August 2016 - International
August 2016 - International
August 2016 - International
2016
www.chemengonline.com
Engineering Reactors
for Continuous Flow
page 40
Facts at Your
Fingertips:
Distillation
Focus on Valves
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August 2016
Cover Story
40
Chementator
H2S-scrubbing regenerates reagent, generates sulfur; Scaleup for
a new P-recovery process; Highly selective rare-earth separation
using bacteria filters; A new, economical way to synthesize twofaced organosilicons; Dow validates recyclable polyethylene that
acts as a barrier; and more
In the News
14
Business News
Dow technology selected for new MEGlobal production facility;
BASF and Markor start up polytetrahydrofuran plant in China;
Ineos to expand ethyl acetate capacity at Hull facility; Solvay to
build integrated hydrogen peroxide unit at pulp-mill site in Brazil;
and more
16
22
40
39
50
58
16
22
50
CHEMICAL ENGINEERING
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AUGUST 2016
62
Focus on Valves
Rotary valve controls the flow of powders and granules; These severe-service
valves come in 12,000 configurations; Diaphragm valves meet the demands of
sterile applications; Pressure- and vacuum-relief valves reduce fugitive losses;
Miniature solenoid valves are designed for long service; and more
30
62
New Products
Measure viscosity over a wide temperature range; Monitor debris in hydraulic
and lubrication oiling systems; Inspect this pump without disturbing piping layout;
Stainless-steel local control stations can be designed online; New software for
enhanced corrosion management; and more
Departments
26
84
Economic Indicators
71
79
80
82
83
Advertisers
30
Chemical Connections
Follow @ChemEngMag on Twitter
Join the Chemical Engineering Magazine
LinkedIn Group
Visit us on www.chemengonline.com for Latest News,
Webinars, Test your Knowledge Quizzes, Bookshelf
and more
Coming in September
Look for: Feature Reports on Wastewater Treatment; and Pumps;
A Focus on Process Chemicals and Performance Materials; A Facts
at your Fingertips on Water Analysis; News Articles on Flow
Batteries; and Mobile Apps; an Engineering Practice article on Design
of Experiments; New Products; and much more
Cover design: Rob Hudgins
Cover photo: Courtesy of DSM, the photo shows flow reactor modules
manufactured by 3-D printing
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AUGUST 2016
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allows continuous, efficient
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compactors for
total dust
containment.
CONDITION
BLOCK-BUSTER Bulk Bag Conditioners
loosen bulk materials that have solidified
during storage and shipment. Variable height
turntable positions bag for hydraulic rams
with contoured conditioning plates to press
bag on all sides at all heights.
CONVEY
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AUGUST 2016
surprise.
Everyone likes a
Except with hazardous substances.
6504
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Chementator
H2S scrubbing process regenerates reagent,
produces sulfur
Macrotek
n innovative H2STreated gas, 99%
scrubbing process
Vent air
removal of H2S
employs iron particles to catalyze Sulfcat
reagent
reactions that convert H2S
to elemental sulfur. The new
Oxidation
approach improves upon
vessel
traditional H2S-scrubbing
Filter
Absorber
processes that constantly
vessel
consume reagents (like Untreated
gas
NaOH and bleach) and genAir
erate sulfate-laden wasteSulfur
water that must be treated.
The new process also improves upon more recent approaches that a specially designed absorber system. The
use chelated iron compounds to oxidize sul- H2S then undergoes a series of reactions
fur, because the chelates degrade over time that convert the absorbed gas to elemental
and the ligands pose potential health and en- S and water. The reactions are promoted by
a suspension of stabilized, sub-micron-sized
vironmental concerns.
Developed by Macrotek Inc. (Markham, iron-based particles. The addition of air in
Ont.; www.macrotek.com), the Sulfcat pro- an oxidation vessel regenerates the iron recess dramatically reduces the amount of agent. Elemental S is filtered for recovery.
Macroteks Ristevski says the company
consumable reagents and water required,
significantly lowers wastewater treatment continues to optimize the technology to further
costs and generates a potentially market- lower operating costs. Sulfcat will be used to
able byproduct (elemental sulfur). Emissions capture H2S in syngas production and landfill
of H2S are removed at levels greater than gas treatment, wastewater treatment, petro99%, and the process can be configured to leum refining and other areas where efficient
remove H2S down to less than 1 part per removal of H2S is required, the company says.
Eventus APC, LLC (Neshanic Station, NJ;
million (ppm) if needed, says Chris Ristevski,
www.eventusapc.com) has been retained by
development engineer at Macrotek.
The Sulfcat process (diagram) works by Macrotek to represent it in the commercial
first absorbing H2S from the gas stream with deployment of the Sulfcat technology.
Edited by:
Gerald Ondrey
MODIFIED YEAST
Researchers at the Joint BioEnergy Institute (JBEI; Emeryville, Calif.; www.jbei.org)
have developed a genetically
engineered strain of Saccharomyces cerevisiae that is capable of utilizing both glucose
(a six-carbon sugar), and
xylose (a five-carbon sugar)
when presented with plant
biomass sugars in bioprocessing operations. By using
pentose and hexose sugars
as a carbon source, this strain
of yeast is capable of producing a variety of compounds
from a greater proportion of
the starting material, the JBEI
researchers say. Native yeasts
have a minimal ability to metabolize xylose. The strain is
available for licensing or for
collaborative research and
development projects.
FAST REACTIONS
A microfluidic technique that
outpaces the very rapid anionic Fries rearrangement
reaction to selectively functionalize iodophenyl carbamates at the ortho position
has been developed by the
research groups of professor Jun-ichi Yoshida at Kyoto
University (Japan; Kyoto,
www.sbchem.kyoto-u.ac.jp)
and professor Dong-Pyo Kim
at Pohang University of Science and Technology (South
Korea; www.postech.ac.kr).
The researchers designed
and fabricated a chip microreactor (CMR) consisting of six
heat-tolerant polyamide films
with fine channels created by
laser ablation. The CMR has
a reaction volume of 25 nL,
and is capable of operating
at cryogenic temperatures
a feature that enables the
device to perform reactions
that occur within less than 10
ms. As a result, reactions with
short-lived intermediates can
be performed before side reactions or isomerizations can
occur.
(Continues on p. 10)
Note: For more information, circle the 56-digit number on p. 82, or use the website designation.
CHEMICAL ENGINEERING
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AUGUST 2016
sodium
cyclosiloxanolate and cyclic
fluorosiloxane
Silicon
half-cubes.
The reaction
Oxygen
is performed
under
mild
Carbon
conditions,
does not generate any byproducts and
1 nm
is expected to
be applicable for making organicinorganic hybrid materials, the researchers say.
The achievement is part of a project that is being led by Kazuhiko
Satoh at the National Institute of
Advanced Industrial Science and
Technology (AIST; Tsukuba; www.
aist.go.jp) with support from the
New Energy and Industrial Technology Development Organization
(NEDO, Kawasaki City, both Japan;
Various organic
functional groups A
Organic functional
groups differing from A
Gunma University
www.nedo.go.jp).
Organosilicon
compounds are widely used in a
number of industry fields, such as
the manufacture of green automobile tires, which have enhanced,
fuel-saving performance. The market for such tires is projected to
be worth $10 billion by 2030, and
NEDO aims to contribute to Japans competitiveness through the
expanded exporting of Japanese
organosilicon components.
CHEMCAD Version 7 has a new graphic interface that ts your workow. Grayscale
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AUGUST 2016
WWW.CHEMENGONLINE.COM
Energy-ef cient
thermal separation
GEA -the leader in energy
optimization
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AUGUST 2016
NANOFILTERS
Scientists at Nanyang Technological University (NTU;
Singapore; www.ntu.edu.sg)
have invented a new type of
nanofilter that could reduce
the energy needed to treat
wastewater by up to five
times. The proprietary nanofiltration hollow-fiber membrane is said to eliminate the
need for both ultrafiltration
and reverse osmosis (RO)
by combining these two operations. Unlike RO, which
requires pressures of 10 bars
or more, the NTU nanofilters
operate at 2 bars to achieve
comparable water purity,
thereby significantly reducing
operating costs for wastewater treatment, says NTU.
This breakthrough technology took about two years to
develop, and is now being
commercialized by an NTU
spin-off company, De.Mem
Pte. Ltd. (Singapore; www.
demembranes.com).
De.Mem, which owns water
treatment plants in Vietnam
and Singapore, will be building a pilot-production plant
in Singapore to manufacture
the new membranes.
GLASS-LINED PARTS
De Dietrich Process Systems Inc. (Mountainside,
N.J.; www.dedietrich.com)
has developed a new exterior coating for glass-lined
parts, such as manhole covers, protecting rings, some
reactor covers and piping.
Traditionally, the external
protection of process equipment in glass-lined steel is
protected by paint, which,
although offering excellent
corrosion protection, can
be subjected to mechanical
stress, and flake. The new
nickel coating provides corrosion protection, while eliminating the risk of chipping.
10
Pre-protonation separation
ixtures of rare-earth
metals (REMs) are
Wash with lanthancide ions
Initial condition - sites unbound
only Tm, Yb and Lu biosorb
iii)
Bacterium
notoriously difficult i)
to separate, but a
team of researchers from Harvard University (Cambridge,
Ma.; www.seas.harvard.edu)
Wash with pH 1.5 acid
Wash with pH 2.5 acid
Tm, Yb and Lu desorb
iv)
has developed a method for ii)
efficiently extracting REMs
with a high level of selectivity. By taking advantage of
the complex surface chemistry of bacteria-coated filters,
the team discovered that it
could essentially tailor the filter to control tional extractive metallurgy techniques.
The team believes the scaleup potential
the bio-absorption of certain REMs while
allowing others to pass through the filter for this process is promising, and provides
for extraction. The key to this selectivity is many benefits over current industrial practhe affinity of the bacterias surface groups tices. REMs are typically separated using
for bioabsorbing different REMs. By pass- liquid-liquid extraction processes that can
ing various low-pH solutions through the often require over 50 passes to achieve
filter prior to any REMs a step the team useful purity. The bacteria-filter technology
calls pre-protonation certain surface would not only work more efficiently, and
groups become occupied with protons, with a much smaller footprint, but would also
and the REMs for which these occupied be more environmentally benign, as fewer
groups have affinity will pass through the harsh chemicals are required.
