ChemicalEngineering Chemical Engineering October 2023

Imagine the
possibilities.
Lorem Ipsum
World’s Most Accurate

Thermal Mass Flow Meter
QuadraTherm 640i ®
• +/- 0.5% of reading (inline); +/- 0.75% of reading (insertion)
• No drift sensor with lifetime warranty
• Ultra-low resolution for flares, vents, and leak detection
• Flow calibration as low as 0 -100 sfpm and as high as 0-60,000 sfpm
• Direct measurement of gas mass flow / No volume to mass calculations
• 100% field configurable
• QMix creates any gas mix or single gas in the field
TM
Measurably Different.
sierrainstruments.com / 831.373.0200
TM
50
YEARS
October
2023
www.chemengonline.com
Maintenance
Strategies page 32
Overpressure Protection Preventing Dust Explosions

Steam Methane Reforming AI In Biomanufacturing
Bolted Flange Joint Assemblies Compressors, Fans And Blowers
Data Analytics Software
CONVEY DUMP UNLOAD
FLEXI-DISC® Tubular Cable Conveyors FLEXICON® Manual Dumping BULK-OUT® Bulk
gently slide fragile foods and non-foods Stations allow dust-free dumping Bag Dischargers
through smooth stainless steel tubing of bulk material from bags and unload free- and
routed horizontally, vertically other containers. Automatic non-free-flowing
or at any angle, over reverse-pulse filter cleaning solids from bulk bags
short or long distances, allows continuous, efficient automatically. Allow
dust-free. Single operation. Available untying, discharging,
or multiple with integral bag retying and collapsing
inlets and compactors for of bulk bags—all
outlets. total dust dust-free. Available
containment. with weigh batching
controls.
CONDITION FILL CONVEY

BLOCK-BUSTER® Bulk Bag Conditioners loosen SWING-DOWN®, REAR-POST FLEXICON® Flexible Screw
bulk materials that have solidified during storage and and TWIN-CENTERPOST™ Conveyors transport free- and
shipment. Variable height turntable positions bag for Bulk Bag Fillers can fill one non-free-flowing bulk solid materials
hydraulic rams with contoured conditioning plates to bulk bag per week or 20 per from large pellets to sub-micron
press bag on all sides at all heights. hour at the lowest cost per bag. powders, including products that pack,
Numerous performance cake or smear, with no separation
options. Available to of blends, dust-free at low cost. No
industrial or sanitary bearings contact material. Easy to
standards. clean quickly, thoroughly.
CONVEY DUMP SUCCEED

PNEUMATI-CON® TIP-TITE® Container Dumpers dump The FLEXICON® Lifetime Performance
Pneumatic Conveying bulk material from drums (shown), boxes Guarantee* assures you of a successful result,
Systems move a broad or other containers into vessels up to whether you purchase one piece of equipment
range of bulk materials over 10 ft (3 m) high. Dust-tight (shown) or an engineered, automated plant-wide system.
short or long distances, or open chute models improve From initial testing in large-scale laboratories,
between single or multiple efficiency and to single-source project management,
inlet and discharge points safety of an to after-sale support by a
in low to high capacities. age-old task. worldwide network of
Available as dilute-phase factory experts, you
vacuum or positive pressure can trust your process—
systems, fully integrated and your reputation—
with your process. to Flexicon.
USA UK +44 (0)1227 374710

sales@flexicon.com AUSTRALIA +61 (0)7 3879 4180
1 888 FLEXICON SOUTH AFRICA +27 (0)41 453 1871
SPAIN +34 930 020 509
FRANCE +33 (0)7 61 36 56 12
GERMANY +49 173 900 78 76
SINGAPORE +65 6778 9225
INDONESIA +62 81 1103 2400
MALAYSIA +60 10 282 2400
LL-0757
©2023 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.
*See full Lifetime Performance Guarantee for details.
For details visit adlinks.chemengonline.com/84652-01
October 2023 Volume 130 | no. 10
Cover Story
32 Proactive Industrial Hose Maintenance
Proper hose maintenance can prevent failures, increase profitability and
improve safety
35 Predictive Maintenance Basics

Enabled by modern digitalization tools, predictive
maintenance strategies have distinct advantages over
traditional maintenance approaches and preventive
maintenance protocols
.In the News

5 Chementator
A new electrolyzer system makes propane from CO2;
Scaled-up facility under construction for single-step
CO2-to-fuels process; Seawater electrolysis stabilizes
and immobilizes atmospheric CO2; Taking graphene into
the next dimension; Piloting a chemical recycling process for
polycarbonate plastics; and more
32
11 Business News
OCI Global to double U.S. production capacity for ‘green’ methanol; Air
Liquide announces investment in ‘green’-hydrogen production capacity; LG
Chem to expand RO membrane manufacturing capacity; Evonik expands
production capacity for precious-metal powder catalysts in China; and more
13 Newsfront Methane Reforming: Solving the

Hydrogen Blues Improved catalysts and reconfigured reformer 35
designs make steam-methane reforming the most scalable, industry-
ready source of ‘blue’ H2
18 Newsfront Data Analytics Software for Process
Optimization Advanced software solutions drill down through
data to provide actionable information
22 Newsfront The Next Generation of Overpressure 13
Protection Overpressure protection is at the center of process safety
across all CPI sectors. As processes and technologies evolve, it is essential
that safety systems can adapt to provide the utmost levels of protection
.Technical and Practical 22
31 Facts at your Fingertips Avoiding Leaks in Bolted

Flange Joint Assemblies This one-page reference provides
information related to leaks in bolted flange joint assemblies, including design
considerations and installation tips
CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023 1

38 Engineering Practice Breaking New Ground: AI’s
Role in Biomanufacturing Advanced technologies employing
artificial intelligence (AI) and deep-learning models can reshape product
inspection and quality control in bioprocesses, but users must understand
both the capabilities and the limitations of such digital platforms for optimal
implementation
40 Solids Processing Preventing Dust Explosions with

Flow Analysis Dust collection systems are often designed using simple
rules of thumb that may not be sufficient for proper operation. Flow analysis
can ensure that the systems meet requirements
38
.Equipment and Services
24 Focus on Compressors, Fans and Blowers
Scroll compressors for sensitive work environments; Battery-driven
portable screw compressor; Reduce compressor surge risk with this valve
technology; Monitor rotating machinery with this dual-channel device; These
24 blowers are energy efficient with a small footprint; and more
26 New Products
New breather system for enhanced food safety; This new vacuum pump
optimizes operating conditions; A new gateway for secure communication
of field devices; New compact, variable-speed reciprocating compressors;
Comprehensive solutions for level measurement; and more
26 .Departments
4 Editor’s Page The hydrogen economy moves ahead
Discussion at the recent HydrogeNext conference focused on large-scale H2
projects, hydrogen-production technologies and operational best practices
48 Economic Indicators
Coming in Advertisers
November 44 Hot Products
46 Classified Ads
Look for: Feature 46 Subscription and Sales Representative Information
Reports on Valves;
47 Ad Index
and Heat Exchange; A
Focus on Industrial
Housekeeping; A
Facts at your .Chemical Connections
Fingertips on Milling; Follow @ChemEngMag on X
Newsfront articles
on Modular Construction; Join the Chemical Engineering Magazine
and ‘Turquoise’ H2; LinkedIn Group
New Products; Visit us on www.chemengonline.com for more
and much more articles, Latest News, New Products, Webinars, Test
your Knowledge Quizzes, Bookshelf and more
Cover design: Tara
Bekman
Cover photo: Courtesy
of Swagelok
2 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023

Pop-A-Plug® Tube Plugs
ASME PCC-2 Compliant Heat Exchanger Tube Plugging System
Trusted by chemical plants around the world as their preferred tube plugging solution, Pop-A-Plug Tube Plugs from Curtiss-Wright
are engineered for optimal performance throughout the life cycle of heat exchanger equipment. Simple hydraulic installation eliminates
welding and time-consuming heat treatments that can cause damage to tubes, tube sheet ligaments, and joints.
• No Welding Required
• Pressure Ratings Up to 7000 PsiG (483 BarG)
• Simple Hydraulic Installation
• Helium Leak Tight Seal to 1 x 10-10 cc/sec
• 100% Lot Tested to Ensure Unmatched Quality
• Wide Range of Sizes & ASME/ASTM Certified Materials Available
877.537.9120 l est-sales@curtisswright.com l cw-estgroup.com/ce-23

Editor s Page
EDITORS ART & DESIGN
The hydrogen economy moves ahead
H
DOROTHY LOZOWSKI TARA BEKMAN
Editorial Director Graphic Designer ydrogen is clearly one of the key drivers for decarbonizing
tzaino@accessintel.com
dlozowski@chemengonline.com industry and meeting crucial environmental objectives, as
GERALD ONDREY (FRANKFURT) PRODUCTION evidenced by the numerous announced projects and funding
Senior Editor
gondrey@chemengonline.com GEORGE SEVERINE initiatives across the globe. This point was further underlined
Production Manager
gseverine@accessintel.com at the third annual HydrogeNext conference, part of Experience Power
SCOTT JENKINS
Senior Editor INFORMATION Week, presented by Chemical Engineering and POWER (www.hydro-
sjenkins@chemengonline.com SERVICES genextevent.com). The event covered ongoing hydrogen projects, pro-
MARY PAGE BAILEY CHARLES SANDS duction technologies, operational best practices and much more.
Senior Associate Editor Director of Digital Development
mbailey@chemengonline.com csands@accessintel.com
GROUP PUBLISHER CONTRIBUTING EDITORS

Logistics, mobility and decarbonization
SUZANNE A. SHELLEY
Experience Power Week keynote speaker Tim Echols, commissioner of
MATTHEW GRANT
Vice President and Group Publisher, sshelley@chemengonline.com the Georgia Public Service Commission, highlighted hydrogen as one of
Energy & Engineering Group
mattg@powermag.com PAUL S. GRAD (AUSTRALIA) seven major trends in the energy world, emphasizing its importance in
AUDIENCE
pgrad@chemengonline.com
decarbonizing logistics and transport operations. “I really think the place
DEVELOPMENT TETSUO SATOH (JAPAN) to start with hydrogen fueling is in material-handling facilities. The low-
tsatoh@chemengonline.com
JENNIFER McPHAIL hanging fruit for hydrogen use is forklifts, followed by Class 8 heavy-duty
Senior Marketing Manager
jmcphail@accessintel.com
JOY LEPREE (NEW JERSEY)
jlepree@chemengonline.com
trucks,” he said. When compared to electrification for heavy-duty truck-
ing, Echols points out several benefits hydrogen offers. “Vehicle batteries
GEORGE SEVERINE
Fulfillment Director add weight, and with hydrogen you can refuel quickly and easily. With
gseverine@accessintel.com battery-electric trucks, you will have to sit and wait longer for charging.”
DANIELLE ZABORSKI Another key point was hydrogen’s decarbonization synergy with
List Sales: Merit Direct, (914) 368-1090
dzaborski@meritdirect.com
nuclear power generation. In a session focused on financial metrics of
hydrogen projects, Mike Kramer, vice president of growth and finance
EDITORIAL ADVISORY BOARD
at Constellation Energy Corp. (Baltimore, Md.; www.constellation.com)
JOHN CARSON
Jenike & Johanson, Inc.
JOHN HOLLMANN
Validation Estimating LLC
outlined the economics of integrating hydrogen and nuclear, pointing out
that electrolysis can be modularly ramped onto existing nuclear assets
DAVID DICKEY HENRY KISTER from the pilot stage through at-scale production, which allows iterative
MixTech, Inc. Fluor Corp.
cost reductions and quick production scaleup for new off-takers. As an
HEADQUARTERS example of a successful deployment of nuclear hydrogen production, he
40 Wall Street, 16th floor, New York, NY 10005, U.S.
Tel: 212-621-4900
detailed the Nine Mile Point nuclear plant in Oswego, N.Y., which started
Fax: 212-621-4694 up a nuclear-powered hydrogen plant in March 2023.
EUROPEAN EDITORIAL OFFICES
Zeilweg 44, D-60439 Frankfurt am Main, Germany Stabilizing the supply chain
Tel: 49-69-9573-8296
Fax: 49-69-5700-2484 As with any emergent technology, the production of “green” hydrogen via
CIRCULATION REQUESTS:
electrolysis comes with some uncertainty surrounding the supply chain
Tel: 800-777-5006 and delivered costs. In a session covering supply-chain considerations
Fax: 301-309-3847
Chemical Engineering, 9211 Corporate Blvd.,
for electrolyzers, Anthony DeOrsey, research manager for Cleantech
4th Floor, Rockville, MD 20850 Group (San Francisco, Calif.; www.cleantech.com) emphasized that pre-
email: clientservices@accessintel.com
cious metals, such as the iridium often used in electrolyzers, are not the
ADVERTISING REQUESTS: SEE P. 46
only bottleneck in the electrolyzer supply chain. Seemingly more abun-
CONTENT LICENSING dant, the nickel used in electrolyzers must also compete with growing
For all content licensing, permissions, reprints, or e-prints, please contact
Wright’s Media at accessintel@wrightsmedia.com or call (877) 652-5295
demand from lithium-ion battery manufacturers. Supply-chain concerns
notwithstanding, he also stated that the tax credits and other incentives
ACCESS INTELLIGENCE, LLC brought about by last year’s Inflation Reduction Act (IRA) will help enable
HEATHER FARLEY JONATHAN RAY a “faster track to economies of scale for renewable hydrogen.”
Chief Executive Officer Vice President, Digital
JOHN B. SUTTON TINA GARRITY The U.S. moves its hydrogen economy forward
Chief Financial Officer Vice President of Finance
Another highlight was a panel discussion on the regional Hydrogen
MACY L. FECTO DANIEL J. MEYER
Vice President,
Hubs in the U.S. vying for federal funding under the
Chief People Officer
Corporate Controller IRA. Representatives from four hubs discussed the
JENNIFER SCHWARTZ
Divisional President, STUART BONNER
unique benefits and challenges in implementing an
Industry & Infrastructure Vice President, overarching hydrogen economy in each particular re-
Marketing Operations
MICHAEL KRAUS
gion. The regional variation of industries served, as
Vice President, well as differences in production and transport infra-
Production, Digital Media & Design
structure and workforce considerations, illustrate the
9211 Corporate Blvd., 4th Floor
Rockville, MD 20850-3240
many avenues that the hydrogen economy may take
www.accessintel.com as more production capacity comes onstream. ■
Mary Page Bailey, senior associate editor
Chementator
A new electrolyzer system makes Edited by:
Gerald Ondrey
propane from CO2
E
lectrolyzers are typically associated 3-methylimidazolium-functionalized Mo3P CARBON CAPTURE
with the production of “green” hy- nanoparticles coated with an anion-ex- Membrane Technology and
drogen from water and renewable change ionomer. “The ionomer is a con- Research, Inc. (MTR; New-
electricity, but a new device bor- ductive polymer that suppresses the hy- ark, Calif.; www.mtrinc.com)
rows from traditional electrolyzer principles drogen and water in the system, which Carbon Capture announced
to convert CO2 into propane. Developed also has very good CO2 absorption prop- it has commenced con-
by a team of researchers from the Elec- erties, to deliver the CO2 efficiently to the struction of a large pilot plant
trochemical Energy Materials and Devices catalyst’s reaction region,” says Asadi. at the Wyoming Integrated
Laboratory (e2MDLab) at Illinois Institute Currently, the electrolyzer has been dem- Test Center (ITC) in Gillette,
Wyoming. When operational
of Technology (IIT; Chicago; www.iit.edu) onstrated in a proof-of-concept laboratory
in 2024, it will be the largest
led by chemical engineering professor Mo- model. While the current runs have used membrane-based capture
hammad Asadi, the team developed a new pure CO2 streams, the team believes that plant in the world.
catalyst material to target the production the system could handle streams as dilute MTR Carbon Capture will
of C3 products — using only CO2, water as 15% CO2 due to the system’s ability to operate out of ITC’s Large
and electricity as inputs — by optimizing readily uptake CO2 to the catalyst region. Test Center to collect CO2
the proton-electron transport reaction to “This is an ongoing project within the group, from fluegas produced by
ensure there was not excessive production and we are working with funding agencies Basin Electric’s Dry Fork Sta-
of co-reactants and byproducts. Since the to evaluate what is the minimum range of tion, a coal-based power
process consumes both water and CO2, CO2 we can handle,” adds Asadi. plant firing Powder River
Basin coal. The Wyoming ITC
and there is competition between Mohammad Asadi, IIT is one of the world’s largest
the two, it is crucial that more CO2 is post-combustion demon-
available in the system and less water. Water outlet stration-scale test facilities.
Excess water will lead to excess hy- MTR Carbon Capture will
drogen in the system and disrupt the Water inlet use its proprietary Polaris
balance of the proton-electron cou- polymeric membrane to
pling reaction that is required to bring capture more than 150
together carbon and hydrogen to form ton/d of CO2 at Dry Fork Sta-
propane, explains Asadi. tion. The process uses no
As reported in a recent issue of chemicals and requires little
water, making its approach
Nature Energy, at the heart of the Cathode to carbon capture cleaner
electrolyzer is a catalytic system com- Membrane
Anode and more environmentally
posed of a new material — 1-ethyl- friendly than conventional
solvent-based methods.
Scaled up facility under construction for The project is part of the
single-step, CO2-to-fuels process U.S. Department of En-
C
ergy’s large-scale pilot car-
onstruction is underway by half of F-T processes.” bon-capture program.
AIR Co. (Brooklyn, N.Y.; www. Key to the process is a proprietary cat-
aircompany.com) for a commer- alyst that consists of a mixture of earth- CHEMICAL LOOPING
cial demonstration plant capable abundant metals supported on alumina. The world’s largest chemical
of converting captured carbon dioxide into The catalyst is loaded into a fixed-bed re- looping combustion (CLC)
fuel-grade paraffins, as well as ethanol and actor into which the captured CO2 is intro- unit, constructed by a Sin-
methanol, in a single step. The facility will duced. The company has filed for a patent tef-led Chinese-European
project (CHEERS), is now in
be a larger version of a pilot plant the com- on its catalyst composition and production
its main testing phase, and
pany has been running for the past two method that mimics photosynthesis. results are expected in the
years in Brooklyn, N.Y. The reactor-catalyst system is capable of coming weeks. As part of
AIR’s power-to-liquids technology, known making paraffins in the range from hexane the project, a 3-MWth CLC
as AIRMade, is intended to be a single- to octacosane (C28), with the majority of demonstration unit was de-
step alternative for utilizing waste CO2 for products in the octane to eicosane (C20) signed and constructed in
production of hydrocarbon fuels and other range. Jet-A fuel consists of alkanes from Deyang City, China. Com-
industrial and consumer products. “Tradi- C8 to C18. The AIR Co. process also pro- missioned in May, the 50-m
tional chemistry for making hydrocarbons duces ethanol as a byproduct, from which high demonstration unit has
from CO2 involves the reverse water-gas the company has been making consumer two different configurations
for different fuels: petroleum
shift reaction to make carbon monoxide, products, including perfume and vodka.
coke and lignite coal. The
followed by Fischer-Tropsch [F-T] synthesis “By converting waste CO2 into fuels and goal is that the unit will be
to make hydrocarbons,” explains Stafford alcohols, we are able to establish a circu- able to convert a solid fuel
Sheehan, co-founder and chief technology lar process for making high-energy-density flow of up to 4 MWth into
officer of AIR. “Our technology can gener- fuels for aviation and other transportation steam, while achieving a
ate hydrocarbons in the size range suitable sectors that are not amenable to electrifi-
for aviation fuels with energy costs that are cation,” the company says. (Continues on p. 6)
Seawater electrolysis stabilizes and immobilizes
atmospheric carbon dioxide
S
eawater is being used in a new electrolysis struction and subsurface exploration. “Unlike other land-
scheme for carbon dioxide removal (CDR), while based direct-air capture technologies, this is functionally
also producing hydrogen as a byproduct. De- permanent CO2 removal. There is no ocean degassing
veloped by Equatic (Los Angeles, Calif.; www. caused by atmospheric CO2 removal. And unlike other
equatic.tech), the platform draws seawater into a closed ocean-based technologies, Equatic is able to measure,
electrolysis system, taking advantage of the pH differ- report and verify the CO2 drawdown within the boundar-
ence between the produced streams for efficient cap- ies of the plant, without requiring open-ocean measure-
ture and storage of atmospheric CO2 (diagram). “Split- ments,” adds Sanders.
ting the seawater into hydrogen and oxygen also creates The company recently published details of its compre-
two streams — one alkaline from the cathode side of the hensive methodology for verifying its CDR performance,
cell, and the other acidic from the anode side. The acidic using an array of sensors to provide continuous process
seawater is neutralized with crushed minerals to restore readings. Equatic currently operates two CDR plants in
its natural pH, and is returned to the ocean. The alkaline in Los Angeles and Singapore, each with 100 kg/d of
seawater stores carbon as a solid mineral before atmo- CDR capacity. “Our next plant will be commissioned in
spheric air is passed through to immobilize additional mid-2024 with a capacity of 10 tons/d,” says Sanders.
CO2 as dissolved bicarbonate ions. Finally,
the sequestered CO2 is returned to the ocean
as CaCO3,” explains Edward Sanders, chief
operating officer of Equatic. Proprietary elec-
trodes have been developed to prevent the
production of chlorine gas species in the cell.
This is a major breakthrough, says Sanders,
since the presence of Cl2 gas creates safety
issues and requires treatment with granular
activated carbon.
Using the ocean for CO2 storage holds
several benefits over other CDR methods,
explains Sanders, including the elimination of
costs associated with transport, pipeline con- Equatic
Taking graphene into the next dimension
G
carbon capture rate of 96%.
CLC technology features a metal raphene has been touted as that we can tune the material based on
oxide that loops between an air a “super” material, boasting how we operate the reactor. From what
reactor and a fuel reactor. In the ultra-high strength, super- we’ve seen, there are no other technolo-
air reactor, the metal oxide ab-
conductivity and many more gies able to deliver a three-dimensional
sorbs oxygen from the air. It then
goes into the fuel reactor, where
superlative properties, but, as a planar graphene material to the market. The real
this oxygen is used as an oxidizer two-dimensional material, its commercial differentiation lies in the ability to consis-
for the combustion process. The use has been limited in terms of reactiv- tently tune three-dimensional materials to
oxygen-depleted (or reduced) ity, since reactions can only occur at the exact specifications,” explains Norman.
metal then returns to the air reac- material’s edges. “With graphene, it’s not With the unique graphene structures
tor to absorb more oxygen, and highly tunable to the exact application that the technology can yield, Lyten is cur-
the process repeats. Using oxy- you want, so you’re often designing your rently pursuing three distinct application
gen instead of air in the combus- application around what graphene could areas: cathodes for lithium-sulfur batter-
tion process makes capturing do for it, versus designing the graphene ies; light-weighting and reinforcement for
and removing harmful particles
around what’s needed for the application,” thermoplastic composites; and advanced
from the resulting smoke much
easier. This is because when
explains Keith Norman, chief sustainabil- sensors and biosensors.
pure O2 is burned, the only major ity officer of Lyten, Inc. (San Jose, Calif.; Lyten is in the process of closing its Se-
end products are CO2 and water, www.lyten.com). Lyten has developed a ries B fundraising round, which includes
which are then easy to separate proprietary reactor technology to produce investment from leading automotive man-
through steam condensation. three-dimensional graphene (photo) at ufacturer Stellantis. Lyten currently oper-
However, producing pure O2 is scale from a methane feedstock, creating ates an automated pilot-scale manufac-
often expensive. CLC technology a new class of material that is more reac- turing line for graphene-enhanced Li-S
avoids this cost, as extracting the tive and tunable for a wider variety of ap- battery cells in San Jose, and has com-
oxygen already present in the air plications. Norman likens the production mercial partnerships in place to utilize its
is an inherent part of the process.
of three-dimensional graphene to crum- graphene in engineered composite-based
CHEERS is an international
project with nine partners from
pling and twisting a sheet of paper. “In our consumer products. Discussions are also
Europe and China: Sintef Energy reactor, bending and folding the material underway with a major tire manufacturer
Research (coordinator; Trond- increases the number of reactive sites by to employ flexible graphene-based sen-
orders of magnitude. Equally important is sors on the interior of tires.
(Continues on p. 8)
Adapt-ability
in mixing
ROSS Multi-Shaft Mixers are built for rigorous
applications that are highly viscous, temperature
sensitive or reactive. They also offer versatility for
low viscosity mixing and flexibility in shear input.
Independently-driven agitators can be engaged

