- 38) is a self-contained, batch weighals, in six spring-pressure ranges from ing and metering system that delivers CHEMICAL ENGINEERING


MARCH 2015

BETE Fog Nozzle

Crystal Engineering

Marsh Bellofram

Telular

37

Ingredient Batching Systems

Siemens AG

that traditionally have been dosed by hand. The system can be made of one or any number of pods linked together via a common vacuum conveying line and a central controller. The ingredient is loaded onto each pod from flexible intermediate bulk containers (FIBCs) or sacked product. The system is sealed, so airborne dust is eliminated. — Ingredient Batching Systems, London, U.K. www.ingredientbatchingsystems.com

Rugged cellular router offers broadband wireless connectivity

dry powder ingredients directly into a vacuum-conveying line with high accuracy and low cost, according to the company. The new pod system is suitable for the food and pharmaceutical industries, where a product may have a number of different ingredients

The Ruggedcom RX1400 (photo) is a multiprotocol intelligent node that combines Ethernet switching, routing and firewall functionality with various WAN connectivity options. The device is IP40 rated, does not use fans for cooling, operates continuously within a –40 to 85°C temperature range and comes with a rugged metal housing that supports DIN rail, panel or rack mounting. The Ruggedcom RX1400 provides a high level of immunity to electromagnetic interference, heavy

electrical surges, extreme temperature and humidity for reliable operation in harsh environments. — Sie mens AG, Munich, Germany Germany www.siemens.com

A float-level transmitter transmitter with many fittings options The NML-308 is a miniature, synthetic float-level transducer suitable for level measurement in vessels up to 48 in. tall. The floats are made from PTFE and the tubes are 316

’     ... IT’S A CHECK-ALL ® Our spring loaded check valves are assembled to your exact needs, ensuring absolute precision and reliability. They work as they should in any orientation. Most lead times are less than one week. That’s what makes Check-All® the only choice.

T r a n s fe r r in

t o x

s u b s t a Müller Containment Valve MCV

– S u i t a b l e f o r E E B 3)5 ( O – A v a i l a b l e s i z e s : D N 1 0 D N 2 0 0 a n d D N 2 5 0 – E x p l o s i o n p r e s s u r e s h u p to + 1 0 b a r – V a c u u m - t i g h t v e r s i o n – E x p l o s i o n - p r o o f t o A T – E a s y - t o - w i p e f l a t s u r f a – A I S I 3 1 6 L s t a i n l e s s s t a v a i la b le o n r e q u e s t G M P - c o m p lia n t d e s i – Müller GmbH - 79618 Rheinfelden (Germany) Industrieweg 5 - Phone: +49(0)7623/969-0 - Fax: +49(0)7623/969-69 A company of the Müller group [email protected] - www.mueller-g www.mueller-gmbh.com mbh.com

Circle Cir cle 27 27 on p. p. 82 or go go to adli adlinks nks.ch .che.c e.com/ om/561 5619595-27 27 38

SINCE 1958

GET ME A CHECK-ALL®! Manufactured Manufacture d in West Des Moines, Iowa, USA

515-224-2301  @.  ..

Circle Cir cle 9 on on p. 82 or go to adli adlinks nks.ch .che.c e.com/ om/561 5619595-09 09



MARCH 2015

WIKA Alexander Wiegand

stainless steel. The fittings are avail- pumps (photo) are ideal for situations able in PTFE, polyethylene (PE), poly- where metal pumps could suffer propylene (PP) or polyvinyl chloride from the effects of corrosion. ARBO (PVC). The transmitted level signal is single-stage immersible pumps can converted to a 4–20-mA analog sig- handle capacities up to 300 m 3 /h nal via a remotely mounted DIN rail at differential heads up to 80 m and transmitter. — Kobold Instruments liquids with viscosities up to 100 cP. Inc., Pittsburgh, Pa. The pumps can be supplied in PP as standard, as well as the options www.koboldusa.com of high-modulus PE, polyvinylidene difluoride (PVDF) and PTFE for appli A sealless thermoplastic thermoplastic pump for open tanks and sumps cations where more corrosive liquids, higher temperatures, or higher solid Michael Smith Engineers concentrations are involved. — Michael Smith Engineers Ltd., Woking, Surrey, U.K.

and voltage signals, as well as those from resistance thermometers and thermocouples can be displayed. The instrument is also suitable for frequency and rotational-speed measurements, and, in addition, as an up/down counter. The indicator also records minimum or maximum values, enables the linearization of sensor values with up to five programwww.michael-smith-engineers.co.uk mable points and has a tare function. — WIKA Alexander Wiegand SE & A space-saving digital digital indicator Co. KG, Klingenberg, Germany

with many functions

www.wika.com

The model DI32-1 (photo) is multifunctional and, with its small dimensions (48 × 24 × 52 mm), ideal for applications with limited mounting space. The multifunction input of the DI32-1 digital indicator offers 23 input The new range of ARBO sealless, configurations. Thus, the measured thermoplastic immersible centrifugal values from transmitters with current

Analyze steels in the field, even for hot-tapping applications The Belec Compa Compact ct Port (phot (photo, o, p. 40) is a versatile mobile spectrometer currently going through the evaluation process with a Fortune-500 oil-andgas organization for the detection of www.burkert.com www.burke rt.com

Insider Tip! Did you know…? The Bürkert Type 330 is more than just a solenoid valve: it’s many in one. Featuring a body made of plastic, brass, aluminium or stainless steel and with various ports and sealants, it adapts to perfectly fit every requirement. Which means its unique and versatile valve technology is suitable for use in nearly all industries. Full encapsulation, the IP65 rating and an explosion-proof enclosure make the 330 fit for rough environments and critical media. Its long service life ensures it won’t be a thing of the past tomorrow. So spread the word! We make ideas ideas flow.

lers MicroFluidics Mass Flow Controllers Solenoid Control Valves Circle 7 on p. 82 or go to adlinks.che.com/56195-07

Rota Val

culations at 350°F for hot tapping applications — Innovated Analytical Solutions LLC, Bremen, Ala. www.steelanalyzer.com

CFD optimizes this modular range of blowing seal valves One of the problems faced with blowing-seal type rotary valves is to maintain the air velocity between the valve and the conveying pipe while still achieving a good rotor pocket purge. Designers at this company have solved this problem using computational fluid dynamics (CFD) software, in conjunction with a standard CAD package to determine the profile that would guarantee minimum pressure loss and maximum pocket purge. One of these CFD-designed profiles was chosen (photo) for the comany’s new modular valve range. There is hardly any drop in air velocity during conveying with the smoother airflow through the valve, which results in improved rotor life and efficient pocket purging. This in

Innovated Analytical Solutions

sulfidation corrosion in hot applications. The Compact Port incorporates features required by oil-andgas inspection professionals. The system has ultraviolet (UV) probes to detect C, P, S, B and N in Duplex stainless steels, with probe lengths from 3 to 5 m for hard-to-test areas. The system has temperature-stabilized optics for stable low-level detection limits. The system detects low levels of carbon in stainless or low-alloy steels while meeting the requirements of API 578 and API 939-C in the field, and is capable of conducting carbon-equivalency cal-

turn leads to increased valve life, because high velocity-wear erosion is reduced by the fuller, smoother airflow. — Rota Val Ltd., Chippen ham, Wilts Wiltshire, hire, U.K. www.rotaval.co.uk

A highly concentrated additive that prolongs biodiesel shelf life Introduced in January, January, Baynox Ultra is a highly active liquid stabilizer specially designed for biodiesel made from polyunsaturated fatty acids, such as soybean and sunflower methyl esters. This easily easily metered additive additive contains contains a balanced blend of highly active antioxidants and a chelator chelator,, dissolved in a “green” solvent. Thanks to the high active-ingredient content of over 40%, 200 to 500 ppm of Baynox Ultra is generally sufficient to ensure a reliable shelf life for biodiesel. As the product also remains liquid to –5°C, storage

Visit us Interphex NY 21 – 23 April 2015 booth 1025

“Your “Y our #1 replacement for C.T.F.E, C.T.F.E, Silicone & FluoroSilicone Lubricants”

Inert Light Oil & Grease

Achema, Germany 15 – 19 June 2015 booth D8, hall 5.0

We keep you safe Reactor Charging · Powder Handling Process Isolation

Designed For: • Ch Chemical Me Metering Pu Pumps • Hy Hydrocar bo bon Me Metering Pu Pumps • Diaphragm Pumps • Mechanical Seals • Valves • O-rings

Focus Industries: • Ch Chemical To Toll Pr Processing • Fu Fuel Re Rener ies • Cryogenic Plants • High Pressure Gases • Water Treatment • Oxygen

MS-1010

MS-2010

m

TM

s An Alliance of Technology & Expert Knowledge www.dec-group.net Circle Cir cle 12 12 on p. 82 or or go to adli adlinks nks.ch .che.c e.com/ om/561 5619595-12 12 40

Connecticut • Illinois • California • Canada For technical information: 800.992.2424 or 203.743.4447 [email protected] • miller-stephenson.com

Circle Cir cle 26 26 on p. 82 or or go to adli adlink nks.c s.che. he.com com/56 /56195 195-26 -26



MARCH 2015

tanks and pipes do not need to be heated in winter. Another additive (Baynox Cargo), designed to stabilize biodiesel tanks in ships and ports, has also been introduced. — Lanxess AG, Cologne, Germany www.lanxess.com

transmitter housing keep critical components isolated from environmental hazards — a leading cause of electronics failures. Enhanced diagnostics, including Smart Meter Verification and the new Electrode Coating Detection provide users with more information than ever before about the flowmeter, installation and process, enabling more informed decisionmaking, easier identification of process issues, and simplified flowmeter verification. The Electrode Coating Detection diagnostic identifies coating on the electrode before the sensor signal is compromised, helping to prevent inaccurate flow measurement. — Emerson Process Management, Shakopee, Minn.

Wilden

(photo) is ideal for use in the company’s Saniflo FDA pumps, as well as its Original, Advanced and Advanced FIT series of AODD pumps. Emerson Process These 3-in. diaphragms are said to be well-suited for hygienic applications because they are constructed of food-grade Wil-Flex W il-Flex (Santoprene), and unlike conventional diaphragms, the integral piston is completely encapsulated within the TPE ma The new Rosem Rosemount ount 8700 8700M M Magterial, meaning there is no outer netic Flowmeter line (photo) provides www.rosemount.com/8700 piston that can trap fluid and parenhanced safety for hazardous-area ticles. The diaphragms withstand applications, along with intelligent di- A new full-stroke, integral piston temperatures from –40 to 107°C, agnostics. Glass feed-throughs trans- diaphragm model and meet the requirements of FDA mit signals between isolated compart- This manufactur manufacturer er of airair-operated operated CRF 21.177, EHEDG and 3A. — ments of the transmitter enclosure, double-diaphragm (AODD) pumps Wilden, part of PSG, a Dover Co., providing the most effective barrier for has recently introduced its 76-mm Grand Terrace, Calif. safety and reliability. The all-welded (3-in.) size Full-Strok Full-Stroke e Integral Piston www.wildendiaphragms.com ■ sensor design and dual-compartment Diaphragm (FSIPD). The new FSIPD Gerald Ondrey and Mary Page Bailey

Safety and diagnostic features enhance this flowmeter line

MONITOR VISCOSITY SIMPLY SENSE MIXER MOTOR HORSEPOWER WITH UNIVERSAL POWER CELL PROFILING A PROCESS

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Circle 23 on p. 82 or go to adlinks.che.com/56195-23 CHEMICAL ENGINEERING


MARCH 2015

41

Show Preview

Newark Wire Cloth

Rigaku Raman

NJM Packaging

42

H

ighlighting technology and allows measurement even through innovations in the sectors of thick polymer materials or dark glass. pharmaceutical and biophar- Booth 2878 — Rigaku Raman Techmaceutical manufacturing, nologies Inc., Inc., Wilmington, Mass. Mass. Interphex 2015 is taking place April www.rigakuraman.com 21–23 at the Jacob Javits Convention Center in New York City. Over 12,000 This compact tablet counter professionals are expected to visit accommodates four modules the event’s workshops, networking The Cremer Model CFS-622*4 foursessions and exhibit hall. The follow- module tablet counter (photo) can ing product descriptions represent a count almost any kind of tablet or capsmall selection of the more than 600 sule, and fill almost any kind of plastic exhibitors who will be showcased or glass bottle, including those with at Interphex 2015. round, oval or rectangular shapes. The small-footp small-footprint rint design allows for These strainers handle both simple integration into new or existing coarse and fine-particle filtering lines, and its transparent enclosure The SaniClean line of strainers are provides accessibility accessibilit y. A vision-inspecspecifically designed for use in pro- tion feature allows for the detection cessing applications where cleaning of broken and rogue tablets; when a is critical, such as those requiring faulty container is detected, the CFScoarse straining or fine-particle filtra- 622*4 will reject it. Other standard tion in the pharmaceutic pharmaceutical, al, food, dairy features include a central product and beverage industries. The strainers hopper, a touchscreen control panel are suitable for both continuous pro- and a servo-driven feedscrew. A cenduction cycles and small-batc small-batch h runs. tral dust-extraction mechanism, a A variety of capacities are available, product eject system and an ionizer ranging from low creeping flowrates to eliminate static electricity are opto high-volume production outputs. tional add-ons. Booth 2353 — NJM The strainers can be integrated into Packaging, Lebanon, N.H. existing or new piping configurations. www.njmpackaging.com The standard material of construction is 316L stainless steel (photo), This isolator system features a but other corrosion-resistant alloys fast decontamination process are available. Booth 3370 — Newark The Pharmaceutic Pharmaceutical al Safety Isolator Wire Cloth Co., Clifton, N.J. L-Flange (PSI-L) system is a modular isolator system outfitted with an www.sanicleanstrainers.com L-shaped flange. The unique flange Positively validate materials with design enables equipment to be this handheld Raman analyzer changed quickly, and the possibil The Progeny line of handheld Raman ity of using an empty flange plate analyzers (photo) is designed for provides maximum flexibility. The quick, non-destructive material vali- system’s short (less than 20 min) dedation, allowing for immediate re- contamination cycle and a return air jection of non-conformi non-conforming ng materials filter create a sterile environment for and fewer quarantined shipments. aseptic or highly active pharmaceuti The raw-material identificatio identification n pro- cal products. Booth 3055 — SKAN vided by Raman spectroscopy helps AG, Allschwil, Switzerland Switzerland to ensure that manufacturing stan- www.skan.ch dards are met, and that final products meet specifications and comply with Constant-pressure processors regulations. regulatio ns. With a design inspired by that ensure uniform handling smartphones, Progeny analyzers fea- This company’ company’s s Microflui Microfluidizer dizer famture touchscreen user interfaces, an ily of high-shear fluid processors enintegrated digital camera and large- ables uniform particle-size reduction, sized display buttons. Also included bottom-up crystallization and efficien efficientt are a 1,064-nm excitation laser and a cell disruption, and can be used in built-in, adjustable nose cone, which the development of nano-enabled CHEMICAL ENGINEERING


MARCH 2015

CASE STUDY SUCCESSES 2015 AFPM Reliability & Maintenance Conference and Exhibition Austin Convention Center Austin, Texas May 19 – 22, 2015 Register at www.afpm.org 202.457.0480

Join your colleagues as Operating Companies share strategies they implemented to meet and beat operational challenges through a series of case studies. Reap the benefits of others’ experiences and learn from f rom your peers.

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Boccard Life Sciences

medicines, chemicals and consumer products. The key to the Microfluidizer’s uniform material-handling capability is its ability to maintain a consistent process pressure within the system. Suitable for a variety of applications, including both laboratory use and full commercial production, these processors provide size reduction and disruption in the sub-micrometer range, and numerous scaleup options are available. Booth 1653 — Microfluidics Internationall Corp., Westwood Internationa Westwood,, Mass. www.microfluidicscorp.com

Forming, filling and sealing for multi-product manufacturers

Adaptive Manufactu Manufacturing ring Tec Technologies hnologies

Optima Packaging Group

The QuickPouch Ve Vertical rtical (photo) is a compact, customizable machine designed to form, fill and seal pouches. The system can handle package package sizes of up to 6 in. in width and 9 in. in height. The machine’ machine’s s simple design is is advantageous to manufacturers with multiple products; changeovers are simple, taking as little as 15 min. The QuickPouch Vertical is available with many options, including printing, automatic loading, liquid or powder filling, diecutting and more. Applying a hot die to imprint the pouch form, the cycle-ondemand system is equipped with time, pressure and monitoring functions. Pouch materials include foil laminate, paper laminate and plastic laminate. Booth 3857 — Adaptive Manufactur Manufactur- ing Technologies Technologies,, Ronkonkoma, N.Y. N.Y. www.amtautomation.com

A compact filling and closing machine with 10 filling positions

Watson-Marlow Watson-Ma rlow Pumps Group

44

This company’ company’s s H4 filling and closing machine (photo) can process nested vials, syringes and cartridges, and also allows for the pre-manufacture of certain modules, providing cost savings and flexibility for a number of diverse applications. Even within a compact footprint, the H4’s transport system achieves a high output rate of 24,000 objects/h, which can be expanded to 36,000 objects/h with certain retrofitting options. The H4 comes equipped with a ten-position filling system. For filling flexibility and simple format changes, rotary-piston pumps, as well as peristaltic or time-pressure filling systems can be added at any time. Further customizations are availCHEMICAL ENGINEERING

able through the addition of upgraded in-process controls and the insertion of vacuum stoppers. Booth 3103 — Optima Packaging Group GmbH, Schwäbisch Hall, Germany www.optima-packaging-group.de

Safeguard sensitive connections with this tool The Boc BocLoc Lock k intel intellig ligent ent con connec nectio tion n syssystem (photo) safeguards process connections in mechanical and automated systems, and is specifically designed for flow-transfer panels with frequent connections. Suitable for very sensitive processes, the system features a multicolored indicator light that continuously informs the operators of the connection status. This includes notifying the operator if the connection is awaiting action, or if the connection is dirty dirty,, clean or incomi ncompatible. The BocLock’s stainless-steel construction allows for in-situ cleaning, and the system comes equipped with an integral passage with a standard hygienic seal. Booth 3168 — Boccard Life Sciences, Inc., Sugar Land, Tex. www.boccard-bls.com

Cloud-based temperature and humidity monitoring The OneVue intelligent platform is a cloud-based system that monitors critical temperature and humidity data. With its responsive design, the One Vue platform can be configured on any tablet, smartphone, laptop or desktop computer. Alert routing rules can be set up to deliver notifications via email, text message or phone. According to the company, the platform is unique in that the data generated by sensors are tied to the room, physical equipment (such as refrigerators) or inventory (such as pharmaceuticals) being monitored, rather than to the sensor itself, creating historical data trails. Booth 1015 — Primex Wireless, Lake Geneva, Wisc. www.primexwireless.com

Single-use fluid-path components designed for bioprocessing This company’ company’s s BioPure family of single-use fluid-path components is manufactured specifically for bioprocessing applications, and includes the following products: BioClamp plastic quick-release tri-clamps (photo); BioWWW.CHEMENGONLINE.COM