To further the technologys potential for
filter (see diagram). The team found that
pre-protonation with subsequently lower- customization, the team is investigating the
pH solutions resulted in the extraction use of various types of bacteria with different
of heavier REMs. By fine-tuning the pre- binding affinities. Recycling REMs is another
protonation step, the filter can differenti- area where the technology could be emate between extremely similar REMs, even ployed, and the team has demonstrated the
among neighboring lanthanides. The REMs use of bacteria filters for REM recovery from
are recovered from the filtrate using tradi- magnets in the laboratory.
CHEMICAL ENGINEERING
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It mixes like a
PowerMix
on steroids!
The Ross PDDM Planetary Dual Disperser is
engineered in the U.S.A. by the company that introduced
the original Double Planetary mixer and the PowerMix,*
the industrys first hybrid disperser/planetary mixer.
With independent drive controls, a choice of
interchangeable blade designs and US-based support,
the PDDM is the worlds most versatile tool for mixing
battery pastes, adhesives, sealants and other products
requiring high-viscosity, multi-stage mixing.
Learn more.
Visit www.planetarydispersers.com
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Mike Morse
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Employee Owner
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Call 1-800-243-ROSS
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uid fuels and waxes has been reported by a research group from
the Shanghai Institute of Organic
Chemistry, Chinese Academy of
Sciences (www.sioc.ac.cn) led by
Zheng Huang, in collaboration with
the group of professor Zhibin Guan
at the University of California at Irvine (www.uci.edu).
The new method involves a tandem-catalytic, cross-alkane metathesis process, whereby one
catalyst is used for alkane dehydrogenation and another catalyst for
olefin metathesis. First, an iridiumbased dehydrogenation catalyst
removes hydrogen from both PE
CHEMICAL ENGINEERING
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AUGUST 2016
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Business News
LINEUP
BASF
BP
CLARIANT
COVESTRO
DOW
HONEYWELL UOP
INEOS
JACOBS ENGINEERING
LUBRIZOL
MEGLOBAL
MITSUI
NIPPON ELECTRIC
GLASS
PPG
SOLVAY
TECHNIP
TESORO
VEOLIA
W.R. GRACE
WACKER
Plant Watch
Dow technology selected for new
MEGlobal production facility
July 11, 2016 MEGlobal, a wholly owned
subsidiary of Equate Petrochemical Co., has
selected process technology from the Dow
Chemical Company (Midland, Mich.; www.dow.
com) for its monoethylene glycol (MEG) production
facility in Freeport, Tex. The new MEG production
facility has a capacity of 700,000 metric tons per
year (m.t./yr), and is expected to come online
in mid-2019.
WWW.CHEMENGONLINE.COM
AUGUST 2016
Austrian quality
www.berndorf-band.at
www.berndorfband-group.com
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CHEMICAL ENGINEERING
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15
Newsfront
IN BRIEF
GLOBALLY SUSTAINABLE
OPERATIONS
THE NEW BLACK
TAKING CARE WITH TIO2
GETTING BACK TO
NATURE
16
he
complex
chemistries that
enable pigments
to provide bright
colors also open up much
potential for advances
in production and performance. Although pigments from nature have
been used for centuries,
synthetic pigments continue to evolve, and in
some cases, mimic their
biological
predecessors. Some advances in
pigment
technologies,
as well as the industry FIGURE 1. Lanxess recently employed a new production technique for yellow-red pigments at a site in Ningbo, China
trends that support more
sustainable operations,
ditional shades in between. This effect is
are presented here.
most noticeable in China, explains Baldus,
where production capacities have shrunk
considerably and a significant number of
Globally sustainable operations
As with countless other industries, global- small- and medium-sized producers have
ization trends are impacting pigments pro- exited the market since 2014. Baldus atducers. The leading paints and coatings tributes this trend to the recent estabmanufacturers have become increasingly lishment of environmental restrictions by
international in their activities ever since Chinese authorities.
To address the environmental implications
the onset of market globalization. Consequently, pigment suppliers are now ex- of the Penniman Red process the tradipected to grow worldwide along with them, tional production technique for yellow-red
and to make pigments of consistent quality iron-oxide pigments in China Lanxess
available everywhere in the world, explains developed an alternative production method
Hans-Peter Baldus, head of that is more efficient and sustainable. The
Lanxess AGs (Cologne, Ger- company employed this production process
many;
www.lanxess.com) for the first time earlier this year at a plant in
Inorganic Pigments business Ningbo, China (Figure 1). The hallmark of the
unit in North America. At the technology is the comprehensive waste-gas
same time, consolidation is treatment process, which eliminates harmbringing about change as ful nitrous oxide emissions. Furthermore,
well, specifically in the global Lanxess patented Ningbo Process inteindustry for the production grates an efficient water-treatment system
of synthetic iron-oxide pig- and also incorporates precise control of the
ments, which are produced formation reaction and altered synthesis of
in red, yellow, brown, black the starting materials. This process, says
and a wide variety of ad- Baldus, sets new standards worldwide in
Lanxess
CHEMICAL ENGINEERING
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AUGUST 2016
Circle 35 on p. 82 or go to adlinks.chemengonline.com/61498-35
Melior Innovations
M-Tone
Addictive requirement
5
4
Color
Rheology
3
2
1
Density
Cost-in-use
Thermal performace
Microwave transparency
Environmental
FIGURE 3. The ceramic nature of M-Tone pigments gives them beneficial properties and capabilities when
compared to traditional black pigments
WWW.CHEMENGONLINE.COM
AUGUST 2016
Surrey Nanosystems
FIGURE 4. Precisely aligned arrays of carbon nanotubes enable Vantablacks distinctive light-absorbing
behavior
WWW.CHEMENGONLINE.COM
AUGUST 2016
SAFETY FIRST
Electric actuators for industrial
valve automation
Safe, robust, precise.
For decades, AUMA actuators
have excelled by their outstanding
reliability throughout many
market segments. Their capability
for overall host system integration
is of crucial importance for safe
and economical operation in
process technology.
For highest safety requirements
SIL 3 capability (1oo2)
Certiication according to
IEC61508
Patented fail safe functionality
Available in ire-proof version
www.auma.com
Circle 44 on p. 82 or go to adlinks.chemengonline.com/61498-44
19
Dow
In a typical formulation,
TiO2 distribution is
random
As a formulation dries,
crowding creates
areas of high and low
concentration
Where concentration is
low, gaps in the resulting
film may occur
Where concentration is
high, overlap creates
inefficiency
FIGURE 5. Hollow-sphere polymers interact with titanium dioxide to increase formulations efficiency
technological developments.
Mary Page Bailey
WWW.CHEMENGONLINE.COM
AUGUST 2016
ASK YOUR
Across a range of industries, separation is
essential to sustainable growth. Whether
youre processing the worlds largest wastewater
flows,
the
most
valu able
minerals, or the next line of baby food
products, the right separation technologies
and services can have a vital impact on your
bottom line.
Whatever your separation challenge, you
can rest assured that no one has a broader
range of technologies and services
or deeper process know-how than
ANDRITZ SEPARATION. In fact, over the
past century weve consistently expanded
SEPARATION
SPECIALIST
SERVICE
andritz.com/separation
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Newsfront
IN BRIEF
REDUCING
DEGRADATION/
SEPARATION
SIMPLIFIED CLEANING
INCREASING RELIABILITY
AND UPTIME
INTEGRATION AND
SMARTER CONTROLS
22
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AUGUST 2016
Flexicon
Seepex
CHEMICAL ENGINEERING
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AUGUST 2016
FIGURE 3. Flexicons Bulk-Out bulk bag dischargers are available with several accessories designed
to increase efficiency and deal with difficult-tohandle materials, including the Spout-Lock clamp
ring and Tele-Tube telescoping tube
23
Hapman
Simplified cleaning
Many processors dont have systems that are dedicated to the same
material 24/7/365. Instead, they may
be a compounder who cant have
two colors mixed or running two
incompatible materials, so crosscontamination is a major concern,
says Todd Messmer, applications
engineering manager with Schenck
Process (Whitewater, Wis.; www.
schenckprocess.com).
Because
cleanability and the time associated
with cleaning are concerns we have
to take into consideration, weve
come up with a couple of systems
that assist processors with cleaning
24
WWW.CHEMENGONLINE.COM
AUGUST 2016
For more than 40 years, chemical process industries professionals- engineers, manager and technicians, have
used Chemical Engineerings Plant Cost Index to adjust process plant construction costs from one period to another.
This database includes all annual archives (1947 to present) and monthly data archives (1970 to present). Instead of waiting more than two
weeks for the print or online version of Chemical Engineering to arrive, subscribers can access new data as soon as its calculated.
Sep 06
Prelim.
Aug 06
Final
Sep 05
Final
CE Index
513.1
510.0
467.2
Equipment
606.5
602.3
541.2
565.1
560.9
509.2
Process Machinery
559.6
556.2
521.7
734.7
731.7
620.8
Process Instruments
441.4
437.2
379.5
788.9
788.3
756.3
Electrical equipment
418.9
414.2
374.6
Structural supports
643.7
637.7
579.3
Construction Labor
314.7
312.9
309.1
Buildings
476.9
475.2
444.7
Engineering Supervision
350.7
351.9
346.9
510
500
490
480
470
460
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Electronic notication of
monthly updates as soon
as they are available
All annual data archives
(1947 to present)
Monthly data archives
(1970 to present)
Option to download in
Excel format
CHEMICAL ENGINEERING
WWW.CHEMENGONLINE.COM
AUGUST 2016
25
Focus
Valves
Rotary valve controls the flow
of powders and granules
Coperion K-Tron
Conval, Inc.
Note: For more information, circle the 3-digit number on p. 82, or use the website designation.