in any combination, at a wide range of speeds,
for any interval of a batch. Closed systems, and
no bearings or seals within the product zone,
provide protection against contamination.
Dual and Triple Shaft agitator assemblies

are customized to your specific application,
with multiple options for configuration.
Call us to discuss the possibilities for
improving the efficiency of your process.
Sizes from ½ gal. to 3,000 gal. are available.
mixers.com/multi-shaft 600-gallon VM-600 model
mixers.com 1-800-243-ROSS

Immobilizing enzymes as a stable, active foam
R
heim, Norway; www.sin-
tef.no) and Sintef Industry, esearchers at the Karlsruhe Institute chips and dried, which causes the proteins
IFP Energies Nouvelles, of Technology (KIT; Germany; www. to polymerize and form a stable hexagonal
Tsinghua University, To-
kit.edu) have developed a new class lattice (photo). “These monodisperse all-en-
talEnergies, Dongfang
Boiler Group, Zhejiang
of materials — enzyme foams. Nor- zyme foams are three-dimensional porous
University, Politeknika mally, foaming modifies the enzyme structure networks consisting of biocatalytically active
Slaska and Bellona. It is and enzymes lose their biocatalytic activity. proteins exclusively,” Niemeyer says. The
funded by the E.U.’s Ho- The new protein foams, however, are said to stable hexagonal honeycomb structure of
rizon 2020 research and have “tremendous” stability and activity. the foams has a mean pore diameter of 160
innovation program, the To produce the protein foams, two dehy- µm and a thickness of the lamellae of 8 µm.
Chinese Ministry of Sci- drogenase enzymes are mixed, which carry In industrial biocatalytic processes, en-
ence and Technology and matching sites to spontaneously form a zymes have to be immobilized in large quan-
industry partners. stable protein network. “Then, a gas flow is tities under the most gentle conditions in
added to this mix in a microfluidic chip for the order to maintain their activity. Up to now,
MICROWAVE SMR controlled formation of microscopic bubbles enzymes have been immobilized on poly-
In late August, Nu:ionic
Technologies, Inc. (Fred-
of uniform size,” explains Christof Niemeyer, mers or carrier particles. However, these
ericton, Canada; www. professor at the KIT’s Institute for Biologi- require valuable reactor space and enzyme
nuionic.com) entered cal Interfaces 1. The foam with the uniform activity may be reduced. “Compared to our
into a memorandum- of- bubble size is applied directly onto plastic ‘all-enzyme hydrogels,’ the new foam-based
understanding (MoU) materials have a far larger surface area on
commercial agreement KIT which the desired reaction can take place,”
with Liberty Utilities (New Niemeyer points out. Also, the newly de-
Brunswick, Canada; www. veloped enzyme foams are far more stable
libertyenergyandwater. after drying for four weeks than the same
com) for the development
enzymes without foams, he says.
of a 2,400-kg/d hydrogen-
production system utilizing
The researchers used the foams to produce
Nu:ionic proprietary Mi- tagatose, which is a promising alternative to
crowave Catalytic Reform- refined sugar. The achievement is described in
ers (MCRs). This is the first a recent issue of Advanced Materials, and a
commercial application patent application has been filed.
of Nu:ionic’s on-site, on-
demand H2-production
technology, which uses
Unlocking the commercial feasibility of
microwave energy to de- graphene-based water sensors
A
carbonize natural gas with
new, non-intrusive screening compromise the sensors, and performance
electrified reforming. The
proposed facility is sched-
method developed by researchers problems will be further exacerbated with
uled to be in operation in from the Pritzker School of Molec- exposure to water.
the first half of 2025. ular Engineering (PME) at the Uni- “Typically, quality control for this type of
Nu:ionic’s proprietary versity of Chicago (pme.uchicago.edu), as device involves measuring its electrical
process technology will well as Argonne National Laboratory (Lem- characteristics, such as transport curves
be used to generate low- ont, Ill.; www.anl.gov) and the University and current-voltage [I-V] curves, but in
carbon H2 at low cost, of Wisconsin-Milwaukee (www.uwm.edu), many cases, this is not enough. Even if you
for blending into Liberty’s shows promise for scaling up commercial have very uniform curves, these sensors
natural-gas-distribution production of a special class of graphene- may not necessarily demonstrate corre-
system and clean power
based water sensors. The sensors are tai- sponding sensing performance. You need
generation and fuel pro-
duction for zero-emission
lored for the detection of lead, mercury and to also look into the quality of the dielectric
fuel cell electric vehicles. E. coli in flowing water down to the parts- layer to make sure we find uniform sensing
The MCR design includes per-billion (ppb) or colony-forming unit (cfu) responses beyond just the pure electrical
a carbon-capture system concentration. “The graphene sensors are transport measurements,” explains Chen.
to produce readily trans- coated with a layer of aluminum oxide. To The new approach developed by Chen’s
portable liquid CO2. achieve the selectivity or specificity of the team identifies high-performing devices by
Nu:ionic’s MCRs elimi- detection, we use gold nanoparticles with scanning with A.C. voltage at a wide range
nate the need for fuel com- capturing functional groups on top of this of frequencies to measure its impedance
bustion, greatly reducing dielectric layer,” explains PME professor response. “We can find the specific thresh-
the amount of feedstock
and Argonne’s lead water strategist Jun- old to differentiate good devices from bad
required to produce H2
and significantly reducing
hong Chen. However, a hurdle in com- devices by looking at the ratio of the ca-
greenhouse gas emis- mercializing these types of functionalized pacitive and resistive impedance compo-
sions, while also allowing field-effect-transistor (FET) sensors is the nents,” says Chen. Furthermore, he says,
for the efficient use of re- difficulty in quality assessment, since the this screening method can also indicate if
newable electricity to re- sensors are just a few nanometers thick. there is a need to tune the manufacturing
duce the carbon footprint When there is porosity present in the dielec- recipes used for the dielectric layer depo-
of the natural gas grid. The tric layer, electrical charge can accumulate, sition, giving an opportunity to potentially
or even travel through the layer, which will improve manufacturing yield.
(Continues on p. 9)
Piloting a chemical-recycling process for MCR process uses approximately 30% less
polycarbonate plastics natural gas as compared to conventional
reformer methods (for more on methane re-
C
forming, see Newsfront on pp. 13–17).
ovestro AG (Leverkusen, by 2050. The mechanical recycling
Germany; www.covestro. process is used whenever waste ETHANOL-TO-SAF
com) has developed a che- streams are sufficiently pure and the
Last month, Lummus Technology LLC
molysis process for recy- recycled polycarbonate meets the
(Houston; www.lummustechnology.com)
cling polycarbonate back into mono- requirements profile of the future ap- announced the commercial availability of
mers. In laboratory trials, the process plication. The new chemical-recycling its ethanol-to-SAF (sustainable aviation fuel)
has been shown to recycle waste process complements mechanical process technology. The technology provides
streams with more than 50% poly- recycling, converting the plastic back operators with a large-scale, commercially
carbonate content into monomers, into monomers, which can be sepa- demonstrated solution to reduce the aviation
closing the loop to a direct polycar- rated and serve as raw materials for industry’s greenhouse gas emissions.
bonate precursor. The technical im- future plastic. Chemical recycling can Lummus’ ethanol-to-SAF technology in-
plementation of chemical recycling therefore make larger waste streams tegrates ethanol-to-ethylene (EtE), olefin
is now beginning on a pilot scale at that are unsuitable for mechanical oligomerization and hydrogenation tech-
nologies in a process configuration that
Leverkusen, where the process will processes accessible for recycling.
maximizes the final yield to SAF while mini-
be further optimized and will undergo The company is investigation three mizing capital and operating costs, and car-
further development. The pilot plant alternative recycling routes, includ- bon emissions, the company says. Central
(kilogram scale), to be located in ing enzymatic depolymerization and to this process is Lummus and Braskem’s
Leverkusen, will operate in a semi- “smart depolymerization,” a special- technology partnership for producing green
continuous manner, with startup ized and energetically optimized py- ethylene, which accelerates the use of bio-
planned for 2025–2026. The com- rolysis process, the company says. ethanol and supports the industry’s efforts
pany is investing “millions of euros” Unlike conventional pyrolysis, which towards a carbon-neutral economy. Since
over the next few years. breaks plastic waste down to smaller 2010, Braskem has been operating an
Mechanical recycling of polycar- molecules, the smart pyrolysis tar- ethanol dehydration unit in Brazil. Using EtE
EverGreen technology, the unit provides a
bonate is already an important com- gets high-value molecules that can
proven and reliable foundation for produc-
ponent of Covestro’s recycling strat- be directly used in the production of
egy, which aims to be fully circular new polymer. (Continues on p. 10)
CHEMCAD process
simulation software
can’t get kids to eat
their veggies.
But it can take a lot of
tasks off your plate.
CHEMCAD models your toughest processes, runs
on your local computer or your global network
and is backed by a global network of support
resources. Contact us today for a free trial.
CHEMSTATIONS.COM/VEGGIE15
ChemE’s
HAVE A NEW
Discover CHEMCAD NXT –
SUPER The evolution of simulation software
HERO.

23-CMS-9119 CE NXT Veggie 7x4.875 Sept.indd 1 9/5/23 1:10 PM
Solar cells integrated into car hoods
I
ing 260,000 ton/yr of ethylene from
n recent years, some car manufac- occur due to the curved surface area, ethanol. Lummus has integrated
this world-scale dehydration pro-
turers have developed vehicles that and to maintain the overall integrity of
cess with its light-olefins oligo-
integrate photovoltaic cells into the the hood structure.” merization and advanced hydro-
roof — the easiest surface to use for The researchers constructed their processing technologies through
onboard solar-power generation. Now, prototypes using a selection of com- Chevron Lummus Global, a joint
researchers at the Fraunhofer Institute mercial solar cells (IBC, PERC shingle, venture with Chevron.
for Solar Energy Systems (Fraunhofer and TOPCon shingle). In principle, any
ISE; Freiburg, Germany; www.ise. solar cell technology can be used. The LOW-CARBON CEMENT
fraunhofer.de) have now gone one step 115-W rated vehicle-hood prototype Last month, Terra CO2 Technol-
further. As part of two publicly funded exhibited at IAA Mobility features more ogy (Golden, Colo.; www.ter-
research projects, they have integrated than 120 PERC shingle solar cells and raco2.com) entered into a definitive
solar cells into the standard sheet- is finished in MorphoColor gray. agreement with Asher Materials
metal hood of a regular passenger car. Together with partners from industry, (Southlake, Tex.; ashermaterials.
Coupled with ISE’s MorphoColor tech- Fraunhofer ISE developed the patented com) for an exclusive market li-
nology, the solar-active surface can be MorphoColor interface, which gives cense of Terra’s first commercial-
scale advanced processing facility.
color-matched to that of the vehicle. photovoltaic modules an intense color,
Under the agreement, Asher Mate-
The technology was introduced last while maintaining at least 90% of their rials will acquire the plant, based in
month at the IAA Mobility tradefair in efficiency. Besides cars, the technol- the Dallas-Fort Worth, Tex. market,
Munich, Germany (September 5–11). ogy can be used in building-integrated after construction and commis-
“We applied the solar cells to the hood photovoltaic systems for colorful fa- sioning are complete. The plant will
panel of a car model that is frequently cades or brick-red roofs. The Morpho- produce 240,000 ton/yr of OPUS
sold in Germany, interconnected them Color interface is a photonic structure Supplementary Cementitious Ma-
and laminated them with film,” explains in which an interference layer is com- terial (SCM), which can substitute
Martin Heinrich, coordinator for PV bined with a geometrically structured up to 40% of Portland cement in
mobility at Fraunhofer ISE. “To achieve substrate in such a way that a particu- common concrete mixes and sig-
nificantly reduce CO2 and NOx pol-
this, the lamination process was opti- larly narrow-band reflection maximum
lution in the cement industry (Chem.
mized to minimize air pockets, avoid results. The module design is inspired
Eng., September 2022, p. 10). ❐
wrinkling of the film module, which can by the Morpho butterfly. n

Business News
Plant Watch LG Chem to expand RO membrane
manufacturing capacity
LINEUP
OCI Global to double U.S. production
August 28, 2023 — LG Chem Ltd. (Seoul, AIR LIQUIDE
capacity for ‘green’ methanol
September 14, 2023 — OCI Global N.V. South Korea; www.lgchem.com) announced ALBEMARLE
(Amsterdam, the Netherlands; www.oci- that it is spending 124.6 billion won ($94.1
ANDRITZ
global.com) plans to double its green-methanol million) over the next two years to expand the
production capacity to approximately 400,000 manufacturing facility for its key filter-membrane BASF
metric tons per year (m.t/yr) in Beaumont, elements used in water desalination. The facility,
DUPONT
Tex. The scaleup plans include entering into located in Cheongju, South Korea, will have
supply agreements for renewable natural gas an annual production capacity of 400,000 ENI
(RNG). This will be OCI’s first upstream RNG reverse osmosis (RO) membranes, enough
EVONIK
production facility. Production is slated to to desalinate 1.57 billion m.t./yr of seawater.
start in 2025. FLUOR
Sumitomo Chemical to begin mass LG CHEM
Air Liquide announces investment in production of ultra-fine alumina
green-hydrogen production capacity August 28, 2023 — Sumitomo Chemical OCI GLOBAL
September 14, 2023 — Air Liquide S.A. (Paris, Co. (Tokyo, Japan; www.sumitomo-chem. REPSOL
France; www.airliquide.com) is investing co.jp) is set to begin mass production of ultra-
over €400 million for the construction of its fine α-alumina using a recently developed SABIC
200-MW Normand’Hy electrolyzer project. This manufacturing technology. The new ultra- SINOPEC
electrolyzer will deliver low-carbon hydrogen to fine alumina products are characterized by
homogeneous particles with a particle size SUMITOMO CHEMICAL
TotalEnergies’ petroleum refinery in Gonfreville,
France starting in 2026. of 150 nm or less. TECHNIP ENERGIES
TEIJIN
Evonik expands production capacity for Andritz starts up carbon-capture plant at
precious-metal powder catalysts in China Voestalpine steel mill in Austria VERSALIS
September 12, 2023 — Evonik Industries August 21, 2023 — Andritz AG (Graz, Austria; VOESTALPINE
AG (Essen, Germany; www.evonik.com) has www.andritz.com) supplied its first carbon-
completed the relocation and expansion of capture plant to the steel industry. The pilot
its precious-metal powder catalyst plant in plant started operating at Voestalpine’s steel
Shanghai Chemical Industrial Park (SCIP) in mill in Linz. The plant separates CO2 from the
China. Production is scheduled to commence fluegases resulting from iron making using an
in late 2023. With this new plant, Evonik has amine-based process. The captured CO2 is
completed the upgrade of its global network being delivered to an Austrian energy-storage
of five precious-metal catalyst plants. company that is investigating new ways of
making it available for reuse in steel production.
Sabic and Sinopec start up
PC plant at JV site in China Mergers & Acquisitions
September 5, 2023 — Sabic (Riyadh, Saudi LG Chem and Eni exploring a joint
Arabia; www.sabic.com) and China Petroleum biorefinery in South Korea
& Chemical Corp. (Sinopec; Beijing; www. September 14, 2023 — LG Chem and Eni
sinopecgroup.com) began the commercial S.p.A. (Milan, Italy; www.eni.com) jointly
operation of a new polycarbonate (PC) plant announced that they are exploring developing
at their 50-50 joint venture (JV) site, Sinopec and operating a new biorefinery at LG Chem’s
Sabic Tianjin Petrochemical Co. (SSTPC). Daesan chemical complex. Final decision for
The new PC plant has a designed capacity of the investment is scheduled by 2024 and
260,000 m.t./yr. SSTPC’s site also includes the plant will be completed by 2026. The
a mega-scale petrochemicals complex that proposed biorefinery would be designed to
produces polyethylene and polypropylene. process approximately 400,000 m.t./yr of
bio-based feedstocks.
BASF begins construction of
syngas plant in Zhanjiang, China Repsol sells Canadian
September 5, 2023 — BASF SE (Ludwigshafen, oil-and-gas assets for $468 million
Germany; www.basf.com) has commenced September 12, 2023 — Repsol S.A. (Madrid,
construction of its syngas plant at the Verbund Spain; www.repsol.com) has agreed to sell
site in Zhanjiang, China. This world-scale syngas its oil-and-gas assets in Canada to Calgary-
facility is scheduled to start up in 2025. The based firm Peyto Exploration & Development
production technologies deployed in the for $468 million (approximately €433 million)
syngas plant will mainly utilize CO2 offgas, a as part of its ongoing portfolio management.
byproduct of the ethylene oxide process, and The agreement encompasses all the mineral Look for more
excess fuelgas from steam-cracker operations rights, related facilities and infrastructure of latest news on
to manufacture syngas. Repsol’s Canadian oil-and-gas business, chemengonline.com
including the assets in the Greater acquire a 100% shareholding in AlRajhi developing a technological platform
Edson area in Alberta, which has a net Steel Industries Co., in exchange for for the advanced chemical recycling
production capacity of 23,000 bbl/d. newly issued shares in Hadeed. of plastic waste. This collaboration
Repsol retains operations in Canada aims to create a completely circular
through its St John LNG facility. Albemarle confirms plans to plastic-recycling loop, producing new
acquire minerals firm Liontown polymers that are identical to polymers
Fluor sells Stork business September 5, 2023 — Albemarle Corp. derived from fossil-based materials.
in Europe to Bilfinger (Charlotte, N.C.; www.albemarle.com)
September 7, 2023 — Fluor Corp. confirmed that it will be working toward Teijin to sell its GH Craft
(Irving, Tex.; www.fluor.com) agreed the execution of a binding agreement composites business in Japan
to sell its Stork business in Belgium, to acquire battery-minerals company September 1, 2023 — Teijin Ltd. (Toyko,
Germany and the Netherlands, as well Liontown Resources Ltd. (West Perth, Japan; www.teijin.com) has agreed
as its turbo-blading manufacturing Australia; www.ltresources.com.au). to sell its entire stake in GH Craft Co.,
operation in the U.S., to Bilfinger SE Albemarle’s proposal values Liontown a subsidiary of Teijin’s composites
(Mannheim, Germany; www.bilfinger. at $4.3 billion (A$6.6 billion) on an business in Japan, to TIP Composite
com). Stork mainly offers services in equity value basis. Liontown currently Co., a manufacturer headquartered in
the areas of maintenance, modification controls two major lithium deposits. Matsumoto City, Japan. Teijin acquired
and asset integrity. GH Craft in July 2008.
Technip Energies and Versalis
Sabic sells its Hadeed combine recycling technologies DuPont to divest 80% ownership
iron and steel business September 1, 2023 — Technip in acetal homopolymer business
September 7, 2023 — Sabic has Energies N.V. (Paris, France; www. August 21, 2023 — DuPont (Wilmington,
announced that Saudi Arabia’s Public technipenergies.com) and Versalis Del.; www.dupont.com) announced a
Investment Fund (PIF) signed a share S.p.A. (San Donato Milanese, Italy; definitive agreement to sell an 80.1%
purchase agreement to acquire a 100% www.versalis.eni.com), Eni’s chemical ownership interest in the Delrin acetal
shareholding in the Saudi Iron & Steel company, have signed an agreement homopolymer business to TJC LP (New
Co. (Hadeed), currently owned by Sabic. aimed at integrating Versalis’ Hoop York, N.Y.) in a transaction valuing the
Based on a cross-conditional share- and Technip Energies’ Pure.rOil and business at $1.8 billion. ■
exchange agreement, Hadeed will also Pure.rGas purification technologies by Mary Page Bailey
12
ac24_Chemical_Engineering_206,4x142,9.indd 1
CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM
03.07.2023 13:27:18
OCTOBER 2023
Newsfront
Methane Reforming:
Solving the Hydrogen Blues
Improved catalysts and reconfigured reformer designs make steam-methane reforming the
most scalable, industry-ready source of ‘blue’ H2
F
or many decades, steam-methane conventional reforming technologies, but IN BRIEF
reforming (SMR) has been, and still combined with carbon capture, utilization IMPROVED SMR
is, the technology of choice for the and storage (CCUS). EFFICIENCIES
large-scale production of synthesis
BLUE HYDROGEN
gas (syngas; a mixture of H2 and CO), which Improving SMR efficiencies
is used for making a large number of chemi- A first step for reducing CO2 emissions from AUTOTHERMAL
cals, including ammonia, methanol, acetic SMR (or any process) is to improve the over- REFORMING
acid, liquid fuels and more. When only H2 all efficiency. One example of a new-gener- OTHER NEWS
is desired, such as for ammonia production, ation SMR developed by Air Liquide Engi-
steel making and petroleum-refining appli- neering & Construction (Frankfurt, Germany;
cations, the CO in the syngas is “shifted” www.engineering-airliquide.com) is SMR-X
to CO2 using the water-gas shift reaction technology. SMR-X is a new type of reformer
(WGSR). In the past, the CO2 produced that produces H2 without excess steam, a
from SMRs — both from the burning of fuel byproduct that is declining in demand from
to heat the reformer tubes and the product users. Compared to conventional steam
from the reforming reaction — has been, for methane reforming, SMR-X features higher
the most part, released to the atmosphere. thermal efficiency at low steam co-produc-
Now, with goals to reduce the global tion ratios and emits less CO2.
emissions of greenhouse gases (GHGs) tak- Some of the notable advantages of this
ing center stage, efforts are underway to next-generation reforming technology are
generate H2 with a low carbon footprint. As increases in the overall yield of the H2 pro-
a result, there has been a growing interest duction process by roughly 5%, together with
in water electrolysis as a source for “green” an intrinsic reduction of CO2 emissions (pre-
hydrogen. However, electrolyzers are still capture) of 5%, making it a reforming process
expensive, are not scalable to meet the with a significantly reduced carbon footprint.
large demands for H2, and the availability In combination with Air Liquide’s CO2-
of a reliable, inexpensive source of “green” capture technologies, like Cryocap, the
electricity to run them is still not a reality. SMR-X technology route can provide the
Until these issues hampering the shift to lowest carbon intensities and highest con-
green H2 are addressed, the medium-term version efficiencies, making it a key pillar for
solution is “blue” hydrogen — H2 made by the energy transition and decarbonization
projects, unlocking attractive H2 routes for
Air Liquide small- and medium-production capacities,
says the company.
Air Liquide has been operating an indus-
trial-scale plant (Figure 1) with this technol-
ogy in Antwerp, Belgium since April 2021
and is said to be the first industrial-size
greenfield recuperative-reforming plant in
the world. The SMR-X technology is cur-
rently selected in many ongoing low-carbon
H2 concept and technology studies, as well
as projects advancing to the front-end engi-
FIGURE 1. This plant in Antwerp, Belgium is the first to use neering and design (FEED) stage.
Air Liquide's SMR-X process. The plant started up in 2021 Catalyst developments are also leading