MARCH 2015

Barb hose-tail to tri-clamp adaptors; FlatBioEndCap connectors for endcaps, BioEndCaps, which are designed to permanently terminate a disposable manifold until an inprocess new sterile connection is to be made; BioY equal-barbed Yconnectors; and BioValve restriction flow-control and shutoff valves for silicone tubes. These fully traceable components are intended to emulate over-molded products. Featuring full-through bore diameters, these components are designed to reduce dead spots in processes. Booth 2833 — Watson-Marlow Pumps Group, L.B. Bohle Maschinen + Verfahren Wilmington, Mass. www.watson-marlow.com gaps between the rollers are controlled and monitored with sensors, Filter bags designed with safety and can range from 1 to 6 mm. Senand security in mind sors also monitor the forces on the rollers. Below the rollers is a chopper Sefar unit, where the flakes are processed into granules. A built-in conical sieve with exchangeable sieve units allows control over particle size. Within the machine, the axes are mechanically stable so that elastic deformation is prevented, eliminating the need for complete axis control. Booth 2811 — L.B. Bohle Maschinen + Verfah Verfahren ren GmbH, Ennigerloh, Germany www.lbbohle.de This company’ company’s s Pharma-Grade Filter Bags (photo) for fluid-bed dryers are constructed in a dedicated cleanroom to ensure high standards of purity and detail. The bags have been developed to avoid possible contamination from staple fibers. A microporous membrane laminated on polyester or polytetrafluoroethylene (PTFE) provides efficient filtration. An antistatic version of the bags is available, with an incorporated high-conductivity stainlesssteel matrix, which provides excellent explosion protection. Booth 2137 — Sefar, Inc., Depew, N.Y. www.sefar.com

These dry granulators have sensor-controlled rollers BRC 25 dry granulators (photo) process powders into free-flowing granules. Fed via a dosing unit, the powder is compacted between two rollers and discharged as flakes. The

Achieve precise precis e wet milling milli ng and emulsifying with this system The HV model combination emulsifier and wet mill is designed for precise emulsifying in a single pass, and is capable of wet milling some active pharmaceutical ingredients to the 10–20 µm range. Operating at an extremely high rotational velocity, tooling tip speeds of up to 70 m/s are achieved, providing more than 55 times the shear-energy input compared with conventional rotorstator systems, says the company. This performance envelope fills the gap between existing rotor-stator technologies and high-pressure homogenizers. The HV emulsifier and wet mill is available in three models with scalability ranges for laboratory, pilot and production volumes. Booth 1653 — Quadro Engineering, Waterloo, Ontario, Canada www.quadro.com ■ Mary Page Bailey

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MARCH 2015

45

Facts At At Your Your Fingertips Fing ertips Steel Corrosion

TABLE 1. ALLOYING ELEMENTS AFFECT STAIN STAINLESS-STEEL LESS-STEEL CORROSION PROPERTIES

Department Editor: Scott Jenkins

C

orrosion of steel is a key concern in many industrial settings, both from an assetmanagement perspective and from a safety perspective. The following briefly describes corrosion mechanisms for various classes of steel, and provides information on the corrosion resistance of these ubiquitous iron-based alloys. Carbon steels contain only iron and carbon, with carbon making up between 0.002 and 2.1 wt.%. Lowalloy steels contain a variety of other elements added to achieve desired properties of corrosion resistance, strength, formability and other characteristics.. Steel is classified as stainacteristics less steel if its chromium content is at least 10.5 wt.%, and its carbon content is less than 1.20 wt.%, as defined in ASTM Standard A240 (ASTM International; West Conshohocken, Pa.; www.as www.astm.org). tm.org). Iron oxidation

Steel corrosion is an electrochemical process requiring the simultaneous presence of water and oxygen. The anode reaction involves the formation of Fe2+ ions and the release of electrons, while the cathode reaction involves a reduction of dissolved oxygen, with water as an electrolyte. Fe0 —> Fe2+ + 2e O2 + 2H2O + 4e–

–

—>

4OH–

Iron ions react with the hydroxide to form iron hyroxides [such as Fe(OH)2], which react further with oxygen to give Fe 2O3·H2O (rust). The presence of acids and chlorides accelerates the corrosion process. Stainless steel

The chromium in stainless steels allows the generation of a complex chromium-oxide surface layer that resists further oxidation (passive layer). The chromium-oxide layer is thin (microns) but tough. It will reform if removed by scratching or machining. The addition addition of nickel nickel to the structure structure (8 wt.% Ni minimum in the commonly used 304 type stainless steel and 10 46

ELEMENT

EFFECT ON STAINLESS STEEL

Chro Ch romi mium um

Molybden Molyb denum um Copper Mang Ma ngan anes esee

Formss a pa Form pass ssiv ivee fil film m wit with h oxy oxyge gen n tha thatt pre preve vent ntss fur furth ther er di diff ffus usio ion n of of oxy oxyge gen n int intoo the the surface of the steel Increases ductility and toughness; increases corrosion resistance to acids; Ni addition creates non-magne non-magnetic tic structure Increa Inc reases ses pit pittin ting g and and cre crevic vicee corr corrosi osin n resi resista stanc nce; e; inc increa reases ses res resist istan ance ce to chl chlori oride dess Increases corrosion resistance to sulfuric acid Acts Ac ts as a sub subst stit itut utee for for ni nick ckel el in 20 2000-se seri ries es st stai ainl nles esss ste steel el

Titianium/Niobium Titianium/Ni obium

Ties up carbon and prevents inter-granular corrosion in welded zone of ferritic grades

Nitr Ni trog ogen en

Incr In crea ease sess str stren engt gth h and and co corr rros osio ion n res resis ista tanc ncee in in aus auste teni niti ticc and and du dupl plex ex gr grad ades es

Silicon

Improves resistance to high-temperature scaling

Sulfur

Usually kept low except for “free-machining” grades

Carb rboon

Usu suaall llyy kep keptt low low;; use used d in in mar marttens nsit itic ic gr graades to in incre reaase st strren engt gth h and and ha hard rdne ness ss

Nickel

Source: “Alloying Elements in Stainless Steel” by Pierre-Jean Cunat, Published by the Internation Chromium Development Association Association

wt.% Ni minimum in the more corrosion-resistant 316) broadens the range of passivity established by the chromium. Further, addition of molybdenum (2 wt.% minimum in 316) further expands the passivity range and improves corrosion resistance (see table). Corrosion mechanisms

Stainless steel resists general corrosion well, but several mechanisms can result in localized corrosion of stainless steel. For example, pitting occurs in areas where the stainless steel’s protective passive layer breaks down on an exposed surface. Once initiated, the growth rate of the pit can be relatively rapid and can result in localized, deep cavities. Crevice corrosion occurs in locations where oxygen cannot freely circulate, such as tight joints, under fastener heads and in other areas where pieces of metal are in close contact. Pitting and crevice corrosion of stainless steels generally occurs in the presence of halide ions (chloride is most common). Moisture from the environment, along with chloride salts and pollutants, accumulates in the crevices, creating an acidic environment inside the crevice where oxygen is depleted and chloride concentration is elevated. This environment promotes the breakdown of the passive film and anodic dissolution. The main environment environmental al factors that favor localized attack include higher chloride concentration, elevated temperature, lower pH and more cathodic corrosion potentials. CHEMICAL ENGINEERING

Specific corrosive environments, such as the presence of chlorides, combined with tensile stress, can crack stainless steels in a mode of attack known as stress corrosion cracking (SCC). Another corrosion mechanism involves the metal’s microscopic grain structure. Rapid corrosive attack of immediately adjacent grain boundaries with little or no attack of the grains is called intergranular corrosion. Corrosion resistance

Corrosion of carbon steel can be minimized with protective paints and coatings, or by cathodic protection, such as galvanizing (applying a zinc coating to interfere with the natural electrochemical reactions in corrosion). Modifying the operating environment with corrosion inhibitors can also be effective in some cases. The resistance of a stainless steel to localized attack is strongly related to its alloy content. Chemical passivation refers to the chemical treatment of stainless steel with a mild oxidant, such as nitric acid or citric acid solution, for the purpose of enhancing the spontaneous formation of the protective passive chromium oxide film. n For more on corrosion, see Chem. Eng ., ., March 2014, pp. 40–43 and July 2012, pp. 26–29.

Relevant links 1. Specialty Steel Industry of North America. www.ssina. www.ssina. com/overview/alloyelements_intro.html 2. ASTM International. Standard A380. www.astm.org/ Standards/A380/ 3. Steelconstruction.info 4. Corrosionist. www.corrosionist.com/Pitting_Crevice_Corrosion.htm


MARCH 2015

When the Temperature Rises, Will You be Able to Handle the Heat? It’s no secret that corrosion prevention is a huge issue many industries face every day. day. Industries with infrastructure that is exposed to high temperatures face an increased challenge in their prevention and mitigation efforts. To educate those addressing this challenge, NACE is once again hosting the popular Bring on the Heat Conference. The event brings together

over 300 end-users,

contractors, inspectors,

and manufacturers to discuss the following topics: •

Corrosion under insulation (CUI)

•

Passive fire protection (PFP)

•

Thermal spray aluminum

•

High-temperature coatings

•

Generic coatings for CUI

•

• • • •

Case Studies Round Table

•

Application of cement, light weight we ight cementitious cementi tious and epoxy intumescent PFP

•

SHOW FEATURES: Owner’s panel Demonstration day 20+ exhibits Copy of presentations

Coatings needs for owners

area

To register or for more information go to both.nace.org

REGISTER TODAY Save $25 when you register by March 27, 2015

Official Publications:


Technology T echnology Profile Propane Dehydrogenation: Oxydehydrogenati Oxydehydrogenation on By Intratec Solutions

P

60

ropylene is a major compo- the required heat of reaction. Figure 2 55 nent of the global olefins mar- shows the effect of O2 addition on proket and is widely used as an pane conversion, according to different ) 50 % ( intermediate for an array of O2-to-propane molar ratios. e n 45 p chemical and plastic products. Reaction. Propane is fed into a depro- a Reaction. o r 40 Propylene is produced as a byprod- panizer column for heavy impurities p n o i s uct in steam crackers and through removal. The depropanizer distillate is r e 35 v n Without oxygen o fluid catalytic cracking (FCC) process- vaporized, mixed with steam, and pre- C 30 02 /HC ratio = 0.05 es. However, due to the increased heated before entering the reformer re02 /HC ratio = 0.1 25 availability of inexpensive ethane from actor, which is an externally fired tubushale gas, ethane has been prefer- lar reactor where most of the propane 20 550 560 570 580 590 600 entially used as a feedstock in steam conversion occurs. Next, the reformer Temperature (oC) crackers over naphtha, a practice that effluent is fed to the oxyreactor, where results in minor propylene production. H2 is selectively combusted by O2. FIGURE 2. O2 impact on propane conversion In this context, on-purpose propyl- The process gas is cooled in a series from the cold box is sent to the fracene production routes are of great of heat exchangers to recover process tionation area, which consists of a deinterest to the petrochemical market- heat. Then, it is compressed and sent ethanizer column for removal of lights place. Among them, propane dehy- to the next area. and a propane-propylene (P-P) splitter, drogenation (PDH) technology is an at- CO 2 separation. The compressed where polymer-grade (PG) propylene is tractive option, and has been applied gas is fed to an absorption column, obtained. Unreacted propane from the in several plants around the world. where CO2 is removed in the bottoms splitter bottoms is recycled. by washing with an aqueous piperaThe process zine-activated methyldiethanolamine Economic performance The PDH process depict depicted ed in Figur Figure e (MDEA) solution. The bottoms stream An economic evaluation of a PDH plant 1 is similar to the STAR (steam active is depressurized, liberating gases that was conducted, assuming a facility reforming) process (Uhde GmbH; Dort- are recycled to the absorption column. with a nominal capacity of 450,000 mand, Germany; now ThyssenKrupp The CO2-rich liquid solution from the ton/yr of PG propylene erected at a Industrial Solutions; www.thyssenk- flash vessel is fed to the solvent re- petrochemical complex on the U.S. rupp.com), which applies the oxydehy- generation column, which separates Gulf Coast (no storage for feedstock drogenation principle. Two other PDH CO2 in the overheads from the MDEA and product was considered). Estimated capital expenses (total processes were previously discussed solution in the bottoms, which is rein this column (Chem. Eng., Feb. 2013, cycled to the absorption column. fixed investment, working capital and p. 33 and Jan. 2014, p. 27). Gas separation. The overhead initial expenses) for such a plant are The ST STAR AR process was the first to stream of the absorption column is $400 million and estimated operating apply the oxydehydrogenation principle dried in a molecular sieve and fed to expenses are $770/ton of product.■ for propylene production, significantly a low-temperature separation system Editor’s Note: The content for this column is supplied by enhancing performance. In this tech- (cold box) for the removal of lights. In Intratec Solutions LLC (Houston; www.intratec.us) and edited nology, O2 is added to the system to this system, a H2-rich stream is also by Chemical Engineering . The analyses and models preare prepared on the basis of publicly available and react with H2, forming water. This reac- obtained, and is purified in a pressure sented non-confidential information. The content represents the opintion lowers H2 partial pressure, shifting swing adsorber (PSA) unit to obtain ions of Intratec only. More information about the methodology for preparing analysis can be found, along with terms of use, the equilibrium to higher conversion of high-purity H2 byproduct. www.intratec.us/che. .us/che. propane into propylene while providing Fracti Fractionatio onation. n. The liquid fraction at www.intratec H2 byproduct

3

ST

RF

14

11

Air

Lights to fuel

9

RF

FU Lights to fuel

10

2 CW CW

4

CO2

PG propylene

8

ST

1

CW

12

BFW O2 /air Propane

RF

6

5

7

ST 13

ST BFW

ST Heavies to fuel

FIGURE 1.

48

ST Water MDEA Piperazine make-up make-up make-up

ST

1) Depropanizer column 2) Reformer reactor 3) Feed pre-heater 4) Oxyreactor 5) Compression system 6) Absorption column 7) Flash vessel 8) Regeneration column 9) Molecular sieve unit 10) Cold box 11) PSA unit 12) Deethanizer column 13) P-P splitter 14) Refrigeration unit MDEA Methyl diethanolamine BFW Boiler feed water CW Cooling water FU Fuel RF Refrigeration fluid ST Steam

Propane dehydrogenation process similar to the Uhde (now ThyssenKrupp) STAR process CHEMICAL ENGINEERING


MARCH 2015

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Why Bad Things Happen to Good Steam Equipment

Part 1

Accounting for an entire steam-trap population is crucial to avoiding safety incidents and suboptimal production — high-priority consideration must be given to steam-system management

James R. Risko

TLV TL V Corp.

IN BRIEF WHAT CAN GO WRONG IN A STEAM SYSTEM? ANALYZING A STEAM ANALYZING TRAP POPULATION POPULATION MANAGEMENT PRIORITIZATION EVALUATING THE NUMBERS SYSTEM GOALS CREATING A NEW PARADIGM

50

H

istorically, steam systems have provided the most effective source of readily conveyable heat to industrial process applications, including those in the chemical process industries (CPI), and there is no similar low-cost substitute that can replace steam. Without steam, industrial production would be dramatically curtailed, and the low-cost manufactured products that are made from steam’s heat or powergeneration assistance would not exist. Without steam, our quality of life, economies and society in general would suffer. While many CPI workers may appreciate that steam systems are a necessity, the same individuals may have also experienced negative steam-related incidents throughout their careers, making them harbor unfavorable thoughts. Specifically, these events may have resulted in safety issues, equipment failures and unscheduled shutdowns of a unit or a full production line. Safety events are extremely challenging and sorrowful issues if someone FIGURE 1. Effective steam traps keep heat in the system to optimize production rates and heat quality quality,, and they also discharge condensate to is injured, and shutdowns can be provide for system safety and reliability. Major problems can occur if condisruptive to the entire workforce. densate is not readily drained from the system It is not surprising, then, that people lack an enthusiastic attitude when it ment. Such destruction may render critical comes to steam. process equipment, such as turbines, flares or heat exchangers, unusable. Additionally, What can go wrong in a steam system? high return-system backpressure caused by What types of issues can arise in a steam steam leakage or blowthrough from bypass system, and can listing and classifying these steam might restrict production quantity or items help to determine an executable pre- quality through heat-exchange equipment. vention path or risk-mitigation procedure? Of Backpressure can also cause the heat-excourse, it is relatively easy to identify the most change application to be put on bypass or common maladies seen in a steam system. to waste condensate by routing to ground There Ther e can be waterha waterhammer mmer,, erosion erosion damage damage level. While some steam-system failures are and steam leaks in utility systems or equip- common, the challenge then is to identify the CHEMICAL ENGINEERING


MARCH 2015

12,000

FIGURE 2. A typical steam

plant has less in-service condensate discharge locations (CDLs) than the original design. As total failures are reduced through monthly replacements, the number of “good” “good” CDLs increases. If actual replacements are less than known total failures, carryover failures result, thereby reducing available good CDLs to effectively drain the system in the subsequent year. For more details, see the calculation box on p. 26

Design CDLs In-service CDLs

10,000 Good 8,000 s L D C f o r e b m u N

6,000

4,000

Total failures – actual

2,000

Carryover failures

Total failures – target Target monthly replacements 0 1

2

3

4

5

6

7 Month

sources of these incidents. This leads to the larger question, “Why do bad things happen to good steam equipment?” The technic technical al answer answer lie lies s in understan understandin ding g that the cause for a large percentage of failures might be due to the steam system not being maintained to the “as-built” or “design” specification. The original designers analyzed the plant requirements and determined the most suitable design, according to their expertise and standards. That original design included the correct number of steam traps and the assemblage of piping and components that help to drain condensate from the system. Commonly referred to as a condensate discharge location (CDL), the total assembly is required to remove condensate and effectively maintain the design performance of the steam system. Once built, the plant is handed over to the end user for operation and maintenance — with the expectation of sustaining the initial design. Unfortunately, that is when operational budgets, personnel turnover and, in some cases, inexperience with steam systems may play a causal role in negative events.