CHEMICAL ENGINEERING
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AUGUST 2016
Solenoid Solutions
Compact press-regulating
valves withstand harsh fluids
This family of pressure-regulating valves (PRVs; photo) features
compact size, modular design and
highly chemical-resistant plastic
construction with no exposed metal
parts. Offered in two models, the
WWW.CHEMENGONLINE.COM
AUGUST 2016
GF Piping Systems
27
DMN
AS-Schneider
The new KB and KC Ball Valve Series products (photo) are designed
for the most demanding CPI and
petroleum-refining applications. A
floating ball allows for relatively low
torque, even under difficult conditions. They withstand pressures
up to 420 bars, and temperatures
of 30 to 232C. Carbon steel
and stainless steel are available as
standard body materials, but other
special alloys (such as Alloy 400
and Alloy C-276) can be used for
the body. Polyether ether ketone
(PEEK) and reinforced polyetrafluoroethylene (PTFE) are used for the
ball seat. The valves are tested and
certified according to ISO 15858
and are also Fire Safe tested and
certified according to ISO 10497/
API 607. AS-Schneider, Nordheim, Germany
www.as-schneider.com
The DMN High-Pressure Rotary Airlock Valve (photo) has a special body
and rotor configuration that protects
the product against degradation,
and prevents axial air leakage. It is
said to reduce air leakage by 30%
compared to competing standard
high-pressure valves. The DMN HP
rotary airlock valves are suitable for
use during metering and pneumatic
conveying of granular products. The
configuration of the body, rotor and
seals is designed to retain the best
possible pocket-fill efficiency while
reducing product degradation, says
the company. They are supplied with
a Type 316 stainless steel body and
aluminum end covers to withstand
wear. The HP valves are available
in 8-, 10- and 12-in. models, which
can handle products up to 176F.
DMN Inc., Memphis, Tenn.
www.dmn-inc.com
Roto-Disc
28
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AUGUST 2016
Hnqy"Ogcuwtgogpv
Yqy#"Qt"cu"yg"ecnn"kv<"
gzvtgogn{"eqorcev""UKVTCPU"HE632"cpf"HE6520
Ukgogpu"Rtqeguu"Kpuvtwogpvcvkqp""ogcuwtkpi"gxgt{vjkpi"vjcv"ocvvgtu0
RFRC/C32345/22/9822
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{qwt"rtqhkvcdknkv{""vjcpmu"vq"203'"ceewtce{"cpf"vjg"dguv/kp/encuu"322"J|"fcvc"wrfcvg0"Ejqqug"vjg"UKN"5"
u{uvgo"egtvkhkgf"rtgokwo"uqnwvkqp"UKVTCPU"HE652"ykvj"uwrgtkqt"fgcgtcvkqp"ogcuwtgogpv"rgthqtocpeg"
cpf"fkcipquvkeu0"Qt"vjg"cnn/kp/qpg"uqnwvkqp"UKVTCPU"HE632."kfgcn"hqt"QGO"umkf"dwknfgtu"cpf"crrnkecvkqpu"
ykvj"vkijv"urcegu0
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Rtqeguu"Kpuvtwogpvcvkqp"hcokn{."dg"kv"hnqy."rtguuwtg."ngxgn."ygkijkpi."vgorgtcvwtg"ogcuwtgogpv."
qt"qwt"rqukvkqpgt0"Dgecwug"yg"dgnkgxg"gxgt{"dwukpguu"uweeguu"dgikpu"ykvj"itgcv"ogcuwtkpi0
ukgogpu0eqo1hnqy
Circle 39 on p. 82 or go to adlinks.chemengonline.com/61498-39
New Products
Measure viscosity over
a wide temperature range
RheoSense
This companys new oil-debris sensor (photo) offers continuous, realtime monitoring of particle accumulation and contamination in hydraulic
and lubrication systems. The sensor features a three-channel output
that provides both an early warning
of damaged bearings or gears that
need maintenance to prevent unexpected downtime. Typical applications include monitoring gas-turbine
engines, turbine gearboxes and other
industrial applications. Solid particle
contamination is a major cause for
breakdown in hydraulic and lubrication oil systems, which can not
only be costly to fix, but when compounded with unscheduled downtime, can cause even higher recovery
costs. Gill Sensors & Controls Ltd.,
Hampshire, U.K.
www.gillsc.com
Quintex
30
The Model 1400LF low-flow centrifugal pump (photo) can handle flowrates up to 50 gal/min and heads
up to 345 ft, at temperatures as high
as 250F. Applications for this basemounted horizontal pump include
boiler feed, chemical processing,
washdown and spray washers. Back
pullout construction allows for simplified inspection or maintenance without disturbing the piping to the pump.
Packing or various mechanical-seal
CHEMICAL ENGINEERING
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AUGUST 2016
ASCO Valve
The Numatics 503 Series valve manifold (photo) enables end users to
configure up to three safety circuits in
a production machine. The manifold
can create up to three independent
electro-pneumatic safety zones, while
also allowing independent non-safe
sections to coexist within one manifold assembly. The operator does not
Pepperl+Fuchs
Festo
32
WWW.CHEMENGONLINE.COM
AUGUST 2016
Pump Engineering
www.cashco com
Innovative Solutions
Cashco, Inc. P.O. Box 6, Ellsworth, KS 67439-0006 Ph. (785) 472-4461, Fax: (785) 472-3539
Circle 08 on p. 82 or go to adlinks.chemengonline.com/61498-08
CHEMICAL ENGINEERING
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AUGUST 2016
33
Voith Turbo
Pfeiffer Vacuum
CHEMICAL ENGINEERING
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AUGUST 2016
Circle 13 on p. 82 or go to adlinks.chemengonline.com/61498-13
Emefcy
Piab
generates a low residual gas spectrum in the chamber, which is desirable for mass spectroscopy applications. The vacuum pump comes in
a radiation-resistant version with external electronics as an option. With
its sophisticated rotor design, the
HiPace 300 H has a very high backing
pressure compatibility of 30 hPa. This
helps the pump achieve ultra-high
vacuum when operating with high
backing pressure in combination with
diaphragm pumps. The HiPace 300
H also has an integrated intermittent
operation function that switches on
a backing pump only when the backing pressure is no longer sufficient.
This lowers the energy consumption
of the entire vacuum system by up to
90%, says the company. Pfeiffer
Vacuum GmbH, Asslar, Germany
www.pfeiffer-vacuum.com
Gericke USA
CHEMICAL ENGINEERING
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AUGUST 2016
The FlowCam ALH automated liquid-handling system (photo) automatically processes up to 96 samples per run without requiring human
involvement or supervision. This
eliminates the potential for human
error in sample handling and pipetting, and ensures that data are accurate. Ideal for particle characterization and quality control in a variety
of liquid and dry particle-analysis applications, the FlowCam autosampler includes built-in mixing, heating
and cooling for sample conditioning,
control over evaporation and protection against sample degradation.
The FlowCam ALH liquid-handling
system is entirely self-contained on
a compact footprint in a protective
enclosure suitable for cleanrooms to
prevent contamination and outside
activities from disturbing the operation. Fluid Imaging Technologies,
Inc., Scarborough, Me.
www.fluidimaging.com
EnviroGear Pumps
Circle 36 on p. 82 or go to adlinks.chemengonline.com/61498-36
CHEMICAL ENGINEERING
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AUGUST 2016
37
Distillation column design is best accomplished using process simulation software, such as Aspen HYSYS
or a similar program. Balancing the
key design factors shown in Table 1
starts by sizing the column for maximum superficial vapor velocity (vapor
factor Fs).
Once a working design is established, engineers should check the
ratio between flowrate (gallons-perminute; gpm) and column area (gpm/
ft2). The next step should be to ensure that flood ratio, weeping point,
reflux ratio, and efficiency ratios are
all within reasonable parameters.
For basic categories of column internals, the appropriate ratio ranges
TABLE 2.
Column internals style
Trays
Random/dumped packing
Structured packing
gpm/ft2
120
120
120
Fs
0.21.6
0.52
0.23.5
Efficiency
5080%
HETP 3040 in.
HETP 1230 in.
P (mmHg)
410 mmHg / Tray
0.71.5 mmHg / ft
0.20.5 mmHg / ft
References
1. Terry Tolliver, retired senior fellow Solutia/Monsanto
2. Kister, H. Z., Distillation Design, McGraw-Hill, 1992.
3. Couper, J. R. and others, Chemical Process Equipment
Selection and Design, 2nd Ed., Elsevier, Amsterdam,
2004.
Editors note: The content for this edition of Facts at your
Fingertips was provided by EPIC Systems, Inc. (St. Louis,
Mo.; www.epicmodularprocess.com). If you have additional
questions or comments, please email Stephen Benbrook:
sbenbrook@epicsysinc.com
Disclaimer: Although the information and recommendations set forth herein are presented in good faith, EPIC
Systems, Inc. and its subsidiaries make no representations
or warranties as to the completeness or accuracy thereof.
No representations or warranties, either express or implied,
or merchantability, fitness for a particular purpose or of any
other nature are made hereunder.
When is it applied?
Downcomer flood
Weeping point
Entrainment ratio
To all columns
To any column
Efficiency ratio
38
HETP
Fs vapor
To all columns
Ratio used to find column area requirements and to determine initial equipment sizing
To all columns
CHEMICAL ENGINEERING
Col. efficiency
Entrainment
Vapor rate
WWW.CHEMENGONLINE.COM
AUGUST 2016
Technology Profile
Chlorine Production from NaCl (Chlor-Alkali)
By Intratec Solutions
The process
The following describes chlorine production by the electrolysis of aqueous
sodium chloride (brine) using a conventional membrane process (Figure 1).
Brine purification. Initially, recycled,
depleted brine is mixed with water and
re-saturated with fresh sodium chloride. Since other metal ions (such as
Ca2+ and Mg2+) present in the brine
would harm the membranes, the brine
is treated with precipitants, so that the
metals precipitate. The precipitated
solids form a sludge, which is removed
by settling in a clarifier. Subsequently,
the clarified solution is filtered and purified by ion-exchange resins to remove
residual hardness and achieve acceptable levels of Ca2+ and Mg2+ ions.