Clariant
centric tubular structure and a tailor- catalyst’s high activity and low pres-
made structured catalyst, which can sure-drop leads to lower operating
be applied as a simple drop-in solu- costs, increased profit margins and
tion in existing or new reformer tubes. reduced energy usage, Topsoe says.
This unique setup results in superior Meanwhile, “there has been an in-
heat recovery, higher throughput, crease and more volatility in natural
and significantly lower pressure drop gas prices,” says Ken Chlapik, mar-
compared to conventional SMR. ket manager, Low Carbon Solutions,
EARTH can reduce CO2 emissions Johnson Matthey plc (London, U.K.;
FIGURE 2. Clariant Catalysts' ReforMax LDP Plus
SMR catalyst is said to provide a lower pressure by up to 10% and increase capacity www.matthey.com). “This has in-
drop than its predecessors by up to 20% compared to conven- creased the interest in pre-reforming
tional SMR. EARTH has been suc- applications, for which Johnson Mat-
to improved SMR efficiencies. For cessfully implemented at Ak-Kim’s they has developed Katalco 65-3X.
example, BASF SE (Ludwigshafen, syngas plant in Turkey, resulting in This catalyst provides the same feed-
Germany; www.basf.com) devel- fuel savings of 38%, higher radiant stock flexibility as other pre-reforming
oped the Synspire G1-110 catalyst, efficiency, lower steam export, and catalysts, enabling it to operate with
which reduces the steam demand 20% lower CO2 emissions. With the a range of feeds, including ROG
for SMR (steam-to-carbon ratio addition of process and fluegas car- [refinery offgas], natural gas, LPGs
down to 1.5) and maximizing the bon capture and other synergistic [liquefied petroleum gas] and naph-
utilization of CO2. BASF’s new for- design changes, such as increased thas, however the catalyst uses new
mulation is said to increase the cok- reaction severity to maximize hydro- proprietary promotors to provide en-
ing resistance of the catalyst. Com- carbon conversion and supplemental hanced thermal stability. This enables
pared to standard SMR processes, hydrogen firing, a CO2 footprint re- the retention of a high catalyst activ-
the new catalyst can save up to 5% duction of more than 99% is achiev- ity deeper into the operating cycle,
of operating costs, up to 3% of in- able, says Clariant Catalysts. thereby enabling plants to confidently
vestment costs and decrease the Clariant also notes that, in the move to longer changeout cycles.”
CO2 emission of the process by up case of fluegas carbon capture, re- Also, because of higher natural gas
to 13% by reducing demand for fuel, cuperative reforming brings signifi- prices, investment in new large plants
steam and electricity, BASF says. cant advantages, because it directly has been scaled back and hence a
Last month, BASF began con- translates into a smaller energy con- shift to smaller projects including the
struction on its syngas plant at the sumption and capital investment for revamp of existing units, Chlapik con-
Verbund site in Zhanjiang, China. the carbon-capture unit. tinues. “Structured catalysts, such as
Scheduled to start up in 2025, the By investing in R&D and perform- Catacel SSR, provide a perfect option
new plant will produce syngas and ing fundamental studies of the differ- for a low-cost means to improved ef-
H2 using “unique process concepts” ent carrier systems and their proper- ficiency and intensification of existing
to reduce CO2 emissions, compared ties, Topsoe A/S (Lyngby, Denmark; SMR. The structured form of Catacel
to conventional syngas plants, the www.topsoe.com) developed a new SSR provides a step change in per-
company says. and more robust carrier system, formance, where fundamental sci-
Meanwhile, Clariant (Pratteln, which forms the basis for its Titan ence limits further improvements in
Switzerland; www.clariant.com) re- series of steam-reforming catalysts. the design of randomly packed pel-
cently introduced its new generation The Titan series of SMR catalysts, lets. The structured catalyst is higher
of ReforMax LDP Plus catalyst for- launched in 2020, is said to offer im- in voidage and GSA [geometrical
mulation (Figure 2) with high activity proved performance and longer cat- surface area], thus providing a higher
and 20% pressure-drop reduction. alyst lifetime thanks to the hibonite- activity, but at a lower pressure drop.
The reduced pressure-drop, without rich composition. Prior to the launch, The catalyst is also designed to ac-
penalty on performance, leads to selected users experienced benefits tively disrupt the boundary layer at
lower overall compression needs for of the Titan series, including 8% re- the inner of the reformer catalyst tube
the H2 product gas and, hence ap- duction in pressure-drop and 25%
preciable energy savings, says Clari- higher catalytic activity when com-
ant Catalysts. pared to conventional catalysts avail-
In addition, Technip Energies N.V. able on the market.
(T.EN; Zoetermeer, the Netherlands; The hibonite-rich composition of
www.technipenergies.com) and the catalysts provides a remarkable
Clariant have introduced a new heat- performance boost, which becomes
recuperative reformer concept called especially evident after long opera-
enhanced annular reforming tube tion. The addition of titanium pro-
for hydrogen (EARTH, a tradename moters adds exceptional mechanical ZoneFlow Reactor
Technologies
of T.EN) to improve the efficiency, strength while a seven-hole cylindrical
capacity and sustainability of SMR. shape yields both a very low pressure FIGURE 3. Pilot trials have sucessfully been com-
EARTH consists of an innovative con- drop and a high surface area. The pleted on ZoneFlow's structured SMR catalyst

by jetting the process gas towards this ready-now technology can play blue H2. These innovative engineer-
it, thus increasing the heat transfer a major role in the energy transition ing designs have made it possible
coefficient. Together these features as refineries look to burn hydrogen to capture 95% or more of the CO2
have provided our customers a 15% instead of natural gas to lower their from SMR units, compared to 60%
performance/throughput benefit, as carbon emissions.” achievable in older designs. As a
well as a 15% saving in required firing result, “blue hydrogen is the most
fuel over a full catalyst lifecycle,” says Blue hydrogen scalable and readily available low-
Chlapik (Catacel SSR technology In addition to improvement in en- carbon hydrogen technology on the
was a finalist for the 2019 Kirkpatrick ergy efficiency, SMR technology market right now,” according to a
Chemical Engineering Achievement providers have also been busy de- recent podcast of the John Wood
Award; see Chem. Eng., January veloping new concepts for making Group plc (Wood; Aberdeen, Scot-
2020, pp. 23–26).
In a related development, Hon-
eywell UOP LLC (Des Plains, Ill.;
uop.honeywell.com) and ZoneFlow
Reactor Technologies, LLC (ZFRT;
Windsor, Conn.; zoneflowtech.com)
successfully conducted pilot plant
testing of the ZoneFlow Reactor (Fig-
ure 3) in ZFRT’s large-scale pilot plant
at Université Catholique de Louvain
in Louvain-la-Neuve, Belgium. The
near-commercial-level testing vali-
dated increased steam reforming
capacity by at least 15% in terms
of feed flow compared to conven-
tional state-of-the-art pellets, with
no higher methane slip and without
increasing the maximum tube skin
temperature or pressure drop. This
increased production of hydrogen
allows for the SMR to convert hydro-
carbon feeds, such as natural gas or
naphtha, and steam into syngas.
In 2021, the two companies signed
a joint development agreement to
grow and commercialize the Zone-
Flow Reactor technology (Chem.
Eng., December 2021, p. 5). This
technology can provide a significant
improvement in the productivity and
cost-effectiveness of SMR for H2 and
syngas production. “The combina-
tion of Honeywell’s domain expertise
and ZoneFlow’s reactor technology is
geared to provide high value creation
for both new and existing SMR units.
There are over 800 SMRs world-
wide for H2 generation and a similar
number employed for ammonia and
methanol production. The successful
testing can allow for significant capi-
tal savings for new steam methane
reforming plants and higher produc-
tivity for existing plants,” says Ted Fa-
iella, vice president and general man-
ager of Equipment, Honeywell UOP
Process Technologies. “As Zone-
Flow’s reactors can increase hydro-
gen production with existing assets,

Johnson Matthey Isothermal
GHR ATR temperature CO2 relatively high pressure and purity.
Removal
Steam shift
CO2 export to This removal can be done with well-
H2
O2
storage established CO2 separation tech-
Natural Pressure swing
absorption
nologies and requires significantly
gas
Hydrogen smaller and, therefore, cheaper
export
equipment. “Process side removal
can be done in a conventional SMR,
Purification Balance but would only provide CO2 reduc-
Saturator gas to
fuel tions of around 50–60% as it misses
Water Process the additional combustion CO2, he
condensate
says. “In an ATR-based flowsheet,
FIGURE 4. Johnson Matthey’s LCH GHR-ATR flowsheet is said to be adept at producing hydrogen with very this technique can enable CO2 re-
low CO2 emissions
ductions of up to 99%.”
land; www.woodplc.com). quested from customers either This means to produce CCS-
Last year, Wood introduced its included CO2 capture or were partly enabled blue hydrogen, where re-
BlueSMR technology, which re- fed by biogenic feedstock, so low ducing the maximum amount of
volves around the company’s ter- carbon, the company says. Air Liq- CO2 will be key to meeting stringent
race-wall reformer, the core of its uide is involved in a multitude of carbon-intensity standards, ATR-
hydrogen technology, says Richard SMR-based, low-carbon H2 studies, based flowsheets are a better fit
Spires, director of Technology De- many of them moving towards FEED than SMR. Johnson Matthey’s Ad-
velopment at Wood. “With this tech- or project implementation phase. vanced Reforming technologies in-
nology, there is an even distribution One example is Air Liquide and clude ATR and gas-heated reform-
and good control over how the heat TotalEnergies SE (Courbevoie, ing (GHR), which are optimal for
reaches the reformer, and is the France; totalenergies.com) conver- low-carbon hydrogen production. In
driver for improved efficiency,” he sion of TotalEnergies’ Grandpuits particular, Johnson Matthey’s LCH
explains. “For the reaction of steam site into a biorefinery to produce GHR-ATR flowsheet (Figure 4) is
and methane to give syngas, SMR and valorize renewable and low- adept at producing hydrogen with
is the closest to the thermodynamic carbon H2. This H2-production unit very low CO2 emissions. The ex-
optimum,” he says. (20,000 m.t./yr capacity) will partly ceptional efficiency of this flowsheet
A second point is integrating pre- use biogas from the biorefinery built means it uses 10% less natural gas
combustion carbon capture with by TotalEnergies, and also leverage per unit of hydrogen compared to
Wood’s gas-heated reactor (GHR) Air Liquide’s Cryocap carbon-cap- an SMR and therefore produces
design. “When done properly, it is ture technology. These innovations less CO2 to be stored, which also
possible to achieve greater than will prevent emissions amounting to enables a lower levelized cost of hy-
95% carbon capture.” 150,000 metric tons of CO2 a year drogen, Chlapik says.
Wood offers three variants of its compared to current processes, the The high efficiency of the LCH
BlueSMR technology: BlueSMR, company says. process originates from the use of a
which introduces a number of up- GHR, which reduces the amount of
grades including pre-combustion Autothermal reforming combustion needed for the conver-
carbon capture, a GHR and a pre- Conventional SMR utilizes a fired sion of hydrocarbons and minimizes
reformer to significantly enhance unit heater to produce the energy that the size of thermal gradients in the
performance. Hydrogen-rich gas fir- enables the reaction to take place. flowsheet by transferring heat back
ing will also displace the CO2 emis- This fired heater combusts natural into endothermic reforming reactions
sions from the combustion side of the gas and creates a low-concentration in the GHR rather than eroding high-
process; BlueSMR+, which is similar stream of CO2 at atmospheric pres- grade energy by using it for steam
to the previous option, but with an sure. Although this can be captured, production. By doing this, the funda-
improved catalyst-tube geometry it requires large and expensive equip- mental energy efficiency of the flow-
in the reforming furnace, potentially ment and is harder to capture than sheet is maximized, Chlapik explains.
leading to reduced operating costs; CO2 at process pressure, explains According to Air Liquide, ATR
BlueSMRp, which involves installing JM’s Chlapik. technology is particularly suitable
a separate, parallel H2-production In comparison, autothermal re- for large capacities, whereby smaller
unit with pre-combustion carbon former (ATR) technologies use oxy- capacities tend to favor SMR. The
capture to provide low-carbon fuel gen to drive the reforming reaction company sees clearly in the market
for the existing unit; and BlueSMRe, instead of burning natural gas in a strong interest for ATR technol-
which integrates renewable electric a fired heater, Chlapik continues. ogy for these larger-scale projects,
power to decrease fuel consumption This means in an ATR, there is not mainly driven by the following:
and CO2 production. a separate low-concentration and • Project capacities — often ex-
In the past two years, approxi- low-pressure CO2 stream from natu- ceeding SMR single-train capacities
mately 90% of Air Liquide’s SMR- ral gas combustion and CO2 can be • Ease of decarbonization of ATR
based studies and projects re- removed from the process side at process (simpler decarbonization via
a single pre-combustion capture unit) capture technology, the KBR and Air hydrogen production with up to 99%
• Large-scale low-carbon H2 and Liquide technology solution will allow carbon-capture rate.
NH3 co-production schemes, where users to achieve “outstanding” en- “Our partnership with Casale
an ATR-based setup is the most ergy efficiency and reliability, a simpli- means that Technip Energies, as a
competitive route fied single-train production process, top-tier player with advanced ATR
However, there is still a strong and up to 99% carbon capture in a and SMR technologies, can provide
market demand for SMR-based highly integrated industrial facility. its clients with a fully integrated so-
H2 production technology (coupled Last month, Technip Energies, in lution to meet their decarbonization
with a strategy of decarbonization), partnership with Casale (Lugano, and performance goals at any scale
mainly for: small- to mid-sized H2 Switzerland; www.casale.ch), added and type of hydrogen plant,” com-
production linked to hydrotreated Advanced ATR technology to Blue ments Loic Chapuis, senior vice
vegetable oil (HVO)/ sustainable avi- H2 by T.EN — the company’s suite president Gas & Low-Carbon Ener-
ation fuel (SAF) production, with a of fully-integrated, low-carbon H2 gies of Technip Energies.
recycle of biogenic feedstock to the solutions. It is part of Capture.Now, In August, Lummus Technology
SMR for green H2 production. T.EN’s strategic platform for CCUS. LLC (Houston; www.lummustech-
BlueH2 by T.EN was launched last nology.com) and Biohydrogen Tech-
Other news year (Chem. Eng., December 2021, nologies Ltd. (BHT; London, U.K.)
In July, KBR Inc. (Houston; www.kbr. p. 5). Casale’s ATR combined with established an agreement to de-
com) and Air Liquide (Paris, France; Technip Parallel Reformer (TPR) and velop and deploy advanced syngas
www.airliquide.com) announced carbon capture is a cost-effective reactor technology primarily for the
that they are now offering fully-inte- way to produce low-carbon hydro- production of blue H2.
grated and flexible ATR technology gen at large-scale with optimized Lummus’ Green Circle business unit
for the production of low-carbon steam production. will provide BHT its expertise in H2 and
ammonia at mega scale. The offer- ATR is a game-changing technol- syngas plant design, reactor scaleup
ing combines KBR’s ammonia-syn- ogy as it breaks the upper capacity and design, and proprietary equip-
thesis technology with Air Liquide’s limit of traditional hydrogen plants, ment supply. The technology is said to
experience and proprietary ATR for which were economically con- have the ability to capture more than
large-scale syngas production. strained by the size of the SMR, and 99% of the CO2 at pressure. n
When combined with carbon- enables large-capacity, ultra-blue Gerald Ondrey
REMBE®
Pressure Relief
and
Explosion
Safety.
© REMBE® | All rights reserved
rembe.com
hello@rembe.com
For details visit adlinks.chemengonline.com/84652-06 For details visit adlinks.chemengonline.com/84652-07