8

9

10

11

12

Actual monthly replacements

commissioned, because no part of the plant commissioned, had been shut down. When the in-service quantity of CDLs is lower than the design calls for, then it may be that the reduction was due to a misunderstanding of the importance in maintaining the design total, or possibly from general neglect of the trap population. If the discrepancy is not explainable, then the system’s drainage is restricted from the originally required capability. Here, the target for total inservice CDLs should be increased to equal the original design total of 11,000 CDLs. When routinely administered, steamtrap surveys conducted by plant personnel (Figure 3) provide invaluable information for evaluating the health of the steam system. As it turns out, in this hypothetical example, several years had passed since the last trap survey was completed. So, when the current survey was finished, it was found that there were 3,000 trap failures (both hot leaking failures and cold-blocked low-temperature failures occurred); and 7,000 traps were considered to be in good condition. This sit-

FIGURE 3. Accurate and

regularly sustained diagnosis of steam traps’ operating conditions is essential to determining the population’ population’ss current health (state of the population). Once failures are identified, the information is valuable for allocating resources to restore all condensate discharge locations to an “as designed” operating condition for safety and reliable performance

Analyzing a steam-trap population Steam traps (Figure 1) are ubiquitous in steam systems, and when operating effectively, they can efficiently retain heat in the system. Consider the analysis of a hypothetical plant’s steam-trap population shown in Figure 2. Based on this plant’s “state of the population” summary, it is seen that the original design (and as-built) condition included 11,000 CDLs. Over Ove r time, the plant’s management decided to decommission and remove 1,000 steam traps from service, leaving only 10,000 in-service CDLs. In this example, no plant personnel could find documentation to support why 1,000 steam traps were deCHEMICAL ENGINEERING


MARCH 2015

51

CALCULATION CALCULATI ON EXAMPLES

Estimating annual new failures (Reported failures – Carryover failures) / Years between surveys Example: (3,000 reported failures – 1,000 carryover failures) / 2 years = 1,000 annual new failures

(Annual new failures) / (Total in-service population) Example: 1,000 traps / 10,000 traps = 10% annual failure rate

State of the Population

Average Aver age trap life (Total in-service population) / (Annual new failures) Example: 10,000 traps / 1,000 traps failed in a year = 10 year trap life expectancy

uation creates a significant operational and maintenance dilemma for the site. If the goal is to have a “zero reset” scenario, in which all failed traps must be repaired, and the cost to repair the average failure is $600, then $1.8 million is needed from the year’s budget to accomplish the target. To To achieve this goal, 250 steam traps must be replaced each month, which represents two or three maintenance crews working full time for a year, assuming that every trap is accessible and can be isolated for repair or replacement. It is certainly a monumental task that may have been caused by an improper course of action a number of years before, when trap replacements were not completed in sufficient quantity to keep pace with the annual failure rate (amount of failures per year) of the population. Consider that the average annual failure rate of a steam trap population in a mature plant can be estimated from historical records, provided that there are at least two survey events within a period of 4–5 years. Simply subtract the carryover failures (failed traps recorded from a prior survey for which no action was taken to repair) from the reported failures that were recorded in the survey.. The remainder is the quantity of new survey failures. The number of new failures can be divided by the number of years since the prior survey to provide an estimate of the average annual new failures of a steam trap population. Several related useful calculations are shown in the box above. In this hypothetical plant history, if the management of the trap population had been continuous and sustainable at an annual failure rate of 1,000 (10%), then the plant should only have to support the repair of 84 traps per month, not 250 traps. However,, in this case, the trap population was alever lowed to deteriorate to 3,000 failures (30% failure state), and this situation places a tremendous burden on resources. Worse still, if not corrected, the failures can be expected 52

Annual Failure Rate

(Failures) / (Total in-service population) (Good traps) / (Total in-service population) Example: 3,000 failures / 10,000 traps = 30% state of failure 7,000 good traps / 10,000 traps = 70% good state

to grow until catastrophic events occur occ ur.. One takeaway from this example is that for every 1,000 traps that must be repaired in a year, there is a requirement for the planning and repair resources to correct 84 traps monthly without fail. That replacement requirement equates to repairing 4–5 CDLs per day, with any lesser amount creating a gap at year-end; the difference here equaling the next year’ yea r’ss carryover failures. Steam traps must be replenished or repaired in order to maintain a sustainable operation. Not taking the highest-priority corrective action with regard to steam trap failures is somewhat comparable to reusing a teabag even though it no longer dispenses flavor — although there is a teabag in service, it no longer provides a useful purpose. Similarly, if a steam trap has failed — particularly via a cold failure — then the CDL is no longer serving its intended purpose, and must be repaired. Is there any question about what outcome should be expected if all of the steam traps and related CDLs in a system were simply isolated by valving, thereby completely removing their drainage capability? There would be no way to automatically remove condensate from the system, creating a highly dangerous dange rous situation. What about if just 30% were shut off, or 50%? It is akin to gambling with the safety of the plant, as the potential formation of condensate slugs in the pipeline can lead to unstable, hazardous conditions. It is extremely distressing to consider a site that is not replacing trap failures due to a budget constraint, because the timely repair of traps allows the system to operate at the intended conditions. This must be seen as an inflexible demand. Timely action should be mandatory, not optional, to optimize the operation of a steam system. Management prioritization In a properly drained and maintained steam system, it is critical that the steam flowing



MARCH 2015

1,600

FIGURE 4. Often, high priority is given to

35,000

Number of steam leaks

* 20 lb/h average leak

fixing the leakage failures or hot failures to reduce steam loss and increase profit. Commonly, the repair of hot failures with high-value loss is given first priority in instances other than very critical applications. A representative example of the correlation of yearly repairs to reduction in steam loss is shown here

Cumulative steam loss

1,400

30,000

1,200 s k a e l m a e t s f o r e b m u N

25,000

* 15 lb/h average leak 1,000

20,000 800 * 10 lb/h average leak

15,000

600

) h / b l ( s s o l m a e t S

10,000 400 5,000

200

0

0 0

1

2

3

4

5

6 Month

7

8

9

10

11

12

within the system remains at near- Evaluating the numbers saturated quality and that avoidable In many plants, the typical program to backpressure in the return header is manage the steam trap population may reduced, in order to diminish the likeli- be controlled by budget constraints, by hood of waterhammer, erosion, corro- changing responsibilities or by a lack of sion and plating. Superheated steam priority. Although plant operations can or steam with near-saturation quality be critically affected, the budget may be normally cannot cause hammer or high controlled by maintenance that requires erosion at normal velocities because close collaboration and coordination there is not enough condensate to be between departments. However, repropelled downstream. Hammer and gardless of the circumstance or cause, erosion occur when liquid pools in the it sometimes seems that once a syssystem are thrust at high speeds, but tem has reached a manageable level when a system is properly drained, the after years of cooperation and dedicadamaging component is missing. Once tion, then the operational problems are again, it is evident that steam-trap fail- minimized and some portion of the trap ure rates are reduced in successfully maintenance budget is reassigned to a maintained steam systems, enabling different project not related to trap repair. efficient condensate removal from Then, the portion of the trap population the system. considered to be “good” suffers by seeMaintaining CDLs to manufacturer ing an increase in carryover failures, and specifications helps to eliminate steam often no survey action takes place for leakage (hot failures) and blocked dis- an extended time. All the while, new failcharge conditions (cold failures). When ures are accumulating, thereby reducing CDL failures — both hot and cold — the safety, reliability and performance are minimized, insulation is maintained of the system. This situation is unforand boilers are not pushed beyond their tunate, because the system had finally specified limits, the steam system can reached a relatively sustainable condibe optimized with regards to conden- tion. Subsequently, after several years of sate drainage, as well as the ability to inaction, the plant’s trap population may sustain steam quality when transported deteriorate so much that a significant throughout the system. negative incident occurs. At this point, It sounds simple enough — maintain the follow-up (some might say knee-jerk) the insulation, keep the boiler within its reaction may be to fix the steam system limits and ensure that the steam trap very hastily. This is an all-too-frequent population provides for quality con- scenario that can lead to the previously densate drainage. It certainly sounds presented example where 3,000 traps straightforward in concept. If it were failed at a single site. so readily attainable, then why isn’t this Once failures have been identified, goal accomplished more often? then the focus is often placed on fixing CHEMICAL ENGINEERING


MARCH 2015

53

FIGURE 5. For

zero reset of all 3,000 failures, monthly replacement of 250 CDLs is required. If actual replacemnents monthly are reduced, the gap results in year-end carryover failures that reduce the effective good in-service CDLs in the next year

3,000

2,500 Total failures – actual

2,000 s e r u l i a f f o r e b m u N

Total failures – target 1,500

1,000

Carryover failures

500 Target monthly replacements Actual replacements

0 0

1

2

3

4

5

6 Month

7

8

9

10

11

12

the hot failures, because these repairs can a plant with an average steam-trap lifecycle be readily justified by simple energy-cost of ten years, the actual failures could be esanalysis. Figure 4 illustrates a typical close timated as 2,000, consisting of the 1,000 relationship relationsh ip between hot-failure traps and re- carryover failures just identified and 1,000 duced steam loss. Especially in times of very new failures. While the diagnosis of each high energy prices, incredible emphasis is trap in the population is performed at regular placed on reducing the cost of operations by intervals (usually annually or semi-annually), fixing leaking steam traps. A progress chart, new failures are constantly occurring, as ilsimilar to the one shown in Figure 4, can be lustrated in Figure 6. generated and tracked. Thus, if the project If carryover failures are included as part of plan is to eliminate 3,000 failures from the the repair strategy, a significant number of hypothetical plant, then the corresponding CDLs will be operating improperly, thereby requirement is to repair 250 CDLs per month, increasing the chances of a debilitating inotherwise there will be a carryover failures cident occurring within the plant. For this gap (see Figure 5 for additional analysis). reason, it is not recommended to adopt a The carryover failures represent the real work process that allows carryover failures world; rarely do plants correct all or even and focuses only on those traps that have nearly all of the failures. The result is that already been fixed. Instead, a paradigm shift a significant number of CDLs are not re- is required. stored to proper drainage operation, and it is not uncommon to carry a sizable number System goals of failures over to the following year. Once Applying maintenance action to individual carryover failures are accepted in a plant’s steam traps is a path action, but not an operations, the steam system becomes overarching system goal. Risk lies in the destined for sub-optimal and potentially false sense of security that is given when unreliable operation. the goal is simply to repair a given number What follows when 1,000 carryover failures of steam traps, and the real goal of achievare extended into the following year? Instead ing an optimized steam system is neglected. of correcting all 3,000 failed steam traps (a So, if the annual target is established to fix zero reset mentality), suppose that the plant 2,000 steam traps and only 1,000 traps are management allocated a budget for repair repaired, there might be some explanation of of only 2,000 failures instead. Perhaps this mitigating events that explains the lapse. In thought process stems from the expecta- such a situation, the carryover failures might tion that with 2,000 failures corrected, the be considered acceptable under the circumnext annual period will only require budget stances, and a new goal is assigned for the for 1,000 failures. However, that is not an next year. However, this is a dangerous situaccurate scenario, because those 1,000 ation, because while the potential for damCDLs represent carryover failures only, and age is not visible, it is prevalent in the unadthe plant also must consider new failures. In dressed sections of the steam system, and 54



MARCH 2015

12,000

FIGURE 6. There is always an

Design CDLs

identification-repair responseidentification-repair time lag between diagnosis and maintenance action. Although a site may elect elect to perform sufficient repairs to reach a target state of the CDL population at year-end, new failures occuring during the repair period always lower the actual year-end state. It is just one of many justifications for adopting a zero reset mentality for maintenanceresponse planning

In-service CDLs

10,000

Target state

Zero reset 8,000 s L D C f o r 6,000 e b m u N

Actual

4,000

2,000 New failures 0 0

1

2

3

4

5

6

the downstream recipients of that steam. The potential for peril can increase in severity over time. Without a full understanding of the longterm impact on a steam system, there can exist a false impression that a system can be well managed, even if there is allowance for carryover failures. Figure 7 provides additional insight into a longer-term view. As it turns out, the best possible theoretical state of the population occurs only after a zero reset condition is experienced from the prior survey report, and when accumulated repairs equal new accumulated failures. After the midway point, zero reset has been theoretically reached, and new replacements cease, as there are no known failures that remain to be repaired. However, unidentified new failures are still occurring and will not be

7 8 Month

9

10

11

12

13

14

recognized until the next survey. The result is that the best state deteriorates between the prior and new surveys, with the theoretical “best sustainable” condition being realized at the beginning date of the next survey. This theoretical point occurs midway between the prior survey and the next survey date — if annual surveys are conducted, and repair is immediate and linear, then the best good state occurs at midyear. If the original goal of the designers is recalled, it was to have 11,000 fully functional CDLs at the site. For whatever reasons, the plant’s management decided to decommission and remove 1,000 installations, leaving a population of only 10,000 in-service CDLs (a 9% reduction from the design). Even if there is perfect harmony

12,000

FIGURE 7. Sites

Design CDLs In-service CDLs

10,000

*

* Best

Best sustainable

*

Target 8,000 s L D C f o r e b m u N

Actual

6,000 for * Adjustment new failures

sometimes decide upon a fixed number of annual repairs instead of striving for zero reset, thinking they can achieve a nearly 100% good in-service CDL population state over several years. However, due to new failures during the repair cycle, the theoretical “best sustainable” condition is reached midway through a perfectly correlated, linear inspection and repair term, after which the number of CDLs in good condition will decline

4,000

Accumulated repairs 2,000 New accumulated failures

0 0

6

12

18

24

30

36

Month CHEMICAL ENGINEERING


MARCH 2015

55

Design

FIGURE 8. The number of

in-service CDLs is already a reduction from the number of CDLs in the original design, which is not desirable unless clearly justified; and even with a zero reset focus and perfectly harmonized inspection and repair, the “best sustainable” condition is controlled by the number of annual failures. Establishing critical threshold values provides clear direction for sustainable steam-system performance

In-service Best Best Sustainable Minimum Caution Warning s L D C f o r e b m u N

Cold failures Hot failures Total failures Danger Warning Caution Minimum Best sustainable Best Design In-service

Danger

3,000

Total failures

2,000 1,000 0 Hot failures 0

1

2

3

4

5

6 Month

with replacement equipment to achieve a “best sustainable” state, that already represents an 18% drop in drainage capability from the design. At this point, it is also important to consider how much redundancy the professional engineering firm included in the original design. Understanding the effect of reducing the number of in-service good CDLs from the design, it can be seen that a key step is to increase the quantity of in-service CDLs until it reaches the design total, less any trap stations clearly suitable for decommissioning. Furthermore, once carryover failures and

7

8

9

10

11

12

new failures are considered, it is possible to have only 7,000 or 8,000 correctly functioning CDLs; which in the case of the former, represents just 63% of the original design. Starting the next year with only 63% of the original design total considered to be in good condition is dangerous, especially if there is an additional lapse in repair action. It can be expected that another 1,000 traps would fail without any repair of previously failed traps. In such an instance, the portion of the population functioning correctly for system drainage could be reduced to 6,000 traps — only 54% of the original design.

FIGURE 9. A paradigm shift

directs full attention to the performance-based performance-base d method, rather than focusing mainly on hot failures. Knowing the number of “good” CDLs relative to key threshold levels provides a clear indication of the steam system’s health and performance expectations

Best sustainable good

Minimum good Caution Warning Danger

s d e r l u o l C i a f s e r u l i a f t o H

1

s e r u l i a f d l o C s e t r o u l H i a f

2

s e r u l i a f d l o C s t e o r u H l i a f

3

Year Failure-based method 56

d o o G

d o o G

d o o G

1

2

3

Year Performance-based method CHEMICAL ENGINEERING


MARCH 2015

Creating a new paradigm

repaired CDL. In some instances at least, the engagement and dedication to a steam system by owner personnel can be higher than with contractors, so a regular and ongoing audit process is recommended to help obtain sustained high-quality work on such critical responsibilities. With consideration for the site employees who manage the steam system — because responsibilities and personnel change — guidelines must be established. In order to

This is where the necessity of a paradigm shift comes to the forefront. The goal is not to repair failed traps, but rather to maintain a minimum threshold of CDLs in functional condition. That quantity of good CDLs should always refer to the original design total, not to the quantity that are currently in service. Instead of the focus on hot failures, steam loss or accumulated repairs, a site should shift attention to sustaining an acceptable “good” threshold value for the state of the population — with specific, strict dates to start the survey every period. The established survey start date becomes sacrosanct and is held steadfast, regardless of daily interferences. The survey takes Introducing Corzan HP, creating piping systems with better such a high priority simply because a steam system is indispensable to the production success of a safely operating plant. It should not be a second- or third-priority focus, but AND HIGHHIGH-TEMPE TEMPERA RATURE TURE PERF PERFORMA ORMANCE NCE the key focus, thus helping to enfor transmission of CHEMICAL FLUIDS sure an optimized steam system. Another important factor that must all made with LUBRIZOL TECHNOLOGY be addressed is outsourcing, which is the allocation of responsibilities to third-party entities as contractors to perform certain work. In order to achieve a sustainable program under an outsourcing scenario, there are several crucial requirements: certified test personnel; validated equipment for making accurate condition judgments; and standardized application drawings for correct installation of repaired equipment. In some plants, testing and maintenance may be conducted by Corzan HP is a high-pressure, high-temperature, high-impact-strength the same third-party entity entity.. Regardpiping system engineered with Lubrizol’s specially formulated chlorinated less, whether a singular third-party polyvinyl chloride (CPVC) compounds that meet the ASTM D1784 or multiple entities are involved with certification for 24448 cell class. It’s the first pipe that meets ASTM F441 materia F441 materiall classificati classification on 4120-06, 4120-06, with with a pressu pressure re rating rating activities that can affect the state of 25% higher than standard CPVC at 180ºF (82ºC). the population, it is important that the capability for each process is Choose Corzan HP for Chemical Processing, Semiconductor & Electronics, Follow us Water Treatment, Treatment, Industrial Manufacturing, Mining and Power confirmed. For example, an incredon Twitter @LZ_CPVC Generation applications. ibly capable contractor for piping repair may be insufficiently trained See how the details on the inside make all the difference on the outside. for testing activities, and must be Call a piping systems consultant at 1.216.447.7397 or visit corzancpvc.com corzancpvc.com to to learn more. suitably educated and certified for these tasks. Most critically, there should exist a regular audit process to check and confirm the accuracy of the surveyors’ qualification cer© 2014 The Lubrizol Corporation, all rights reserved. All marks are the property of The Lubrizol Corporation. tificates, the actual judgments perThe Lubrizol Corporation is a Berkshire Hathaway company. GC 140681 formed by those surveyors, and in the case of maintenance contractors, the correct installation of each ®

CORROSION RESISTANCE

TO GIVE YOU MORE INSIDE

™

.




MARCH 2015

57

implement clear ongoing parameters for safe and reliable operation, a plant should determine required threshold target and notification values that can be used as the primary focus for the team responsible for maintaining system performance. Figure 8 shows the different key threshold levels of “good” CDLs as: “minimum,” “caution,” “warning” and “danger.” Note that “best sustainable” is a theoretical condition for which it is possible to approach this level, and “minimum” is the

determined threshold below which safe and reliable operation of the steam system can be adversely affected. Other tiers provide information to operations and maintenance personnel on the reasonable expectations of increased risk, should appropriate action not be executed. If a plant wants to have a secondary focus on cold failures to reduce problems caused by condensate in the system, or to repair hot failures to reduce backpressure and recover profits lost to unnecessary energy production, that is certainly a fine approach to fixing failed CDLs. However, when the big picture is to achieve safe and reliable plant operations, the primary focus, as shown in Figure 9, must be to measure the number of good CDLs that are draining the system. Plants should establish the target of keeping the good CDLs between the “minimum good” and “best sustainable good” state threshold values. When the goal is to maintain a state of the population at or above “minimum good” levels for safety and reliability considerations, the target is straightforward. Now, the repair of failures becomes just a path, not a goal. With a clear message to personnel, the steam-system drainage can be optimized and sustained for best plant performance. ■ Edited by Mary Page Bailey For suggested additional reading on steam systems, see the online version of this article at www.chemengonline.com.

Author James R. Risko is the president

of TLV Corp. (13901 South Lakes Dr., Charlotte, N.C. 29873; Phone: (704) 597-9070; Email: [email protected]). The author of more than 30 articles related to steam and condensate systems, Risko is active in both the standards and technicalwriting activities of the Fluid Controls Institute (FCI), and has previously served as the organization’s chairman, standards chair, and chair of the Secondary Pressure and Steam Trap sections. He has earned three energy-management certifications, from the Association of Energy Engineers, North Carolina State Univ., and the Institute of Energy Professionals. He holds an M.B.A from Wilkes University, and two B.S. degrees, in mathematics/education and business administration/accounting, from Kutztown University. He is also licensed as a Certified Energy Manager (CEM) and a Professional Energy Manager (PEM).




