Respondents select technology leaders in more than 40 categories.

Properly Assess Compressed Air Demand Make the Most of Radar

J U LY 2 0 1 1

Pneumatic Conveying Keeps Moving Ahead Mixer Seal Gets Major Makeover

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I have someone retiring after 33 years on the job. I have someone taking 33 years of experience with him. And now someone with just 3 years has to do that job.

With new Human Centered Design technologies from Emerson, its like the experience never left. Using our deep insights into how your people perform their roles and tasks, Emerson is designing all of our new products based on the science of Human Centered Design. This lets us embed the same experience and understanding thats walking through your plant into our control and monitoring technologies making them the easiest and most intuitive to use. Tasks are accomplished in fewer steps, and with greater confidence, even when relying on less expertise and specialization. Its the certainty that jobs are done right, no matter whos doing them. Find the experience youve been missing at EmersonProcess.com/Experience

The Emerson logo is a trademark and a service mark of Emerson Electric Co. 2011 Emerson Electric Co.

contents
July 2011 | Volume 74, Issue 7

22

34

37

cover story

22 The Best Get Hand Picked Respondents chose their favorite technology leaders in 47 different categories in Chemical Processings eighth annual Readers Choice Awards survey. Read on to see if your favorite vendor is a top pick.

columns
7 9

From the Editor: How Do You Picture Safety? Chemical Processing Online: Benefit From Our Brain Trust.

Features

DesIgN AND oPTImIzATIoN

29 Properly Assess Compressed Air Demand Most compressed air systems offer significant opportunities for improvement. A thorough evaluation of an existing or new system can help increase reliability and performance, and minimize lifecycle costs.
solIDs AND FluIDs HANDlINg

11 Field Notes: Survey the Sources of Electrical Risk. 19 Energy Saver: Recover Low Level Heat, Part I. 21 Compliance Advisor: U.S. Wants More Transparency in Trade. 45 Plant InSites: Pick the Proper Centrifugal Pump. 58 End Point: Energy Policies Threaten U.K. Chemical Firms.

34 Pneumatic Conveying Keeps Moving Ahead Demand for conveying solutions that increase throughput, shorten lead times, handle various solids, reduce costs, improve safety and simplify maintenance are spurring suppliers to develop innovative solutions.
INsTRumeNTATIoN AND CoNTRol

37 Make the Most of Radar The emergence of radar has significantly advanced level monitoring. However, there are some important considerations to keep in mind when applying radar technology.
mAkINg IT WoRk

departments

13 In Process: Method Makes Z Alkenes | Energy Harvesting Gets Hot Option 43 Process Puzzler: Prevent Pump Problems. 47 Equipment & Services 55 Product Spotlight/Classifieds 57 Ad Index

41 Mixer Seal Gets Major Makeover Effectively sealing a shaft entry point in a vessel used for high temperature mixing of titanium tetrachloride required a unique retrofit. A dry-running split seal and sleeve prevent leaks and offer additional benefits.

Chemical Processing (IssN 0009-2630) is published monthly by Putman media Inc., 555 West Pierce Road, suite 301, Itasca, Il 60143. Phone (630) 467-1300. Fax (630) 467-1109. Periodicals postage paid at Itasca, Il, and additional mailing offices. PosTmAsTeR: send address changes to Chemical Processing, P.o. Box 3434, Northbrook, Il 60065-3434. suBsCRIPTIoNs: Qualified reader subscriptions are accepted from operating management in the chemical processing industries at no charge. To apply for a qualified subscription, fill in the subscription card. To nonqualified subscribers in the united states, subscriptions are $68 per year. single copies are $14. Canadian and foreign annual subscriptions are accepted at $115 surface per year. single copies are $16. Canada Post International Publications mail Product sales Agreement No. 40028661. Canadian mail Distributor information: Frontier/BWI, Po Box 1051, Fort erie, ontario, Canada, l2A 5N8. Copyright 2011 Putman media Inc. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the copyright owner. RePRINTs: Reprints are available on a custom basis. For price quotation, contact Foster Reprints, (866) 879-9144, www.fostereprints. com also publishes Control, Control Design, Food Processing, Pharmaceutical manufacturing and Plant services. Chemical Processing assumes no responsibility for validity of claims in items reported.

chemicalprocessing.com July 2011

Advanced Temperature Engineering.

Temperature is the most frequently measured parameter in the process industry. While the technology necessary to measure temperature is used worldwide, Endress+Hauser has the proven expertise and product basket to meet your extreme and challenging process requirements. Endress+Hauser has the necessary experience and competence to meet your needs from the planning stage up to commissioning. www.us.endress.com/temperature

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From The eDiTor

how do You Picture safety?