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM
Newsfront
Data Analytics Software for
Process Optimization
Advanced software solutions drill down through the data to provide actionable information
T
here is no shortage of data courage processors to use the data chemicals industry principal with
produced in a chemical to find potentially impactful situations Seeq (Seattle, Wash.; www.seeq.
processing facility, but sift- in advance, as opposed to reacting com). “Advanced analytics software
ing through the data to drill and ‘firefighting’. provides the data connectivity, visu-
down to the useful information can “Current solutions allow users to alization and analytics capabilities
be particularly cumbersome. Further, move away from using data analytics needed to maximize uptime, im-
it is often challenging to understand to figure out why there was a prob- prove quality and consistency and
what those data are trying to tell you lem yesterday and begin monitoring push throughput rates to meet pro-
and how that knowledge can be ap- and finding the problems before they duction and sustainability goals,”
plied to create a plan of action that affect production,” he says. “It’s like she says (Figure 2).
prevents inefficiencies, equipment making chocolate chip cookies but Andreas Eschbach, founder and
downtime or process disruptions. waiting until you taste them to learn CEO of Eschbach Software (Boston,
Fortunately, today’s advanced data- that they are burnt versus monitoring Mass.; www.eschbach.com) agrees:
analytics software effectively present the temperature of the oven so you “Better access to data improves de-
data analysis results in a format that don’t have to worry about burning the cision making across all levels of the
is both understandable and action- cookies again. Today’s data-analytics organization because analytical tools
able, which helps chemical proces- software packages focus on preven- turn data from various sources into
sors shift from reactive to proactive tion — seeing a problem and mitigat- actionable, understandable informa-
process management and encour- ing it before it negatively impacts the tion about plant status, processes
ages optimization of the process. process, the equipment, the quality or and products. When everyone has
“Employing data analysis is nothing the throughput” (Figure 1). access to the information they need
new,” says Josh Shupp, vice presi- to do their jobs effectively, they can
dent of customer success with North- Helping to stay competitive make better operational decisions
west Analytics (Portland, Ore.; www. Smart processors are using data an- both individually and collectively,
nwasoft.com). “People have been alytics software to monitor all sorts which drives continuous improve-
doing it for years using spreadsheets of impactful data in an effort to op- ment across the organization, en-
or standard historian-type software. timize the process, upgrade quality abling optimization of processes,
What is different is that today’s data- control, perform predictive mainte- better quality control, increased
analytics software solutions apply nance, enhance safety and improve throughput and improved asset uti-
meaning to the data, focus on key resource efficiency, all of which are lization,” notes Eschbach (Figure 3).
process indicators [KPIs] and en- becoming increasingly important as He adds that advanced data ana-
chemical processors lytics solutions can help with virtually
struggle to remain every aspect of plant performance,
competitive. from environmental, health and
However, achiev- safety (EHS) compliance to predic-
ing these goals in tive maintenance decisions. “A cen-
today’s fast-paced tralized knowledge-management
environment de- platform allows team members to
mands an advanced learn from past events to optimize
data-analytics plat- processes,” Eschbach continues.
form that is capable “For example, operators can mine
of joining disparate information from digital platforms to
sources to enable correlate variations in product qual-
seamless analytics ity to equipment parameters, batch
and visualizations, timing or other variables. Often in-
Northwest Analytics
in addition to ad- formation that could be useful for
FIGURE 1. Northwest Analytics’s Knowledge Suite helps processors iden- hoc and highly pol- troubleshooting, process optimiza-
tify early warning signals, codify institutional knowledge and take quick ished reports, says tion and planning is hiding in the
and decisive actions Allison Buenemann, vast amounts of data collected in a
Seeq
possible, because data enough tangible benefits to be de-
analysis can identify rived by employing data-analysis
opportunities to en- software versus sticking with more
hance production rates traditional methods of collecting and
and reduce cycle times using data and the answer is “yes,”
through process optimi- according to experts.
zations. “Real-time ana- “The obvious benefit of using data-
lytics can help identify analysis software and the one most
production bottlenecks, ask about is a financial benefit,”
allowing timely correc- says Northwest’s Shupp. “And that
tive actions to improve is certainly there, as optimizing the
throughput,” says Hold- process and increasing throughput
FIGURE 2. Seeq, an advanced analytics solution, combines the
data from numerous subsystems to create enterprise-wide insights away. And, data-anal- provide obvious financial benefits,
and facilitate data sharing specific to the level required by each ysis solutions can also as does the ability to detect main-
software user help reduce downtime tenance issues or process anoma-
processing facility every day. Ana- because real-time monitoring and lies early on. Even if the facility can’t
lytical tools and emerging AI [arti- anomaly detection can help uncover avoid downtime entirely, they are
ficial intelligence] tools can help to early signs of equipment issues, en- likely able to use the data to reduce
surface this information and make it abling proactive maintenance before downtime from days to a few hours
findable and usable.” breakdowns occur, reducing down- and that’s huge as the lost profit
time and increasing availability of chemical processors can experience
Optimization and improvement equipment to further enhance uptime from downtime is significant.”
But how can chemical processors and throughput. Bob Rice, vice president of engi-
use data-analysis software to opti- He continues to say that product neering with Control Station, Inc.,
mize their own operations and meet quality improvements are also possi- (Manchester, Conn.; www.control
specific goals? “Data analysis and ble. “Data-analysis software can also station.com), which provides con-
the associated software can play a monitor and analyze real-time quality trol-loop performance monitoring
significant role in helping chemical parameters, ensuring adherence to (CLPM) solutions that simplify the
manufacturers achieve their goals, quality standards and early detection identification, isolation and correc-
including optimizing and streamlin- of deviations, so factors affecting tion of common regulatory control
ing processes, increasing efficiency, product quality can be identified and issues that negatively impact both
reducing downtime and increasing adjustments to the process can be process performance and plant
throughput,” says Keith Holdaway, made for improved quality.” profitability, says the ability of data
global advisor for IoT at SAS (Cary, Energy efficiency and sustainabil- analysis and CLPM solutions to in-
N.C.; www.sas.com). “Additionally, ity goals may also be achieved, ac- crease throughput while also reduc-
data analysis can contribute to sev- cording to Holdaway, because data ing waste and energy consumption
eral other crucial goals for modern analysis identifies energy-intensive is noteworthy. “Studies put gains in
chemical manufacturers” (Figure 4). processes and provides insights to production throughput between 2%
Holdaway suggests multiple ways optimize energy consumption and and 5%, with increases in yield top-
that data analytics software can help reduce emissions for sustainability ping out at 10%,” says Rice.
processors achieve a variety of goals. goals. “It helps track environmental In addition to improved produc-
For example, for processors who are metrics, supporting efforts to reduce tivity and operational and efficiency
looking for process optimization and the carbon footprint and comply with gains, there are “softer” benefits,
efficiency, data-analysis software environmental regu-
can analyze historical process data lations,” he says. Eschbach Software
to identify inefficiencies and opera- Safety and risk man-
tional bottlenecks. “By leveraging agement may also
advanced analytics, the software be enhanced as data
can suggest optimal process pa- analysis can identify
rameters to improve efficiency and potential safety haz-
reduce waste, because real-time ards and deviations,
data analysis allows for continuous aiding in proactive
monitoring and adjustment of pro- risk management.
cess variables for ongoing optimi-
zation,” Holdaway explains. Further, The benefits
data analysis drives a culture of con- Although these
tinuous improvement by providing sound like great ap-
insights for ongoing process optimi- plications, chemi- FIGURE 3. A centralized knowledge management center, such as Es-
chbach’s Shiftconnector, helps team members communicate, generate
zation and performance evaluation. cal processors may ideas, preserve best practice information and apply them into chemical
Increases in throughput are also wonder if there are factory solutions

as well, says Eschbach, including and event conditions SAS
error reduction and improvements and relational systems,
in worker and process safety, better allow information to
communication and accountability be brought together in
across teams and shifts, enhanced specific context and by
access to information for trouble- dismantling data silos,
shooting, continuous process im- it mitigates the prolifer-
provements and quality control, and ation of redundant data
efficient reporting for compliance, copies, thereby align-
strategic planning and daily opera- ing with and streamlin-
tional decision making. ing an organization’s
“In addition, centralized knowledge master data-manage-
management preserves important ment strategies.” FIGURE 4. For chemical companies, data analytics solutions,
institutional knowledge that is hid- Seeq’s Buenemann such as SAS Viya AI and Analytics platform, can help optimize and
ing in shift notes, maintenance logs agrees: “Live data con- streamline processes, increase efficiency, reduce downtime and
and other disparate data sources,” nectivity is essential. increase throughput
explains Eschbach. “As experienced Without it, near real-time monitoring and actionable.”
workers retire, this becomes a valu- and predictive analytics use cases are Control Station’s Rice adds: “The
able knowledge source for onboard- not possible. Software that federates distinction chemical processors
ing new workers and ensuring or- data sources simply by connecting to should consider is the one between
ganizational continuity. Enhanced the source, indexing signal metadata dashboards and diagnostics. Many
access to data and analytics em- and querying on-demand is a great applications in the analytics category
powers people in the plant to do their alternative for those looking to avoid are powerful tools, but they lack the
best work.” data duplication.” diagnostic capabilities needed to
Buenemann adds that it’s best proactively address common pro-
Applying analytics software to go for both “breadth and depth” duction-related challenges. So, be
The key to successfully employing when it comes to analytics capa- wary of just another dashboard. For
and reaping the benefits of data ana- bilities. “Many software solutions go sure, intuitive design is important
lytics software lies in selecting a solu- deep in one particular use case, but and ease of use is essential, but
tion that presents data in an action- that leaves operations teams learn- users should expect their tools to
able way and implementing it wisely. ing and IT teams maintaining dozens include analytics and forensic capa-
“By empowering knowledge workers of applications to achieve opera- bilities that are based on actual do-
with intuitive self-service graphics tional excellence,” she says. “An ad- main expertise.”
and dashboarding tools, data analyt- vanced analytics application that can And implementing the chosen
ics software facilitates the seamless go 90% of the way there in 100% of data-analysis solution in a chemical
integration and utilization from vari- use cases will receive better adop- processing plant requires a thought-
ous operational, business and IT sys- tion than numerous point solutions.” ful approach to ensure successful
tems, leading to more agile decision It is also important to ensure that adoption and integration, according
making,” explains Sasha Jones, lead the information is presented in a to SAS’s Holdaway. He says the first
technical advisor, with IOTA Software way that makes it useful, adds Phil step is to identify goals and objec-
(Raleigh, N.C.; www.iotasoftware. Pearce, applications engineer with tives. “Define clear goals and objec-
com). “The exceptional value comes Northwest Analytics. “There are lots tives for using the software. Identify
from the ability to seamlessly connect of data and a lot of analytical tech- specific processes or parameters
with a diverse array of manufacturing niques, but none of that really mat- that require optimization or improve-
data sources concurrently, making ters if you can’t make a decision,” he ment,” he explains. “This could be
it an optimal solution for scenarios says. “Data need to be presented in related to energy efficiency, product
demanding holistic, cross-system vi- a way that is consumable by the par- quality, process stability or another
sualization and comprehensive data ticular user. Some of our customers crucial aspect of the operation.”
aggregations” (Figure 5). have coined the term ‘action boards’ Gathering relevant historical data
Jones continues: “Use cases may as opposed to dashboards, meaning for the selected parameters is the
include condition-based maintenance that the information is presented in next step, so it is important to en-
enabled by connectivity, operational a manner where if something is sig- sure that the data are clean and
historians and asset management naling, you know you’re supposed to consistent and in a format compat-
systems, as well as initiatives that in- take an action, not just see an infor- ible with the software.
volve predictive and prescriptive ana- mational-type beacon. Being able to Once the initial leg work is done,
lytics that require the display of analyt- tie the signal with the desirable ac- Holdaway suggests starting with a
ical outputs alongside current actual tion is the goal, so it’s important that pilot project. “Choose a critical pro-
operating conditions. Real-time data- it is presented in an action board, cess or parameter significantly im-
querying capabilities, along with the message alert or some way that is pacting the plant’s performance. This
integration of asset attributes, batch overwhelmingly consumable, usable allows for a focused evaluation of the
Testing will and operators to encourage knowl-
ensure the edge sharing and a deeper under-
accuracy standing of insights generated by
and reliability the software. It is also essential to
of the mod- continuously refine and improve the
els. Once data analysis models and encourage
the pilot proj- feedback from plant personnel to
ect is suc- enhance performance and address
cessful, the specific plant requirements.
IOTA Software data analysis Finally, as the software becomes in-
FIGURE 5. IOTA Software developed VUE as a dynamic process visualization and software can tegral to the plant’s operations, says
analytics platform, able to seamlessly integrate data from all aspects of a business be imple- Holdaway, explore opportunities to
and empower users with intuitive self-service graphics and dashboarding
mented in scale its use across the entire plant.
software’s effectiveness,” he says. the selected area of the plant. “But Integration with other plant systems,
“Next, perform data analysis using monitor the project closely to assess such as process control systems, will
the software to gain insights into the impact of the software’s recom- help streamline data flow and deci-
the selected process or parameter. mendations and optimizations,” he sion making. Eventually users can de-
This may involve exploring patterns, says. “And then, as the data analysis velop a long-term strategy for using
trends and correlations in the data. software proves its value in the pilot the software in the plant.
Develop appropriate models, such project and selected area, expand its “By following a systematic ap-
as statistical models or machine use to other critical processes and proach, chemical processing plants
learning algorithms to predict behav- parameters in the plant. Gradually can effectively start using data anal-
ior or optimize the process and then integrate the software into various ysis software, gradually expand its
follow a repeatable and scalable areas of operation.” use and derive maximum benefits
suite of workflows.” Once it has been successfully in process optimization, cost sav-
Following this, the results should be proven, adequate training and col- ings and improved product quality,”
validated by comparing them with the laboration should be fostered among notes Holdaway. n
actual plant data and performance. process engineers, data scientists Joy LePree
RELIABLE AND
Written for engineers,
by engineers EFFICIENT VACUUM
More and more,
business in the 02
Hea
ww w.chem
Februa
2015 ry SOLUTIONS
Fundam
Two-Pa t Exchanger engonl

ine.co
entals
rt Feature s: m
Chemical Process
for Chemical Processes
Report
oF HigH-sH
Adv
in 3-D ances
ear dispers
Printing
Focus
on
Housek Industrial
ers
eeping
• Heat
Industries (CPI) is
excHan
gers
Facts
at
Dimens Your Fingertip
ionless
Numbers:
s
not local, it’s global.

Valv
Extrem es for
• Environmentally friendly
Funda
e Service
m
High-S entals o
page
hear D f
ispers
40
To keep up with
ers
• Safe pumping of hazardous flammable material
Vol.
122 No.
this rapidly evolving

februar 2
y 2015
marketplace, you • Meets all your specific requirements

need a magazine
that covers it all, not just one country
t our
or region, not just one vertical market, ask abou
ST
but the entire CPI. With editorial LE A K T E ON S
offices around the world, Chemical S O LU T I
Engineering is well-positioned to keep
abreast of all the latest innovations in Busch designs and provides
the equipment, technology, materials, optimal vacuum solutions to meet
and services used by process plants the latest technical standards and
worldwide. No other publication even process developments for all chemical
comes close. applications. Rely on the trusted
name for vacuum. Rely on Busch.
To subscribe or learn more about
membership, please visit 1-800-USA-PUMP │ info@buschusa.com
www.chemengonline.com/subscribe
buschusa.com
25430

Newsfront
The Next Generation of
Overpressure Protection
Overpressure protection is at the center of process safety across all chemical processing
sectors. As processes and technologies evolve, it is essential that safety systems can adapt to
provide the utmost levels of protection
A
ll over the chemical process University (MKOPSC; College Sta- when compared to normal operating
industries (CPI), almost re- tion, Tex.; www.psc.tamu.edu). In conditions,” he explains.
gardless of the product this article, Faisal Khan, professor of In such highly complex instru-
being made or the material chemical engineering and director of mented systems as a typical pres-
being handled, protecting against MKOPSC, discusses some of the sure-relieving scheme, any type of
overpressure is of the utmost con- most important safety issues facing failure can create a potential safety
cern. Whether the situation involves the CPI, and gives some insight into incident, but advanced digital tech-
a potential release of hazardous or what the next generation of smart nologies enable the study of vast
toxic vapors, a runaway exothermic pressure-relieving systems may look numbers of overpressure scenarios
reaction or the formation of a poten- like. in ways that were not previously pos-
tially explosive dust cloud, there are As a simple analogy to the critical sible. “Within the digital world, we
numerous state-of-the art technolo- nature of overpressure-protection can discover the boundaries of how
gies available to help mitigate these systems to process operations, Khan and where systems fail and enable
dangerous situations. Alongside brings to mind a car’s braking system. sufficient redundancy and operational
these commercial offerings, research “Can you imagine having a car with- control to minimize failures. Digitaliza-
institutions and standards organiza- out a brake pedal? Pressure protection helps us to better understand
tions are ensuring that there are reli- tion in today’s industrial plants, where those gray areas where we might see
able pressure-relieving technologies we are pushing the limits in terms of equipment fail,” notes Khan.
for new and emerging processes. operation, serves a similar purpose He also emphasizes the impor-
One organization at the forefront of as the brake in the car. It provides tance of applied research and experi-
dedicated research and technology broader operability to the system,” mentation alongside advanced math-
development related to overpressure he says. And like a car, he points out, ematical models to help guide safer
protection is the Mary K. O’Connor alongside the conventional brake, industry practices. “We can set up
Process Safety Center at Texas A&M you will also find an emergency brake. experimental methodologies along
Similarly, within a pressure-protection with mathematical models to form
system, there will also be elements in- basic tools that vendors and opera-
stalled that are uniquely designed for tors can use to interrogate and study
emergency conditions. their systems to find weak links. Our
experimental facilities, along with
Digitalization our computational abilities, are able
As with any operational function in to create the methods that must be
the CPI, digital technologies and carried out, step by step, to under-
data analysis are becoming integral stand the hidden risks, calculate and
in overpressure-protection systems. develop the models to help users
The key benefit of digitalization in pro- to understand their associated risks
cess-safety applications, says Khan, and how they can follow strategies
is its ability to reveal hidden risks and to minimize it. The outcome of our
so-called gray areas where gaps in work is to set the stage for vendors
protection may exist. and operators to better study their
“In any process there are certain systems.”
elements that create some hidden Ultimately, Khan says what the in-
Edison Sripaul,
risks. And while these risks could dustry really desires is to effectively
MKOPSC cause a significant impact or even use their data to make informed
FIGURE 1. At MKOPSC, a dust-explosion testing catastrophic consequences, be- safety decisions. “That’s one of the
system helps researchers generate guidance for cause their likelihood of occurrence is things team members are working
industrial processors to help them optimize their relatively low, they may remain hidden closely with industry to unleash.”
operating conditions to avoid dangerous situations
Uncovering dust-explosion risks in a totally different pressure domain Edison Sripaul, MKOPSC
One of the main hidden hazards in than what we typically expose tra-
the CPI is dust, as many people may ditional protection devices to, so
not understand the risks of dust ex- those systems may not be directly
plosions. Crucial to advancing the applicable to the particular environ-
dust-control sector is to expand the ment where hydrogen operates,”
industry’s understanding of the con- says Khan. More research will be
ditions that can lead to dust explo- required to provide more suitable
sivity — from the size of particles to overpressure-protection solutions,
the optimal operating conditions and which not only must be vetted from
what type of protection devices might a technical standpoint, but also must
be required (Figure 1). “MKOPSC eventually be accepted by the pub-
works closely with industry to analyze lic as safe. “One thing that is very
data from many different substances clear is that overpressure protec-
to provide guidance about under tion systems for hydrogen cannot be
which conditions dust could become open-release, which is very unique
explosive, therefore demanding the when compared to other hydrocar-
specification of an overpressure-pro- bons or fuels, where the protection
tection system,” states Khan. system can provide safe relieving FIGURE 2. Experimentation using reactor calorim-
eters can help shed light on the conditions that
One area where such guidance has of the pressure to a relatively open can lead to runaway reactions, such as those seen
changed drastically in recent years is atmosphere. Unfortunately, in the sometimes in battery systems
in biomass-handling applications for case of hydrogen, given its low ig-
converting solids, such as sugar or nition energy, its release to an open have been significant commercial ad-
wood, into biofuels and bio-based atmosphere is sufficient to ignite and vancements in installing relief devices
chemicals. “The operating envelopes create an explosion,” explains Khan. into individual battery pack systems,
have changed significantly with new To address this added complexity, but incidents can still occur at very
applications for biomass. Guidance work is underway to develop unique large scales. “We have witnessed
can be as simple as changing the pressure-protection systems that di- quite a few major accidents at those
size of particles, or potentially speci- rect the release into a safe, confined levels of facilities due to overpressure
fying a device that can relieve excess space. Otherwise, says Khan, the and explosions, where a single pack
energy levels in the system to avoid pressure-relieving action itself could experiences overpressure and ends
explosivity,” he adds. According to be the source of an accident. “In a up creating overpressure over the
Khan, the biomass-handling indus- very simplistic system, you might entire installation. We have a good
tries have learned a great deal over have a full cylinder of hydrogen being understanding at the smaller scale,
time and have built more robust sys- transported, with an empty cylin- but at the utility level, there is still a
tems to better avoid explosivity limits der beside it in the event of a pos- knowledge gap,” says Khan.
by maintaining certain operating con- sible overpressure situation. Then
ditions, while at the same time install- you could use the second cylinder The next steps
ing appropriate protection systems as the pressure-relieving system,” Considering the current state of over-
that will enable them to safely relieve he notes. pressure protection, and looking
pressures in case they must operate Batteries also have special char- ahead at the next generation, Khan
outside their normal conditions. acteristics that make them prone to sees sensors and process monitor-
overpressure events related runaway ing as key elements. On the hori-
Emerging energy systems reactions and overheating (Figure zon are devices that not only relieve
As the world continues to explore 2). However, as battery systems are or divert pressure buildup, but that
lower-carbon energy options, such scaling up for utility-scale energy minimize the pressure buildup itself.
as battery energy storage and hydro- storage, there is still a need to de- “This means that we are monitoring
gen, there are many challenges and velop proper overpressure protection pressure conditions at the relief de-
process-safety risks that must be for individual battery packs. “We are vice such that they can operate on a
addressed. “In evolving fields, such designing relief and overpressure de- continuous basis rather than based
as hydrogen and batteries, overpres- vices to be as miniscule as possible on a certain threshold.” This enables
sure protection is one of the most im- at the pack level. This is a whole new a more circular system where mate-
portant elements,” says Khan. dimension for overpressure-protec- rial can be re-circulated through the
Hydrogen — with its low ignition tion systems. The industry is work- device continuously to avoid pressure
energy, propensity to leak and its ing to design such systems now, not buildup in the system. “This is in stark
detection difficulties — poses many only to safely run battery systems at contrast to current threshold-based
unique safety challenges that must a larger scale, but to also monitor models, where you allow pressure to
be addressed as larger volumes of operation in abnormal conditions to build up within the system and then it
hydrogen enter the energy land- relieve pressure and avoid major ac- is all released at once,” Khan adds. ■
scape. “Hydrogen absolutely works cidents.” says Khan. Indeed, there Mary Page Bailey