MARCH 2015

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Pressure-Vessel Pressure-V essel Quality Control Requirements

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Compressible Fluid Flow Calculation Methods

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Mass Transfer in Fermentation Scaleup

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Implementing a Corrosion- Under-Ins Under-Insulation ulation Program

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Protecting Against Compressor Pulsations

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Integrally Geared Compressors in the CPI

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Overcoming Solids Caking with Flow Aid

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Piping-System Leak Detection and Monitoring for the CPI

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Unlocking the Secrets of Plate-and-Fra Plate-and-Frame me Heat Exchangers

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Industrial Industri al Control Systems Security: The Owner-Operator’s Owner-Operator’s Challenge

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Combining the use of Rupture Discs with Relief Valves

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Part 2

Mitigate Corrosion in Condensate-Return Systems Understanding the chemistry behind corrosion in condensate-return systems can aid in selecting and properly employing the best mitigation technique S.K. Mukherjee Consultant

IN BRIEF CORROSION MECHANISMS COMBATTING CORROSION CONTROLLING CORROSION MONITORING CORROSION

T

he importance of steam-condensate TABLE 1. EFFECTS OF CORROSION ON FUEL-OIL return systems to boilers in the chemCOSTS AND MAKEUP MAKEU P WATER WATER USAGE ical process industries (CPI) cannot Condensate header pressure, barg 5 be overemphasized, especially with Condensate temperature, °C 159 regard to enhancing operating efficiency. Makeup water temperature, °C 30 This also enables water conservation by reducing waste. However, condensate-return Boiler efficiency, % 80 systems are prone to severe corrosion due Fuel-oil cost, $/million kJ 24.2 to the presence of non-condensable gases, Additional fuel-oil cost, $/yr $/yr 97,300 like carbon dioxide (CO2 ) and oxygen (O2 ), water, metric tons (m.t.)/yr 5,900 which are associated with steam generation. Additional makeup water, This often renders a condensate-return condensate-return system ineffective, and can result in additional Absorption of non-condensa non-condensable ble gases in energy costs, as well as the extra cost of reequipment that is initially full of air (steamplacing lost boiler b oiler feedwater feedwat er.. Table Table 1 provides ing operation during startup) or air leakan example of the costly effects of corrosion age in equipment that is handling steam at (in this case, two 2-mm holes that developed sub-atmospheric pressures in a condensate line due to corrosion that CO2 produced in the boiler by caused water loss). The cost impact of lost the decomposition of boiler-feedwacondensate and makeup water can be subter alkalinity that has dissolved into stantial if several leaks develop in the entire the condensate condensate-return system. This article pro- The following section outlines some spevides an overview of some current technolo- cific chemical-reaction mechanisms that gies used to combat the underlying corrosion can cause corrosion in steam-condensate issues in condensate-return systems, and the return systems. ways to deploy these corrosion-mitigation Condensate system corrosion in the prestechniques effectively. ence of oxygen. The oxygen. The following following reaction reaction represents the corrosion of iron (Fe) in water [ 1]: •

•

Corrosion mechanisms

As a first step to combat condensate condensate-sys-sys- Fe + 2H2O D Fe(OH)2 + H2 tem corrosion, the ingress of gases into the condensate system should be mini- This reaction continues to equilibrium if no mized. Ingress of gases can occur in the O2 is present [ 2]. Also, the formation of ferfollowing ways: rous hydroxide (Fe(OH)2 ) increases the conNon-condensable gases (CO 2 or O2 ) densate pH and retards the reaction rate. absorbed from the air can dissolve in When O2 is present in the condensate, the boiler makeup water; in this case, the following reaction occurs, forming hydrated non-condensable gas flashes over the ferric oxide (Fe 2O3 H2O): steam and eventually finds its way into the condensate 4Fe(OH)2 + O2 D 2Fe2O3 H2O + 2H2O •

.

.

60



MARCH 2015

TLV

leads to debris that can deposit in small parts, causing blockage, as seen in Figure 2.

Combatting corrosion

FIGURE 1. In the presence of

oxygen, ferric-oxide corrosion occurs, and can wreak havoc on condensate-

system equipment

As stated previously previously,, the ingress of O2 or CO2 into the condensate is the main cause of corrosion in condensate systems. Hence, any effort to reduce corrosion to acceptable levels must deal with expelling these gases from boiler water and neutralizing their corrosive effect with the addition of chemicals [ 1,3]. The main processes for fighting condensate-system corrosion are summarized in the following sections. Deaeration. The Deaeration. The boiler feedwater is mainly comprised of makeup water and return condensate. Dissolved O 2 is primarily present in boiler makeup water, while dissolved CO2 can be present in the return condensate. Both gases introduce corrosion potential for the boiler and the condensate system. Deaeration effectively reduces dissolved non-condensable gases from feedwater. In the deaeration process, the makeup water and return condensate are heated in a deaerator vessel with lowpressure steam to a temperature that is sufficient to reduce the partial pressure of the dissolved gases over the water surface. This results in almost all of the dissolved gases coming out of the liquid phase. The dissolved gases are vented from the deaerator vessel along with a small amount of low-pressure steam to aid venting. This process is known as mechanical deaeration. Chemical oxygen scavenging. Some residual O 2 remains after mechanical deaeration, as the partial pressure of O2 cannot be reduced to zero. This is a potential source for O2 corrosion. Chemicals are added to react with the leftover O 2. The chemical is usually added below the water level in the water-storage section of the deaerator. The most common O2 scavenger is catalyzed sodium sulfite (2NaSO3 ), which has the following reaction:

Ferric oxide, also called hema- 2NaHCO3 + heat D Na2CO3 + tite or red rust, is a loosely adhering CO2 + H2O oxide layer, and can travel with the condensate flow through the con- Na2CO3 + H2O + heat D 2NaOH densate piping. An example of iron- + CO2 oxide corrosion is shown in Figure As the stea steam m from the boile boilerr 1. The ingress of dissolved O 2 in the condensate prevents equilibrium transfers its latent heat and confrom being reached, and ferrous hy- denses, the CO2 dissolves in the droxide is removed continuously condensate, depressing the pH. from the inner walls of the piping The follo following wing reve reversibl rsible e reac reactions tions and fittings [ 2]. take place: The follo following wing are the two types of corrosion that occur when O 2 H2O + CO2 D H2CO3 is present [3]: Generalized corrosion on the metal H2CO3 D H+ + HCO3– surface, which causes a loss of metal from the entire surface HCO3– D H+ + CO32– Oxygen pitting, which causes a highly localized loss of metal that The corrosion of iron by carbonic can result in a catastrophic failure in acid (H2CO3 ) is promote promoted d by hy+ a short time. Pitting begins at weak drogen ions (H ) from the above points in the oxide film and at lo- dissociation reactions. The overall cations where the film is damaged. reaction forming ferrous bicarbonate The corr corrosion osion pene penetrate trates s into the (Fe(HCO3 )2 ) is: surface, effectively drilling a hole into the metal 2H+ + 2HCO3– + Fe D Fe(HCO3 )2 + H2 Condensate system corrosion in the presence of CO 2. Carbonates A low pH causes generalized loss and bicarbonates, such as sodium of metal, rather than the localized bicarbonate (NaHCO3 ) or sodi sodium um pitting caused by O 2. Corrosion is carbonate (Na2CO3 ), are comm commonly only characterized by the general thinning 2NaSO3 + O2 D 2NaSO4 present in boiler makeup water, and of the pipe wall or grooving along the these anions are generally called bottom of the pipe [ 2]. This thinning Another O2 scavenger is diethylhy“water alkalinity.” alkalinity.” With the application often leads to failures, particularly at droxylamine (DEHA; 4(C 2H5 )2NOH). of heat, these carbonates undergo the threaded joints. In addition, corro- The overall reaction of O 2 with DEHA is following reactions in the boiler [ 1, 3]: sion that causes decay of pipe walls as follows: •

•



MARCH 2015

61

TLV

existing deposits and the sludge can foul the condensate-return system. This sludge can potentially reach the boiler, causing tube failures. However, for uniform and effective coverage of a large condensate-return system, a blend of a straight filming amine with a neutralizing amine and emulsifiers provides a superior film bond, reduces deposit problems and provides better and more economical system coverage [ 3]. Yet Y et another option for abating abating corcorrosion in condensate systems is the use of DEHA as a metal passivator and O2 scavenger. DEHA converts loose, unprotective iron oxide (red hematite) deposits on the condensate pipe’s inner surfaces to a black magnetite protective film, ferrous oxide magnetite (Fe 3O4 ). The following is the chemical reaction for this conversion [ 1]: 4(C2H5 )2NOH + 6Fe2O3 + 4CH3COOH + 3H2O FIGURE 2. Corrosion in pipe walls can lead to

4(C2H5 )2NOH + 9O2 D 8CH3COOH + 2N2 + 6H2O The addition of DEHA also has a passivating action on metal surfaces. When hydroxide alkalinity is present in the boiler water, the acetic acid is neutralized and removed in blowdown as sodium acetate.

Controlling corrosion The objective of chemical control in the condensate is to elevate the condensate’s pH so that the ingress of carbonic acid is neutralized. Neutralizing amines (R–NH2 ) are used to neutralize the acidic H + that is generated by the dissociation of carbonic acid. Neutralizing amines also serve to increase the pH of the condensate. The amines hydrolyze when added to water, and generate the hydroxide ions that are necessary for neutralization. The chemical reaction for a neutralizing amine in water is as follows: D R–NH3+

+ OH–

The overall neutralization reaction is shown below: R–NH3– + OH– + H2CO3 D R–NH3+ + HCO3– + H2O 62

4Fe3O4

widespread issues, issues, including the formation of deposits and

blockages in small piping components

R–NH2 + H2O

D

By regulating the dosing rate of the neutralizing amine, the pH of the condensate can be elevated to the desired level. Many amines are used for condensate-acid neutralization and pH elevation. Morpholine and cyclohexylamine are common neutralizing amines. Often, a blend of morpholine and cyclohexylamine is a better choice than using either alone. The choice of neutralizing amine depends upon the distribution ratio and the number of condensation sites [ 3]. Another option for controlling condensate-system corrosion is the use of filming amines. Octadecylamine is a common filming amine. Filming amines are introduced into the steam header, and form a very thin amine-film barrier on the metal surface by replacing the loose oxide scale. This barrier layer prevents O 2 and carbonic acid from reaching the base metal in the condensate-return lines. During the initial dosing period, loosely adhered oxide deposits are lifted off of the metal surface and replaced by an amine film. This is due to the surfactant properties of the amine. In the case of old or untreated condensate lines, excessive dosage of filming amines can dislodge preCHEMICAL ENGINEERING

The magnetite layer on the metal surfaces reduces corrosion rates from O2 and carbonic acid. DEHA is usually dosed along with a neutralizing amine, as it is most effective at a pH higher than 8. DEHA has a high distribution ratio due to its high volatility, and hence provides effective protection by directly dosing it into the boiler feedwater instead of into the steam header. Due to the high distribution ratio, DEHA also spreads more effectively to the entire steam and condensate system [1]. Boiler makeup water that is low in alkalinity helps in reducing carbonic acid corrosion in condensate systems. Also, less amine addition is required. Dealkalizers and reverse osmosis can be considered for the treatment of boiler makeup water to reduce alkalinity alkalini ty.. When condensate in the piping is near its saturation temperature, carbonic acid formation is minimized, as the solubility of CO 2 in the condensate is low. However, if the temperature of the condensate is below the saturation temperature, likely due to improper insulation of the condensate lines, more CO 2 goes into solution, causing potential carbonic-acid corrosion. Therefore, it is important that condensate return lines are properly insulated and that the in-


MARCH 2015

tegrity of the insulation is maintained during the lifespan of the steamcondensate system.

Monitoring corrosion

of iron which was sitting upstream of the closed valve. There are three different tests that can be run, for which proprietary methods of testing are available. The suspended-ir suspended-iron on test measures insoluble suspended iron by passing the sample through a membrane filter. Suspended iron, mostly ferric iron (Fe2O3 or Fe3O4, which is Fe2O3 + FeO) is the result of an oxidizing condition in the condensate condensate.. The point of this test is to indicate

Similarly, O2 scavenger concentration must be precise within the system. If DEHA is used, a residual of 100–150 ppb should be targeted [5]. This residual quantity will take some time to appear, as the DEHA will initially be consumed in passivating the system. A cooling coil should be used for collecting the sample to avoid loss of volatile chemicals if there is steam flashing. Corrosion coupons. Pre-weighed strips of metal (coupons) with very

Monitoring corrosion in condensatereturn systems allows for early detection of problems — when the problems are still minor. If these problems go unnoticed, they can very soon become major problems, leading to leaks, plugging of condensate lines or catastrophic boiler-tube failure. Without proper corrosion-monitoring procedures in place, steam systems can have underlying issues that Without proper corrosion-monitoring procedures in place, persist for long periods of time. Desystems ms can can have have under underlying lying issue issues s that that persist persist for pending on the treatment method, steam syste condensate monitoring can vary, but long peri periods ods of time. time. generally, the following tests are required: 1. pH testing at various locations in the presence of O 2 in the system, similar composition to the metalthe condensate system either through improved deaera- lurgy of the condensate system can 2. Measurement of iron levels in tion or the use of better O 2 scav- be used to monitor the corrosion the condensate enging in the boiler. Suspended rate. Corrosion coupon racks that 3. Measurement of residual amine iron levels in excess of 50 parts hold three coupons are generally in the condensate per billion (ppb) are indicative of used. One coupon is exposed for 30 4. Corrosion coupons serious corrosion days, one for 60 days and one for Evaluating pH. It is necessary to test The total ferrous and ferric iron 90 days. The coupons are removed the condensate’s pH to determine if test measures both dissolved iron for each time interval, and the weight it is high enough to prevent carbonic(mostly ferrous) and suspended loss of the coupon is determined. acid corrosion from occurring. Coniron (mostly ferric). If a membrane From the observed weight deteriodensate pH measurement should be filter is used to remove the sus- ration in the coupon, the corrosion carried out at more than one locapended iron, the test will measure rate is calculated in mils (0.0001 in.) tion, to ensure that carbonic acid dissolved iron. For most industries, per year (mpy). ■ does not attack differently in sepaa test result of 0.5 parts per milEdited by Mary Page Bailey rate sections of the system. This can lion (ppm) is considered a good happen when neutralizing amines test result References with low distribution ratios (like The total iron test allows for 1. Brenner, M.A., How Steam System Chemistry and Control Affect Steam Side Coil Corrosion, Western morpholine) are used with multiple tracking total iron over time withDry Kiln Association Meeting Proceedings, Portland, condensation sites. out regard for oxidation state. Oreg., May 2004. While collecting condensate sam This test provides valuable feed- 2. Deaerating Boiler Feedwater, Feedwater, HPAC HPAC Engineering, ples, it should be ensured that expoback about the effectiveness of http://hpac.com/heating/boiler-feedwater, April 2008. sure to air is minimized, and that the the amine treatment program of 3. Betz Laboratories Inc., “Betz Industrial Water CondipH test is run as quickly as possithe condensate tioning,” 9th ed., Sept . 1991. ble. Also, the sample should be well Residual filming amine and O 2 4. Hydroserve, Typical Boiler Questions, www. hydroserve.com/boiler_questions.htm. cooled — otherwise, CO 2 and amine scavengers. scavengers. If a filming amine is can both flash off of a hot sample, utilized, the residual should be mea- 5. Jamaica Association of Sugar Technologists, Sugar Boiler Water Treatment Technology, altering the pH. A pH of 8.3 or higher sured. As stated earlier, the most www.jamaicasugar.org/siriSection/jast/jastpapers/ should be targeted. common filming amine for boilers is papers/y2010/boiler%20water.pdf, papers/y2010/boiler%20water .pdf, 2010. Iron measurement. Iron, measurement. Iron, as a corro- octadecylamine. It should be measion byproduct, is an indirect indica- sured on a steam sample — not a Author tor of either low pH or the presence of condensate sample. Dosage can be S.K.Mukherjee (Email: mukher [email protected]) is currently a O2 somewhere upstream of the con- controlled to give 0.2–0.6 ppm octaprocess-safety engineering condensate sampling point. If this area is decylamine in steam. Octadecylamsultant with Cholamandalam MS not being checked for pH measure- ine is most effective in condensate Risk Services Ltd. He is a chemical engineer and a Functional Safety ments, iron measurement should be with a pH range of 6 to 8. Thus, the Professional with more than 40 done. The sample should be from product may require supplemental years of experience in petroleum a continuously flowing stream to neutralizing amine to be added. A refining and process-safety consulting. His interests lie in process avoid a slug of iron oxide from the cooling coil is required during samopening of a valve. A valve which is pling to prevent steam from flashing design, operations, troubleshooting, hazard evaluation and functional safety. He was previously employed at opened from a closed position (while off, which will concentrate the amine Hindustan Petroleum Corp.’s Mumbai refinery. taking a sample) can release a slug in the sample. •

•

•



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63

Feature Report

Prevent Combustible Dust Prevent Explosions with N2 Inerting Targeted use of blanketing with inert gas offers an effective strategy for preventing combustible dust explosions in CPI facilities Bridget Nyland ombustible dust is a critical safety Air Products concern for the chemical process Tom T om Lee, Mitch industries (CPI). The use of nitrogen Lund and gas as an inert blanket offers an efMichael Thiel fective approach to preventing combustible Nol-Tec Systems, Inc. dust explosions by displacing the oxidant required for an explosion. Nitrogen inerting is a practical solution to help prevent the devastation to personnel and property that can result from combustible dust explosions. Moreover,, while nitrogen is not the right over r ight solution for IN BRIEF every system, when properly designed and installed, it is often safer, less expensive and REGULATIONS EXPAND easier to maintain than alternative mechaniDUST HAZARD SCOPE cal solutions. Using a set of examples, this COMBUSTIBLE DUST article explores how nitrogen can be used to FUNDAMENTALS prevent — not just mitigate — combustible dust explosions in CPI facilities. INERT GAS FOR DUST

C

64

EXAMPLES

Regulations expand dust hazard scope

ECONOMIC ANALYSIS

In December 2015, the Occupational Safety & Health Administration (OSHA; Washington, D.C.; www.osha.gov) will begin fully enforcing its new Hazard Communication (HazCom) standard, which adopts the Globally Harmonized System for the Labeling and Classification of Chemicals (GHS). Originally announced in 2012, the standard impacts a wide cross-section of industry sectors. One of the most significant changes in the new standard involves combustible dust. With the new HazCom standard, manufacturers will need to include combustible dust hazards in HazCom labeling, as well as in hazard evaluation and planning [ 1]. As a result, many chemicals not previously classified as hazardous will be officially designated as combustible dust hazards and will require adherence to NFPA 654, the combustible-dust explosion protection standard of the National Fire Protection Association (Quincy, Mass.; www.nfpa.org). While housekeeping and dust mitigation are recommended as a primary step to prevent combustible dust explosions, NFPA 654 also

C o n fi n e m e n t o f d u s t

t u s f d o i o n e r s p s D i

Dust explosion I g n i t i o n s o u r c e

r i a / n e g y x O

Combustible dust/fume

Five elements are required required for a dust explosion to occur.. Nitrogen inerting targets the oxidant by displacing it occur FIGURE 1.

recommends explosion-mitigation devices to control explosions and limit damage. For example, the standard recommends including blowout panels in baghouses to release pressure from an explosion, or inline suppression systems to quickly extinguish an explosion or fire. However, these recommendations still leave the process fundamentally unsafe by only dealing with the explosion rather than preventing it. A safer way to comply with NFPA 654 is to use targeted nitrogen inerting rather than mechanical relief and suppression devices in selected areas.