Electrolysis. The ultrapure brine and
electricity are the main inputs for the
electrolysis section. The brine is fed
into the anolyte compartments (electrolyte near the anode) of the electrochemical cells. These are separated
from the catholyte by cation-exchange
membranes. Chlorine gas is generated at the anodes and sodium ions
migrate through the membranes into
the catholyte solution. The depleted
Sodium
chloride
Water
Precipitants
NaCl, electricity
Electrolysis
(membrane)
NaCl, electricity
Electrolysis
(diaphragm)
NaCl, electricity
Electrolysis
(mercury)
HCl, electricity
Oxidation
HCl, oxygen
Chlorine
Chlorine pathways
Most chlorine produced at commercial scale is based on electrolysis of
aqueous sodium chloride (chlor-alkali
process). Aside from the process described above, electrolytic production
of chlorine can be accomplished by
two other basic processes: diaphragm
cell and mercury cell processes. Fig-
Economic performance
The total capital investment estimated to be required to construct
a plant with a capacity of 500,000
metric tons per year of chlorine in
the U.S. is about $820 million (data
from the first quarter of 2014). The
capital investment includes fixed
capital, working capital and additional capital requirements. The production costs (raw materials, utilities,
fixed costs, corporate overhead and
depreciation costs) are about $500
per metric ton of chlorine produced
(credits from sales of hydrogen and
caustic soda co-products were not
taken into account).
This column is based on Chlorine
Production from Sodium Chloride
Cost Analysis, a report by Intratec.
It can be found at: www.intratec.us/
analysis/chlorine-production-cost. n
Edited by Scott Jenkins
Editors note: The content for this column is supplied by Intratec Solutions LLC (Houston; www.intratec.us) and edited
by Chemical Engineering. The analyses and models presented
are prepared on the basis of publicly available and nonconfidential information. The content represents the opinions
of Intratec only. More information about the methodology for
preparing analysis can be found, along with terms of use, at
www.intratec.us/che.
Demineralized
water
Hydrogen
Electrolysis
Chlorine
10
4
Residues
Water vapor
ST
Caustic soda
(50 wt.%)
8
ST
11
CW
12
6
RF
13
1. Brine saturation
2. Precipitation
3. Filtration
4. Ion exchange
5. Electrolysis
6. Dechlorination
7. H2 compression
8. NaOH evaporation
9. CI2 drying
10. CI2 liquefaction
11. Steam boiler
12. Cooling tower
13. Refrigeration unit
CW Cooling water
ST Steam
RF Refrigerant
FIGURE 1. The above diagram shows chlorine production by the electrolysis of aqueous sodium chloride via a conventional membrane process
CHEMICAL ENGINEERING
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AUGUST 2016
39
Microreactors:
Hold on!
t the heart of
herd!
a chemical
Get ahead of
process
is
No way!
the herd!
the reactor,
Chasm
where the conversion Try it!
valley of death
of reactants to products occurs. DependTechnology Visionaries
Pragmatists Conservatives Skeptics
ing on the need for
enthusiasts (early
(late majority) (laggards)
(early
PROCESS
(innovators) adopters)
majority)
efficiency
or
flexibility,
INTENSIFICATION AS AN
ENGINE FOR INNOVATION the chemical process
industries (CPI) opti Easy to convince
Difficult to convince
BASIC PRINCIPLES
mize their processing
Just being new
Must work properly
DYNAMICS OF
solutions towards FIGURE 1. The critical point in the adoption of a high-tech innovation is reached when the
INNOVATION
continuous,
world- early majority needs to be convinced of their adoption decision by proven feasibility (y-axis is
scale
plants
for
bulk percentage of adopters)
HURDLES TOWARDS
chemicals,
or
to
batch
operated, multi-prod- ences the same processing history.
INDUSTRIAL
uct
plants
for
complex
fine chemicals. The
By increasing the temperature, we could
APPLICATION
struggle to stay competitive and deliver high accelerate the rate of reaction and explore
AN APPROACH TO
quality product at low cost drives the indus- ever higher productivity levels. Of course,
CROSS THE CHASM
try towards the use of increasingly larger- the landscape of possible chemical pathMANUFACTURABILITY
scale reactors. This economy-of-scale prin- ways would still require delicate navigation
VERSUS PERFORMANCE ciple helps to lower the cost level, but also
to avoid unwanted consecutive or side reimposes serious limitations on mass- and actions and maintain sufficient chemical seDESIGN STRATEGIES
heat-transfer, often resulting in moderate lectivity. In the end, when we could design
THE IMPACT OF ADDITIVE space-time yield or productivity.
this ideal reactor that allows us to follow
MANUFACTURING
the optimal pathway, the limitation to the
productivity increase would come from the
CONCLUDING REMARKS PI as an engine for innovation
Process intensification (PI) takes a different chemistry itself rather than the capabilities
approach to optimizing reactions. When look- of the reactor.
The approach of PI towards improving cost
ing at the underlying fundamental physical
and chemical processes and fluxes that occur efficiency, boils down to maximizing the perduring a chemical conversion, we can define formance-to-cost ratio. The volumetric cost
an optimal pathway for the molecules [1, 2]. level of an intensified reactor may exceed that
The aim is to fulfill the needs of the reaction, of conventional reactors due to increased
in the sense of bringing reactant molecules complexity. But as long as the productivity
together in the right stoichiometry at the right gain is more than proportional, the net cost
time and extracting the released reaction per unit of production capacity will go down.
enthalpy in a perfect way to avoid overheating and selectivity loss. The virtual absence Basic principles
of concentration and temperature gradients, Over the past decades, the use of microcombined with near to ideal plug flow, would reactors in chemical synthesis became the
ensure that every product molecule experi- subject of many papers [3, 4]. Laboratory-
IN BRIEF
40
CHEMICAL ENGINEERING
WWW.CHEMENGONLINE.COM
AUGUST 2016
Capacity
Reactor
volume
Pressure
drop
(1,000 ton/yr)
(L)
(bar)
110
~2
105 106
10
10100
~2
106 107
100
1001,000
~2
107 108
Setting
Standards
Number of
channels
FLUXUS F/G721
Dynamics of innovation
Despite its widespread success in
the laboratory, there are just a few reported microreactor applications on
industrial scale. In our opinion, the
reason for this should not be attributed to the unwillingness of industry
to adopt to new technology, as is
often suggested. For a better understanding, we must take a closer look
at the dynamics of innovation and
the factors that influence it.
In the mid 1990s, Mokyr [7] presented a theory of technological
change (innovation) based upon
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AUGUST 2016
Advanced Non-Intrusive
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Highly accurate and reliable
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Bidirectional communication
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Engineered and approved
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Highest cost-effectiveness:
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41
Circle 22 on p. 82 or go to adlinks.chemengonline.com/61498-22
10-1
106
100
101
Productivity (kg/m3h)
105
102
Microreactor
104
CAPEX per
1 kg/h
capacity
(1,000 )
103
Loop reactor
102
Stirred-tank reactor
101
102
103
104
105
106
Cost per unit of reactor volume ( 1,000 /m3)
Moore [9] expanded the model by focusing on this critical point (chasm) in the
bell-curve between early adopters and early
majority (Figure 1). The most difficult step is
making this transition because the expectations of the adopters change. The early
majority is more pragmatic in their decision.
They need to be convinced by real benefits and performance. A lack of technology
readiness is not accepted. Both economic
and technical feasibility need to reach a satisfying level. In our opinion this is the true
reason for the reluctance to implement industrial microreactors.
Primary
flow
A-A
Chaotic in
time and
position
Steady
Increasing
curvature
velocity
42
A-A
Lets go back to the adoption of microreactor technology in the chemical industry. The
early success in the laboratory demonstrated
the potential of the technology and created
high expectations. The product of laboratory-scale experiments, however, is information, and for this we dont need volume. A
microliter-sized reactor can tell us about the
reaction kinetics and the achievable selectivity, or produce a few grams of substance for
a library. The microreactor may be a costly
prototype as long as the value of the information is satisfactory. Things change when
the product is mass, when tons of substance are required, when operation has to
meet plant and business requirements.
The first hurdle we perceived was that
of scaleup to a sufficiently large volume to
deliver the required production capacity. Although productivity in a microreactor can
reach up to 100,000 kg/m3h, the required
reactor volume is still substantial and a single
channel will not be sufficient. Astronomically
high numbers of parallel channels would be
required (Figure 2). Numbering-up is often
hailed as the solution with the added benefit of avoiding scaleup effects. In theory this
is true, but the practical implications on the
technical feasibility (manifolding) are enormous, let alone the impact on the economics of the reactor construction. This problem
poses a true dilemma. The performance of
a microreactor comes from its micrometersized channel dimension, and traditional
scaling-up would inevitably result in loss of
that performance, bringing us back to conventional tube reactors.
The second hurdle that we encountered
was the manufacturability and its impact on
the cost level. In the early 2000s, with the
technology still in its infancy, it was difficult to
find a technology provider who could solve
the numbering-up challenge on a technical
CHEMICAL ENGINEERING
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AUGUST 2016
Where can you find all your CPI solutions in one spot?
The Chemical Processing Industry covers a broad range of products such
as petrochemical and inorganic chemicals, plastics, detergents, paints, pulp
& paper, food & beverage, rubber and many more. Chemical Engineering
magazine is uniquely suited to cover this worldwide market.
WWW.CHEMENGONLINE.COM
27584
AUGUST 2016
43
Diameter
Length
Numbering-up
Production
cost level of a reactor system and the attainable productivity, or volumetric production capacity. Of course the business case
is influenced by many more factors, but it
allowed us to benchmark the economic feasibility of reactor technologies that showed
a wide range in achievable productivity (kg/
m3h) and applied different technology principles. Assuming that license-to-operate and
safety requirements are met, the cost-to-performance ratio is reflected to a large extent in
the investment level to install a certain production capacity. Two technologies can have
a different background, but if they result in the
same cost-per-unit production capacity, they
are business-wise meaningful alternatives.
An exception should be made for the comparison of existing to emerging technologies.
Here, there should be an additional value
proposition to reward the risk thats taken
with the unproven technology. We admit that
this is a simplification of the reality, but it gives
a first estimate that allows convincing of decision makers in the business.