Focus
Compressors, Fans & Blowers Scroll compressors for the motor speed to match air de-
sensitive work environments mand in real time and increasing
This company has re-issued its EO energy efficiency by up to 70%, the
Series of scroll compressors (photo) company says. — Atlas Copco AB,
and expanded its performance range Nacka, Sweden
to 30 kW. The EO Series is very pop- www.atlascopco.com
ular in sensitive work environments,
such as when there is a high demand Monitor rotating machinery
for oil-free use and process safety. with this dual-channel device
The compressors are available in Monitoring the dynamic behavior of
three sizes, from 4 to 7 kW, 11 to smaller rotating machinery, such as
23 kW and 30 kW. The design prin- gas turbines, pumps, motors, fans
ciple ensures the efficient generation and centrifuges, has become in-
of totally oil-free compressed air. The creasingly important in today’s highly
EO series is characterized by its par- competitive, cost-conscious envi-
ticularly small footprint, even for the ronment. The DN26 G3 dual-chan-
version with an integrated dryer. The nel protection system is a compact,
BOGE Kompressorem Otto Boge
compressor is also available with a DIN-rail-mountable unit for a wide
compressed-air receiver, as a duplex range of machinery-monitoring appli-
system and with an integrated or cations. A recent delivery of 25 DN26
external refrigerant dryer. Two-stage G3 dual-channel vibration monitors
aftercooling ensures optimized out- was made to a Middle East-based
let temperatures. The compressors gas-transmission company (photo).
have been designed for a pressure At this site, these panel-mounted
dewpoint of 3°C. — BOGE Kom- monitors are being used on exist-
pressoren Otto Boge GmbH & Co. ing turbine compressors in a gas
KG, Bielefeld, Germany pressure-booster station. They will
www.boge.com be monitoring radial shaft vibration
and axial shaft position on the com-
Battery-driven portable screw pressor and, for the turbine, will be
compressor monitoring absolute casing vibration
The B-Air 185-12 (photo) is a new at both the gas generator and power
battery-driven portable screw air turbine locations. — Sensonics Ltd.,
compressor. The B-Air 185-12 fea- Berkhamsted, Hertfordshire, U.K.
tures 5–12 bars of pressure, a sta- www.sensonics.co.uk
ble flowrate of 5.4–3.7 m3/min and
Atlas Copco 55-kWh battery-storage capacity. Reduce compressor surge risk
With power delivered from its on- with this valve technology
board power pack, a fully charged Surge events can interrupt compres-
unit in operation is independent of sion in upstream and midstream oil-
the need for fuel or a local power and-gas, liquefied natural gas (LNG)
source, and can perform for up to and petrochemical facilities. If left
a full typical work shift. Making the unaddressed, this disruption may
switch from an internal combus- lead to compressor trips or system
tion engine (ICE) to electric motor failures that require expensive re-
brings with it a host of benefits, medial work to resolve damage, ac-
including less downtime and main- cording to this company. To address
tenance requirements. Due to hav- these concerns, this company has
ing far fewer moving (and there- developed an integrated anti-surge
fore wearing) parts compared to a and compressor-recycle valve that
diesel-powered unit, the electric combines multiple, co-acting tech-
B-Air 185-12 only needs to be ser- nologies to balance efficient produc-
viced every 2,000 h, as opposed tion and equipment health. The valve
to 500 h for a typical ICE-powered features the patented DRAG control
Sensonics
unit. The machine’s variable speed valve technology with SC/V actua-
drive (VSD) and permanent-magnet tors and smart, high-performance
motor drives down the total cost of FasTrak or QuickTrak controllers
ownership, automatically adjusting and positioners. These individual
parts continually interact to reduce lowing easy access for cleaning. Built-
the chance of cycle trips to optimize in braces permit the entire package to
performance at startup and during be moved into position with a forklift
operation. — IMI Critical Engineering during installation or maintenance.
plc, Birmingham, U.K. Every blower package incorporates
www.imi-critical.com an industry-proven PD blower. The
blower is dynamically balanced, and
These transmitters help isolation pads are positioned between
improve availability and more the blower and the base to reduce
Introduced in March, Versatilis trans- vibration and noise. — Coperion
mitters provide condition-based moni- K-Tron, Inc., Salinas, Kan.
toring of rotating equipment, such as www.coperion.com
pumps, motors, compressors, fans,
blowers and gearboxes. Versatilis These blowers are energy
transmitters perform relevant mea- efficient with a small footprint Jenny Products
surements of rotating equipment, The EBS rotary screw blower (photo)
delivering intelligence that can im- delivers flowrates from 10 to 41 m³/
prove safety, availability and reliability min, with pressure differential up to
across industries. These transmitters 1,100 mbars and vacuum up to 550
measure vibration, surface tempera- mbars. The SFC version is equipped
ture and acoustics to anticipate rotary with an integrated frequency con-
equipment anomalies. These mea- verter and a synchronous reluctance
surements have additional applica- motor. EBS series machines have an
tions, such as heat-exchange reliability energy-saving drive concept, and an
and substation reliability. — Honeywell intelligent and compact design, which
Process Solutions, Houston allows all maintenance work to be car-
www.process.honeywell.com ried out from the front side of the unit.
This makes side-by-side installation
Two-stage, vertical-tank possible, even when the complete
stationary air compressors electronics are installed. — Kaeser
These two-stage vertical-tank sta- Kompressoren SE, Coburg, Germany
Coperion K-Tron
tionary air compressors (photo) pro- www.kaeser.com
vide 175 psi and displace between
9.1 and 43.6 ft3/min. Each compres- Compressor technology slated
sor uses a heavy-duty, two-stage for Clean Energy Complex
cast-iron pump and powder-coated, This company will supply six air-
ASME-certified tank. A large fly- compressor trains for Air Products’
wheel provides for extra cooling and air-separation unit (ASU) as part of a
easier startup, while special unload- new plant for the production of blue
ing valves further assist the motor in ammonia and hydrogen at the Clean
starting. A directional air shroud helps Energy Complex in Darrow, La. The
reduce pump temperatures, and a scope of the order comprises two
thermal-overload protection feature main air-compressor trains — each
prevents the motor from drawing too equipped with a single-shaft com-
much current and overheating. The pressor type, RIKT 160-3 (photo).
two-stage vertical-tank stationary line It further includes two booster air-
Kaeser Kompressoren
is powered by a one- or three-phase compressor trains — each with an
electric motor that provides between integrally geared compressor type,
2 and 10 hp. — Jenny Products, RG 63-6 — as well as two gaseous-
Inc., Somerset, Pa. nitrogen compressor trains — each
www.jennyproductsinc.com with an integrally geared compressor
type, RG 45-5. All of the trains will
PD blower packages for be electrically driven. The main air-
pneumatic conveying systems compressor trains have three cen-
This company supplies a wide range trifugal stages and deliver more than
of positive displacement (PD) continu- 600,000 Nm3/h of air. The booster
ous vacuum, pressure and vacuum/ compressors are integrally geared
pressure system blower packages types and have six (air) and five (ni-
for conveying bulk materials (photo). trogen) stages, all with external in-
Packages are available for 2- to 10- tercoolers. — MAN Energy Solutions
in. conveying systems. Each blower SE, Augsburg, Germany
package includes a silencer and is www.man-es.com n MAN ENergy Solutions
supported on a heavy-duty base, al- Gerald Ondrey

New Products
New breather system for A new gateway for secure
enhanced food safety communication of field devices
The new CC/FC ventilation system FieldGate SWG50 (photo) is a new
(photo) is integrated into the bung of WirelessHART gateway primed for
the screw cap that covers the filling secure communication from field de-
opening of intermediate bulk contain- vices, providing an easy-to-use solu-
ers (IBCs), enabling users to proac- tion for multiple-standard monitoring
tively avoid contamination risks. It is applications across various industries.
used to quickly and safely ventilate the FieldGate SWG50 is compact and de-
Schütz
container during emptying via the bot- signed for integration with Netilion, a
tom outlet fitting and prevents nega- cloud-based IIoT ecosystem designed
tive pressure that would cause the for industrial processes, connecting
inner bottle to become deformed. In the physical and digital worlds to send
previous systems, either the screw information from the field straight to
cap, which is often sealed, had to a smartphone, tablet or another de-
be opened or the bung plug had to vice. FieldGate SWG50 enables users
be removed completely with tools in to monitor measurements and health
an additional process step. With the status using WirelessHART connectiv-
CC/FC Breather, users simply twist ity. This offering is an economical al-
a screw part manually to open the ternative to complex and costly cable
venting paths in the component. This installations, reducing expenditure for
also minimizes the risk of contamina- process automation by up to 30%, the
tion during the entire emptying pro- company says. — Endress+Hauser,
cess. — Schütz GmbH & Co. KGaA, Inc., Greenwood, Ind.
Busch Vacuum Solutions Selters, Germany www.us.endress.com
www.schuetz.net
New compact, variable-speed
This new vacuum pump reciprocating compressors
optimizes operating conditions The new i.Comp 8 and 9 oilless com-
The Cobra DX 0950 A (photo) is the pressors (photo) are available in two
first vacuum pump to be released as sizes and three configurations (G,
part of the new DX Series. Cobra DX Tower and Tower T). The i.Comp units
0950 A is a dry vacuum pump with deliver oil-free air at up to 160 psi and
advanced screw-vacuum technology 20 ft3/min. The direct-drive motor and
for excellent running characteristics, oilless design eliminate nearly all rou-
high vapor and particle tolerance and tine service. Pressures can be pre-
energy-efficient operation. The new cisely adjusted to each application’s
pump is suited for many rough- and requirements with the company’s
medium-vacuum applications, such Sigma Controller 2. i.Comp compres-
as lithium battery production, drying, sors are also available as Tower con-
food packaging, coating and vacuum figurations, which include a receiver
furnaces, or as the heart of a central and drain trap, while Tower T configu-
Endress+Hauser
vacuum system. An optimal vacuum rations include a refrigerated dryer. A
level can be achieved at all times small footprint and low noise make
thanks to the intelligent driving unit i.Comp suitable for use in tight spaces.
with variable-speed control and vari- — Kaeser Compressors, Inc., Freder-
ous operating modes. This reduces icksburg, Va.
energy consumption and ensures that www.us.kaeser.com
the vacuum pumps run under optimal
conditions. In addition, the patented A new hydraulic bulk-bag
self-balancing screw design of Cobra conditioner streamlines workflow
DX 0950 A ensures low vibration levels A new Block-Buster hydraulic bulk-
and quiet operation. The screws are bag conditioner (photo, p. 28) features
made of one single casting and have arched doorway masts that increase
no gaps. This prevents the ingress overhead clearance for easier insertion
of process fluids or particles, as well and removal of palletized bulk bags
as corrosion and deposits. — Busch using a forklift. The conditioner loos-
Kaeser Compressors
Vacuum Solutions, Virginia Beach, Va. ens hygroscopic chemicals, spice
www.buschvacuum.com blends, heat-sensitive products and
other bulk materials that have solidi- thanks to its higher flowrate, covers
fied during storage and shipment, re- a wider range of applications with a
turning the material to a free-flowing smaller pump. Users not only reduce
state and enabling bulk-bag unload- their material footprint by 23% with
ers to discharge the material through the new design, but also reduce en-
bag spouts. A hydraulically-actuated, ergy demand by 10% due to the im-
variable-height turntable operates in proved efficiency. With variable speeds
concert with two hydraulic rams to of up to 3,000 rpm, the self-priming
press opposing sides of the bulk bag positive-displacement pump conveys
at varying heights, rotate the bag 90 lumpy, shear-sensitive and abrasive
Flexicon
deg and then repeat the conditioning media particularly gently. It can handle
cycle. The number and pressure of liquids with a wide range of viscosities.
hydraulic ram actuations, the height Since the Novatwin+ pumps oper-
of the turntable and the number of 90- ate with nearly no pulsation, they are
deg rotations are user-programmable also suitable for large and sensitive
at the control panel’s human-machine particles. Twin-screw pumps can also
interface (HMI). — Flexicon Corp., serve as clean-in-place (CIP) pumps,
Bethlehem, Pa. because they can be operated at very
www.flexicon.com high speeds. The system pressure of
30 bars also allows for use in high-
Heat recovery saves energy with pressure applications. — GEA Group,
this compressor setup Düsseldorf, Germany
When this company’s heat-recovery www.gea.com
components (photo) are installed onto
an air compressor, up to 94% of the Comprehensive solutions for
BOGE America
energy used to compress air is re- level measurement
covered. This recovered energy can Vibration limit switches reliably detect
be used to heat storage and operat- the fill level of liquids at all times. With
ing areas or for heating water or oils. Vibracon LVL-M3 and -M4 (photo), this
For example, the heat can be used for company offers two new series of vi-
the treatment of drinking water, ser- bration limit switches that can be used
vice water, heating water and process worldwide in hazardous areas due to
water. The latter is used for industrial ATEX and IECEx approvals. The LVL-
washing processes, for example in M3 version is suitable for universal use
recycling processes to clean plastic in all pumpable liquids. The vibration
and synthetic materials. Heat-recovery limit switch can withstand process
components can be used to recover temperatures of –40 to 150°C and pro-
heat in both oil-injection-cooled and cess pressures of up to 40 bars. The
oil-free screw compressors. At the LVL-M4 version is suitable for safety
same time, the energy for cooling pro- applications up to SIL 3. The sensor
GEA Group cesses within the compressor is re- is resistant to process temperatures of
duced, because the heat generated is –50 to 150°C and process pressures
conducted away and used elsewhere. up to 100 bars. The LVL-M4 version
The investment in heat-recovery com- has a Bluetooth interface that can be
ponents pays for itself within a few used to connect the device to the com-
months depending on the applica- pany’s Level App. This mobile applica-
tion. — BOGE America, Inc., Powder tion enables status and fault indication
Springs, Ga. to proof testing. — Pepperl+Fuchs SE,
www.boge.com/en Mannheim, Germany
www.pepperl-fuchs.com
Twin-screw pump for
conveying and cleaning Connectors with
This company launched a new gen- lever push-in technology
eration of twin-screw pumps for food, This lever technology (photo, p. 29)
beverage and pharmaceutical applica- enables fast and effort-saving multiple
tions that combine both the conveying wiring of different conductor types with
and cleaning functions in one pump. and without ferrules. The connectors
The revamped Hilge Novatwin+ twin- are simply integrated into the function
screw pump (photo) is more power- shaft of the terminal blocks. Various
Pepperl+Fuchs ful than its predecessor series, and tests can be carried out quickly and
easily with the LPS service connec- pound slope body; and the Rolled
tors. The contact springs have a silver- Cone Bin Discharger design. For trou-
plated surface to ensure permanent ble-free installation, a pre-assembled
and consistent quality. The company’s mounting ring is offered. A patented
LPO load-contact connectors enable beaded sleeve helps to avoid issues
the easy integration of additional load related to leakage and slippage. Users
contacts. This means the LPO con- can choose from oil- or grease-lubri- Phoenix Contact
nectors provide a significant advan- cated vibrators for their system. —
tage, especially if design changes are Vibra Screw, Inc., Totowa, N.J.
necessary in the control cabinet. The www.vibrascrew.com
special design enables a durable and
robust connection. The new connec- Recycle exhaust air and
tors feature maximum ease of use, a reduce energy costs
secure connection, high flexibility and The new Vibro-Bed Energy Recovery
fast installation. — Phoenix Contact System (ERS; photo) is an exhaust-
GmbH & Co. KG, Blomberg, Germany air recycling system engineered to
www.phoenixcontact.com help material processors lower energy
costs, reduce unpleasant odors and
New two-level terminals for curb emissions. The Vibro-Bed ERS
4-mm² cross-sections can be retrofitted onto this company’s
This company has introduced new and competitors’ fluidized-bed drying
space-saving two-level terminals for systems or added onto new equip- Conta-Clip Verbindungstechnik
rated wire cross-sections up to 4 ment installations. A partial-loop dry-
mm². The compact PRKD 4 terminal ing system, ERS recycles a portion
blocks and the corresponding PSLD 4 of the heated air exhausted by the
PE terminals (photo) are available with fluidized bed, while removing excess
two or three ports per level and halve water vapor from the airstream. A
the required installation space. In addi- programmable logic controller (PLC)
tion to the small footprint, both series opens and closes a series of back-
are characterized by a large variance draft dampers, forcing the previously
and particularly easy handling due to heated air back into the fluidized-bed
enlarged insertion channels and mini- dryer. Ideal applications for the ERS
mized engaging force. An integrated include those with exhaust-air tem- Vibra Screw,
pusher, which can be operated with peratures that exceed 150°F (66°C);
light pressure without special tools, or large particle sizes that do not re-
is used to quickly disconnect wires. lease moisture easily; or low drying
The terminal design and vertical wire rates for materials that have bound
insertion from above enable installa- moisture content, such as grains,
tion close to the wiring channels and fruits and vegetables. — Kason Corp.,
thus very compact setups in the field. Millburn, N.J.
The high contact force of the push-in www.kason/com/fluid-bed
spring ensures secure fixation of the
wire ends that withstands even strong New headgear models merge
vibrations and mechanical shocks. comfort and safety compliance Kason
— Conta-Clip Verbindungstechnik Four new safety helmets have been re-
GmbH, Hövelhof, Germany leased as part of the Skullerz product
www.conta-clip.com line, including models with adjustable
venting and rechargeable three-mode
Bin activators are designed to LED headlamps (photo). The newly
enhance solids handling developed Type 2 safety helmets pro-
This company’s Bin Activators (photo) vide comprehensive protection, offer-
help to eliminate bridging and rathol- ing safeguards to the top, front, side
ing in bulk-solids handling applica- and rear of the head to meet the strin-
tions. They also reduce particle seg- gent ANSI/ISEA Z89.1-2014 (R2019)
regation and promote improved mass Type 2 requirements –– all without
flow. The company offers a number of compromising on breathable comfort,
Bin Activator designs to meet a wide a major point of concern among other
range of processing requirements: Type 2 headgear, says the manufac-
the original Dished Head design; the turer. — Ergodyne, St. Paul, Minn.
Model HDBD, which uses a com- www.ergodyne.com Ergodyne