Combustible dust fundamental fundamentals s While a triangle of required ingredients determines whether or not a fire can be sustained, combustible dust explosions are governed by a pentagon of interacting factors: factors: oxygen, fuel, containment, ignition and dust dispersion (Figure 1). If one side of the pentagon is eliminated, an explosion is not possible. Most materials can explode under the right conditions. In fact, it is easier to identify the materials that will not combust. OSHA’s Na-



MARCH 2015

tional Emphasis Program (NEP) on try. For example, in 2008, 14 people combustible dust defines the term were killed and 44 people were inas, “A combustible particulate solid jured at one of the largest industrial that presents a fire or deflagration incidents at the Imperial Sugar fachazard when suspended in air or tory in Port Wentworth, Ga. Sugar some other oxidizing medium over a dust that had built up to explosive range of concentrations, regardless concentratio concentrations ns in the factory ignited, of particle size or shape.” sending a fireball cascading through Defining which particulate matter the building. Many dust explosions presents a deflagration hazard re- have occurred with seemingly inquires specific laboratory analyses of nocuous materials, such as organic several properties that are essential compounds like sugar. to determine the severity of a comFollowing the Imperial accident, bustible dust hazard for a given ma- OSHA began focusing on the danterial. These properties include, at gers of combustible dust explosions. a minimum, the limiting oxygen for In 2008, OSHA launched its NEP on combustion (LOC), minimum ignition combustible dust. Using the General energy (MIE), minimum ignition tem- Industry Standard 29 CFR 1910, Secperature (MIT), and the layer ignition tion 5(a)(i) of the Occupational Health temperature (LIT). Specialized labo- and Safety Act (commonly known as ratories can conduct these material the “general duty clause” [ 2]), along characterizations and offer analysis with generally accepted good pracof the resulting hazard. tices, such as NFPA 654, OSHA Several parameters define a ma- began conducting extensive inspecterial’s properties with regard to its tions in facilities containing dust. combustibility. In terms of particle In 2009 alone, 1,000 inspections size, 425 µm (40 mesh) is generally were completed, and over 4,900 viodefined as the limiting size to classify lations were issued for non-complia material as a “dust,” although cer- ance, including poor housekeeping, tain materials with high surface area inadequate hazard communication, (such as fibers) may be combustible and inadequate hazard control [ 3]. above that size threshold. A materi To T o date, date, most most of the the regulatory regulatory and al’s Kst (dust (dust deflagration index) pro- industry focus in designing systems vides an indication of the severity of to handle combustible dust has ada dust explosion hazard. NFPA clas- dressed either the dust itself (through sifies dusts by Kst value. A dust is housekeeping initiatives), initiatives), or the cononly considered inert with a Kst value value finement of explosions. For explosion of 0. Class 1 dusts are rated below confinement, systems are designed 200 Kst, Class 2 dusts range from so that energy can be released in a 200 to 300 Kst, and Class 3 dusts controlled manner. Examples of this are rated above 300 Kst . type of control include blowout pan The minimum minimum explo explosive sive concen concentratra- els on silos or overdesigning ducting tion (MEC) is the limiting dust concen- to withstand the force of an explotration to create an explosive atmo- sion. However, such measures focus sphere. The MIE and MIT are values on mitigation — the explosion still used to define explosive conditions occurs. One of the safety infractions for particular materials. Table 1 con- commonly cited by OSHA combustains the applicable dust properties of tible dust inspectors are knock-out some common materials. panel reliefs that vent to areas where Following laboratory analysis, man- employees are working. In such ufacturers will be able to determine cases, the severity of the explosion the severity of the combustible dust may be mitigated, yet the risks of hazard and document whether, whether, in fact, personnel injury still remain. the dust is not combustible. However, However, the majority of dusts are combustible, The case for inert gas for dust so most manufacturers will use these Gas inerting represents an alternative properties not to define whether the approach, and works by disrupting dust is combustible, but rather to de- the oxidant side of the dust-explosion fine the severity of the hazard. pentagon. Insufficient oxygen means Several high-profile accidents have no combustion. Note, however, that recently raised the awareness of this there are some chemicals, such as hazard in the manufacturing indus- peroxides, that contain bound oxygen CHEMICAL ENGINEERING


MARCH 2015

TABLE 1: KST VALUES VALUES OF COMMON MATERIALS Common Dusts

Kst Value Value

Activated carbon carbon

44

Aluminum powder powder

400

Barley grain dust

240

Brown coal

123

Cotton

24

Magnesium

508

Methyl cellulose

209

Milk powder

90

Polyurethane

156

Rice starch

190

Silicon

126

Soap

111

Soybean flour

110

Sulfur

151

Toner

145

Wood dust

102

and could still present a fire of explosion hazard in the absence of oxygen gas. For those chemicals, additional safety steps, including close control of temperature, are required. The CPI has been using inerting to eliminate fires from flammable materials for years. Fires require the presence of oxidant, fuel and heat (the fire triangle). For every chemical, there is a minimum level of oxygen required for combustion, called the minimum oxygen concentration (MOC), measured in percent oxygen. For decades, chemical manufacturers have been mitigating their fire risks from flammable materials by blanketing tanks and reaction vessels with nitrogen to reduce the oxygen content below the MOC. A similar methodology can be transferred to combustible dust explosions, where the inert-gas approach has not been typically applied. The reasons for industry resistance to inerting boil down to three main perceived issues: nitrogen cost, safety and practicality. In reality, the perceived disadvantages can be easily overcome. Cost. The cost of inert gas can be reduced in several ways. Depending on the application, inert gas use may be targeted to selected units or processes. Alternatively, the MOCs of many combustible dusts do not require 99.99% pure industrial grade nitrogen from a liquid nitrogen source. By using lower-purity nitrogen — such as 95 or 98% pure 65

4-in N 2 recovery line Nitrogen supply system (various options)

10 ft3 surge hopper

O2 sensor

Air operated discharge valve

Dust filter

Air operated vent valve 20 ft3 hopper Air compressor Surge tank

Air operated discharge valve 10 ft3 transporter

3-in Conveyline To milling process

FIGURE 2.

The pneumatic conveying system depicted here is equipped with traditional mechanical mechanical protection systems for combustible dust, including explosion-detection systems and blowout panels

nitrogen, such as that generated by a membrane or pressure swing adsorption (PSA) system — total nitrogen operating costs can be reduced. NPFA 69 and 654 provide guidance on determining the MOC for a combustible dust and the required nitrogen purity for safe inerting. Safety. Asphyxiation risks are managed with basic safety training and simple engineering controls, such as O2 monitoring and O 2-concentration control, as well as restricting inerting to appropriate areas. Practicality. Practicalit y. Maintenance on the nitrogen system is typically handled by the nitrogen provider and not by the end user. Nitrogen systems are in fact not all that maintenance-intensive, and unlike explosion detectors they do not require quarterly inspections. Potential dust-related applications of nitrogen inerting include closedloop pneumatic conveying, hopper storage, shredders, reactors, tanks, vessels and enclosures. Through smart design, inerting systems can eliminate the possibility of an explosion, increase worker safety, and provide a more cost-effective solution relative to other mechanical-protection systems.

polyester and polyurethane compounds are also common. At particle sizes less than 100 µm (140 mesh), these plastics are highly combustible. In fact, PE powder is among the most common fuels for combustibledust explosions because of its broad usage and its combustibility. For example, fugitive PE dust caused an explosion at the West Pharmaceutical plant in Kinston, N.C., in 2003. According to the Proceedings of the 5th International Seminar on Fire and Explosion Hazards, the PE was used in a slurry to coat rubber parts, and fugitive PE dust from dried slurries accumulated in the suspended ceilings and cooling air ducts. A spark from a mill motor caused the dust to ignite, sending a flame propagating through the ducting. The ducting then overpressurized, sending the explosion front and burned dust into the suspended ceiling, which caused a larger explosion from the dust that had settled in the ceiling.

66

Economic analysis One of the main misconceptions about nitrogen inerting is that it is much more expensive than traditional mechanical explosion-protection systems. In reality, on a total net-present-value net-prese nt-value (NPV) basis, nitrogen inerting systems are very comparable to reactionary mechanical systems and, in the case of even a small incident requiring cleanup with a mechanical system, the nitrogen inerting system is often more economical. The following example illustrates how the economics could

N2 recovery line

Nitrogen supply system (various options)

Example 1. 1. Plastic powder powder Plastic powder coatings require a very fine powder to ensure a smooth coating when applied. The powders are created by pneumatically conveying plastic pellets into a mill for fine grinding. Particle sizes less than 100 µm (140 mesh) are frequently required for coating production. Polyethylene (PE) is the most common plastic used in powder coating manufacturing, but polyvinylchloride,

This case is particularly particularly noteworthy because there was no previous accumulation of dust in the facility, due to top-class housekeeping practices. The facility had had recently upgraded its dust-collection system and believed that the dust in the ceilings was inert based on previous laboratory testing. Indeed, investigative testing of the dust in the dust collectors indicated a largely inert dust. However, based on investigations following the explosion, only 280 lb of PE was required to produce the magnitude of the explosion felt during the incident. For a 10,000-ft 2 ceiling, that amounts to a layer of PE dust with a thickness of only 0.013 in. — about the thickness of four sheets of copy paper [ 4]. The explosion and subsequent fire resulted in six fatalities and multiple injuries. In the case of West Pharmaceutical, while it would be difficult to inert the ceiling ducting, it is quite possible that the mill itself could have been inerted, preventing the initial reaction. Either way, the incident highlights the significant danger of PE powder.

Dust filter 10 ft3 hopper From process 10 ft3 hopper

6-in Rotary airlock 10-hp blower

Air operated discharge valve Convey line To milling process FIGURE 3.

The pneumatic conveying system depicted here is protected by nitrogen inerting CHEMICAL ENGINEERING


MARCH 2015

Liquid tank

Ambient-air vaporizer

Gauges Control manifold

Telemetry unit Gaseous product to customer

Top fill valve

Bottom fill valve FIGURE 4.

A typical bulk liquid-nitrogen supply system can be laid laid out as showm here

the dilute conveying case requires a higher volume of air for the conveying medium. More air leads to higher severity in the event of an explosion, therefore requiring more robust explosion-prevention capital. When looking at the nitrogen protection case, the combination of the positive-displacement tive-displac ement blower and airlock required for dilute-phase conveying is a higher cost than that of the gasrecovery compressor needed on the nitrogen dense-phase system. Second, operating costs for the dilute-phase nitrogen system are higher due to the higher volume of nitrogen needed for the dilute-phase system. In this case, the dense-phase system concept requires less than 10% of the average air or nitrogen usage than the dilute-phase system concept. Third, Thir d, main maintenan tenance ce cost costs s for the mechanical-protection systems are higher than those for the nitrogenprotection systems, mainly due to the costs of annual inspections required by the explosion-pro explosion-protection tection devices. Finally, looking at the dense-phase conveying scenario and considering the costs from a small incident occurring once in five years, the nitrogen system is cheaper on o n a five-year, NPV basis. Because of the high gas flowrates required, the nitrogen system for the dilute-phase pneumatic conveying system is more expensive on a five-year, NPV basis. However,, beyond a simple NPV calHowever culation, this exercise does not take into account all factors that should be considered when designing a dilutephase pneumatic conveying system. For example, plant layout is i s an important consideration. Due to location in the plant, a system retrofit design would require much more explosion protection than a system that could

work. Consider a pneumatic convey- pending on the working environment, ing and milling system for PE-pow- system layout, and other safety conder-coating manufacturing. Figures 2 siderations, additional explosion deand 3 show the two cases that were tection or suppression devices may developed. In Figure 2, the system is be needed. The estimate includes protected protecte d using traditional mechani- one explosion incident in a five-year cal combustible-dust protection sys- period requiring one week of downtems, including explosion detection time and cleanup. The incident-redevices, suppression systems and lated costs include the time for lost blowout panels. Figure 3 depicts the production and related cleanup and system as protected by nitrogen in- replacement costs. erting. Table 2 shows the technical Tables T ables 4 and 5 summari summarize ze the specifications for the PE that was scope differences between the cases. used in the case study models. The costs for each case are based Both dilute and dense phase con- on actual quotations for capital and veying conditions were modeled in maintenance, and current national the case study. Table 3 shows the U.S. averages for nitrogen and elecprocess specifications for the cases tric costs. An interest rate of 6% was that were modeled. assumed for the NPV calculation. The nitrogen-protected nitrogen-protected system system reWhen comparing the estimated lies on the pressure of the nitrogen cost differences between these four bulk tank to drive the pneumatic con- scenarios, several observations can veying process. A typical liquid-nitro- be made. First, for both the nitrogen bulk system can deliver gaseous gen-protected and mechanically nitrogen to house lines at pressures protected dilute-phase systems, the up to 200 psi without auxiliary com- capital costs are higher than the repression. The vaporized gas is fed spective capital costs for the densedirectly into the pneumatic convey- phase systems. When looking at ing system. Figure 4 shows a typical the mechanical protection case, liquid-nitrogen-supply liquid-nitro gen-supply system layout. The supply tank ranges in size from TABLE 2: TECHNICAL SPECIFICATIONS FOR POLYETHYLENE IN EXAMPLE 1 60 gal to upwards of 11,000 gal to fit Material High-density PE a wide variety of system needs. Flowability Free-flowing To T o make efficient efficient use of the nitro nitro-Density (aerated/loose/packed; (aerated/loose/packed; lb/ft3) 22.7/25.3/28.4 gen, a gas recovery unit was included Kst 134 in the system design. The gas recovery unit can recycle about 80% of the Material Description Fine, subangular, flake/sliver/granular particles nitrogen used in conveying, drastically reducing the nitrogen consumption. TABLE 3: PROCESS SPECIFICATIONS FOR CONVEYING SYSTEM IN EXAMPLE 1 The mechanical mechanically ly protected sysCase 1 Case 2 tem includes blowout panels for exDilute Conveying phase Dense plosion protection. Please note that 400 lb/h Production rate 400 lb/h this is a basic explosion-protection 400 ft Conveying length 400 ft system design, assuming an ideal 3 in. Conveying pipe diameter 3 in. plant layout for blowout panels. DeCHEMICAL ENGINEERING


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67

TABLE 4: COSTS REQUIRED FOR NITROGEN- AND MECHANICAL-PROTECTED SYSTEMS

Mechanical

Nitrogen

Capital costs

Blowout panels Explosion detection (optional) Isolation valves (optional) Suppression devices (optional) Air compressor (dense phase) Positive displacement blower (dilute phase) Rotary airlock (dilute phase)

Nitrogen system foundation Gas recovery unit

Operating costs

Compressor/blower electricity costs

Nitrogen Gas-recovery electricity costs

Mainte Mai ntenan nance ce costs costs

Quart Qu arterl erlyy inspec inspectio tions ns Annual inspections System preventive maintenance

System preventive maintenance

Explosion consequences

Assume system mitigates one explosion in five years. Assume explosion requires one week lost production and cleanup

Explosion is prevented with inerted system

be placed in an ideal location. Vents for explosion panels may requir require e long ducting lines or secondary protection systems to prevent employee injury — a practice discouraged by NFPA 68 because shorter ducts decrease explosion severity. In certain retrofit cases, mechanical explosion protection can leave manufacturers with a difficult challenge in trying to meet code requirements safely. Each incident will be specific to a manufacturer’s particular product and protection system, so the cost and frequency of an incident occurring may vary. However, even small incidents may require plant downtime, replacement of protection systems, and cleanup of hazardous material. A nitrogen system greatly decreases the risk of any explosion happening at all, as well as any related expenses. In this case, an NPV difference of $100,000 is minimal in comparison to the total capital of a pneumatic system and the significantly reduced explosion risk that comes with an inherently safe inert system over the course of the system’s life.

Example 2. Tire manufacturing One industry that will be heavily impacted by the adoption of the GHS

is the tire manufacturing industry. Under the new regulations, carbon black, a material used extensively in tire production, will be classified as a combustible dust. This will require tire manufacturers to review their existing processing plants and retrofit them to comply with NFPA regulations, potentially requiring expensive capital investments if traditional suppression controls are utilized. However, tire manufacturing is an application that lends itself to nitrogen inerting because nitrogen is often already used in the tire curing process at many plants, where it is injected into the tire molds to cure the tires. Because the nitrogen is already onsite, it can easily be incorporated into a dust-control scheme using inerting without incurring additional installation costs. In addition, since the nitrogen used for curing can be recycled through the pneumatic lines, the nitrogen needed for curing easily supplies the need for inerting. This simple system removes the need to install mechanical retrofits to comply with NFPA 654. This system has been installed at large tire producers specifically to combat the dust hazards identified with the new classification of carbon black dust.