We set off to get real input data by executing pilot projects with suppliers that
were identified as capable to deliver a microreactor with at least 1 L of volume. With
a prototype, we investigated the achievable
productivity and tried to boost it to the maximum level. From the supplier quotation and
negotiations, we derived the achievable cost
level. Over time, we filled our database with
information about an increasing number of
suppliers, and kept it up to date by following
their developments.
The dots in the diagram shown in Figure 3
represent individual microreactor suppliers.
FIGURE 6. This schematic
The first striking thing is the relatively wide
illustrates selective laser melting (a), with a closeup of of the span in cost level of the microreactor technology. Probably this is typical for an emerging
laser and metal powder (b)
FIGURE 5. This diagram illustrates the design strategy for
industrial microreactors
Laser
Scanner system scanning
direction
Powder
delivery
system
Roller
Laser
Fabrication
powder bed
Object being
fabricated
Sintered powder
particles (brown
state)
(a)
(b)
Powder delivery piston
44
Fabrication piston
Pre-placed
Laser beam powder bed
(green state)
Laser
sintering
Unsintered material
in previous layers
CHEMICAL ENGINEERING
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AUGUST 2016
27%
-32%
1.6*
1.1*
Indirect
73%
41%
25%
59%
75%
Prerequisites
2013
2018
2023
Build speed
Machine costs
Share of monitoring
Machine utilization
Powder price
Post-processing effort
10 cm3/h
500,000
5%
86%
89/kg
1.52 h/kg
40 cm3/h
700,000
2%
84%
70/kg
1.05 h/kg
80 cm3/h
800,000
0%
81%
30/kg
0.96 h/kg
BUNGARTZ
MASTERPIECES
Inc.
3809 Beam Road Suite K Charlotte, NC 28217, USA
T +1 704 716 7022 | F +1 704 716 7025
info@rembe.us | www.rembe.us
Circle 37 on p. 82 or go to adlinks.chemengonline.com/61498-37
CHEMICAL ENGINEERING
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Circle 06 on p. 82 or go to adlinks.chemengonline.com/61498-06
AUGUST 2016
45
chemengonline.com/chemploy
Dont let the competition score that perfect position you deserve.
Additive manufacturing
In 2010, our search for game-changing manufacturing technologies
came across additive manufacturing, in particular 3-D metal printing.
Additive manufacturing, or 3-D
printing, is an innovative technology,
developed in the 1980s, that allowed
CHEMICAL ENGINEERING
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PROCESS
PLANTS
n HYDROGENATION
n SPECIAL CHEMISTRY
n POLYMERS
n PHARMA, FOOD
COSMETICS
www.ekato.com
Circle 19 on p. 82 or go to adlinks.chemengonline.com/61498-19
47
Concluding remarks
Process-intensification thinking led to
the invention of the microreactor. The early
success in the laboratory demonstrated
the potential of the technology and created high expectations. The expression of
that know-how into industrial microreactors
48
References
1. Freund, H. and Sundmacher, K., Towards a Methodology for the
Systematic Analysis and Design of Efficient Chemical Processes,
Chem. Eng. Process., Vol. 47 (12), pp. 2,0512,060, 2008.
2. Peshl, A., Freund, H. and Sundmacher, K., Methodology for the
Design of Optimal Chemical Reactors Based on the Concept of Elementary Process Functions, Ind. Eng. Chem. Res., Vol. 49 (21), pp.
10,53510,548, 2010.
3. Protasova, L. and others, Latest Highlights in Liquid-Phase Reactions for Organic Synthesis in Microreactors, Org. Process Res. Dev.,
Vol. 17, pp. 760791, 2013.
4. Gutmann, B., Cantillo, D., and Kappe, C.O., Continuous Flow Technology: A tool for safe manufacturing of Active Pharmaceutical Ingredients, Angew. Chem. Int. Ed., Vol. 54, pp. 6,6886,729, 2015.
5. Hessel, V. and others, Novel Process Windows for Enabling, Speeding-up and Uplifting Chemistry, ChemSusChem, Vol. 6 (5), pp.
746789, 2013.
6. Yoshida, J., Flash Chemistry: Flow Microreactor Synthesis Based on
High-resolution Reaction Time Control, The Chemical Record, Vol.
10, pp. 332341, 2010.
7. Mokyr, J., Evolution and Technological Change: A New Metaphor for
Economic History, [ed.] R. Fox. Technological Change, R. Fox. ed.,
Harwood, London, pp. 6383, 1996.
8. Rogers, E., Diffusion of Innovations, 5th ed., Simon and Schuster,
New York, 2003.
9. Moore, G., Crossing the Chasm, Harper Business Essentials, New
York, 1991.
10. Dean, W.R., Note on the Motion of Fluid in a Curved Pipe, Philos.
Mag., Vol. 4, pp. 208223, 1927.
11. Kockmann, N., Kiefer, T., and Engeler, M., Convective Mixing and
CHEMICAL ENGINEERING
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Transferring potent or
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oxic
Mller Containment Valve MCV
Suitable for EEB 5 (OEL < 1 g/m3)
Available sizes: DN100, DN150,
DN200 and DN250
Explosion pressure shock resistant
up to +10 bar
Vacuum-tight version down to 1 bar
Explosion-proof to ATEX for Zone 0/20
Easy-to-wipe flat surfaces
AISI 316 L stainless steel, Hastelloy
available on request
GMP-compliant design
Mller GmbH - 79 618 Rheinfelden (Germany)
Industrieweg 5 - Phone: +49 (0) 76 23 / 9 69 - 0 - Fax: +49 (0) 76 23 / 9 69 - 69
A company of the Mller group
info@mueller-gmbh.com - www.mueller-gmbh.com
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AUGUST 2016
49
Feature Report
IN BRIEF
RISK SOURCES FOR SIS
MAINTAINING LOW
FAILURE RISK
EXTENDING PROOF-TEST
INTERVALS
TRACEABLE
CALIBRATION
VERIFICATION
REDUNDANT
REFERENCES
LIFECYCLE
MANAGEMENT TOOLS
DETECTING PROBLEMS
CONCLUDING REMARKS
50
FIGURE 1. Flowmeters like the one shown here can play key
roles in reducing risks with safety instrumented systems
(SIS)
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3.0E-02
2.5E-02
Under IEC 61511-ANSI/ISA 84, operators and SIS designers are required to qualify the appropriateness
of a SIS measurement subsystem to
be effective in addressing an application-specific safety instrumented
function (SIF). This not only includes
the initial design of the SIS itself, but
the qualification of the measurement
subsystem used in that service.
The capture and assessment of
data is used to qualify the use of
measurement instruments in SIS applications. Even after this qualification, operational data and management of change of these instruments
over their lifetimes in SIS applications
must still be captured and assessed.
SIS measurement subsystems
are typically exposed to challenging
process and environmental conditions, so they tend to contribute a
higher risk to the availability of the
SIS than safety controllers, which
are normally installed in a controlled
environment.
2.0E-02
1.5E-02
1.0E-02
5.0E-03
SIL 3
0.0E+00
0
7
8
Years
10
11
12
13
14
15
FIGURE 2. Flowmeters with a lower dangerous undetected ( du) FIT and in-situ testing capabilities may
allow extension of the interval time needed for proof tests
Krytox Lubricants
BUTTING Group
Germany Brazil
Canada China
Marcel Bartels
Phone: +49 5834 50-7155
marcel.bartels@butting.de
competences.
www.butting.com
SIL 1
TM
Progress by Tradition!
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51
National time
standard
International
mass
standard
Secondary
time
standard
National
mass
standard
Counter/
timer
Flow standard
(calibration rig)
Flowmeter
Reference
mass
Flowmeter
True
mass flow
Sensor
Sensing
element
Transmitter
AV
Transducer
Analog- AV
to-digital
converter
Signal
processing
AV
Data
display
Measured
mass flow
(measurand)
FIGURE 4. The diagram illustrates the relationship among the various subsystem elements of a flowmeter
CHEMICAL ENGINEERING
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AV1
[mA]
AV2
[mV]
AV3
[Hz]
Tolerance interval
Flow [kg/h]
(a)
(b)
FIGURE 5. All measurements results from a particular instrument need to be within the band between the
measuring error of the instrument and the maximum permissible error for the verification to be considered positive (AV = auxiliary variable)
Redundant references
Appointed with the task of coordinating the realization, improvement and
comparability of worldwide measurement systems, the International
Bureau of Weights and Measures
Get me a Check-All !
See us at
WEFTEC
Booth #8521
Manufactured in
West Des Moines, Iowa, USA
515-224-2301
www.checkall.com sales@checkall.com
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53
Safety controller/
logic solver
Flowmeter
subsystem
Lifecycle management/
data
Hart communication
Namur NE107
4-20mAdc LOOP
Device Lifecycle
management
Namur NE43
Ethernet/IP
Serial number F
Serial number F
Field device
management
Serial number F
FIGURE 6. Cloud- or enterprise network-based lifecycle management tools can provide support documentation for specific instruments
Failure information
Failure information
Measurement information
A
mA
3.6 4
20
3.8
21
20.5
Measurement information
A:=0
A:=1
A:=0
A:=1
mA
3.6 4
3.8
20
21
20.5
FIGURE 7. NAMUR NE43 recommendations for 420-mA d.c. transmitters (top) and process control systems (bottom) address the risk of mixing different vendor-specific current range signal levels
54
CHEMICAL ENGINEERING
Figure 4 illustrates the basic concept and the relation among subsystem elements in a flowmeter.
During the lifecycle of any instrument, it is important to monitor measurement performance on a regular
basis (ISO 9001:2008 Chapter 7.6.a),
especially if the measurements from
the instrument can significantly impact process quality.
For example, in Figure 4, the process value is defined as mass flow,
and a traceable flow calibration system can be used to perform a proof
test. Typically, the outcome of this
test is seen in calibration certificates
as a graph depicting the relative
measuring error of the instrument
and the maximum permissible error
band. All of the measurement results
are expected to be enclosed within
this band for the verification to be
considered positive (Figure 5a).
A second approach (Figure 5b)
consists of assessing the functionality of an instrument by looking at
one or more elements that can significantly impact the process value.