These pumps can handle improve design and operational capa-
challenging solid materials bilities for sustainable energy projects,
The Vortex Series of pumps (photo) are including carbon-capture and storage
designed for handling abrasive wastes. (CCS) applications. Maximus 7.4 flow-
Using a recessed impeller design, the assurance software is equipped with
series combines the efficiency charac- integrated production-modeling capa-
teristics of a self-priming pump with the bilities that help production engineers
solids-handling capabilities of a chop- optimize design and operational strat-
per pump. This makes it suitable for egies to improve decision-making,
applications that need to pass solids asset performance and profits while
while also handling flows to meet the reducing risks. Maximus 7.4 software
Pioneer Pump, a Franklin Electric Co. brand application’s high total dynamic head assesses production risks, such as
(TDH) and gallons per minute (GPM) solid formations (hydrates, waxes,
requirements. Recessed impellers as- asphaltenes and scales), as well as
sure that only about 15% of the sol- facility erosion or corrosion. Improved
ids that pass through the pump come compositional modeling seamlessly
into contact with the impeller, accord- integrates Multiflash technology into
ing to the manufacturer. Combining Maximus software, enabling precise
this impeller design with a vacuum- simulation of complex fluid flows for
assisted priming chamber allows the hydrogen, geothermal energy, liq-
pump to move both solids and fluids uefied natural gas (LNG) and CCS,
efficiently. The priming system also en- as well as oil-and-gas production
sures rapid and unattended re-priming, and transport. — KBC, a Yokogawa
and the run-dry lubrication system Company, Houston
avoids premature failure of the seal www.kbc.com
and rotating assemblies. — Pioneer
Pump, a Franklin Electric Co. brand Low-profile enclosures provide
Baumer www.pioneerpump.com maximum mounting space
PolySlim low-profile enclosures
An extremely small (photo) accommodate existing panel
ultrasonic sensor designs, eliminate unneeded depth
The new UR12 ultrasonic sensor and material, optimize installations and
(photo), in M12 size, is said to be the save space. The low-profile design of
world’s shortest ultrasonic sensor, PolySlim enclosures makes them suit-
featuring a housing reduced down to able for use on building exteriors and
a length of just 50 mm, along with a in tight spaces. They protect equip-
15-mm “blind” area. These sensors ment in non-hazardous industrial ap-
provide a response time of up to 16 plications where space is a premium,
ms with a maximum detection range of and safeguard network components,
500 mm (1,000 mm for through-beam such as routers and switches, in harsh
sensors). This allows design engineers conditions. PolySlim enclosures are
more freedom in space-saving machine well-suited for electrical control, wire-
KBC, a Yokogawa Company
designs. As standard, the sensor fea- less communications, measurement,
tures IO-Link interface for easy integra- monitoring and security applica-
tion and delivery of valuable secondary tions with minimal-depth equipment.
data, while advanced functions ensure PolySlim polycarbonate enclosures
optimum sensor settings, such as easy are available in seven sizes and can be
configuration of sonic cones using this configured with a hinged-screw cover
company’s Sensor Suite platform. For or a hinged-latched cover. PolySlim
less demanding distance measure- enclosures feature a nonmetallic hinge
ment applications, a retrofit product that does not penetrate the inside
variant of is available without IO-Link. of the enclosure. Thick and smooth
— Baumer Ltd., Swindon, U.K. side-wall construction eliminates flex-
www.baumer.com ing and maximizes fitting mounting
space. Additional benefits of PolySlim
Stahlin Optimize operational strategies enclosures include inhibitors that pro-
with this flow-assurance software tect against ultraviolet degradation. —
Maximus 7.4 software (photo) is a Stahlin, Belding, Mich.
multiphase flow tool that simulates www.stahlin.com ■
thermohydraulic conditions to help Mary Page Bailey and Gerald Ondrey
Facts At Your Fingertips
Bolted Flange Joint Assemblies
Department Editor: Scott Jenkins
F
lange-bolted joints enable con- gasket load must then
Bolt load
nections of singular segments be greater than the in- Hydrostatic
of pipes into more complex sec- ternal blowout pressure end force
tions, as well as joining measuring and to ensure the integrity of
process devices, such as flowmeters, the seal. If it is not, a leak
pumps, fans and pressure vessels. or gasket blowout can
These joints are potential sources of occur [2]. Gasket
leakage, which can introduce safety
and environmental hazards, as well as Leakage rate Blowout/
process inefficiencies. This one-page The leakage rate refers internal
pressure
reference reviews concepts associ- to the quantity of fluid
ated with preventing leaks in flange- that passes through the
bolted joints. body and over the faces
of a gasket per unit pe-
Design considerations riphery of the gasket over FIGURE 1. The three main forces at play in a bolted flange joint as-
The design of flange-bolted joints de- a specified time [3]. The sembly (shown here) act to prevent leaks and gasket blowouts
pends on the selection of a gasket, as leakage rate is highly in-
well as the proper assembly. Required fluenced by process media, pressure, calibrated torque-control device
design data include the nominal di- temperature, surface pressure and to ensure proper torque values
ameter of the pipeline, the tempera- other factors. It is usually measured are applied
ture and pressure of the process fluid under a specific gasket load and at a • Keep assembly records to verify that
and the chemical and physical prop- specific fluid pressure. For given set proper procedures were followed
erties of the transported medium. of conditions, the lower the leakage
Additional data are external loads on rate, the better the fluid is retained by Gasket materials
joint (and their variations in time), re- the gasket material. Common gasket materials include
quired tightness and durability of the As a general guideline, increas- elastomers, polytetrafluoroethylene
joint. Over the past several decades, ing internal pressure leads to higher (PTFE), flexible graphite, natural fi-
computational algorithms have been leakage rates. Increasing surface bers or mineral-based materials.
developed to help achieve the desired pressure results in lower leakage Gasket manufacturers provide pres-
bolt tightness. In most cases, the al- rates. Increasing molecular size gen- sure-versus-temperature charts to
gorithms apply to flange-bolted joints erally means lower leakage rates. help determine whether or not the
with circular gaskets, and the results Increasing temperature gives lower material is safe to use for a particu-
of the calculations provide the torque leakage rates for some gasket ma- lar application.
at which the nuts should be tightened terials, although toward the end of
to ensure sufficient tightness [1]. service life, the leakage rate is likely Flange compressibility
to increase [3]. Flange compressibility is consid-
Forces on joints ered to be the percentage reduc-
Three main forces act upon a bolted Installation tips tion in thickness of a flange under
flange joint assembly (BFJA; Figure 1). The following are tips to consider compressive pressure (applied at a
The flange/bolt load acts to compress when installing BFJAs [2]. constant rate, at ambient tempera-
the gasket enough to fill any serra- • Make sure the flange sealing sur- ture). This value provides a means to
tions or imperfections on the sealing faces are clean and free of dings, measure the deformation properties
surface. This helps prevent potential marks or indentations of a gasket, and is an indication of
leak paths. The hydrostatic end load, • Flanges should be aligned to maxi- the ability of the material to conform
caused by the internal pressure of the mize sealing contact and to pro- to the flange surface irregularities [3].
fluid in the system, acts to push the vide a uniform gasket load Gasket materials with higher com-
two flanges apart. The internal blow- • Working surfaces of bolts, nuts and pressibilities will more effectively fill
out pressure acts upon the gasket washers should be lubricated to surface roughness. n
and tries to push it out through the ensure uniform friction
gap between the flanges. • Verify the material, grade and con- References
A main concern surrounding the dition of the bolts. Nuts should 1. Jaszak, P. and Adamek, K., Design and analysis of the flange-
bolted join with respect to required tightness and strength, Open
design and installation of the BFJA spin freely onto the bolt thread Engineering, 2019. https://doi.org/10.1515/eng-2019-0031
is determining the gasket stress or without binding 2. Norton, C., Back to Basics: Soft Gaskets, Fluid Sealing Associa-
load that will be applied to the gas- • Number and tighten bolts using a tion (FSA), Sealing Sense, 2016.
ket (the flange/bolt load minus the proven tightening sequence or 3. European Sealing Association (ESA) and the Fluid Sealing As-
sociation (FSA). Flange Gaskets: Glossary of Terms, ESA/FSA,
hydrostatic end load). This remaining assembly pattern, and use a Publication 018/09. 2009.

Cover Story Part 1
Proactive Industrial Hose

Maintenance
Proper hose maintenance can prevent failures, increase profitability and improve safety
D
Alice Chin eciding when to
Swagelok change industrial
hoses is a common
challenge facing plant
managers and engineers — and
IN BRIEF it is a challenging decision for
SETTING UP good reason. If plant managers
A PROACTIVE wait too long to replace hoses,
MAINTENANCE PLAN the hoses may fail and cause
IDENTIFY ALL HOSES safety issues and unplanned
downtime. On the other hand,
TRACK THE LIFECYCLE
replacing those hoses too early
OF EACH HOSE
may cost a plant unnecessary
ELIMINATE HOSE STRAIN time and money. Therefore, find-
ARE PROTECTIVE ing the right balance for proac-
COVERS REQUIRED? tive hose replacements is key. FIGURE 1. Determining which hose is appropriate for specific applications
But it will take some work to de- depends on the specific criteria necessary for the application. Using an im-
INSPECTION AND termine the appropriate timing. properly reinforced hose could result in early catastrophic failure
REPLACEMENT
An excellent starting point for based on their construction. Replacing them
ANALYZE YOUR DATA optimizing hose replacement schedules is all after one year may be cost prohibitive,
BE PREPARED WITH
for plant managers and engineers to create while waiting five years in between replace-
SPARES
preventive hose-maintenance plans. Such ments could result in at least half the hoses
plans should include tracking the life and experiencing failures.
performance of each hose, which will help As a plant manager surveys the situation
plants zero in on appropriate replacement and tracks the performance of each hose,
intervals. In addition, such plans should in- it makes sense to replace the 25 hoses
clude protocols for making frequent inspec- that experience accelerated wear each
tions, proactively replacing specific hoses, year, moving the second set of hoses to
and identifying which hoses to have in stock a five-year replacement plan. If each hose
in case of failure. It may seem daunting to costs $200, this approach could save the
create this sort of comprehensive plan at plant $20,000 in direct costs per year, not
first, but the long-term savings potential for including the value of reduced downtime
a facility makes it worth the effort. and maintenance. That is a significant
Remember that each hose will face its savings potential that demonstrates why
own stresses and strains depending on facilities should seriously consider estab-
its application, which means replacement lishing and adhering to a preventive hose-
intervals will vary by environment and ex- maintenance plan.
posures (Figure 1). Factors like pressure,
movement demands and which equipment Setting up a proactive maintenance plan
is nearby will affect how hoses wear and Start with the recommendations of your
must be considered when designing pre- hose supplier when developing a preventive
ventive maintenance plans. maintenance schedule, but also supplement
For example, a facility may have a specific those tips based on a real-world understand-
application that uses 50 identical hoses, ing of operating environments, hose materi-
50% of which wear out after one year. The als and other factors. Do not guess how long
other 50% may last five times as long. De- the hoses will function properly. Effective
spite the fact the hoses are identical, it is plant managers should observe their hoses
impossible to set a replacement schedule carefully over time and record changes to
determine what the right replace- require system down-
ment interval should be for specific time. During such routine
hoses. Below are the key steps inspections, employees
plant managers should take to help should examine hoses
create a proper preventive hose- for scrapes, cuts, corro-
maintenance schedule. sion, kinks and general
deterioration, which may
Identify all hoses provide an indication
Before creating your plan, it is cru- that it is time to replace
cial to understand what hoses are in the hose. Record all ob-
the plant. That means conducting a servations in the main- FIGURE 3. Exceeding a hose’s recommended bend radius can pro-
full plant audit, tagging each hose, tenance spreadsheet. If duce undue strain and even result in premature failure
and creating a log detailing the full it is determined that it is
roster of hoses. For each one, in- time to change the hose, the service sources or are installed in strain-
clude information, such as the hose interval should be noted for future inducing configurations, remediate
type, part number, process fluid reference. Over time, understanding those conditions immediately. If left
contained inside, pressure or tem- these intervals allows plant manag- unchecked, they could reduce the
perature ratings and which vendor ers to replace hoses before they fail. lifetime of a hose or, in some cases,
supplied the hose, along with the If a hose does fail despite regular cause outright failure.
appropriate contact information. inspections, employees should note
This information will be handy for every detail, including the location Are protective covers required?
not only tracking hose performance, of failure on the hose, how severe In some cases, hoses require
but also for ordering replacements. the break was and how the hose protective covers, including
In addition, plant managers should was mounted. Recording such in- the following:
log other information like the hose’s formation provides a roadmap for • Thermosleeves, which protect
length, size, core material and con- determining why the hose failed and hoses from weld spatter and resist
struction, reinforcement layers, end how to prevent a similar problem in deterioration from ultraviolet light
connections, mounting, cover type, the future. • Fire jacketing, which protects
operating conditions and cleaning hoses from temperature extremes
procedures. Finally, records should Eliminate hose strain posed by internal system fluids
be kept that indicate when a hose Hoses can come under undue strain • Spiral guards, which protect
was installed and when a replace- during their operation due to several hoses against abrasion
ment is scheduled. If nothing else, common circumstances, including • Armor guards, which keep
these steps will offer significant in- the following: hoses from kinking and experienc-
formation on how well a plant is op- • Twisting a hose or bending it on
ing abrasions
erating. If the process seems over- more than one plane (Figure 2)
• Spring guards, which also help
whelming, a reliable hose supplier • Bending the hose beyond its
to minimize kinking and abrasions
should be able to help perform the recommended radius (Figure 3)
audit and offer recommendations • Bending too close to the hose/ Importantly, hose covers do not
about what needs to be done. fitting connection (Figure 4) alter the technical data provided by
• Allowing insufficient hose length suppliers. Before deploying a hose
Track the lifecycle of each hose so the hose is strained during im- cover, it is crucial to understand the
Schedule hose inspections at the pulses (Figure 5) operating temperature of each op-
interval recommended by the hose • Failing to use elbows and adapt- tion and what the cover does effec-
supplier. More often than not, these tively. For example, thermosleeves
ers to relieve hose strain on hori-
inspections may be visual and do not may keep hoses safe from weld
zontal end connections
splatter, but it will not protect them
(Figure 6)
from abrasion.
During regular inspec-
tions, employees should Inspection and replacement
pay particular atten- As replacement intervals reveal
tion to any unusual cir- themselves over time, a preventive-
cumstances that may maintenance schedule will even-
be putting unexpected tually come into focus. Though
strain on the hose body. replacement intervals may offer
If hoses are rubbing good information about when a
against other equipment, hose may need to be replaced,
FIGURE 2. Strain can occur when a hose is twisted or bent on experiencing pulses, are periodic inspections are still es-
more than one plane subject to external heat sential. In the dynamic world of

may be time to investigate alterna-
tive designs that could lengthen the
replacement interval. Cost-benefit
analyses of new hose types will
allow you to make the right decision
about whether a new hose con-
struction should be considered.
Be prepared with spares

FIGURE 4. Always ensure a hose is bent far Another advantage to having a thor-
enough away from the fitting connection to pre- ough understanding of hose replace-
vent shortening a hose’s useful life ment intervals is that spares can be
ordered well before they must be
replaced. For some hose categories,
it even makes sense to have spares
readily available on-site in case unex-
pected replacements are necessary.
For example, plants should consider
keeping the following types of hoses
on hand.
Hoses for critical safety or process
applications. It is imperative to keep
readily available spares in inventory FIGURE 7. Once hose replacement intervals are
FIGURE 5. If a hose is too short, it may allow for to correct any applications that pres- established, it is still critical to continue periodic
increased strain during impulses hose inspections to ensure the intervals remain
ent critical safety hazards or severe correct over time
downtime potential.
Hoses that are likely to fail. When to observe the effects of a well-
a hose’s operating environment considered preventive maintenance
presents a high likelihood of prema- plan and observe a return on the in-
ture failure, extra hoses should be vestment of time and energy spent
on hand to accommodate frequent creating it. For help, they can work
replacements. For example, hoses with hose suppliers capable of put-
that kink, move in two planes, or ex- ting plants on the path to complete
perience vibration will likely fail ear- preventive maintenance plans. ■
FIGURE 6. Not using elbows and adapters when lier than others. However, as a best Edited by Mary Page Bailey
necessary can also result in premature failure due practice, it may make sense to find
to placing undue strain on the hose a more suitable hose for the applica- All images courtesy of Swagelok
plant maintenance, a change in sys- tion or adjust the system completely
tem parameters could change the to remove the hose strain. Author
amount of strain a hose is under, Hoses for special applications. Alice Chin is field engineer super-
thereby altering the replacement Finally, keep spares of any hoses visor, North America, for Swagelok
Company (29500 Solon Road,
schedule (Figure 7). that are difficult to source due to Solon, Ohio 44139; Website:
special materials, lengths, end con- www.swagelok.com). Chin began
Analyze your data nections, and other variables. For her career with Swagelok Malaysia
as a sales engineer in 2002 and
Collecting detailed information will example, if a special-order hose was promoted to senior sales en-
only get you so far. It is important has a three-week lead time, it is im- gineer in 2005 and account man-
ager in 2008. During her career
to look at this historical data and perative to inventory two spares for with Swagelok Malaysia, she worked with customers
determine whether current inspec- good measure. from various industries, including the chemical, power,
tion and replacement frequen- Establishing an effective preventive gas, semiconductor, pharmaceutical, food and beverage
and other industrial sectors. Chin joined Swagelok in
cies are sufficient. Some could be maintenance plan does not happen 2009 as a field engineer supporting the Southeast Asia
shortened, while others may need by accident. Investing time in regular Region and became field engineer supervisor, Asia Pa-
to be lengthened. On occasion, inspections and record keeping is es- cific in 2019.
engineers should perform destruc- sential and could improve a plant’s
tive tests on replaced hoses to see profitability and safety records. Once Further reading
if they were replaced appropriately, the plan is operational, hoses will 1. Extending the Life of Fluid System Components,
as that may influence replacement need to be replaced less often, and Chem. Eng., Feb. 2023, pp. 25–29.
schedule adjustments. those hoses that still require high 2. Corrosion in Flexible Burner Hoses, Chem. Eng.,
March 2013, pp. 41–46.
If a pattern emerges of a hose maintenance will be on hand just in
3. Predictive Maintenance Implementation, Chem. Eng.,
needing frequent replacement, it case. Plant managers will be able March 2023, pp. 39–41.

Part 2
Cover Story
Predictive
Maintenance Basics
Enabled by modern digitalization tools, predictive maintenance strategies have distinct
advantages over traditional approaches and preventive maintenance protocols
T
he era of visual-inspection-only basis to minimize costly downtime. The initial Namit Tripathi
maintenance routines with an em- data collected can be used to train ML mod- Senior process engineer
ployee checking boxes off on a els to teach these algorithms how to make
clipboard could soon become a predictions or perform tasks. It is important
relic thanks to predictive maintenance. In to ensure those algorithms are programmed
today’s highly automated manufacturing to avoid collecting information or noise that IN BRIEF
environment, data collected from sensors is not related to the task at hand, a condition
PREDICTIVE
can be analyzed to detect any maintenance that may impair the PdM methodology. MAINTENANCE DEFINED
issues that need to be addressed. Further- The type of data collected for PdM might
more, those digital clues can also be har- include temperature or pressure varia- SHIFTING FROM
nessed to create predictive maintenance tions (compared to an acceptable range or PREVENTIVE
routines to help mitigate problems before baseline number), flowrates, motor speeds TO PREDICTIVE
they arise. Whether these issues occur in (by monitoring the variable-frequency drive MAIINTENANCE
process equipment, pipelines or in other controller), or other metrics critical to a spe- SCADA FOR DATA
circumstances, information can be relayed cific operation. PdM differs from preventive COLLECTION
to a software program to monitor for prob- maintenance (PvM) — where routine main- MAINTENANCE
lematic conditions before costly downtime tenance occurs at predetermined intervals STRATEGIES
results. When scheduled on a regular, rou- whether or not it is needed. PvM is often
tine basis, predictive maintenance can help based on past experiences and timeframes, MAKING THE MOVE
extend the life expectancy of physical as- but that may not be a reliable predictor of fu- TO PREDICTIVE
sets, an important factor to consider when ture issues. The drawback is that it also may MAINTENANCE
making an investment in current sensor lead to unnecessary downtime. LOOKING AHEAD: THE
technologies. This article describes predic- FUTURE OF INDUSTRIAL
tive maintenance and outlines the benefits Shifting from PvM to PdM MAINTENANCE
of using it for modern processes. There are some issues to consider when
making the shift from PvM to PdM. These
Predictive maintenance defined include upfront costs associated with the
Predictive maintenance (PdM) is a proac- hardware needed for monitoring systems
tive technique that uses data collected in (such as the sensors, for example), ad-
real time through an array of sensors (even vanced analytical software programs to
drones, in some cases), historical perfor- customize, employee hours to install new
mance data and advanced analytics. Those technology, and the hiring and training of
data are then analyzed by PdM software tools employees required to analyze and then for-
that use algorithms to forecast asset failure mulate a PdM plan. As with any major capi-
with a high degree of reliability unmatched tal project, it is vital to factor the return on
by visual inspections alone. Cutting-edge investment (ROI) into the equation. The di-
technologies like artificial intelligence (AI) and rect benefits of using PdM are fairly straight-
machine learning (ML) are now employed forward. One indirect benefit is that a time-
more for PdM routines. The industrial inter- frame for PdM scheduled on a certain day or
net of things (IIoT) allows data from critical time slot can be relayed to customers, who
operations to be transmitted remotely as can plan accordingly around that pause in
well, alerting key personnel to detect failing operations. Performing those tasks on an
assets in real time. This means that mainte- emergency basis can be more costly (for ex-
nance work can be scheduled ahead of an ample, extra shipping costs from expedited
asset failure (a leaking pipeline or a seized shipping of replacement parts, extra labor
pumping station, for example) on a routine costs for repairs made outside of normal

lected to establish those timelines.
Past history, however, may not ac-
curately predict future breakdowns
as equipment ages. Data analytics
using algorithms fueled by AI and ML
make PdM possible. Data screening
is a first step, ensuring that only the
information collected essential to the
PdM process is used to make deci-
sions. Some of the data produced
may not really be an indicator of fu-
ture problems. Statistical analysis
(a monitoring approach without an
actual machine inspection) shows
123RF when components are going “off-
spec,” indicating that a closer look
FIGURE 1. Predictive maintenance can help extend the life expectancy of physical assets, reduce down- is needed. That analysis leads to the
time, improve productivity and increase profitability
prognostics approach — an engi-
business hours). Switching from PvM also keeps end users from looking neering discipline that predicts when
to PdM helps organizations avoid the elsewhere for other suppliers. a system or component will no lon-
surprises that eat away at profit mar- ger perform its intended function.
gins or result in penalties for failing to Maintenance strategies
meet contracted deadlines. PdM can morph into something more Making the move to PdM
like PvM once there is a history devel- As with any major investment, it is
Scada for data collection oped over time through data analy- essential that buy-in for a move to
A supervisory control and data ac- sis. This is a leap forward from run- PdM starts with the executive man-
quisition system (Scada) involves a to-failure (RTF) maintenance, which agers in the “C-suite.” PdM needs to
network of hardware and software involves taking corrective actions be viewed as a “must-have,” rather
systems that allows for real-time after a piece of equipment fails. Be- than as a “nice-to-have,” technology,
monitoring, supervision and control of cause prior planning for maintaining so that it is accordingly incorporated
machines and facilities. Sensors, pro- equipment is not necessary, RTF re- into capital budget expenditures. It is
grammable logic controllers (PLCs) mains feasible for non-critical assets also important to ascertain what oth-
and remote terminal unit (RTU) micro- that will not impact productivity and ers in the industry are doing. Are they
computers collect the data. Human- it can still be employed for cost sav- investing in the hardware and soft-
machine interfaces (HMIs) display the ings. Conversely, the hardware and ware technologies and the human
critical data that enable operators software installed for PdM are geared capital needed to make such a shift?
to control key functions. Operators towards assets that are deemed criti- Do competitors have less downtime
are provided with a deep dive into cal to operations and must be kept or fewer pipeline or compressor fail-
machine performance and produc- up and running at all times, at least in ures, for example? Do preventive or
tion line efficiencies typically found theory. RTF is based on the concept model-based maintenance routines
in automated industrial operations. that operational assets remain con- in place no longer provide enough
While traditional production-monitor- stant and in ideal condition, which protection against unforeseen down-
ing data are often siloed, Scada ties often is not the case, as there can time? As more suppliers of these
systems together to provide a more be unexpected failures and additional technologies enter the marketplace,
comprehensive data-acquisition tool replacement costs with these assets. economies of scale could reduce
and enable an enhanced “big picture” Without employing PdM strategies, those upfront investment costs. Iden-
snapshot across the entire industrial the lifespan of physical assets may tifying the components that should
automated process. also be shortened. This can also im- be upgraded to use AI for PdM, and
The end result is fewer unplanned pact capital expenditures. where it may not be needed at the
setbacks, with scarcer unforeseen Data-driven approaches to mainte- present time, is a step that should
and unplanned shutdowns, such as nance have emerged in recent years involve both upper management and
emergency outages. The supply- to eclipse model-based disciplines other employees who can provide
chain issues that were evident over where degradation is based on prior valuable insight as to where time and
the past few years mean that keeping knowledge — the recorded history of money are being wasted on unex-
physical assets in operation is more when failures have occurred. Once a pected maintenance.
critical than ever, especially with de- model is built, it must be optimized Predictive analytics is helping com-
mand ramping up as a result of world- manually on a regular basis to predict panies in the energy sector using
wide shortages of parts and finished future maintenance more accurately, sensor technology gain new insights
products and the pent-up consumer whereas AI can automatically and from the gleaned data, which help
appetite for goods post-COVID. This continuously optimize the data col- streamline decision-making timelines,
Looking ahead
There are numerous benefits that result from the imple-
mentation of PdM routines, including avoiding costly
downtime, extending the life of equipment, and fore-
casting with more accuracy when a vital component
may need to be replaced or upgraded. PdM provides
a more holistic view of the physical assets that must
be kept operational at all times. Including AI to col-
lect data to monitor for issues using PdM routines can
mean fewer “fires” to put out on a regular basis. De-
spite the possibility of significant upfront investment,
especially for older facilities, less downtime means
more profitability and the optimization of operations.
Companies that take advantage of modern PdM can
create a positive competitive edge. n
Edited by Scott Jenkins
123RF
FIGURE 2. Predictive analytics, fueled by technologies such as artificial intel- Author