Example 3. Grain manufacturing The food industry may be the most impacted with the new changes. Some of the most highly combustible dusts are found in the food manufacturing industry, with sugar and grain being two of the more notorious culprits. It is estimated that 150 people have died in food-related combustible-dust explosions in the last 20 years in the U.S. Some components of a food processing plant are impractical to inert, such as grain elevators, but there are many contained areas that can be inerted safely and economically. Selective inerting as part of a combustible dust plan can reduce the cost of overall protection. Hoppers are a great example of how smart design can make nitrogen inerting possible. The authors were involved with a recently designed and installed nitrogen-inerting system in a large biomass hopper with the aid of computation fluid dynamic (CFD) modeling. The CFD models provided precise estimates of the methane offgas concentration levels throughout the silo and guided the placement and orientation of nitrogen-injection nozzles throughout the silo (Figure 5). Rather than flood the silo with nitrogen, the hopper owner was able to apply nitrogen in locations and amounts that exactly matched what was required to prevent a dust explosion within a large space. The same process could be used for smaller silos and hoppers in the food processing industry, as well as other storage containers. Closedloop pneumatic conveying lines are another prime target for incorporating nitrogen inerting. Beyond economics Beyond the economics, there are several other qualitative differences between mechanical explosion mitigation and nitrogen inerting systems

TABLE 5: ECONOMIC DIFFERENCES BETWEEN FOUR DUST DUST-EXPLOSION-PROTECT -EXPLOSION-PROTECTION ION SCENARIOS

Mechanical Protection

68

Nitrogen Protection

Case1 (dense)

Case 2 (dilute)

Case 1 (dense)

Case 2 (dilute)

Capital costs

$20,000

$35,000

$30,000

$42,500

Continuous operating costs

$15,000

$6,000

$25,705

$84,615

Annual maintenance costs

$8,500

$10,000

$2,500

$4,000

Lost production and cleanup costs

$147,800

$147,800

$0

$0

Five-year NPV

($216,000)

($201,000)

($137,607)

($354,500)



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O2

dryers, spray dryers, grinding mills, well. For example, large dust collecgranulators, shredders and mixers. tors or ductwork are usually not con Nitrogen Nitro gen suppl supply y. Nitrogen require- ducive to nitrogen inerting because ments will vary greatly depending on of high flowrates and large spaces. the material being processed, pro- Similarly, bucket elevators are usuduction rate, process conditions, size ally not practical for nitrogen inerting of the vessels, number of use points, because of the large spaces, lack of and MOC. All of the required flow- containment, and worker presence. rates can be supplied by a nitrogen In such situations, diligent housesystem, but the mode of supply will keeping is the key to reducing the depend on the average consumption, risk posed by dust explosions explosions.. as well as on peak requirements and OSHA’s adoption of the GHS will usage pattern. For example, at low require manufacturers in the U.S. to flowrates, a microbulk system may comply with many aspects of NFPA provide the most cost-effective sup- 654 for materials not previously conFIGURE 5. Computational fluid dynamics modeling modeling can help pinpoint areas of oxygen concentration ply. For the highest flowrates, onsite sidered combustible dusts. Manunitrogen generation systems could facturers can choose to implement that should be considered. First, from be considered. In many cases, a systems that mitigate the damage a safety perspective, the nitrogen nitrogen-recovery and recycling unit caused by combustible dust explosystem creates an inherently safe greatly improves the overall system sions, or they can choose to prevent environment with regard to explo- economics to reduce nitrogen usage. combustible dust explosions from sion protection, while the mechanical With any nitrogen system instal- occurring in the first place. n system reacts to the explosion. In the lation, an oxygen-sampling system Edited by Scott Jenkins mechanical system, there are sev- needs to be installed to verify the References eral modes of failure for the system, atmospheric oxygen content. These 1. OSHA memorandum, 12/23/2013, www.osha.gov/ pls/oshaweb/ and components like blowout panels systems must also be designed with are difficult to test in order to confirm adequate controls to ensure that the 2. OSHA Combustible Dust Standard, www.osha.gov/ dsg/combustibledust/standards.html. functionality. Further, Further, testing suppres- correct oxygen levels are maintained. sion devices and explosion detection Oxygen monitoring can also include 3. OSHA Combustible Dust NEP Report, www.osha. gov/dep/combustible_dust_nep_rpt_102009.html. systems require a system shutdown. built-in controls to provide protection 4. Baker, Q., Kinston Dust Explosion, Proceedings of In contrast, there is only one failure for emergency inerting should the the 5th International Seminar on Fire and Explosion mechanism for the nitrogen system: process conditions change. Hazards, Edinburgh, U.K., April 2007. www.see. ed.ac.uk/feh5. loss of nitrogen. A pneumatic con- Pneumatic conveying system. In veying system can be driven by the general, a pneumatic conveying sys- 5. Air Products, Use Nitrogen Safely, www.airproducts. com/~/media/downloads/article/U/en-use-nitropressure from the nitrogen system, tem should be considered in situagen-safely-312-12-023.pdf. so the system automatically shuts tions where there is limited footprint down with a loss of nitrogen supply. or flexibility. Pneumatic systems are Authors For manufacturers who do not much easier to install in an existBridget Nyland Nyland is an applications engineer at Air Products currently use nitrogen in significant ing plant space because it is easy (7201 Hamilton Boulevard, Allenamounts, one of the major concerns to route a small-diameter conveytown, PA 18195-1501; Phone is the potential risk of nitrogen as- ing pipe around existing equipment. 415-766-1594; E-mail: [email protected]). She phyxiation. Already used widely in the Pneumatic systems are totally enmanages the evaluation and inCPI, nitrogen can be implemented closed, resulting in excellent dust stallation of all industrial gases safely as long as proper procedures control, and they have few moving applications for the chemical, for storage, handling and use are fol- parts, which saves on plant maintepharmaceutical, rubber and plastics industries in the West Coast. She received a lowed [5]. Nitrogen should never be nance costs. B.S.Ch.E. from Villanova University in 2011, and is a vented into a location where workers In all cases, when considering member of AICHE, SWE, EWB and WIB. are present or into a confined space whether to install a nitrogen-inerting Tom Lee is Lee is a research and development engineer at Nolthat could be unintentiona unintentionally lly created. system, it is important to understand Tec Systems (425 Apollo Drive, Lino Lakes, MN 55014; In addition, oxygen monitors must be your current process well, includ- Phone 651-203-2547; E-mail: [email protected]). installed to alert workers in the event ing the properties of the materials in With 27 years of material handling experience, he manages all aspects of Nol-Tec’s test facility, from evaluating of an oxygen-deficient atmosphere. your process and their associated current designs to devising new equipment. combustible-dust combustible -dust hazards. With that Mitch Lund is Lund is a technical services engineer at Nolknowledge in hand, nitrogen experts Tec Systems (same address as above; Phone 612Implementing N2 inerting For manufacturers interested in im- and pneumatic conveying experts 418-7108; E-mail: [email protected]). He a B.S.Ch.E. from the University of Minnesotaplementing nitrogen inerting for dust can be a good resource in the de- received Twin Cities in 2012 and is involved in the innovation safety, there are guidelines that can sign of a safe and economic nitrogen and design of new products and technologies. be followed. inerting system. Michael Thiel is Thiel is the technical services group manager Process design. Nitrogen inertWhile there are many places at Nol-Tec Systems (same address; Phone 612-799ing works best in certain enclosed where nitrogen systems can be de- 4573; E-mail: [email protected]). He received a B.S.Ch.E. from the University of Minnesota-Twin Citor semi-enclosed areas, such as signed practically, cost effectively, ies in 2005 and has managed the Technical Services closed-loop pneumatic conveying and safely, there are situations where Group since 2012, leading product development and systems, storage hoppers, vessels, nitrogen inerting does not work as new technology efforts. 0.21 0.20 0.19 0.18 0.17 0.16 0l15 0.14 0.13 0.12 0.10 0.09 0.08 0.07 0.06 0.05 0.04 0.03 0.02 0.01 0.00



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Environmental Environm ental Manager Post-Combustion Carbon Capture Technologies T echnologies Several CCS processes proc esses hold much promise promi se,, and there are challenges challeng es yet to be met Julie Horn and Raymond Zbacnik Kiewit Power Engineers

IN BRIEF CURRENT CCS REGULATIONS

A

ADSORPTION-BASED TECHNOLOGIES ABSORPTION-BASED TECHNOLOGIES MEMBRANE-BASED TECHNOLOGIES ALGAE-BASED TECHNOLOGIES

COMPRESSION, TRANSPORTATION AND TRANSPORTATION SEQUESTRATION

number of post-combustion carbon capture technologies have the capability to reduce the amount of carbon dioxide emitted to the atmosphere from fossil-fuel-fired industrial and utility-power plants. Further interest has been placed in this technology in light of growing concerns about climate change. This article investigates a few of the more promising post-combustion carbon capture processes, including amine-based absorption, ammonia-based absorption, solid sorbent adsorption, membrane filtration and algae. This article also considers some of the challenges associated associate d with compression, transportation and storage of carbon dioxide. Carbon dioxide in the atmosphere is a greenhouse gas that most scientists consider to be largely responsible for climate change. Among the most significant sources of atmospheric CO 2 is fossil-fuelfossil-fuel-fired fired power generation. For many years, technologies for carbon capture and sequestration (CCS) have been under investigation and development as a means of mitigating CO 2 emissions while still allowing industries to burn fossil fuels. Currently, three of the most promising techniques for CCS are being developed: post-combustion capture, pre-combustion capture, and oxy-combustion capture. Of these three, post-combustion CCS with amines and with chilled ammonia have had the most relative success and are discussed further in this article.

Current CCS regulations Governmental support and regulations are needed to provide the incentive for CCS to become widely used in the chemical process industries (CPI) as well as the utility industries. Except for the case in which CO 2 is used for enhanced oil recovery (EOR) to increase the capacity of oil wells, CCS currently is not considered financially viable. For the power industry, the main reason is that CCS systems impose an energy penalty of up to 40% of the overall output of plants. When EOR is not feasible, it is not likely 70

that the power industry will provide the investment to install capture systems without regulations or legislation that require carbon emissions reductions. On June 25, 2013, U.S. President Barack Obama outlined a new national climate action plan that includes focusing on the use of cleaner energy and reducing carbon pollution. The President specifically called for the U.S. Environmental Protection Agency (EP (EPA; A; Washington, D.C.; www.epa.gov) to complete new limitations on carbon emissions from both new and existing power plants. Following that, in September 2013, the EPA proposed a cap for CO 2 emissions for all new coal-fired power plants. This proposal would limit carbon emissions to 500 kilograms per megawatt hour (kg/MWh), which is about half of what average coal plants currently emit. The fundamental effect of this proposed rule would be that no new coalfired power plants would be built, unless they had the capability for CCS. Furthermore, Fur thermore, the November 2013 United Nations Framework Convention on Climate Change (UNFCCC) laid the foundation for a post-Kyoto Protocol agreement to be made in 2015. The 1997 Kyoto Protocol set international carbonemission-reduction goals and includes two commitment periods. The first period sets a goal that the involved countries will reduce their carbon emissions to 5% below those of 1990. The second commitment period increases that margin to 18% below 1990 emission levels. After the second commitment period ends in 2020, the 2015 agreement will come into place. Reports on the UNFCCC meeting state that the new rule will focus on mitigation, adaptation, finance, technology readiness and transparency of action as it relates to CO 2 emissions. On September 20, 2013, the EPA issued draft carbon-pollution standards for new power plants under Clean Air Act Section 111(b) New Source Provisions. The draft was published in the Federal Register on January 8, 2014. On May 9, 2014 the comment period closed with over 2 million comments.



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EPA is still reviewing comments on the draft and intends to issue a final regulation in the summer of 2015. On October 28, 2014, the EPA issued draft carbon-pollution standards for existing power plants. The draft was published in the Federal on November 4, 2014. After Register on receiving over 2 million comments on the draft regulation, on January 15, 2015, the EPA announced that it would review and restructure the carbon pollution plan for existing power plants including revising the state targets for carbon pollution reduction. A new revised draft is expected in the summer of 2015.

Absorption-based technologies Amine-based . The CPI have had the

most success with developing CCS technologies using amine-based solvents, such as monoethanolamine (MEA), diethylamine (DEA), methyl diethanoloamine diethanoloa mine (MDEA), piperazine (PIPA) and 2-amino-2-methylpropanol (AMP). Such chemical solvents have desirable properties in that they often react strongly and quickly with CO2, yet they also release the CO2 while regenerating the solvent. Amine-based Amine-base d solvents are able to remove large amounts of CO 2 from fluegas at low pressures. The basis behind amine-base amine-based d carbon capture processes is fairly simple (Figure 1). Fluegas from utility and industrial boilers typically contains mostly nitrogen (about 70 vol.%), smaller amounts of water and CO2 (about 20%), and impurities of SO2, NOx, mercury and ash particulate matter. An air-pollution control system must be in place to greatly reduce the presence of these impurities in the fluegas before entering the carbon capture system. The cleaned fluegas then enters a small scrubber vessel to cool the gas and remove more trace sulfur impurities. From the quencher, the fluegas enters the absorber. The absorber uses the amine as a solvent to reduce the CO 2 level in the fluegas. This exothermic reaction typically removes about 85–90% of the CO2 from the entering fluegas. The CO2-rich solvent mixture is then sent to a heat exchanger before entering the regenerator. In the regenerator, the solvent is steam-stripped, causing the essentially pure CO 2 to come out of solution in an endotherCHEMICAL ENGINEERING

Source: Folger, CRS Report [1]

Exhaust gas

Condenser

Water wash

Lean amine cooler

Feed gas cooler Feed gas

r e b r o s b A

Amine solvent makeup

Reboiler

Booster fan

Reclaimer

STM Lean amine

Rich amine FIGURE 1.

Knockout drum

r o t a r e n e g e r / r e p p i r t S

Filter

CO2 product gas

CW

Reflux

Solvent waste

An overview of post-combustion, amine-based carbon carbon capture is depicted here

mic reaction. The overhead CO 2 is then compressed and fed to a pipeline, while the CO2-lean amine solvent is recycled back to the absorber for reuse. Ammonia-based . Ammonia-based CCS systems show promise for a number of reasons. As compared to amine solvents, ammonia solvents are less-expensive, have lower heats of reaction, and require less energy for regeneration. The use of ammonia could drive overall plant costs down as a result of ammonia’s ability to simultaneous simultaneously ly absorb multiple pollutants, such as CO 2, SO2, NOx and Hg. A major challenge associated associated with ammonia-based systems is that of ammonia slip. Because ammonia is more volatile than amines, it can sometimes be released into the fluegas stream during absorption. If ammonia-based processes are to be economically viable, ammonia slip must be controlled to avoid the need for additional fluegas cleanup.

Alstom (Levallois-P (Levallois-Perret erret Cedex, France; www.alstom.com) developed a process using chilled ammonia that has had success on the pilot-plant level. The process uses ammonium carbonate that has been chilled to about 20°C as the solvent solven t to absorb the CO2 from fluegas, which has also been cooled. The relatively low temperature in the absorber prevents significant ammonia slip from occurring. The overall system flow is similar to the amine-based systems: systems: the CO2-solvent stream is sent to the regenerator where heat is added to cause the CO2 to come out of solution. Then the CO 2 stream may be compressed and stored, while the regenerated solvent is recycled to the absorber and used again. While the Alstom process has controlled the amount of ammonia slip by chilling the solvent and fluegas, there are very significant energy costs associated with this chilling. Therefore, ammonia-based processes must be optimized to minimize ammonia slip

Gas Water

Ammonia refrigerant

Clean combustion gas

CO2 rich

fluegas

CO2 lean

Water wash

CO2

Cooling with water

Fluegas

Ammonia refrigerant

Booster fan

r e p p i r t S

CO2 product gas Steam

Note 3

Note 1 r e b r o s b A

Compressor

r o t a r e n e g e R

Refrig.

Cooling Steam

Note 2

Purge Note 1: ammonia-ammonium carbonate-water solution Note 2: ammonium bicarbonate-ammonium carbamate-water solution Note 3: water, with some ammonia FIGURE 2.

HP pump Source: Folger, CRS Report [1]

The chilled ammonia process process has had success on the pilot-plant scale


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71

Source: Folger, CRS Report [1]

CO2

N2

N2

CO2

CO2 N2

CO2 N2

CO2 CO2

CO2

N2

CO2 N2 CO2

N2

CO2

CO2 CO2

FIGURE 3.

N2

CO2

CO2

CO2

N2 N2

Algae-based technologies

Solid sorbents for carbon capture work by adsorbing adsorbing carbon dioxide onto their surfaces

in the most efficient way possible. Figure 2 shows an outline of the Alstom chilled-ammonia process.

ing and degradation over time. Solid sorbents have their own associated challenges, which are different than those found with liquid solvents. Adsorption-based Adsorption-ba sed technologies As noted, care must be taken that the Solid sorbents work by adsorbing solid does not deteriorate over time. the CO2 onto their surfaces (Figure Solids are also more difficult to han3). The sorbent is regenerated by dle than liquids, which typically only changing the temperature or pres- require pumps. One key engineering sure, which causes the CO 2 to be challenge is designing a long-lasting released. Solid sorbents hold eco- sorbent that has a high surface area nomic promise over amine-based available for CO2 capture, called carCCS systems, because less energy rying capacity. Engineers must also is required in the regeneration step. optimize the process to find the best There is no need for steam, steam, and solid solid method of handling solids, how to sorbents typically have lower energy reduce regeneration-energy requirerequirements for sensible heating of ments further, the minimum possible regeneration gas than liquid water- pressure drop, and how to increase based solvents. This means that less reaction rates. sensible heat is required to regenerate the sorbent. Membrane-based technologies Adsorption can be a physical or Membranes are porous materials that chemical process. Physical adsorp- filter CO2 from fluegas streams. Gas tion involves materials such as ac- streams are either pushed or pulled tivated carbon, zeolites and metal through membranes by a pressure organic frameworks (MOFs). Acti- differential. Pressure can be applied vated carbon is known to have a to one side of the membrane to push large inter-particulate surface area, the gas through, or a vacuum can thus increasing its CO 2 loading ca- be created on the other side of the pacity. MOFs and zeolites are crys- membrane to pull the gas through. talline sorbents that capture CO 2 in Membrane quality is determined their void spaces. Concerns about by selectivity and permeability. Sesolids that adsorb physically in- lectivity refers to a membrane’s abilclude: selectivity in carbon capture, ity to filter one component (such as CO2 carrying capacity, and physical CO2 ) rather than a differe different nt one (for degradation. Chemical adsorption is example, N2 ). Permeabilit Permeabilityy denotes similar to the liquid absorption car- how much of a substance may pass bon-capture processes. The sorbent through the membrane for a certain can be certain carbonates or amines pressure difference. Permeability disupported on the surface of other rectly relates to the required memmaterials, such as activated carbon. brane surface area needed for ad Amine sorbents supported on acti- equate CO2 separation. vated carbon have been shown in Research has been done on the bench-scale tests to have high CO 2 laboratory and bench scale to imcarrying capacities and lower regen- prove membrane selectivity. In one eration-energy requirements, since line of research, an amine solvent these systems lack water. However, contacts one side of the membrane care must be taken to prevent foul- to selectively absorb any CO 2 from 72


the inlet gas stream that may have accidentally passed through the membrane. Another concept uses enzymes to mimic nature. A liquid membrane system uses carbonic anhydrase, the enzyme that transports CO2 in mammal respiratory systems, to catalyze the transport of CO2 through the membrane. However, membrane CCS systems encounter issues with fouling and scaleup for industrial settings. Because algae metabolize CO 2 to grow, algae ponds have been considered as a CCS method. In addition, waste heat from industrial plants could be used to warm the ponds in winter. Algae grow quickly and can be used for biofuels. The need for pond water is not of significant concern because many algae strains prefer salt water, meaning algae ponds will have no effect on potable fresh water demand. There are, however however,, many challenges to overcome when considering algae for CCS. Algae do not take in CO2 very quickly, thus mandating the need for huge, city-sized ponds to process a typical industrial plant’s CO2 output. In addition, the algal biofuel will eventually be burned, releasing its CO 2 into the atmosphere. Such an action reduces, but does not eliminate the carbon footprint associated with power production.