In this case, verification can assist in
assessing the instruments functionality by observing the response of
the process variable and the auxiliary
variables. The auxiliary variables are
compared to specific reference values to make sure they are within a
tolerance interval established by the
manufacturer.
Typically, proof testing requires
the flowmeter to be removed from
the process line and examined with
specific equipment, such as a mobile
calibration rig or a verification unit.
This rig or unit needs to be maintained and calibrated by qualified
personnel, thus introducing a costly
and time-consuming procedure.
The process has to be shut down to
perform testing, often resulting in a
loss of production. If removal and reinstallation of the flowmeter are carried out in a hazardous area, safety
issues can arise.
Modern instruments, such as
mass flowmeters, typically have insitu proof testing built into the devices. While many instrument vendors have similar solutions, there are
significant differences in how they
work. In the cases where flowmeter
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Status signal
Color
Symbol
hardware and its associated software can conduct in-situ testing, the
approach is often different as well.
For example, the authors company
embeds the verification functionality
in the device electronics of the flowmeter, so removal of the flowmeter is
not required.
A key requirement for this type of
verification method is high reliability.
The internal references used to verify
the auxiliary variables must remain
stable and avoid drift during the
service life of the instrument. And if
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Circle 29 on p. 82 or go to adlinks.chemengonline.com/61498-29
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55
though the logic solver with the flowmeter via 420-mA HART to monitor the device, to invoke in situ proof
testing and calibration functions,
and to diagnose problems. The
field-device-management tool communicates via Ethernet/IP to a lifecycle management server installed
within the users network or the
Cloud, where all flowmeter data are
stored in accordance with ISA and
IEC standards. The flowmeter data
are synchronized and maintained
from the flowmeter along with all associated data via its serial numbers.
The goal of this kind of field-device-management software is to enable plant operators to design a system that provides the following:
Device power and wiring condition monitoring through the logic
solver or safety controller
Device primary current loop/secondary HART communication and
status management through the
logic solver
Device repair/replace management through the logic solver
Device proof testing management
through the logic solver
Device traceable verification of
calibration management through
the logic solver
Capture and management of device proof testing, calibration, and
other lifecycle data that may reduce risk and cost in SIS designs
and lifecycle management
Detecting problems
A typical SIL-capable instrument,
such as a flowmeter, connects to
the logic solver or safety controller
via 420-mA or 420-mA HART.
These signals are also used to indicate problems.
Current signals per NAMUR NE 43
recommendations (Figure 7) convey
measurement and failure information
from the flowmeter to the safety controller via the 420-mA loop. Most
every instrumentation and control
system supplier offers options to
support this standard. Essentially,
any flowmeter and logic solver that
follows the NAMUR NE 43 recommendation uses 420 mA for the
measurement, and signals of less
than 3.6 mA or greater than 20.5
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Concluding remarks
Authors
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57
Engineering Practice
The Benefits Of Two-Stage Drying
Circular fluidized-bed dryers can boost the capacity, energy efficiency and product
quality when used in conjunction with other primary dryers
James Schak and Sunny Nwadinma
Kason Corp.
First-stage
spray dryer
(SD)
Fluidized bed
exhaust into SD
chamber
Second-stage
fluidized bed
Steam control
valve 50 psig
30o F H20/glycol
Dehumidifying
coil
Condensate
Prefilter
to the discharge. Unlike static fluidized beds that rely on complete fluidization, the vibrating fluidized bed
can handle a wide range of particle
sizes, densities and shapes without rat-holing or excessive elutriation. The airflow can be adjusted to
maximize drying efficiency without
worrying about the degree of fluidization. Continuous vertical, uniform airflow maintains consistent
product moisture and temperature.
500230
900280
300170
300145
500300
900245
Product gain, %
26
21
17
Heat saving, %
24
18
13
CHEMICAL ENGINEERING
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45
Single-stage spray dryers
(retention time in seconds)
40
35
25
20
Warm up
Moisture content, %
30
15
Constant
rate
Falling
rate
10
5
0
Time
FIGURE 2. This typical drying curve helps to illustrate how a second-stage dryer can optimize the drying
process
Operating advantages
Table 1 shows the operating advantages of two-stage drying. The
inefficiency of a direct dryer (that
uses air to dry) is seen in the hot air
exhausted. By reducing the temperature of the air exhausted or the
amount of air consumed, energy
consumption will be reduced. At
the same time, a lower spray-dryer
outlet temperature will increase the
temperature difference (T) and thus
increase the evaporation capacity.
For Example 1, as mentioned in
Table 1, the intermediate temperaInternal (circular fluidized beds):
Wet feed is distributed (seeded to start)
Good localized mixing gives consistent
blended moisture
Once-through design versus multiple passes
with external backmix
Deeper bed in center
Vibrator can be adjusted for plug flow or
backmix direction
Wet feed
Recycled dry
powder
Wet feed
Backmixer
Conveys in one direction
Dry powder
Semi-dried material
blends with wet feed
Dry powder
FIGURE 3. Some products may need re-drying and multiple back mixing passes, but internal back mixing, inherent in circular fluidized beds, accomplishes drying with minimal heat history to the product
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Predryer
Rotary Dryer
Or post
dryer
Or
Belt dryer
Or
Or
Post dryer
Pre- or post-dryer
A circular fluidized-bed dryer can
also function as a pre-dryer and
pre-conditioner upstream or as a
post-dryer and cooler downstream
of an existing rectangular fluidizedbed dryer, rotary dryer, belt, flash
or other dryer (Figure 4). Product
buildup in the feed zone of these
dryers can occur due to moisture
fluctuations, lumps, stickiness,
degradation and contaminants.
Rather than replace the primary
Feed
Heated or cooled
Inlet air-2
Inlet air-1
Heated or cooled
FIGURE 5. A new dryer design includes two separate air inlets and allows for drying and cooling in
one unit
60
CHEMICAL ENGINEERING
Authors
James Schak is product manager of fluidized-bed processing
equipment for Kason Corp. (6771 East Willow St., Millburn, NJ
07041; Phone: 973-467-8140;
Email: jschak@kason.com). He
has 30-plus years of experience
with direct and indirect dryers
ranging from process engineering and design to teaching and
marketing, and previously was Chem Systems national
sales manager for GEA Niro. Schak also teaches a
Drying Technology course for the University of Wisconsin. He holds a B.S.Ch.E. from New Jersey Institute of
Technology.
Sunny Nwadinma is an applications engineer with Kason Corp.
(same address and phone as
above; Email: snwadinma@
kason.com). He covers product
lines of circular fluidized-bed dryers, coolers and moisturizers, circular vibratory and centrifugal
screeners, and static sieve
screeners. He was previously laboratory manager. He studied engineering technology at
Essex Community College and studied mechanical engineering and science at New Jersey Institute of Technology. He holds certificates from the Dale Carnegie
course on fluidized-bed technology from University of
Wisconsin, and the Effective Facilitator Course offered
by the Leadership Strategies institute.
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Environmental Manager
Air-Pollution Control: Assessing the Options
Compliance with air-pollution regulations requires ongoing effort. Follow these
recommendations to assess competing options and optimize system design while
minimizing cost and risk
Tom McGowan
Thomas F. McGowan
TMTS Associates, Inc.
FIGURE 1. This wood-fired boiler furnace with a pneumatic spreader stoker shows lots of wood particles
and burning embers above the grates
cle density and the nature of the upstream process and feedstock. The
smaller the particle, the more easily it is carried by the fluegas, even
at relatively low gas velocity. As the
gas velocity increases, larger particles can be carried by the fluegas
stream, and the number of particles
of all sizes that can be carried increases (Figure 1).
U.S. federal and state regulations related to particulate matter vary with the process and
the scale of the equipment. In
the U.S., historic state and federal particulate limits (for example,
FIGURE 2. The image at left shows two baghouses installed in parallel. On the right, the cage is inserted
into filter bags, and pulse-jet pipes provide blowback to clean the dust off the filter
CHEMICAL ENGINEERING
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Bionomic Industries
Verantis Ceilcote
Charging section
Packing
Venturi throat
Inlet
Acid gas absorber
FIGURE 4. In this two-stage ionizing wet scrubber, particles are charged, then removed on grounded
plates and on packing; a periodic wash flushes and cleans the plates and packing
CHEMICAL ENGINEERING
lations. Disposal options for the removed particulate matter (that is,
the resulting dry dust, wet sludge, or
stabilized mixture that is formed during treatment) is another major factor in decision making. Cement kilns
are an example, where baghouses
are used to capture cement kiln dust
(CKD), which is a salable product,
while a wet capture system would
form unsaleable (and system-fouling)
cement solids.
For dry ESPs, the resistivity of
the collected flyash is an issue, and
changing the coal feed source can
Verantis Ceilcote
100.00%
99.00%
IWS
Removal/efficiency
98.00%
97.00%
Baghouse
96.00%
95.00%
ESP
94.00%
0.0
1.0
Particle size, microns
2.0
FIGURE 5. In this graph of particle size versus removal efficiency, three of the most commonly used APC
devices experience a decline in collection efficiency as the particle size of the pollutants falls. This phenomenon is least pronounced for the ionizing wet scrubber (IWS)
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AUGUST 2016
63
Tom McGowan
and dry ESP. Note that the collection efficiency for all of these devices
begins to fall off for smaller particles,
with the IWS having the least-rapid
decay of its efficiency curve. IWS are
frequently used in series with two or
three in a row, in part, to maintain
removal efficiency during their required periodic wash cycle; in this
scenario, a downstream unit operates while the upstream unit is being
washed down.
Perfection is
Acid-gas removal
www.sturtevantinc.com
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64
CHEMICAL ENGINEERING
AUGUST 2016
FuelTech
Reagent
injectors for
SNCR NOx
control
NOx control
EPA requires control of NOx, as
NOx reacts with organic vapors in
the presence of sunlight to produce
ground-level ozone. The low-cost
way to limit NOx is to do so upCHEMICAL ENGINEERING
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AUGUST 2016
www.tri-mer.com
Since 1960 Factory & Headquarters: Owosso, MI
Copyright 2016 Tri-Mer Corporation
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65
much higher capital costs. Computational fluid dynamics (CFD) modeling (Figure 7) is frequently done for
SNCR systems, to help users to optimize injection points, enhance mixing and estimate NOx-removal efficiency. In general, CFD is not used
as frequently for modeling SCRs, because such systems use a chamber
to house the catalyst and the catalyst pressure drop helps to even out
fluegas flow.