ligence and machine learning, help companies gain new insights from the Namit Tripathi is a process engineer and product manager in
gleaned data, streamline decision-making timelines, and keep automated the industrial gases energy sector (Email: namitgwa@gmail.
processes running smoothly com). He has more than a decade of experience in operations,
process troubleshooting, quality improvement, and product op-
keep automated processes running smoothly and ul- timization. He is a peer reviewer for and editorial board mem-
timately improve the customer experience (Figure 2). ber of multiple chemical engineering journals. Tripathi holds a
B.S.Ch.E. degree from Madhav Institute of Technology and Sci-
With the help of customized software packages, the ence in India and a Ph.D. in chemical engineering from Lamar
identification of failing physical assets and better fore- University.
casts on the remaining life of that machinery is help-
ing to minimize downtime. In the oil-and-gas industry,
where unplanned idle assets due to plant problems can
Call the Experts

be very costly, a production facility shut down for re-
pairs may take several days or even longer to come
back online, if the undetected issue is severe enough.
Downtime is not an option in the energy sector. for all your solids processing
Condition monitoring uses an array of sensors that
may employ vibration analysis, infrared thermography,
ultrasonic testing and oil analysis to look for anomalies Solids Mixing Applications:
in the petroleum refinery or oil transport process. In the Ribbon & Cone Blenders APIs ∙ Ag-Chemicals
oil-and-gas sector, virtual rig monitoring that transmits Fluidizing Mixers
information via IIoT means data can be gathered and Sigma Blade Mixers
Biologics ∙ Catalysts
transmitted elsewhere remotely without an employee (also for high-viscosity mixing) Ceramics ∙ Chemicals
being present onsite at a windswept offshore or des-
Size Reduction
Food Ingredients
ert drilling/pumping station. Detecting oil, natural gas
or other chemical pipeline leaks more quickly can also Herbicides ∙ Minerals
Wet & Dry Size Reduction
help avoid costly fines for environmental regulation vio- Steel & Ceramic Lined Mills Nutraceuticals ∙ Pesticides
lations. Currently, however, many plants constructed Jars & Jar Rolling Mills Pharmaceuticals ∙ Pigments
decades ago continue to use visual maintenance where
PdM technologies have not been installed or retrofitted, Vacuum Drying Polymers ∙ Powdered Metals
at least to an extent that produces maximum benefits. Dryers & Complete Systems Proteins ∙ Resins ∙ Vitamins
It is also important to watch for improper data se-
lection — a lack of coordination when employees from
different departments are involved with data analysis,
as well as poor modeling and inadequate training when
launching PdM. Using the same personnel to collect
the same data from the same location every time,
known as repeatability, increases the confidence level
Quality &
in what datasets are being aggregated. Failing to keep Innovation Since 1911
up with the constant evolution of technology (the lat-
est in sensors and software, for example) can lead to
a competitive disadvantage, which is why it is essential
to maintain and update the model guiding PdM routines www.pauloabbe.com 855-789-9827 sales@pauloabbe.com
as required, based on the latest data. For details visit adlinks.chemengonline.com/84652-11

Engineering Practice
Breaking New Ground: AI’s
Role in Biomanufacturing
Advanced technologies employing artificial intelligence (AI) and deep-learning models
can reshape product inspection and quality control in bioprocesses, but users must
understand both the capabilities and limitations of such digital platforms for optimal
implementation
Riccardo Butta control (QC) process for drug manu- defect detection, but also reliability,
Stevanato Group
A
facturers, because it is essential in allowing for a more precise analysis
rtificial intelligence (AI) has ensuring drug and container quality of inspection data. Moving forward,
revolutionized the phar- before the product gets distributed we foresee human inspection and
maceutical industry, per- to the patient. These systems can AI continuing to work together, le-
meating every aspect from efficiently inspect containers, detect veraging real-time data to improve
drug discovery to drug manufactur- defects, reduce false rejects, and production knowledge.
ing. With its ability to analyze vast ensure product integrity with high
amounts of data, AI has become accuracy, significantly increasing Deep learning for inspection
an invaluable tool in enabling the manufacturing capacity. Deep learning has emerged as a
biopharmaceutical industry to bring By automating the inspection pro- powerful tool within the biomanufac-
safer and more reliable drugs to the cess, pharmaceutical manufacturers turing industry, offering substantial
market. Notable applications of AI can improve productivity, reduce er- benefits in terms of quality control
in biomanufacturing, such as deep rors and enhance overall product and inspection performance. Par-
learning models and digital twin quality. These systems can swiftly ticularly, when applied to visual in-
technology, can be implemented in analyze images and identify even the spection, deep-learning algorithms
visual inspection processes — all of tiniest defects or imperfections that can significantly enhance accuracy
which can provide drugmakers and may not be easily detectable by the and efficiency throughout the bio-
biomanufacturers with increased human eye. By doing so, they provide manufacturing lifecycle. By leverag-
productivity and improved efficiency a level of precision that surpasses ing extensive training on large da-
(Figure 1). While these technolo- manual inspection, ensuring that no tasets, deep-learning models can
gies are redefining the standards of potential issues are overlooked dur- detect subtle defects and anomalies
drug development and manufac- ing the production process. (Figure 2).
turing, they also come with draw- Manual inspection remains the This not only improves the overall
backs that drug manufacturers regulatory standard today. However, product quality but also reduces the
must overcome to reap the ultimate the industry is seeing a pattern of number of false rejects and reduces
benefits of adopting these cutting- increasing automation, using tradi- the need for manual re-inspection of
edge technologies. tional rule-based algorithms and ap- “grey” items that do not meet quality
plying deep-learning models, as AI standards. From manufacturing data,
The evolution of visual inspection continues to permeate the industry. it can be seen that false rejects can
While manual inspection continues Every automated inspection system be reduced tenfold, to less than 1%,
to be the gold standard for detect- is challenged against manual in- and the detection rate can also be
ing defects across the drug manu- spection to prove efficacy, and this improved because of deep learning,
facturing lifecycle, this process is will also be the benchmark to be yielding up to 99.9% accuracy. As a
time-consuming and labor-intensive. reached and
Stevanato Group
The market continues to demand a surpassed
higher volume output. To address by automa-
these limitations, drug manufactur- tion. The use
ers turned to automated inspection of AI-pow-
systems that incorporated advanced ered vision
vision software and machine learn- equipment
ing algorithms. The implementation not only can
of visual inspection equipment has enhance the FIGURE 1. Optical inspection is one of the major applications where AI and deep-
significantly impacted the quality- efficiency of learning technologies are frequently being applied in biomanufacturing processes
Stevanato Group
result, deep learning helps stream- Digital twin technology also ap-
line the inspection process, saving plies real-time data to replicate
both time and resources, and lead- complex supply chain processes,
ing to a reduction in the total cost of enabling drug manufacturers to
ownership (TCO) for manufacturers. identify potential weak spots and
These robust systems can adapt to plan contingencies even before
variations within production with- they occur. By leveraging machine
out the need to constantly adjust learning and AI, the digital twin can
the inspection recipe, ensuring analyze historical data patterns, FIGURE 2. Deep-learning models are being imple-
consistent performance and elimi- compare them with real-time data, mented in quality-control schemes to quickly
detect product defects and learn about manufac-
nating the costs associated with and predict the likelihood of future turing patterns
frequent modifications. issues. As a result, maintenance
Being such a nascent technology, teams can move from traditional, inspection technology enables the
the main roadblock with deep-learn- time-based maintenance sched- detection of even subtle defects,
ing technology is the scarcity of de- ules to condition-based strategies, ensuring product integrity and
fect examples to “train” the technol- intervening precisely when needed. safety. Deep-learning algorithms,
ogy, especially with new products Predictive maintenance minimizes when trained on extensive data-
that have just entered production. downtime, prevents costly break- sets, bring unparalleled precision
This has sparked discussions within downs, extends the lifespan of as- and efficiency to quality control pro-
the industry around how to effec- sets and optimizes maintenance cesses, reducing false rejects and
tively validate the learning process costs by focusing efforts on critical minimizing manual re-inspections.
and identify an effective way forward areas. This approach not only en- Additionally, digital twin technology
that pharmaceutical companies can hances operational efficiency, but offers a virtual replica of the manu-
adopt. Neural networks, which lie at also boosts overall productivity and facturing process, facilitating pre-
the core of the deep learning pro- ensures a more reliable and sustain- dictive analysis, risk mitigation and
cess, possess the ability to continu- able operation of complex systems. resource optimization.
ously learn and adapt. However, this While digital twin technology can The combination of these tech-
adaptability can make them seem be extremely beneficial, the as- nologies can lead to improved ac-
like proverbial “black boxes,” mak- sociated maintenance requires curacy, increased productivity and
ing it challenging to ensure that they consistent money, time and effort streamlined operations in biomanu-
abide by the predefined acceptable from drug manufacturers. If a digi- facturing, ultimately enhancing the
levels of performance. To address tal twin is not maintained properly, quality and reliability of biopharma-
this concern, the practice of “freez- the effort to create the digital twin ceutical products. As these tech-
ing” the neural network is being is voided, because it is no longer an nologies continue to evolve and be
widely considered as the preferred exact replica of the process. For ex- integrated into processes, we can
method of validation. By freezing ample, many errors across the bio- expect even greater advancements
the network at certain points dur- manufacturing lifecycle are a result and innovations in the field, further
ing its learning, researchers and of outdated data, which can cause solidifying their critical role in shap-
developers can evaluate its perfor- major delays as drug manufacturing the future of biopharmaceutical
mance and check that it respects ers need to spend time identifying production. The companies that
the identified appropriate levels the inaccurate data. To combat are best able to leverage these new
of operation. this, drug manufacturers can work capabilities will emerge as the vic-
With its ability to enhance quality, with a partner that facilitates the tors, as AI continues to develop and
increase inspection performance, implementation of infrastructure shape the world we know. ■
and reduce operational expenses, that collects, monitors and inter- Edited by Mary Page Bailey
deep learning has the potential to prets data to ensure processes are
provide significant benefits to the running smoothly. Author
pharmaceutical industry. Overall, the implementation of Riccardo Butta is the president of
digital twin technology in biomanu- the Americas at Stevanato Group
(Website: www.stevanatogroup.
Digital twins facturing holds the potential to sig- com), a global provider of drug
Further to the enhancements that nificantly improve quality, increase containment, drug delivery and
visual inspection technology and operational efficiency and mitigate diagnostic solutions to the phar-
maceutical, biotechnology and life
deep-learning algorithms provide, production issues. sciences industries. He holds an
digital twin technology offers yet an- M.S. degree in mechanical engi-
neering from Politecnico in Milan,
other transformative approach in the Unleashing the power of AI Italy, and a degree in business management and inno-
field of biomanufacturing. By creat- The integration of visual inspection vation from MIP in Milan. Butta was formerly the senior
ing a virtual replica of real-world technology, deep learning and digi- vice president of Flex Health Solutions. At Flex, he was
responsible for the global commercial organization of a
assembly processes, a digital twin tal twin technology has significantly business unit providing contract design, manufacturing
enables risk prediction, minimizes enhanced accuracy and perfor- and logistics services to the healthcare industry. His pri-
errors and reduces delivery time. mance in biomanufacturing. Visual mary focus was on medical devices, drug delivery solu-
tions, diagnostics and life-sciences equipment.

Solids Processing
Preventing Dust Explosions with
Flow Analysis
Dust collection systems are often designed using simple rules of thumb that may not
be sufficient for proper operation. Flow analysis can ensure that the systems meet
requirements
Ben Keiser tainty regarding its functionality. teristics and assess the potential for
Applied Flow Technology (AFT) To reduce the risk of dust explo- explosion. With information from the
T
sions and ensure that a dust collec- DHA, plant designers and operators
he presence of dust is one of tion system is meeting the require- can determine methods of prevention
the many potential causes for ments of the process, it is imperative and mitigation of dust explosions.
explosions and fires at pro- to go a step further than rule-of-
cess plants. Dust collection thumb designs and perform a sys- Design considerations
systems can provide a significant tem-level flow analysis. Accurate The primary function of a dust col-
level of explosion prevention, and system-level flow analysis of dust lection system is to provide points
they can also help maintain a safe collection systems is critical for ex- of entry into the ducting network
working environment and reliable plosion prevention in process plant where dust can be collected and
equipment operation. operations. This article discusses then transported into a primary dust
Despite their status as critical com- considerations for flow analyses of collector. The dust collection system
ponents in a plant’s overall safety in- dust collection systems, including is basically a large vacuum, so high
frastructure, dust collection system the use of flow analysis to aid design velocities and flows are needed to
designs are often based on simplified for normal operation, as well as vari- transport the dust through the duct-
rules of thumb, rather than being rig- ous operating scenarios when differ- ing network.
orously designed like other process ent components and flow paths are When dust collection systems are
units and systems in a plant. Using online at different times, and when- not working as they should, dust
basic rules of thumb to guide de- ever additional branch paths are may start to accumulate within the
signs can be problematic because added into an existing system. ducting. If moisture is present, then
designers assume that the rules of dust can begin to stick to walls and
thumb will necessarily lead to a prop- Potential dust hazards fittings. This is just one of many ex-
erly functional system. Flow analysis There are five critical conditions that amples of how a dust collection sys-
of dust control systems finds that this when met, can lead to a disastrous tem may fail — continued analysis
is often not the case. Dust collection explosion event, such as the one can help avoid this. The following are
systems that are “thrown together” that occurred at the Imperial Sugar some of the main areas that must be
without well-thought-out designs can Refinery in Georgia in February 2008 considered for designing a dust col-
introduce problems and the system that killed 14 people and injured 38 lection system.
may not work properly. In addition, others [1]. In addition to the three Flow velocities. If velocities are
new pieces of equipment get added components needed for all combus- too low, then dust may settle and
to a process over time as production — fuel (in this case a combusti- increase system pressure drop,
tion expands, and the dust collection ble dust), oxidant and ignition source which leads to higher energy costs,
system quickly becomes increasingly — dust explosions also require the because blowers must overcome
complicated. This leads to uncer- dust to be dispersed in the atmo- higher levels of resistance. Even
sphere and confined. worse is potentially plugging up the
Dust is just one of ducting. Excessively high velocities
the many fuel sources can also be an issue. High velocities
that can cause explo- can cause the dust to erode duct-
sions and it is difficult ing and other network components.
to know which types Also, dust flowing at too high a ve-
of dust can explode, locity may hit features like sharp turn
and under what con- elbows or branch line connections,
ditions, and which which can potentially cause an ac-
ones will not. There- cumulation of dust at those points.
fore, whenever dust Another issue is that if dust is moist
is present, a dust haz- or sticky, it might smear along the
ards analysis (DHA) is wall, also leading to potential duct-
FIGURE 1. The diagram shows an example of a simple dust collection performed to deter- ing erosion and accumulation.
system with multiple pieces of equipment after layout and duct sizing mine the dust charac- The velocity in a certain duct
has been determined
Type of dust Velocity in Velocity in ing temperatures do not
branches main reach unsafe levels.
Metalworking Dust 4,500 ft/min 4,000 ft/min Dust buildup. It is critical
Woodworking Dust 4,000 ft/min 3,500 ft/min to ensure that dust does
Other Light Dust 4,000 ft/min 3,500 ft/min not collect and build-up
ft3/min requirements for diameter at specified velocity within the ducting sys-
Diameter 3,500 ft/min 4,000 ft/min 4,500 ft/min tem. If it does, this can
3 in. 170 195 220 cause a dust collection
4 in. 300 350 390
system to become a part
5 in. 475 550 610
of the problem instead of
part of the solution. Ac-
6 in. 700 785 880
cumulated dust inside
7 in. 950 1,100 1,200
the ducting network is an
8 in. 1,200 1,400 1,570
explosion or fire hazard.
9 in. 1,550 1,800 1,990 Another major concern
10 in. 1,900 2,200 2,450 is that the accumulation
12 in. 2,800 3,175 3,600 can cause an explosion
14 in. 3,800 4,300 4,800 or fire that may have been
started and caused by
FIGURE 2. Example dust types have different velocity require-
ments and equipment flow requirements for various duct sizes at some other means in the
specified velocities plant to quickly propa-
gate an explosion or fire
branch line may be adequate for through the ducting system itself.
proper transport. However, when it
ties into another duct line, the com- System-level flow analysis
bined flows may lead to excessive ve- Overall, ensuring flow velocities that
locities. Combined flows and associ- are not too low or too high, and ob-
ated velocities are just as important to taining the proper system flow capac-
pay attention to as individual branch ity is easily achieved through system-
line velocities. Basic, rudimentary level flow analysis. Once the design
designs based on simplified rules-of- has been proven functional through
thumb likely will not allow designs to the flow analysis, other operating
arrive at the correct flow velocities for scenarios must be considered. This
a dust collection system. includes simulating when various
Compressible flow. A major aspect branch lines are online or not, as well
of a dust collection system that is as the effect on system performance
often overlooked is the fact that it is if excessive dust buildup is present,
a compressible flow system. Most or when the dust collector and fil-
often, dust collection systems are ters need to be changed, and when
assumed to be incompressible, and branch lines are added and removed.
this leads to uncertainties when real Dust collection systems often evolve
gas effects are not dealt with cor- significantly over time and a quality
rectly. Various rules of thumb exist flow analysis can save time in rebal-
that some will apply for when to treat ancing the system.
a compressible system as incom- Before designing a dust collec-
pressible and often these assumption system, one needs to know the
tions and rules of thumb fall short. location of the equipment produc-
Due to the nature of compress- ing dust to identify the location of
ibility, the flow inside the system will the dust collection unit. Floor-to-
tend to accelerate. This can lead joist measurements need to be de-
to excessive velocities and pres- termined so elevation data can be
sure drops and would not be de- handled properly. Any obstructions
termined and dealt with properly if interfering with the ducting (such
constant velocities under incom- as walls or other pieces of equip-
pressible flow assumptions are em- ment) or direction changes need to
ployed. Also, temperature change be known.
and heat transfer play an important Next, the ductwork layout can be
role in compressible flow of gas established. The duct sizes are then
piping and ducting systems. Com- determined during the design and
pression heating through blowers calculation process based upon the
will increase temperatures and it is rules of thumb and associated flow
important to monitor that the result- and velocity requirements. Figure 1