Compression, transportat Compression, transportation ion and sequestration Once the CO2 has been captured, it must be compressed, transported, and either used or stored. The compression and transportation steps are mature technologies. Captured CO2 is often compressed to about 140 bars so that it becomes a supercritical fluid and behaves like a liquid, making it possible to transport CO2 via a centrifugal pump through a pipeline. The critical point of CO 2 is reached at 31°C and 74 bars. Therefore, if the temperature and pressure are maintained at about 38°C and 100 bars respectively, the CO 2 will still behave somewhat like a liquid and can be pumped to 140 bars for final disposition disposition.. For the transportatio transportation n of supercritical CO2 in a pipeline, booster pumping stations can be placed along the pipeline to maintain sufficient termi-


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nal point pressure if needed. The portance in the near future. Intertransport of CO2 through pipelines is national focus on reducing carbon a well-understood and safe practice. emissions has brought forth new Carbon dioxide pipelines typically regulations that enforce and prohave very few leaks and have not mote CCS technologies. The most caused any recorded injuries or fa- advanced CCS methods include talities. Carbon dioxide may also be post-combustion amine-based transported by ship, but this is only and ammonia-based absorption of done in small quantities. CO2, but other methods are being Storage and use. It use. It is the final step researched and developed as well. of CCS, the sequestration or stor- While the compression and transage of CO2, that has resulted in the port of CO2 is a mature technology, greatest controversy. Much of the the storage and use of CO 2 have captured CO2 will be injected un- been a source of controversy. More derground and stored with minimal research needs to be done in order leakage. Public opinion as of late has to find additional ways to permapushed for the practical use, rather nently use CO 2, and to ensure the than simple storage of the CO 2. For safety of underground injection. ■ Edited by Dorothy Lozowski industrial boilers in CPI facilities, carbon capture can sometimes be used for the production of chemicals such Acknowledgments as urea, methanol, formic acid, cy- The authors aut hors thank t hank Mitchel Mi tchelll KrasnoKras noclic carbonates and polycarbonat polycarbonates. es. poler of Kiewit Power Engineers for Carbon dioxide can also be used providing valuable comments for in the production of food and soft this article. drinks. However, this consumption provides only temporary storage for References CO2 because much of it is immedi- 1. Folger, P., Carbon Capture: A Technology Assessment, Congressional Research Service Reports , Retrieved from Digital Comately released into the atmosphere mons@University of Nebraska-Lincoln: digitalcommons.unl.edu/ crsdocs/19/, November 5, 2013. upon use. More permanent uses for 2. Mills, R. M., “Capturing Carbon: The New Weapon in the War CO2 include the production of plas Against Climate Change”, New York, Columbia University Press, tics, fertilizers, ceramics and new 2010. 3. Rameshni, M., Carbon Capture Overview, Worley Parsons, Retypes of cement. Integration of CO 2 trieved January 7, 2014, from www.worleyparsons.com/CSG/ use in these areas is likely to take hydrocarbons/specialtycapabilities/documents/carbon%20capture%20overview%20(3).pdf, 2010. time, so other storage options must be considered. For more on CCS, see CO2 Gets Grounded, Chem. Grounded, Chem. It is expected that most captured Eng .,., April 2014 at www.chemengonline.com. CO2 will be injected and stored underground. The ability to do this depends on the presence of appropriate Authors geological formations that can hold Julie Horn Horn is a process engineer for Kiewit Power Engineers the CO2. Characteristics of an apCo. (9401 Renner Blvd., Lenexa, propriate formation include sufficient KS 666219; Email:julia.horn@ volumetric capacity to hold the CO 2, kiewit.com). She recently graduated with honors from the Univerthe ability to prevent this CO 2 from sity of Nebraska-Lincoln, where reaching the atmosphere or potable she obtained a B.S.Ch.E. Horn groundwater sources, and the ability performed research as part of an to accept CO 2 injection at rates comREU (research experience for undergraduates) at Iowa State University and has also inparable to those of oil-and-gas externed at Aventine Renewable Energy. traction in industry. Some formations that can have the ability to accept is a Raymond Eric Zbacnik is CO2 injection include sedimentary senior process engineer for Kiewit rock, oil and gas fields, saline aquifers Power Engineers (Email: raymond. [email protected]). Zbacnik and coal seams. Underground injechas about 40 years of chemical tion is a safe practice, provided that process engineering experience, the injection site is carefully selected, which includes 20 years of airthe injection operations are properly quality control systems (AQCS) experience in the power industry. performed, and the CO 2 is monitored He worked at Babcock & Wilcox, during and after injection. at HDR: Cummins & Barnard and at Foster Wheeler.

Looking ahead Carbon capture and sequestration are both likely to increase in imCHEMICAL ENGINEERING

Zbacnik has a B.S.Ch.E. from Purdue University, and an M.E.Ch.E. from Manhattan College. He is a member of the AIChE, IChemE, ACS and AWMA.


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Engineering Practice Rotating Machinery: What You Should Know About Operational Problems Follow this guidance to improve the operation, safety and reliability of rotating machinery in chemical process plants Amin Almasi Consultant

T

roubleshooting problems in rotating machinery (such as compressors, pumps, steam turbines, gas turbines, turboexpanders and more) can present difficult challenges during day-to-day operations in facilities throughout the chemical process industries (CPI). Reliable operation is an important factor in keeping plants running, par par-ticularly as plants push to operate at higher capacities. Lost profits due to persistent machinery problems can never be recovered. Rotating machinery often presents the most difficult operational problems in a CPI plant. This article FIGURE 1. Shown here is a steam turbine dismantled for repair. repair. This is the driver of the centrifugal comprovides a practical, in-depth review pressor of the art and science of machinery troubleshooting and problem solv- A systematic systematic approach approach is the key for proach provides greater value, by ing. Five case studies are presented solving any machinery operational enabling earlier machinery troubleto cover a variety of relevant rotat- problem. Comprehensive machinery shooting through improved early ing-machinery systems, such as assessments should be carried out detection of unusual deviations. This compressors, pumps, gas turbines using advanced data-collection tools can provide an earlier indication of and steam turbines. All of the case and methods (Figure 1). For instance, problems that may be developing. studies presented here were devel- the use of automated machineIn modern operations, expert opoped from actual field experience. data-collection software — which erators often opt to manage critical This article offers a broad working automatica automatically lly collects a wealth of in- machine components using timeknowledge of troublesho troubleshooting oting princi- formation specific to the machinery based data trends. Useful trends can ples and practice, to help operators component — coupled with sophis- be developed when the behavior of gain insight into different techniques ticated modeling techniques, can individual performance variables, and various methods for machinery provide great insight to support trou- such as pressure, temperature, flow, problem solving. bleshooting efforts related to com- lubrication oil characteristics and plex rotating machinery. Such insight more, are plotted over time on a A systematic approach can help operators to diagnose the graph. These trends can then be anProper CPI plant operation requires actual root causes of underperform- alyzed in conjunction with additional sustained attention to the following: ing machinery and premature ma- information, such as that derived Identifying opportunities to im- chinery failures. from alarm screens and plant conprove machinery reliability and When CPI operators rely too trol-system graphics. By monitoring safety heavily on alarms and trips, there is trends, operators can anticipate poDeveloping solutions for chroni- limited time to take remedial action tential problems and propose smart cally problematic rotating main response to a machinery issue. solutions before any major upset chines Instead, a proactive monitoring ap- occurs. Trends in relevant data can •

•

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support operators and machinery engineers, allowing them to stay aware of situations as they begin to arise, diagnose the root cause of problems and resolve abnormal situations. The ability to gather and analyze trend data can also help operators to compare past and present behavior, thereby supporting efforts to anticipate future changes.

THE IMPORTANCE OF MONITORING In one situation, a CPI company avoided an estimated $10 million in property damage and business-interruption loss in a year as a result of the early detection of high vibration levels in its rotating machinery. The high-vibration monitors indicated the deteriorating conditions (a developing problem) within a large, critical compressor train. The developing problem resulted in the loss of half of the bolts, a circumferential crack in the coupling spacer (about 80 mm long) and a radial crack emanating from the initial break at the time of shutdown. If the fault had progressed and all of the bolts had sheared before operator intervention, the compressor would have been unrestrained — with potentially disastrous consequences. This clearly illustrates why, particularly in large CPI plants, it is vital to monitor critical components on a continuous basis.

tance thermal detectors (RTDs; also Keep an eye on key variables Vibration monitoring is an important known as resistance thermometers), indicator that can help operators to thermistors, filled thermal systems, identify machinery problems at an pyrometers, infrared thermography early stage. The location of vibration techniques and glass thermometers. sensors is vital, to avoid introducing All are widely used to provide errors during the measurement. In process and machinery temperature general, the best location for vibra- measurements. tion sensors in rotating machinery The measurement of flowrate prois at the bearing or bearing housing vides another useful indicator for the (Figure 2). Vibration measurements health of many processes and maat the machinery casing, in addition chinery systems. Traditionally, techto bearing vibration, can provide niques based on differential presuseful data for identifying and solv- sure, turbine and vortex shedding ing machinery problems. have been used to measure fluid However, monitoring vibration flowrate. However, these methods alone is not sufficient to gauge the might not be suitable if an accurate health of rotating machinery espe- measurement is required for gases, cially when large, critical machines since errors can be introduced in the are concerned. For instance, in a re- measurement due the compressible cent case, it was observed that one nature of gases. To use these methelectric motor’s temperature and ods with gas flows, it would be neccurrent increased when the machine essary to compensate for the gas was overloaded — well before any density fluctuation in order to reduce vibration was detected. This under- the errors. scores the importance of monitoring Modern Coriolis mass flowmeother parameters (such as tempera- ters are a more appropriate choice ture and current), in addition to vibra- for measuring gas flowrate, which is tion, to allow for early fault diagnosis usually independent of temperature, of electric machines. pressure, density and composition. When vibration analysis is used This meter uses the Coriolis effect to alone, it may be difficult to estab- measure the amount of mass movlish the real cause of the vibration. ing through the element. In a simple In general, it is better to monitor form, the fluid to be measured runs both vibration and overall machin- through a U-shaped tube that is ery performance (such as delivered caused to vibrate in a perpendicupressure and flow in pumps or com- lar direction to the flow. Fluid forces pressors) to obtain a more reliable running through the tube interact fault diagnosis. And, it is important with the vibration, causing it to twist. to realize that the vibration produced The greater the angle of the twist, by the machinery is not a fault on its the higher the flow. These flowmeown — but rather a symptom (and ters have no rotating parts. Modern early warning sign) of a developing Coriolis flowmeters are highly accufailure condition. rate (providing accuracy to around Temperature T emperature is another critical ±0.5% of the mass flowrate). variable, and the ability to moniFor relatively low-speed rotating tor it accurately is of paramount machines, vibration analysis may not importance in CPI plants. Today, a be suitable to detect degradation wide range of temperature sensors or operational problems. However, and measurement systems exists, acoustic-emission sensors, strateincluding thermocouples, resis- gically located on the machine, can CHEMICAL ENGINEERING


MARCH 2015

give operators early indication of deterioration in the machine’s machine’s operating condition. Control valves are vital components in every process and in many types of equipment packages where fluid is handled and regulated. However, the most common malfunction with control valves is internal leakage, which cannot be detected easily. Internal leakage can result from one of several factors, including an eroded valve plugs or seats, or insufficient seat load. Five case studies Case study 1: Insects in an aircompressor inlet filter. In a CPI

plant in a remote area, insects caused problems for the inlet-air filtration unit of a large process-type air compressor. compressor. The accumulation of insects on the filters led to high differential pressure in the unit, leading to periodic compressor shutdowns. Multiple cases of surge and surgerelated trips occurred because of this issue. Regarding a problem of persistent insects impacting the aircompressor,, two solutions should be compressor considered: 1. A multi-sided insect screen. For example, three-, four- or fivesided insect screens can be constructed (for instance, in a cube or similar configuration) in the front of the air filter, with a surface area roughly three to four times that of the front face of the air filter inlet. The rationale is that insects will gather on the larger-surface area of the screen (far from actual intake) and thus experience less intake air velocity, allowing them to fly away, reducing their opportunity to trap and plug the air filter. When a screen is built with three times the area of the air intake, the air velocity across the insect screen would be around 33% of the original velocity. When the 75

map. This test was completed by hooking proper surge-detection hardware into the compressor’s vibration-monitoring system. At each operating speed, the compressor discharge valve was slowly closed. Prior to the surge, the surge-detection system (using vibration sensors as part of the compres compressor sor vibration-monitoring system) detected an increase in low-frequency vibration, which indicated the onset of surge. This was used to define the surge line. The compressor was not actually surged, just taken to the point of onset of stall. Once the as-built These FIGURE 2. Tilting pad thrust bearings are widely used in relatively high-speed rotating machinery. These surge line was identified using this bearings are vulerable and can be damaged easily; shown here is one that was removed for repair technique, it was seen to be different screen is built at four times the in- fit, by helping to keep rain and dirt from what both the vendor and the take area, the air velocity across from being driven into the filter inlet sub-vendor indicated in their respecthe screen would be just 0.25% by wind. tive performance maps. of the original velocity. Case study 2: Discrepancies in Often, it is common to obtain a 2. Specially designed pulse-clean performance maps. maps. During the site-tested, as-built surge line that filters.. Another possibility is to commissioning stage of a CPI plant, differs from the vendor-calculated filters install pulse-clean filters that it was noted that there were two dif- surge line, or even the shop-tested apply a periodic reverse pulse of ferent sets of performance maps in surge line, because of different comair to dislodge the accumulated the manual for a particular, critical pressor piping and arrangement in dirt and insects from the filter centrifugal compressor — one from the vendor shop test compared to inlet at a pre-disposed differen- the compressor manufacturer and the final site installation. The sitetial pressure. This will require a another from the anti-surge-system tested, as-built surge line should be specialized filter assembly with sub-vendor. The compressor had considered the most reliable data for a compressed-air supply and been delivered three years earlier any operator. associated equipment and con- but it was not installed and commis- Case study 3: Re-rating a steam trols. However, this solution is not sioned upon delivery because of a turbine. The steam turbine driver usually recommended since this three-year delay in the project and a of a large pump train in a CPI unit is a complex, expensive and risky stop in the plant construction. Some created a bottleneck that prevented option. of the engineers who had worked the unit from achieving a desired 5% In this case study, the first pro- on this machine and associated unit increase in capacity. The operation posed solution was used and a had left their jobs and there was no team asked to run the steam turfour-sided insect screen was built. proper documentation documentation to clarify how bine using 49-barg steam instead For such an installation, the mesh this discrepancy originated. of 46-barg steam to achieve higher size should be selected properly to At this facility facility,, there were concerns concerns power generation from the turbine stop the smallest anticipated insects about surge. During the initial period and higher pump capacity. Simulafrom penetrating, and it should be of operation, the compressor was tions showed that using 49-barg reasonably reasonab ly rigid to allow for cleaning tripped several times because of steam, it was possible to generate with a soft brush. If the mesh has a surge or other operational issues re- higher power, and this modeling also dense or tight weave (say, with holes lated to the existence of two different showed that the pump train could around 1-mm dia.) to ensure that performance maps and the allow- handle higher power and generate small insects cannot pass through, able operating range. Any attempt to more flow within the pump curve. In then it may be necessary to com- identify which performance map and fact, this investigation showed that pensate with increased surface area surge line were the most appropri- the new pump operating point was a (so that air intake is not impeded and ate for use failed because of person- bit closer to the best efficiency point pressure drop is not increased). For nel changes at both the compressor (BEP) than the old operating point. In this case, a window screen mesh vendor and the anti-surge- system general, significant engineering as(with holes roughly 1-3-mm dia.) sub-vendor during the 3-yr period. sessments are required in order to was selected. Routine inspections In general, turbocompressors re-rate a steam turbine. by technicians have been required should be surge tested once they The steam turbine casing in this to clean the screen. The structure of are installed, to develop accurate, case was originally designed and the insect screen was made rugged as-built surge lines. For this machine, rated to 46 barg. In order to increase enough to resist wind and ensure it was decided to perform the surge the pressure rating, the design of longevity of the asset. This insect test at the site to identify the surge the casing was checked by both screen provides an added bene- line and the correct performance the vendor’s engineering team and 76



MARCH 2015

an independent consultant. It was mulated dirt in the air-compressor in order to reduce drag and improve determined that it could safely and section of a gas turbine can increase the heat rate and power output. Inlet reliably contain steam at 49 barg. fuel consumption, and lead to more air filters play a significant role in the The casing was re-rated, after frequent maintenance outages and a degree of fouling that gas turbines a proper hydro-testing, as per decreased hot-section life. experience. With the original, oldercode requirements. At a given CPI plant, gas turbines style air filters, the operators of this Using the same rotor, the pressure were used to both generate power plant were faced with a tradeoff: Indrop per stage was increased. The and drive the gas compressor. The stalling higher-efficiency filters that existing impellers were checked to original air filters were used in these remove more of the airborne parensure that they were strong enough gas turbine air-inlet systems, which ticles creates a higher initial pressure and the rotor did not require chang- mandated turbine shutdown and of- drop and typically have a shorter life ing. Simulations and investigations fline water washing every six months. span compared to lower-efficiency showed that diametric changes and The dirty air reduced the efficienc efficiencyy filters. The filter pressure drop dechanges to internal static compo- of the gas turbine fleet between creases the density of the air going nents within the casing were not cleanings. For instance, the gas tur- to the gas turbine, which reduces required. The steam turbine was bine trains exhibited efficiency drop the gas turbine’s output power. re-rated for 49 barg. The steam-tur- of as much as 2.5% on average in Added pressure drop across the air bine-driven pump train has enjoyed the three-month period before each filters increases the amount of ensmooth and trouble-free operation offline water washing. The sched- ergy needed to draw air into the gas since re-rating after the changes uled offline water washing every six turbine, which increases the gas turwere made. months on each gas turbine of the bine’s heat rate. Case study 4: Inlet filter for gas CPI plant (just for cleaning), in addiIn general, there are tradeoffs beturbines. In general, gas turbines tion to other outages for inspection tween efficiency, cost, filter life and turbines. “ingest” different materials depend- and maintenance, was wasteful and pressure drop that all need to be ing on the location and the plant — non-productive. The operation team considered when evaluating which primarily dirt and dust, but also ice, asked for a solution. air filters may be best for a particurain, snow and salt. The cleanliness Getting maximum performance lar operation. The small particles that of a gas turbine is the key factor in its and reliability out of a gas turbine cause most of gas turbine fouling efficiency, reliability and safety saf ety.. Accu- requires keeping the blades clean are less than 3 micrometers (µm;

F e eb r b ru a u r a ry y 2 0 0 1 15 5 0 2 2

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F a ac c t t s s a t t Y o ou u r D i i m r F i in me n g e n ge n s e r si i o r t t i ip on p s n l le s : : e s s s s N u u m mb b e e r r s s V a a l lv v e e s s f o o r r E x x t t r re e m e m e S e e r rv v i i c c e e

F u u n nd a d m a e m n e t n H i ig ta l l s a h g h- s o f -S h S he f a e ar r D i is sp e p er r s s e r e r s s

p a ag e g 4 0 e 0 V O L . 1 2 2 N O . 2 F E B R U

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•

Written for engineers, by engineers More and more, business in the Chemical Process Industries (CPI) is not local, it’s global. To keep up with this rapidly evolving marketplace, you need a magazine that covers it all, not just one country or region, not just one vertical market, but the entire CPI. With editorial offices around the world, Chemical Engineering is well-positioned to keep abreast of all the latest innovations in the equipment, technology, materials, and services used by process plants worldwide. No other publication even comes close. To subscri To subscribe be or learn more about membersh membership, ip, please visit www.chemengonline.com/subscribe




MARCH 2015

77

sometimes less than 0.5 µm) in size, below the standard capabilities of old-fashioned filters. Thus, emphasis should be placed on comparing the differences in filter efficiency for the removal of particles smaller than 3 µm (as well as considering filter efficiency on particles smaller than 0.5 µm) since those particle sizes generally contribute more to air-compressor fouling rather than larger particles. Switching to better, higher-efficiency air-inlet filters is a good way to keep air-compressors cleaner, but they can offer some drawbacks. The most most appropriate appropriate air air filter should be selected with respect to the efficiency, the filter life and pressure

they reach their expected lifespan. Modern hydrophobic HEPA filters were installed for all gas turbines in this CPI plant. They completely eliminated the need to shutdown the gas-turbine trains for offline water washing. The operation has been satisfactory satisfacto ry since the filter change. Case study 5: Problems in tur bine’s steam-admission valves. In this case, problems in the steamadmission valves used to supply the steam turbine reduced the required steam flow into the steam turbine, which impacted the performance of a critical centrifugal compressor driven by the turbine, and this negatively impacted the plant’s production rate. There were were four poppet valves in the