VOC control
The primary non-transportation
sources of VOC emissions are chemical process operations (such as reactions); storage and transfer (such
as pumping and working losses and
tank-breathing losses); manufacturing (solvents); and surface coating
(spray painting and dipping).
Three primary control technologies
are used for VOC: thermal oxidation;
adsorption via activated carbon or
www.weftec.org
New Orleans Morial Convention Center
September 24 28, 2016
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66
CHEMICAL ENGINEERING
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Emission
Organic vapors
Organic vapors
Particulate matter
Acid gases
Submicron liquid aerosols
Particulate matter
Particulate matter
Particulate matter
Pressure drop
1 in. water column (w.c.)
15 in. w.c.
1080 in. w.c.
26 in. w.c.
10 in. w.c.
48 in. w.c.
1 in. w.c. per stage
1 in. w.c. per stage
Pressure
Drop, in. w.c.
10 in.
60 in.
7 in.
Particulate
loading, gr/dscf
<0.08
<0.02
<0.02
Motor
horsepower
75
400
50
emissions do not exceed limits. Capture tests can be eliminated if a permanent total enclosure (PTE) is used
to prevent VOC losses in a manufacturing environment. For tank farms,
conservation vents reduce losses to
the ductwork system [7].
Condensing systems return the
vapor back into a usable liquid; however, they only work on vent streams
with relatively high concentrations
(for instance, 50 vol.% VOC). Carbon and zeolite adsorbers capture
the VOCs temporarily, then release
them when the adsorbent is heated
with steam or hot air. Some of these
systems can concentrate the material sufficiently for recovery while others send the concentrated vapors to
thermal oxidizers.
Circle 42 on p. 82 or go to adlinks.chemengonline.com/61498-42
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67
John Zink
Durr Environmental
Independent burners
Clean
process air
Purge air
Heat
exchange
media
Auxiliary systems
Fans and blowers. These components are of prime importance because they move both the air into a
combustor and the fluegas or process vent streams out of it. Combustion air is supplied by either a
forced-draft fan, an induced-draft
fan or both.
Fans may be driven by electric
motors or in large sizes, steam turbines. The speed of the fan may be
variable or fixed. Fixed-speed fans
Tri-Mer
Particulate
captured
on filter
surface
Nano-catalysts embedded
in the walls of the filter
PM does not
penetrate walls
of the filter
Airflow
Airflow
Multi-pollutant control
While individual APC components
can be placed in series to get the job
done, single units with multiple capabilities also exist. An example are fil68
FIGURE 10. This example of an all-in-one, multi-pollutant-removal system uses reagent injection and
catalytic bag filters
CHEMICAL ENGINEERING
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PROTECT PUMPS
DRYRUNNINGCAVITATIONBEARINGFAILUREOVERLOAD
MONITOR PUMP POWER
BestSensitivity
DigitalDisplay
PUMP POWER
AMPS
POWER
VALVE CLOSING
PUMPING
FULL LOAD
VALVE OPENING
No Sensitivity
For Low Loads
NO LOAD
NO FLUID
FULL LOAD
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69
70
Closing thoughts
When selecting new APC or upgrading old, look first at your regulatory
limits, then factor in the characteristics of the fume, and all the pollutants that must be controlled. Then
select candidate systems, and estimate capital and operating costs
before making your final, welln
informed choice.
Edited by Suzanne Shelley
References
1. McGowan, Thomas F., D. Coughlin, B. Axon, T.
Wechsler and J. Santoleri, VOC Emission Controls
for the CPI, Chem. Eng., February 2007.
2. McGowan, T., Chief Editor, Biomass and Alternate Fuels Systems: An Engineering and Economic
Guide, AIChE/John Wiley & Sons, 2009, ISBN: 9780-470-41028-8. Associate Editors Brown, M., Bulpitt, W., and Walsh Jr.
CHEMICAL ENGINEERING
3. McGowan, Thomas F., Charting a Path for Costeffective NOx Control, Chem. Eng., October, 2004.
4. U.S. EPA AP-42, Emission Factors; by chapter and
fuel type (www.epa.gov/ttn/chief/ap42/ch01/) and
by industry (www.epa.gov/ttn/chief/ap42/).
5. McGowan, Thomas F., VOC and Air Toxics Control by
Oxidation and Other Methods, Air Pollution Control,
September 2014.
6. McGowan, Thomas F., Oxidizers for Control of VOCs
and Other Air Toxics: Application and Design, Process Heating, October 2013.
7. Industrial Ventilation: A Manual of Recommended
Practice for Design, 28th Ed., www.acgih.org/
Author
Thomas F. McGowan is president
and founder of TMTS Associates
Inc. (399 Pavillion St., Atlanta, GA
30315; Phone: 404-627-4722;
Email:
tmtsassociates1000@
mindspring.com; www.tmtsassociates.com), a firm that specializes in thermal systems and airpollution control. He was
previously employed by RMT/Four
Nines, the Georgia Tech Research Institute, and Particulate Solid Research, Inc. McGowan has 40 years of experience in air-pollution control, filtration, combustion,
and bulk-solids handling. He holds an M.S.Ch.E. from
Manhattan College in New York City, and an M.S. in
industrial management from Georgia Tech.
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AUGUST 2016
China
LUXIZENG/ISTOCK
CHEMICAL
ENGINEERING
ESSENTIALS FOR CPI PROFESSIONALS
AK ROCKEFELLER/FLICKR
Despite slower growth in recent years, plenty of business opportunities remain for Western
firms as China works to transform itself into a consumption-driven economy
investors from the U.S., Europe, and Japan. Increasingly sophisticated projects thus give U.S. and European equipment vendors a chance
to compete on performance against lower-cost Chinese suppliers.
That was certainly the view of several German experts in
the run-up to AchemAsia 2016, which took place in Beijing in
May. The three-yearly trade exhibition and conference is run by
DECHEMA e.V. (dechema.de/en/; Frankfurt-am-Main). Even with
lower growth, business opportunities are still good, said Martin
Wansleben, Chief Executive of the Association of German Chambers
of Commerce and Industry (DIHK) in an interview with the Neue
Osnabrcker Zeitung newspaper.
Sanjeev Gandhi, Head of BASFs operations in Greater China and
Asia Pacific, told the China Daily that BASF was very, very confident about the China market. And speaking to the Berlin newspaper Tagesspiegel, Axel Schweitzer, CEO of Alba Group, said: The
second-largest national economy in the world cannot grow continuously by six or seven percent. Schweitzer sees the slowdown as a
healthy development, and Alba has recently invested massively in
plants for recycling electronic scrap and urban waste in China.
he 8th China
(Shanghai)
International
Chemical
Technology &
Equipment Fair
(CTEF) takes place
2325 August at
the Shanghai New
International Expo
Centre. This annual
event, the largest of its kind in China, acts
as an indicator of the state of the nations
chemical process industries.
Last years CTEF occupied 35,000 m2 of
exhibition space and attracted 502 exibiting
companies from 35 countries, including the
U.S., Germany, the U.K., France, Italy, and
Russia. This year, the focus will be on technology and equipment for the manufacture
72
CHEMICAL ENGINEERING
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Inside:
Andritz Separation
AUMA
Bungartz
Butting
Eastman Chemical Co.
EKATO
Flexicon
FLEXIM
GEA
Mller
Siemens
76
73
77
75
74
77
75
77
76
75
74
CHEMICAL ENGINEERING
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AUGUST 2016
the completion of a new $10 million coatings center of excellence at its existing
complex in Tianjin. The new facility will
serve regional customers in automotive
plastics and decorative accessories. PPG
built its first coatings plant in China at the
Tianjin site in 1994.
June 1, 2016 SABIC (Riyadh, Saudi
Arabia; www.sabic.com) has signed a project development agreement with Shenhua
Ningxia Coal Industry Group Co. (SNCG),
a subsidiary of Shenhua Group Corp.,
relating to a proposed greenfield petrochemical complex in the Ningxia Hui region of China. SNCG would supply coal for
use as a feedstock.
June 1, 2016 KBR, Inc. (Houston; www.
kbr.com) has been awarded a license
and basic engineering design contract
by a confidential client for a grassroots
Distill-Max stabilizer column in Shandong
Province in China. KBRs Distill-Max dividing-wall technology cuts column costs by
improving separation efficiency.
Original reporting by Scott Jenkins
and Mary Page Bailey
73
ince 1978, China has averaged nearly 10% per annum GDP
growth. Therminol heat transfer fluids have been a trusted solution in China during this same period. And for more than 50 years,
Therminol heat transfer fluids have been the products of choice in
more than 15,000 heat transfer system installations worldwide.
With a broad product line having an operating range of 115C to
400C, and backed by Eastmans expertise in more than 120 different heat transfer and cooling applications including renewable energy, oil and gas, chemicals, plastics, food/beverage manufacturing
Therminol fluids have demonstrated high performance and long
life in nearly every operating condition and environment. In China,
Therminol 66 and VP-1 have been products of choice for the PET,
chemical, and concentrating solar power (CSP) industries due to the
high-temperature performance of these products.
Thousands of design and operations engineers have relied on
the Eastman TLC Total Lifecycle Care program, a collection of services and tools offered to extend the life of a heat transfer fluid system: design assistance, startup assistance, operational and safety
training (seminars, webinars), flush fluid/refill assistance, calculators, and more.
As part of the TLC program, four global Eastman labs test and
analyze a combined 5,000 customer in-service fluid samples each
year, providing performance trends and insights for each Eastman
customer to optimize their plant performance for the life of the system and avoid costly downtime and expense.
Eastman Therminol fluids are manufactured in four regional operational facilities, including the companys newest site in Newport,
U.K., and a manufacturing site in Suzhou, China. The Suzhou manufacturing site provides the same high-quality, reliable Therminol
products, available in stock for local purchase and also available
globally. Inside China, Eastman has a dedicated team of Therminol
heat transfer fluid sales and technical specialists ready to serve.