FIGURE 3. The diagram shows a system flow analysis model of the dust collection system example from Figure 1. Input is displayed for duct sizes, lengths,
schedules, elevations and so on
is an example of a very simple dust the other three are during the main determining pressure drop based
collection system for a manufactur- ducting header sizing process. upon a certain length of ducting at
ing facility. The system in Figure 1 The design basis with only three different ducting sizes and velocities.
is what the dust collection system “primary” pieces of equipment oper- Minor losses can either be dealt with
might look like after the layout and ating is another reason why flow anal- by determining the losses in terms
duct sizing has been determined. ysis is critical. Consider the possibility of inches of water, for example, or
The basics of dust-collection sys- that all five pieces of equipment are to convert the losses to equivalent
tem design start with the duct ve- on at the same time? Will the duct- lengths of piping. Once the design
locity requirements for transporting ing header still be the right size to is finished, parts and equipment can
dust of different types. Velocities handle the additional flow capacity to be ordered and installed.
typically range between 3,500 and the dust collector? How much more However, the question is: will this
4,500 ft3/min. Based upon the spe- pressure drop will there be with the system work as designed? Unless
cific velocities needed for the type of higher velocities? Will main ducting users conduct a proper flow analy-
dust being dealt with, the ductwork velocities be too high that may cause sis, the assumption would be that it
can be sized for the branch lines problems discussed earlier? does work, and that can be poten-
from the equipment to the main duct These are all important questions tially dangerous, if unchecked.
headers depending on the flow re- that can only be answered with a
quirements of the equipment. Figure detailed analysis. And this is only Software requirements
3 provides some examples of vari- one other operating scenario where A flow model of the simple system in
ous velocity requirements for differ- all pieces of equipment are operat- Figure 1 can be constructed relatively
ent kinds of dust and the flow re- ing. These same types of questions easily with flow-analysis software.
quirements for different duct sizes at would apply for
specific velocities. other cases that
can include but
Dust collection example are not limited to
This manufacturing facility has a com- the addition of
bination of “primary” and “second- more branch lines
ary” pieces of equipment. Primary for new pieces of
equipment usually includes major equipment, the
equipment units that are operating at impact from dust
the same time. This would typically buildup inside the
start as a base-case scenario in a ducting, and many
flow model to simulate the maximum other scenarios.
flow requirements. In this system, the System resis-
radial saw machine has a higher flow tance is usually
requirement than the table saw and also determined
lathe. The floor sweep and sander under rudimentary
are secondary components that are rules of thumb, FIGURE 4. The example dust collection system now contains added equip-
considered to not be operating while which includes ment: a secondary table saw, lathe and radial saw
Figure 1 the two table saws (upper table saw
with only the and lower second table saw). Re-
table saw, viewing how various system param-
lathe and eters change over a flow path gives
radial saw great insight into how the system
operating, is performing and where you might
it was ob- have an issue. Figure 5 is an exam-
served that ple of the velocity profile plotted from
the minimum both table saws to the dust collector.
required ve- At least half of the ductwork in both
locities and paths from each table saw is not able
flowrates to operate at a sufficient velocity for
were not properly carrying the dust particles.
met in sev- Cross-plotting system parameters
FIGURE 5. A plot of the velocity in the flow paths from each table saw to the dust eral areas. with their minimum or maximum val-
collector from Figure 4. Velocities are well-below minimum velocities required in the
first 125 ft (approximately) of ducting from each table saw
The ve- ues allows one to easily see where
locities and design requirements are violated.
Make sure it is a flow-analysis soft- flowrates were significantly lower Overall, dust collection systems
ware that properly handles the com- than what they needed to be in the are a very important piece of the
plex nature of compressible flow. branch line with the table saw and strategy for prevention and protec-
Basic required input for the model the main ducting header between tion against process plant explo-
would include duct sizes, lengths, when the lathe branch line ties into sions and fires. Simple rules-of-
elevation data, loss factors for minor the main header and where the ra- thumb approaches to the design of
losses and the flow requirements for dial saw branch line ties in. There- dust collection systems are likely to
the blower or fan. The system flow fore, we immediately can determine fall short. Therefore, it is critical to
model might look something like that that the design that was established perform a system-level analysis to
in Figure 3. based upon rudimentary rules-of- determine design feasibility, as well
A quality flow-analysis software thumb does not get the job done. as how to start modifying design
tool should allow users to easily dis- If this design was not checked and potentially the operation to meet
play system model input information with a system flow analysis, then the appropriate requirements. Flow-
directly on top of the graphical model dust collection problems may have analysis software makes it easy to
itself. This allows engineers to ensure started to occur and lead to a po- effectively analyze systems for their
the model is correct to achieve accu- tentially terrible explosion incident function and effectiveness. Ideally,
rate results. It also helps others to be that we all want to avoid. This analy- software will be employed that can
able to easily follow along with what sis was only for one scenario. Other not only analyze design, but can also
is happening in the system if they are scenarios, such as when all pieces of help with design by automatically
not intimately familiar with the design. equipment are operating, resulted in determining proper duct sizes that
Another helpful feature that all the primary pieces of equipment will meet requirements. n
a quality flow-analysis software and their branch lines not being able Edited by Scott Jenkins
should have is the ability to alert the to meet the required velocities, as
user when a design limitation is ex- well as the main header line up to Reference
ceeded. The system model in Fig- the point where the sander ties in. 1. Chemical Safety and Hazard Investigation Board (CSB),
ure 3 has design requirements for Again, this is another clear example www.csb.gov/imperial-sugar-company-dust-explosion-
and-fire/. 2008.
minimum velocities and minimum of how the rules of thumb governing
flowrates in the various flow lines. the dust-collection-system design
Maximum velocities can be set up will fail to produce a properly operat- Editor’s note: All diagrams courtesy of AFT
as well, to alert the user of pos- ing system.
sible erosion velocities. But for the Figure 4 provides an example of Author
sake of simplicity, this model only how systems quickly evolve and ex- Ben Keiser is a technical sales
considers minimum velocities and pand as new pieces of equipment manager for Applied Flow Tech-
nology (AFT; 2955 Professional
flowrates. Erosion may take a long and branch lines are added into ex- Place, Suite 301, Colorado
time and depends on the material isting systems. Expansions of dust Springs, Colo.; Phone: 719-686-
and how long the system operates collection systems are rarely ever 1000; Email: info@aft.com; Web-
at erosional velocities. This may not analyzed, and similar to the way the site: www.aft.com), a leading dy-
namic fluid-flow-analysis and
always be as much of a concern in initial design (based upon simple waterhammer-mitigation soft-
cases where velocities and flow- rules of thumb) does not work, the ware company located in Colo-
rates are too low, where dust can flow analysis model shows that the rado Springs, Colo. Keiser holds a B.S.Ch.E. from the
Colorado School of Mines. Keiser helps engineers un-
begin to accumulate. dust collection for the expanded derstand how to design safe and efficient piping and
network shown in Figure 4 will not ducting systems. His passion and expertise can be ac-
Identifying issues work either. cessed around the world as he trains engineering
teams how to efficiently preform flow analysis simula-
After running a flow analysis for the The two most remote pieces of tions to find optimized solutions.
scenario shown in the example in equipment to the dust collector are

Boost Wastewater Process
Efficiency
Sierra Instruments’ New BioTrak™ 645i Wastewater Thermal Mass
Flow Meter meets the rugged demands of municipal and industrial
wastewater plants where aeration, digestion, and cogeneration play
pivotal roles. The BioTrak is designed and manufactured to be the
most cost-effective and best-performing flow meter in the wastewa-
ter industry. It makes operators smarter and their processes more
reliably efficient.
• Field selectable air, methane, and digester gas
• Air: +/-1% of reading, +/-0.2% of full scale
• Other gases: ±1.5% of reading ±0.5% full scale
• AC or DC power input, optional hot tap capability, and remote
configuration
www.sierrainstruments.com
• Easy to install, operate, and adjust in the field to avoid costly and
time-consuming delays
Learn More: https://info.sierrainstruments.com/645i-biotrak-
Chemical Engineering’s premium

product showcase for the latest
products and technologies in the
chemical processing industries.
to subscribe to the e-letter, please visit:
www.chemengonline.com/eletter-signup
26033

High Energy Efficiency Plateflow®
Gasketed Plate and Frame
Heat Exchangers
Through advanced engineering and high-efficiency technology, Stan-
dard Xchange High Energy Efficiency Plateflow® Gasketed Plate and
Frame Heat Exchangers deliver increased heat transfer performance
in a smaller footprint and support applications such as oil and process
cooling and heating.
Available in a range of standard configuration options, the new High
Energy Efficiency Plateflow delivers up to 20% increase in heat transfer
thermal performance, up to 20% reduction in surface area, and up to
15% reduction in material.
Standard Exchange Watch the Video

www.xylem.com/en-us/brands/
standard-xchange
Multi-Purpose Iris Diaphragm Valve

for Bulk Solids
The Mucon AD Iris Diaphragm Valve is a ruggedly designed valve for
heavy bulk material applications and frequent operation. Designed as
a double diaphragm valve for in-line applications the AD has no
atmospheric leakage. Each valve is manufactured with aluminum body
parts, but is also optionally offered in stainless steel construction for
hygienic processing areas. Stainless steel screws are used to combat
corrosion. The AD valve can be utilized in a wide range of applications
ranging from an outlet valve for silos, bins, hoppers and chutes to con-
trolling discharge from sifters, ribbon mixers and double cone blender out-
lets. Material handling up to 100 pounds per cubic foot is achievable.
Kemutec/Schenck Process FPM
130 Wharton Rd
Keystone Industrial Park
Bristol, PA 09007
Tel: 215-788-8013
sales@kemutecusa.com
Kemutec/Schenck Process FPM www.kemutecusa.com
www.kemutecusa.com

New & Used Equipment
HEAT EXCHANGERS
RIBBON Liquid Cooled
▼
BLENDERS
Customizable for your
blending process Air Cooled
▼
•High quality materials & construction FOR GASES & LIQUIDS!
•Many options available Talk Directly with Design Engineers!
Blower Cooling Vent Condensing
•Sizes from 1/2 cu. ft. to 1000 cu. ft.
•Standard models in stock for
faster delivery
(952) 933-2559 info@xchanger.com
1-800-243-ROSS For details visit
adlinks.chemengonline.com/84652-242
mixers.com/ribbon-blenders
For details visit For details visit

adlinks.chemengonline.com/84652-240 adlinks.chemengonline.com/84652-243
Software
Engineering e-material, e-solutions, e-courses
and e-seminars for energy conversion systems: ADVERTISE IN
THE CLASSIFIEDS
● Physical Properties ● Steam Approximations
● Power Cycles ● Compressible Flow
● Power Cycle Components/Processes
ENGINEERING SOFTWARE
Phone: (301) 919-9670
Web Site: http://www.engineering-4e.com Contact your Sales Representative
Check out free online calcs, demos, etc.
For details visit
for More Information:
JASON BULLOCK | 832-771-1478

jbullock@chemengonline.com
TERRY DAVIS | 404-434-5123

tdavis@chemengonline.com
PETRA TRAUTES| +49 49 58604760

ptrautes@accessintel.com
Advertising Sales Representatives

North America International
Matthew Grant | VP & Group Publisher Terry Davis | District Sales Manager Petra Trautes Katshuhiro Ishii
mgrant@accessintel.com Tel: 404-634-5123 Tel: +49-69-58604760 Tel: 81-3-5691-3335
E-mail: tdavis@accessintel.com Fax: +49-69-5700-2484 Fax: 81-3-5691-3336
Chemical Engineering 2276 Eastway Rd., Email: ptrautes@chemengonline.com E-mail: amskatsu@dream.com
Jason Bullock, CBC | Decatur, GA 30033 Chemical Engineering Zeilweg 44 Chemical Engineering Ace Media Service
District Sales Manager Connecticut, District Of Columbia, D-60439 Frankfurt am Main Germany Inc., 12-6, 4-chome Nishiiko, Adachi-ku,
Tel: 832-771-1478 Delaware, Georgia, Maine, Maryland, Europe Tokyo 121, Japan
E-mail: jbullock@chemengonline.com Massachusetts, New Hampshire, New Japan
Chemical Engineering 1940 Fountain View #514 Jersey, New York, Pennsylvania, Rhode
Houston, TX 77057 Island, Vermont, Canada, Latin America Dipali Dhar
Alabama, Alaska, Arizona, Arkansas, California, Tel: 718-263-1162 Rudy Teng
Colorado, Florida, Idaho, Hawaii, Idaho, Illinois, E-mail: ddhar@accessintel.com Tel: +86 13818181202, (China)
Indiana, Iowa, Kansas, Kentucky, Louisiana, Chemical Engineering 40 Wall Street, +886 921322428 (Taiwan)
Michigan, Minnesota, Mississippi, Montana, 16th Floor, New York, NY 10005 Fax: +86 21 54183567
Missouri, Nebraska, Nevada, New Mexico, India E-mail: rudy.teng@gmail.com
North Carolina, North Dakota, Ohio, Oklahoma, Chemical Engineering 8F-1
Oregon, South Carolina, South Dakota, #181 Wulin Road Hsinchu 30055 Taiwan
Tennessee, Texas, Utah, Virginia, West Virginia, Asia-Pacific, Hong Kong, People’s
Wyoming, Washington, Wisconsin Republic of China, Taiwan

Advertisers Index
Advertiser.............. Page number Advertiser.............. Page number Advertiser.............. Page number
Phone number Reader Service # Phone number Reader Service # Phone number Reader Service #
Abbe, Paul O...........................37 Kemutec/Schenck Process....45 Rembe.....................................17

1-855-789-9827 adlinks.chemengonline.com/84652-14 +49 2961 7405-0
Lechler USA.............................17
ACHEMA 2024........................ 12 adlinks.chemengonline.com/84652-06 Ross Mixers..............................7
www.achema.de 1-800-243-ROSS
Load Controls......................... 10
Busch USA.............................. 21 1-888-600-3247
1-800-USA-PUMP adlinks.chemengonline.com/84652-08 Sierra Instruments...................44
MathWorks.......................... CV4
Chemstations............................9 adlinks.chemengonline.com/84652-16 Xylem......................................45
Plast-O-Matic Valves, Inc........27

Curtiss-Wright EST-Group.........3 973-256-3000 Zeeco...................................... 15
1-877-537-9120 adlinks.chemengonline.com/84652-10 918-258-8551
Flexicon............................... CV 2
1-888-FLEXICON
Classified Index October 2023
New & Used Equipment..........................................................46

Software...................................................................................46
Fluid Line Products.................. 41
440-946-9470
Advertiser Page number Advertiser Page number
Phone number Reader Service # Phone number Reader Service #
Engineering Software.............46 Vesconite Bearings................46

(301-919-9670 713-574-7255
See bottom of opposite page adlinks.chemengonline.com/84652-243 adlinks.chemengonline.com/84652-242
for advertising
sales representatives' Ross Mixers...........................46 Xchanger...............................46
1-866-243-ROSS (952) 933-2559
contact information
FOR ADDITIONAL NEWS AS IT DEVELOPS, PLEASE VISIT WWW.CHEMENGONLINE.COM

October 2023; VOL. 130; NO. 10
Chemical Engineering copyright © 2023 (ISSN 0009-2460) is published monthly by Access Intelligence, LLC, 9211 Corporate Blvd., 4th Floor, Rockville, MD 20850. Chemical Engineering Executive, Editorial and Publication Office: 40 Wall Street,
16th Floor, New York, NY 10005. Phone: 212-621-4694. Subscription rates: U.S. and possessions 1-year $199.97, 2-years $ 359.00, Canada and International 1-year $ 399.97, 2 years $ 719.00. Back Issues & Single Copy Sales $59.00 per
copy. Periodical postage paid at Rockville, MD and additional mailing offices. Postmaster: Send address changes to Chemical Engineering, 9211 Corporate Blvd., 4th Floor, Rockville, MD 20850. Phone: 1-800-777-5006, Fax: 301-309-3847, email:
clientservices@accessintel.com. Change of address two to eight weeks notice requested. For information regards article reprints please contact Wright’s Media, 1-877-652-5295, accessintel@wrightsmedia.com. Contents December not be reproduced
in any form without permission. Canada Post 40612608. Return undeliverable Canadian Addresses to: The Mail Group, P.O. Box 25542 London, ON N6C 6B2 Canada.

Economic Indicators
2021 2022 2023
Download the CEPCI two weeks sooner at www.chemengonline.com/pci
950
CHEMICAL ENGINEERING PLANT COST INDEX (CEPCI) 900
(1957–59 = 100) July ’23 June ’23 Jul. ’22 Annual Index: 850
Prelim. Final Final
2015 = 556.8
CE Index_______________________________________________ 798.3 803.3 829.8 800
Equipment _____________________________________________ 1,004.5 1,013.1 1,054.5 2016 = 541.7
Heat exchangers & tanks __________________________________ 824.4 835.5 891.0
Process machinery ______________________________________ 1,026.7 1,033.9 1,073.9 2017 = 567.5 750
Pipe, valves & fittings _____________________________________ 1,348.0 1,366.2 1,480.2 2018 = 603.1
Process instruments _____________________________________ 561.9 563.1 558.8 700
Pumps & compressors ____________________________________ 1,459.5 1443.1 1,304.4 2019 = 607.5
Electrical equipment _____________________________________ 802.3 799.0 770.0 2020 = 596.2 650
Structural supports & misc. ________________________________ 1,129.9 1,142.6 1,199.5
Construction labor ________________________________________ 369.2 364.4 357.1 2021 = 708.8
Buildings ______________________________________________ 812.6 816.8 834.2 2022 = 816.0 600
Engineering & supervision __________________________________ 313.7 313.9 312.0
Starting in April 2007, several data series for labor and compressors were converted to accommodate series IDs discontinued by the 550
U.S. Bureau of Labor Statistics (BLS). Starting in March 2018, the data series for chemical industry special machinery was replaced
because the series was discontinued by BLS (see Chem. Eng., April 2018, p. 76–77.)
500
J F M A M J J A S O N D
CURRENT BUSINESS INDICATORS LATEST PREVIOUS YEAR AGO

CPI output index (2017 = 100)_____________________________________________________ Jul. '23 = 99.1 Jun. '23 = 99.3 May '23 = 99.3 Jul. '22 = 100.9
CPI value of output, $ billions _____________________________________________________ Jun. '23 = 2,312.5 May '23 = 2,311.0 Apr. '23 = 2,344.4 Jun. '22 = 2,611.7
CPI operating rate, % ___________________________________________________________ Jul. '23 = 79.0 Jun. '23 = 79.2 May '23 = 79.2 Jul. '22 = 81.3
Producer prices, industrial chemicals (1982 = 100) _____________________________________ Jul. '23 = 313.7 Jun. '23 = 320.4 May '23 = 323.3 Jul. '22 = 379.7
Industrial Production in Manufacturing (2017 =100)* ____________________________________ Jul. '23 = 99.5 Jun. '23 = 99.0 May '23 = 99.6 Jul. '22 = 100.2
Hourly earnings index, chemical & allied products (1992 = 100) _____________________________ Jun. '23 = 223.0 May '23 = 219.0 Apr. '23 = 219.5 Jun. '22 = 200.9
Productivity index, chemicals & allied products (1992 = 100)_______________________________ Jul. '23 = 92.7 Jun. '23 = 91.6 May '23 = 90.9 Jul. '22 = 90.5
CPI OUTPUT INDEX (2017 = 100)† CPI OUTPUT VALUE ($ BILLIONS) CPI OPERATING RATE (%)
110 2400 85
105
2300 80
100
2200
95 75
2100
90
70
2000
85
65
80 1900
75 1800 60
J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D
*Due to discontinuance, the Index of Industrial Activity has been replaced by the Industrial Production in Manufacturing index from the U.S. Federal Reserve Board.
†For the current month’s CPI output index values, the base year was changed from 2012 to 2017
Current business indicators provided by Global Insight, Inc., Lexington, Mass.
CURRENT TRENDS
T he preliminary value for the CE Plant

Cost Index (CEPCI; top) for July
FREE On Demand Webinars 2023 (most recent available) fell com-
CHEMICAL pared to the previous month’s value,
ENGINEERING
ESSENTIALS FOR THE CPI PROFESSIONAL
the second straight monthly decline. To
arrive at the decline in the overall CEPCI
for July, decreases in the Equipment,
Learn about the industry’s critical Buildings and Engineering & Supervi-
topics by viewing the latest sion subindices offset an increase in
the Construction labor subindex. The
On Demand webinars. current CEPCI value now sits at 3.8%
lower than the corresponding value
For a list of FREE from July 2022. Meanwhile, the Current
Business Indicators (middle) show de-
webinars, visit creases in the CPI output index and the
chemengonline.com/webcasts CPI operating rate for July 2023, and a
slight increase in the CPI value of output
for June 2023.
48
28180 CE Economic indicator On Demand Webinar House Ad.indd 1 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM
5/24/16 4:43 PM OCTOBER 2023
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.
Written for engineers by engineers, Chemical Engineering delivers solid engineering essentials
and developing industry trends to keep its readers abreast of everything they need to keep their
facilities running smoothly.
Missing archived issues or what to share

Chemical Engineering with your colleagues?
Visit www.chemengonline.com/chemical-engineering-magazine
for more information.
27584
MATLAB
FOR AI
Boost system design and simulation with explainable and
scalable AI. With MATLAB and Simulink, you can easily train
and deploy AI models.
mathworks.com/ai
© The MathWorks, Inc.

ChemicalEngineering Chemical Engineering October 2023

Uploaded by

Copyright:

Available Formats

ChemicalEngineering Chemical Engineering October 2023

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ChemicalEngineering Chemical Engineering October 2023

Uploaded by

Copyright:

Available Formats

Imagine the

World’s Most Accurate

Overpressure Protection Preventing Dust Explosions

CONDITION FILL CONVEY

CONVEY DUMP SUCCEED

USA UK +44 (0)1227 374710

October 2023 Volume 130 | no. 10

35 Predictive Maintenance Basics

.In the News

13 Newsfront Methane Reforming: Solving the

.Technical and Practical 22

31 Facts at your Fingertips Avoiding Leaks in Bolted

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023 1

40 Solids Processing Preventing Dust Explosions with

2 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023

For details visit adlinks.chemengonline.com/84652-02

877.537.9120 l est-sales@curtisswright.com l cw-estgroup.com/ce-23

GROUP PUBLISHER CONTRIBUTING EDITORS

Taking graphene into the next dimension

Independently-driven agitators can be engaged

Dual and Triple Shaft agitator assemblies

Sizes from ½ gal. to 3,000 gal. are available.

mixers.com/multi-shaft 600-gallon VM-600 model

For details visit adlinks.chemengonline.com/84652-03

For details visit adlinks.chemengonline.com/84652-04

For details visit adlinks.chemengonline.com/84652-08

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023 13

14 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023 15

For details visit adlinks.chemengonline.com/84652-06 For details visit adlinks.chemengonline.com/84652-07

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023 19

Two-Pa t Exchanger engonl

not local, it’s global.

this rapidly evolving

marketplace, you • Meets all your specific requirements

For details visit adlinks.chemengonline.com/84652-09

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023 21

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023 23

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023 25

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023 29

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023 31

Proactive Industrial Hose

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023 33

Be prepared with spares

34 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023 35

FIGURE 2. Predictive analytics, fueled by technologies such as artificial intel- Author

Call the Experts

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023 37

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023 39

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023 41

CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023 43

Learn More: https://info.sierrainstruments.com/645i-biotrak-

For details visit adlinks.chemengonline.com/84652-13

Chemical Engineering’s premium

44 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM OCTOBER 2023

Standard Exchange Watch the Video

For details visit adlinks.chemengonline.com/84652-15

Multi-Purpose Iris Diaphragm Valve

For details visit adlinks.chemengonline.com/84652-14