There are tradeoffs between efficiency, cost, filter life and pressure drop that need to be considered when evaluating which air filters may be best for a particular operation. drop. Today, new filter designs can steam chest of this steam turbine. keep the gas turbine clean with the These should be staged to open at same pressure drop and a better fil- different load requirements. ter life compared to older-style filters. Problems and issues for steam Today’ T oday’s s modern filters have a struc- admission valves have been reture and layers that allow for the ef- ported extensively for steam turbines fective capture of even the smallest in different CPI plants. For any steam particles (below 3 µm and some- turbine governor or admission-valve times below 0.5 µm) to keep the issues, the following initial investigagas-turbine intake air clean without tions are recommended: significant filter plugging. 1. Study the changes in perfor Advanced hydrophobic high-efmance of the steam-admission ficiency particulate air (HEPA) filters valve system and governor syshave the same pressure drop as the tem older filters. However, the key to their 2. Evaluate the actual performance improved filter performance performan ce is a novel of steam turbine versus the demulti-layer media construction that sign specification includes a hydrophobic membrane 3. Investigate the possible causes layer. Usually the first filter layer capfor discrepancies tures most of the airborne dirt. The Usually one or more of the followmiddle layer — or layers — are most ing issues are reported for steamoften made from expanded polytet- admission valves: rafluoroethylene (PTFE) membranes Insufficient Insuffici ent nozzle-openin nozzle-opening g size or similar, and they stop both subBlockage inside the admission micron particles and water that may valve system penetrate the first layer. Other layers Incorrect calibration of the admisare support layers added to provide sion valve system strength and burst pressure resisProblem with internal setup of the tance. These support layers give the steam-admission valve system filter more than twice the required Gradual buildup of deposition or burst strength of the old-fashioned degradation products filters. This extra burst strength preBased on the steam-turbin steam-turbine e manvents filters from breaking before ual for this unit, the governor should • •

•

•

•

78


only be opened to around 78% for the first normal operating condition case. The investigation showed the position indicator on the governor was at 90% for this operating case (around 12% discrepancy). The initial suggestion suggestio n was that the governor or steam-admission valves might not be correctly calibrated. The physical movement of the admission valves has not changed since commissioning, which which indicated indicated that that the probproblem was not related to the gradual build-up of deposition or to degradation. A highly nonlinear relationship was reported at low valve-opening positions (around 0–20% of the rated flow). Below 20% of the governor position, there was very little steam flow through the steam turbine. This indicated that there was a problem with the first poppet valve. There was almost zero increase in the steam flow once the governor position got higher than 91% of the rated flow. This was evident from the sharp drop-off at the end of the stroke-versus-steam-flow curve of the admission valve. There was also a problem with the last poppet valve. In other words, the lack of response during the first 20% of governor opening indicated a problem with the first poppet valve. The lack of response to the final 9% of governor opening indicated a problem with the last poppet valve. The steamadmission valve was overhauled for quick replacements of the first and last valves. The steam turbine operation has been satisfactory after this valve change. n Edited by Suzanne Shelley Author Amin Almasi is

a rotating-equipment consultant in Australia (Email: [email protected]). He previously worked at Worley Parsons Services Pty Ltd. (Brisbane, Australia), Technicas Reunidas (Madrid, Spain) and Fluor Corp. (various offices). He holds a chartered professional engineer license from Engineers Australia (MIEAust CPEng – Mechanical), a chartered engineer certificate from IMechE (CEng MIMechE), RPEQ (registered professional engineer in Queensland) and he also holds M.S. and B.S. degrees in mechanical engineering. He specializes in rotating machines, including centrifugal, screw and reciprocating compressors, gas and steam turbines, pumps, condition monitoring and reliability. Almasi is an active member of Engineers Australia, IMechE, ASME, Vibration Institute, SPE, IEEE, and IDGTE. He has authored more than 60 papers and articles dealing with rotating machines.


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Advertising Sales Represe Representatives ntatives North America Terry Davis Sales Director Chemical Engineering 2276 Eastway Rd., Decatur, GA 30033 Tel: 404-634-5123; Fax: 832-201-8823 E-mail: [email protected] Alabama, Canada, Connecticut, Delaware, Georgia, Idaho, Kentucky, Latin America, Maine, Maryland, Massachusetts, Mississippi, Montana, Nebraska, New Hampshire, New Jersey, New York, North and South Carolina, North and South Dakota, Ohio, Oregon, Pennsylvania, Rhode Island, Tennessee, Utah, Vermont, Virginia, Washington D.C., West Virginia, Wyoming

International Petra Trautes Chemical Engineering Zeilweg 44 D-60439 Frankfurt am Main Germany Phone: +49-69-58604760 Fax: +49-69-5700-24 +49-69-5700-2484 84 Email: [email protected] Austria, Czech Republic, Benelux, Eastern Europe, Germany, Scandinavia, Switzerland, United Kingdom 82

Jason Bullock District Sales Manager Chemical Engineering 8325 Broadway, Ste. 202/PMB 261 Pearland, TX 77581 Tel: 281-485-4077; Fax: 281-485-1285 E-mail: [email protected] Arizona, Arkansas, California, Colorado, Florida, Kansas, Louisiana, Missouri, Nevada, New Mexico, Oklahoma, Texas, Washington

Dipali Dhar Chemical Engineering 88 Pine Street, 5th floor, New York, NY 10005 Tel: 718-263-1162 E-mail: [email protected] India Katshuhiro Ishii Chemical Engineering Ace Media Service Inc., 12-6, 4-chome 4-chome Nishiiko, Adachi-ku, Tokyo 121, Japan Tel: 81-3-5691-3335; Fax: 81-3-5691-3336 E-mail: [email protected] Japan

Dan Gentile District Sales Manager Tel: 512-918-8075 E-mail: [email protected]

Alaska, Hawaii, Illinois, Indiana, Iowa, Michigan, Minnesota, Wisconsin,

Ferruccio Silvera Chemical Engineering Silvera Pubblicita Viale Monza, 24 Milano 20127, Italy Tel: 39-02-284-6716; Fax: 39-02-289-3849 E-mail: ferruccio@silvera. [email protected]/www.si it/www.silvera.it lvera.it Andorra, France, Gibraltar, Greece, Israel, Italy, Portugal, Spain


Diane Burleson Inside Sales Manager Chemical Engineering; 11000 Richmond Ave, Suite 690, Houston, TX 77042 Tel: 512-337-7890 E-mail: [email protected]

Product Showcase, Literature Reviews, Classified Display Advertising

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MARCH 2015

Advertisers Index Advertiser Adver tiser ..... .......... .......... .......... ......... .... Page numb number er Reader Service #

Phone number

Abbe, Paul O. ..... .......... .......... .......... .......... .......... .........24D ....24D 1-800-524-2188

adlinks.che.com/56195-01

AFPM - American American Fuel & Petroche Petrochemical mical Manufacturers................................... ...................................43 43 1-202-457-0480

Advertiser Adver tiser ..... .......... .......... .......... ......... .... Page numb number er NACE International ...................... ............................ ...... 47


Orion Instruments.............................. Instruments.............................. 25


Paharpur Cooling Towe Towers rs...................21 91-33-4013 3000


Pfeiffer Vacuum GmbH ..................... ..................... 35 49 6441 802-0


* Berndorf Band GmbH ................ 36I-11

* Phoenix Contact GmbH & Co. KG ..... 36I-9

1-847-841-3300

49 5235 3-00


Beumer Group GmbH & Co. KG .......13


Bürkert Werke GmbH ....................... .......................39 39


Buss-SMS-Canzler Buss-SMSCanzler GmbH ................34 ................ 34 49 60 33-85-0


Check-All Valve Mfg. Co. .................. .................. 38 1-515-224-2301


Chemshow 2015 ............................... ............................... 26 1-203-221-9232


Corzan HP Piping Systems ............... 57 1-216-447-7397

Ross, Charles & Son Company..... Company .......... ....... 6 1-800-243-ROSS


Saint-Gobain Ceramics ......................14 adlinks.che.com/56195-39

Sandvik Materials Te Technology chnology............ 17



BASF ........................ ...........................SECOND ...SECOND COVER

Reader Service #

Phone number

1-716-278-6233



AUMA Riest Riester er GmbH GmbH & Co. KG KG ..... .........31 ....31

Advertiser Advert iser ..... .......... .......... .......... ......... .... Page numb number er

Reader Service #

Phone number

Sandvik Process Systems ................. ................. 45 49 711 5105-0


Seepex Inc. ....................................... ....................................... 58



* Plast-O-Matic Valves, Valves, Inc. ........ 36I-16 1-973-256-3000

1-800-992-0209


PNC Financial Services Services Group 32a-32b 1-855-762-2361

Sturtevant Inc. ................................... ................................... 32

Team Tea m Industrial Services ....................19 1-800-622-8326



ThyssenKrupp Industrial Solutions AG29 AG29


* PompeT PompeTravaini ravaini ............................ ............................ 36I-7 39.0331.889000



Tiger Tower, an EMCOR Industrial Ser vices comp company any ..... .......... .......... .......... .......... .......... .......... ....... 3

Quest Integrity ................................... ................................... 36

1-866-890-7794

RedGuard ........................................ ............................................ .... 4

Titan Metal Fabricators, Inc. .............. 23

1-855-REDGUARD

1-805-487-5050





* VEGA Grieshaber KG ..................36I-5



Dechema E.V E.V.......................................12 .....................................12


Classified Index In dex March 2015

Dietrich Engineering Consultants SA . 40


Emerson Process Management ......... 9 Endress + Hauser...............................15 Hauser...............................15 1-888-ENDRESS


* Finder Pompe ...................... ........................... ..... 36I-13 39-039-9982.1


Fluid Line Products..................... ........................... ...... 11D 1-440-946-9470


* GEA Process Engineering A/S ....36I-3 45 39 54 54 54


* GEA Wiegand GmbH ................ 36I-15 49 7243 705-0


Hawk Management ........................24D 1-978-304-3000


Interphex 2015 ........................ ....................................10 ............10


* Italvacuum...... Italvacuum............................ ..............................36I-1 ........36I-1


Advertiser Advert iser

Page numb number er Reader Service #

Advertiser’s Advertiser ’s Produ Product ct Showcase . . . . . . . . . . . . . . . . . . . . 79

Aaron Equip Equipment ment Comp Company any..... ......... ......... ..... 80

Computer So Software . . . . . . . . . . . . 80

Phone number

1-855-714-8359

Consulting . . . . . . . . . . . . . . . . . . . . 80 80 adlinks.che.com/56195-241

Applied Applie d e-Simula e-Simulators tors Soft Software ware..... .......... ..... 80

Equipment, New & Used . . . . . . . . . . . . . . . .80–81

Busch LLC ..................... ......................................... .................... 80

Recruitment . . . . . . . . . . . . . . . . . . 80

adlinks.che.com/56195-242 adlinks.che.com/56195-243

1-847-439-2303

Phone number


KnightHawk Engineering ................... ...................80 80

1-914-381-7500

1-281-282-9200 adlinks.che.com/56195-244

1-301-540-3605



Heat Transfer Transfer Research, Inc./HTRI ... ... 80

Ross, Charles & Son Company..........81 1-800-243-ROSS



Vesconit Ves conite e Bearings Bearings ..... .......... .......... .......... .......... ........81 ...81 27 11 616 11 11

H2ecO Bulk Water LLC .................... ...................... ..81 81

Load Controls..................... .....................................41 ................41 adlinks.che.com/56195-23


Genck International .......................... ............................ 80 1-708-748-7200


Neuhaus Neotec .................... ............................... ........... 79

Engineering Software ........................ ........................ 80

1-888-227-7177

1-888-600-3247

Page numbe numberr Reader Service #

Elcan Industries ................................. ................................. 80

List AG .................................... ................................................18 ............18


Advertiser Advert iser

CU Services LLC ....................... ............................... ........ 79


VisiMix VisiM ix ..... .......... .......... .......... .......... .......... .......... .......... .......... ....... .. 80 972 52 383 4174



Wabash Waba sh Power Power Equip Equipment ment Co...... ......... ...... 81

Indeck Power Equipment Co. ............81

1-800-704-2002

Magnetrol ...................FOURTH COVER

1-800-446-3325

Miller-Stevenson Miller-Ste venson................................40 ................................ 40

John R. Robinson, Inc. ...................... ...................... 80

Xchanger,, Inc. .................................... Xchanger ....................................81 81

1-800-726-1026

1-952-933-2559

adlinks.che.com/56195-25 1-800-992-2424 adlinks.che.com/56195-26





Müller GmbH ..................................... .....................................38 38 49 (0) 76 23/969-0


Send Advertisements and Box replies to: Diane Burleson Chemical Engineering, 11000 Richmond Ave, Houston, TX 77042 * E-mail: [email protected] * Tel: 512-337-7890 512-337-7890

FOR ADDITIONAL NEWS AS IT DEVELOPS, PLEASE VISIT WWW.CHEMENGONLINE.COM March 2 015; VOL. 122; NO. 3

copyright @ 2015 (ISSN 0009-2460) is published monthly by Access Intelligence, LLC, 4 Choke Cherry Road, 2nd Floor, Rockville, MD, MD, 20850. Chemical Engineering Executive, Editorial, Advertising Advertising and Publication Offices: 88 Pine Chemical Engineering copyright Street, 5th Floor, New York, NY 10005; Phone: 212-621-4674, Fax: 212-621-4694. Subscription rates: $149.97 U.S. and U.S. U.S. possessions, $166.97 Canada, and $292 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. P.O. Box 3588, Northbrook, IL 60065-3588. Phone: 847-564-9290, Fax: 847-564-9453, email: chemeng@omeda. com. Change of address, two to eight week notice requested. For information regarding article reprints, please contact Wright’s ght’s Media, 1-877-652-5295, [email protected]. [email protected]. Contents may not be reproduced in any form without written permission. Canada Post 40612608. Return undeliverable Canadian Addresses to: IMEX Global Solutions, P.O. P.O. BOX 25542, LONDON, ON N6C 6B2 CHEMICAL ENGINEERING


MARCH 2015

* International Edition

83

Economic Indicators 2012

2013

2014

2015

Download the CEPCI two weeks sooner at www www.chemengonline. .chemengonline.com/pci com/pci

CHEMICAL ENGINEERING PLANT COST INDEX (CEPCI) 625

(1957-59 = 100) CE Index __ ______________________________________________ Equipment ____________________________________________ Heat exchangers & tanks _ __ ________________________________ Process machinery __ _____________________________________ Pipe, valves & fittings __ ____________________________________ Process instruments _ __ ___________________________________ Pumps & compressors ___________________________________ Electrical equipment _ __ ___________________________________ Structural supports & misc __ ________________________________ Construction la labor _______________________________________ Buildings _ __ ____________________________________________ Engineering & supervision _________________________________

Dec. '14 Prelim.

Nov. '14 Final

Dec. '13 Final

575.8 698.8 642.5 662.8 872.2 410.8 943.4 515.2 765.8 322.1 546.4 319.6

578.4 702.5 649.3 662.9 875.4 411.7 942.9 516.2 769.9 322.4 546.9 320.1

567.5 687.9 621.6 656.0 875.7 412.5 925.8 513.8 746.9 318.7 532.8 322.0

Annual Index: 2006 = 499.6

600

2007 = 525.4 2008 = 575.4

575

2009 = 521.9 2010 = 550.8

550

2011 = 585.7 525

2012 = 584.6 2013 = 567.3

500

J

F

M

A

M

J

J

A

S

O

N

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 INDICA IND ICATORS TORS

LATEST

CPI output index (2000 = 100) ____________________________________________________ CPI value of outp ut ut, $ billions _____________________________________________________ CPI operating rate, % __________________________________________________________ Producer prices, industrial chemicals (1982 = 100) ____________________________________

Jan.'15 = 93.9 Dec.'14 = 1,917.2 Jan.'15 = 78.6 Jan.'15 = 246.4

Dec.'14 = 93.5 Nov.'14 = 2,024.2 Dec.'14 = 78.3 Dec.'14 = 271.0

Nov.'14 Oct.'14 Nov.'14 Nov.'14

Industrial Production in Manufacturing (2002=100)* ____________________________________ Hourly earnings index, chemical & allied products (1992 = 100) ____________________________ Productivity index, chemicals & allied products (1992 = 100) ______________________________

Jan.'15 = 102.1 Jan.'15 = 157.5 Jan.'15 = 109.2

Dec.'14 = 102.0 Dec.'14 = 157.3 Dec.'14 = 108.2

Nov.'14 = 102.0 Nov.'14 = 157.5 Nov.'14 = 107.6

CPI OUTPUT INDEX (2000 = 100)

PREVIOUS

CPI OUTPUT VALUE ($ BILLIONS) 2300

80

95

2200

78

90

2100

76

85

2000

74

80

1900

72

F M A M

J

J

A S O N D

93.1 2,057.2 78.2 283.4

Jan.'14 = 88.8 Dec.'13 = 2,177.3 Jan.'14 = 75.1 Jan.'14 = 295.8 Jan.'14 = 96.8 Jan.'14 = 157.9 Jan.'14 = 107.3

70

1800

J

= = = =

CPI OPERATING RATE (%)

100

75

YEAR AGO

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.

EXCLUSIVE EXCLUSI VE AD A D SPACE SPACE AVAILABLE AVAILABLE!! Feature your marketing message

The Economic Indicators Indicators department includes includes current industry industry trends and the Plant Cost Index. As one of the most valued sections in the magazine, your ad is guaranteed to reach decision makers each month. Contact your sales representative to secure this spot.

84

JASON BULLO BULLOCK CK

TERRY DAVIS

jbullock@chemen jbulloc k@chemengonline gonline.com .com

[email protected]

DAN GENTILE

PETRA TRAUTES

[email protected]

[email protected]

chemengonline.com/mediakit


CURRENT TRENDS

T

he preliminary value for the December 2014 CE Plant Cost Index (CEPCI; top; most recent available) inched downward compared to the final value for November, continuing a three-month trend. The index value sits at 1.45% above its level from December 2013. Meanwhile, updated values for the Current Business Indicators from IHS Global Insight (middle) show a very small increase for CPI output, but a decrease for CPI value of output. This is the second consecutive month for similar behavior in these categories. Producer prices fell in January.


MARCH 2015

D

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This guidebook contains how-to engineering articles formerly published in Chemical Engineering . The articles in Volume 2 provide practical engineering recommendations for process operators faced with the challenge of treating inlet water for process use, and treating industrial wastewater to make it suitable for discharge or reuse. There is a focus on the importance of closed-loop or zero-discharge plant design, as well as the selection, operation and maintenance of membrane-based treatment systems; treating water for use in recirculatedwater cooling systems; managing water treatment to ensure trouble-free steam service; designing stripping columns for water treatment; and more. Table of Contents         

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Chemical Engineering Magazine, March 2015

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