For a list of applications using Therminol heat transfer fluids in
China, visit: http://www.szsolutia.com/yyzx_en.html. For more information, contact a Therminol fluid specialist in China by calling:
+86-512-68258167.
To locate an Eastman sales or technical specialist outside China,
visit www.therminol.com and click on the contact us tab.
www.therminol.com
oxicity, reactivity,
corrosivity, and
instability are just a
few of the everyday
hazards the chemical
industry faces. Add
in business demands
such as tight margins
and feedstock cost pressure, and it is obvious
why the twin imperatives
of safety and efficiency are
number one priorities, points
out control and instrumentation
supplier Siemens.
Process materials, temperatures and
pressures can all affect the choice of components. With on-board maintenance and
diagnostic functions, Sitrans devices translate data and alerts into timely and effective
action. Advanced diagnostics and functions
such as self-test, drag indication, partial
stroke tests and multiple adjustable limit
values are accessible at any time during operation. Safe upper and lower limits for
74
CHEMICAL ENGINEERING
WWW.CHEMENGONLINE.COM
AUGUST 2016
lexicon engineers and manufactures a broad range of equipment that handles virtually any bulk material, from large pellets
to sub-micron powders, including free-flowing and non-free-flowing
products that pack, cake, plug, smear, fluidize, or separate.
Individual bulk handling equipment includes: flexible screw conveyors, tubular cable conveyors, pneumatic conveying systems,
bulk bag dischargers, bulk bag conditioners, bulk bag fillers, bag
dump stations, drum/box/container dumpers, and weigh batching/
blending systems. Each of these product groups encompasses a
broad range of models that can be custom engineered for specialized applications, and integrated with new or existing upstream and
downstream processes and storage vessels.
All equipment is available to food, dairy, pharmaceutical and industrial standards.
For large-scale bulk handling projects, Flexicons separate Project
Engineering Division provides dedicated Project Managers and engineering teams on four continents to handle projects from concept
to completion. Working with each customers preferred engineering
firm or directly with their in-house team, Flexicon adheres strictly to
the customers unique standards, documentation requirements and
timelines through a single point of contact, eliminating the risk of
coordinating multiple suppliers. Flexicons worldwide testing facilities simulate full-size customer equipment and systems.
In 2015 the company doubled the size of its manufacturing facility and world headquarters in Bethlehem, PA, and also operates
CHEMICAL ENGINEERING
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AUGUST 2016
75
GEAs innovative column design uses multiple vaporrecompression units to slash energy requirements
of equipment and technology to the food processing industry and a
wide range of other process industries. Consolidated revenues totaled approximately eur 4.6 billion in 2015. More than 70% of this
revenue comes the food sector, which is enjoying long-term sustainwww.gea.com
able growth.
76
CHEMICAL ENGINEERING
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AUGUST 2016
Hydrogenation
plant technology
EKATO has the expertise to
scale up from lab to plant
and self-regulating. Typical applications include problems with shaft seals, poor feed
conditions, entrained gas, liquids close to
their boiling points, and corrosive or abrasive media. The companys success is based
on three pillars:
1. Sealing technology: Almost all Bungartz
pumps combine a hydrodynamic primary
shaft seal with a downstream secondary
seal (a packed gland, mechanical seal or
magnetic drive).
2. Special physics: Bungartz V-AN (abnormal) centrifugal pumps adapt automatically to changing feed rates, and require
zero NPSH.
3. Materials: These range from gray cast
iron to stainless steel, titanium, zirconium, other special alloys, and even SiC.
Horizontal and vertical pumps are available
in radial, axial and torque-flow designs,
with non-contact hydrodynamic shaft seals
or mechanical seals. Models suitable for
dry running also include magnetically coupled pumps in horizontal, vertical and submerged designs.
www.bungartz.de
CHEMICAL ENGINEERING
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AUGUST 2016
77
Details Include:
Advanced lead-acid batteries
Driving forces
Battery materials
Supply-chain logistics
Advanced batteries
Li-ion variants
Next-generation batteries
Developments by application area
Grid-energy storage
Lithium-ion technology
78
Wearable batteries
Lithium-sulfur battery technology
Redox ow batteries
Battery materials and components
Production capacity
Research stage
Advanced battery companies and specic
technologies
References
WWW.CHEMENGONLINE.COM
28014
XXXXX 2015
Industrial Cooling
Tower Services, Inc.
www.ictsinc.com
Positive Shutoff:
An improved gasket system allows complete (positive) shut-off of the water
stream without the persistent leaking associated with conventional valves.
Circle 02 on p. 82 or go to adlinks.chemengonline.com/61498-02
Pick steam injection heaters provide 100% heat transfer efciency eliminating ash and heat losses inherent with indirect exchangers. Pick Heaters are the right choice for:
Tank and Equipment Cleaning
Batch Filling of Tanks
CIP and Sterilization
Plant Sanitation / Hose Stations
Jacketed Vessel Heating
Circle 34 on p. 82 or go to adlinks.chemengonline.com/61498-34
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AUGUST 2016
79
UltraCat Catalytic
Filter System
Low Temperature NOx Removal
- Particulate to less than 0.001 grain/dscf
Advertise in
the Buyers' Guide
Outlet
Particulate captured
on the surface; does not
penetrate the surface wall
Nano-catalyst embedded
in the filter walls destroys
NOx, dioxins, Cement O-HAPS
CLEAN
AIR
Air Flow
Buyers' Guide
2017
Contact:
Diane Burleson
Tel: 512-337-7890
Fax: 512-213-4855
Email: dburleson@
accessintel.com
Polluted Gas
www.tri-mer.com
Technology Leader, air pollution control
Since 1960 Factory and Headquarters: Owosso, Michigan
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Hot Topics
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& Son Company ...................... 11
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83
Economic Indicators
2014
2015
2016
(1957-59 = 100)
CE Index ______________________________________________
Equipment ____________________________________________
Heat exchangers & tanks _________________________________
Process machinery _____________________________________
Pipe, valves & fittings ____________________________________
Process instruments ____________________________________
Pumps & compressors ___________________________________
Electrical equipment ____________________________________
Structural supports & misc ________________________________
Construction labor _______________________________________
Buildings _____________________________________________
Engineering & supervision _________________________________
May '16
Prelim.
Apr. '16
Final
May '15
Final
543.5
649.2
560.5
649.7
813.0
385.3
970.4
508.7
719.1
325.8
543.5
316.0
537.5
640.5
548.8
649.3
801.6
382.7
970.5
508.2
701.5
325.0
540.8
316.2
560.5
675.6
603.5
658.7
843.6
402.6
958.0
513.0
740.1
322.7
542.7
319.5
Annual Index:
2008 = 575.4
600
2009 = 521.9
2010 = 550.8
575
2011 = 585.7
2012 = 584.6
550
2013 = 567.3
525
2014 = 576.1
2015 = 556.8
500
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
LATEST
PREVIOUS
YEAR AGO
Jun. '16
May '16
Jun. '16
Jun. '16
=
=
=
=
101.2
1,713.3
74.4
227.9
May '16
Apr. '16
May '16
May '16
=
=
=
=
101.6
1,711.2
74.7
225.0
Apr.'16
Mar.'16
Apr.'16
Apr.'16
=
=
=
=
101.5
1,702.4
74.6
221.6
Jun '15
May '15
Jun '15
Jun '15
=
=
=
=
101.3
1,864.2
74.9
251.2
Jun. '16
Jun. '16
Jun. '16
=
=
=
103.2
165.2
101.3
May '16
May '16
May '16
=
=
=
102.8
164.4
101.6
Apr.'16
Apr.'16
Apr.'16
=
=
=
103.0
161.4
102.0
Jun '15
Jun '15
Jun '15
=
=
=
102.8
157.6
101.7
2300
80
2200
78
100
2100
76
95
2000
90
74
1900
85
72
1800
80
75
70
1700
J F M A M J
J A S O N D
J F M A M J
J A S O N D
J F M A M J
J A S O N D
*Due to discontinuance, the Index of Industrial Activity has been replaced by the Industrial Production in Manufacturing index from the U.S. Federal Reserve Board.
For the current months CPI output index values, the base year was changed from 2000 to 2012
Current business indicators provided by Global Insight, Inc., Lexington, Mass.
CURRENT TRENDS
T
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Pump Essentials
Most engineers would agree that pumps represent the workhorse component
in any chemical process industries (CPI) facility. Every day, countless decisions
must be made related to the proper selection and specification, sizing and
installation, operation and maintenance, and troubleshooting of these critical
machines.
This Chemical Engineering reference book provides a wealth of practical engineering guidance on the proper use and operation of several different types
of pumps. Articles focus on the sizing and selection of centrifugal pumps, and
tips for managing the impact of pumps whose operation deviates from the best
efficiency point (BEP). Others provide engineering tips for understanding and
optimizing magnetically driven and sealless pumps, and guidance for calculating net positive suction head (NPSH).
Pump Essentials
Valve Essentials
Engineers are routinely challenged when it comes to the proper selection,
specification and sizing, and installation, operation and maintenance, and
troubleshooting of valves to control fluid flow while ensuring overall reliability
and safety.
This resource provides engineering articles which focus on the proper selection and operation of control valves and control valve positioners and sensors.
Included is information provide sizing calculations for pressure-relief valves
and related systems, plus tips for using pressure-relief valves with rupture
disks.
Valve Essentials
WHEN IT COMES
TO MAINTENANCE,
LESS IS MORE.
In your industry, the more you produce, the better. However, this can
also lead to more maintenance, more downtime and more headaches.
Thats why, at Eastman, we specialize in keeping you up and running with
our advanced Therminol heat transfer luids. And with our industry-deining
Total Lifecycle Care Program, you can count on us being there throughout the
systems lifecycle. To learn more about our TLC Program and what the
Eastman Therminol team can do for you, go to Therminol.com or call
1-800-426-2463 in North America. In Europe, call 32.2.746.5134.
2014 Eastman Chemical Company or its subsidiaries. All rights reserved. As used herein, denotes registered trademark status in the U.S. only.
Circle 18 on p. 82 or go to adlinks.chemengonline.com/61498-18