An unusual photo contest seeks your creative take on the topic
Cameras Prohibited or No Picture Taking proclaim signs at guardhouses and reception areas at many chemical facilities. This policy may stem from a legitimate concern about photographs revealing details about proprietary technology, such as the type of reactor or separator used in a process, or commercial information, such as the supplier of a key raw material or the amount of product inventory on hand. Often, undoubtedly, it simply reflects the innate conservatism of the legal department at company headquarters. Some critics of our industry certainly will contend that the ban frequently relates more to corporate anxiety about outsiders snapping shots of less-than-stellar safety and environmental practices. In May, the U.S. Occupational Safety and Health Administration (OSHA) launched a program to get photos. But its not for the reason you might think. OSHA isnt trying to obtain evidence of wrongdoing or workplace lapses instead, the agency is looking for shots that celebrate safety. OSHA unveiled its Picture It! Safe Workplaces for Everyone contest as part of its yearlong 40th anniversary celebration. OSHA challenges anyone with a passion for photography to capture an image of workplace safety and health and share it with the agency. The goal of the contest is to collaborate with the public relying on the talent, imagination and creativity of participants to kick off a national effort to raise awareness about workplace safety and health, noted the press release announcing the photo competition, which is the first in OSHAs history. Photographers may interpret image of workplace safety and health in any way they choose. They are not restricted to particular subject matters or themes, adds the agency. Moreover, digital manipulation of images is allowed. However, entries must comply with two key restrictions: 1. Photos cant appear to endorse a commercial product or service. They shouldnt show brand names, recognizable places of business, or other subjects identifiable with a specific manufacturer; and 2. Images must not depict a violation of an OSHA standard, uncontrolled hazard or unsafe procedure or practice. Be aware of any unmarked hazard, improperly installed piece of equipment or other violation that might be visible in your frame, cautions the agency. In addition, the shots must have been taken in the United States or its territories, and you must have a release form for each person who is recognizable in a photo. Anyone 18 years old and up (except OSHA and on-site consultation employees) can enter up to three photos by midnight Eastern time on Friday, August 12th. The images must be submitted online via www.osha.gov/osha40/photo-contest.html. There, you also can find more details on the contest, acceptable photo file types and size, and a sample release form. The panel of judges consists of Earl Dotter, a photojournalist; Kathleen Klech, photo director of Cond Nast Traveler magazine; George Tolbert, official U.S. Senate photographer (retired); Shawn Moore, chief photographer of the U.S. Department of Labor; and Carl Fillichio, senior advisor for communications and public affairs at the Department of Labor. They will evaluate the entries for artistic value, and ability to raise awareness about safety and health to the general public. Judging criteria are the photo quality, originality, creativity, the clarity of the safety and health message conveyed, inclusion of worker, employer or workplace imagery, and suitability for possible use in OSHA publications. Framed copies of the first-, second- and thirdplace photos will be displayed at OSHAs headquarters in Washington, D.C. where they will serve as a daily reminder for leading policymakers and prominent professionals on the real-life impact of OSHAs mission, says the agency. The winner also will get a framed letter of congratulations from U.S. Secretary of Labor Hilda L. Solis, while the two runners-up will get framed certificates signed by OSHA Director David Michaels. The winning and finalist photos also will appear prominently on the contest web page in September. Chemical plants and other industrial sites have a reason to soften their stance on photographs at least for a while.

OSHA is looking for shots that celebrate safety.

mark rosenzweig, Editor in Chief mrosenzweig@putman.net

chemicalprocessing.com

July 2011

PERFORMANCE THROUGH ENGINEERING

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chemical processing online

555 West Pierce Road, Suite 301 Itasca, IL 60143 Phone: (630) 467-1300 Fax: (630) 467-1109 www.chemicalprocessing.com E-mail: cpnews@putman.net Subscriptions/Customer Service: (888) 644-1803 or (847) 559-7360 Editorial Staff Mark rosenzweig, Editor in Chief, x478 mrosenzweig@putman.net amanda Joshi, Managing Editor, x442 ajoshi@putman.net traci Purdum, Senior Digital Editor, x428 tpurdum@putman.net Sen ottewell, Editor at Large Ireland sottewell@putman.net Contributing EditorS andrew Sloley, Troubleshooting Columnist lynn l. bergeson, Regulatory Columnist Ven Venkatesan, Energy Columnist dirk Willard, Columnist dESign & ProduCtion Stephen C. Herner, Vice President of Creative Services, x312 sherner@putman.net brian Hertel, Associate Art Director, x413 bhertel@putman.net rita fitzgerald, Production Manager, x468 rfitzgerald@putman.net Editorial board Vic Edwards, Aker Solutions tim frank, Dow Chemical ben Paterson, Eli Lilly roy Sanders, Consultant Ellen turner, Eastman Chemical ben Weinstein, Procter & Gamble Jon Worstell, Consultant Sheila Yang, Bayer ExECutiVE Staff John M. Cappelletti, President/CEO Julie Cappelletti-lange, Vice President rose Southard, Vice President of Technology Jerry Clark, Vice President of Circulation Jack Jones, Circulation Director rEPrintS Jill Kaletha , reprint Marketing Manager jillk@fosterprinting.com 866-879-9144 ext. 168 fax 219-561-2033 4295 S. ohio Street, Michigan City, in 46360

benefit from our brain trust

Insight from industry experts is just a mouse click away.
i lEarnEd long ago to surround myself with smart people. Not only am I lumped into the group by association, but I get to tap the brain trust whenever I need answers to lifes many questions. I certainly cant take credit for the idea of a brain trust I was inspired in my grade school history class after reading about Franklin D. Roosevelts team of educated advisors. That was the first time I realized I didnt need to have all the answers, I just needed to know where to look for enlightenment. You dont have to have all the answers either. You can just look to one of our myriad resources for expert advice. Recently I added a section that houses all of our Special Reports (www.chemicalprocessing.com/special_reports). Here you will find several in-depth pieces on single topics. Do note that you must register to download each one, but it is a quick process that grants you instant access. There is a report on pilot plants from Continental Technologies that highlights ten factors that will impact the design, construction and operation of next-generation pilot plant units. Want to learn more about conveyors? Hapmans special report looks at the different types of conveyors, discusses the use of tubular bag conveyors, and provides ten tips to prevent a variety of common problems that could occur with pneumatic conveyors. Some of these special reports feature podcasts that delve even deeper into the topic at hand. For example, Edgewater Fullscopes report on condition monitoring has a podcast I recorded with the companys senior vice president Russell Smith. We chat about how enterprise resource planning (ERP) can help manage the supply chain. Another section of the website that will help you find the answers you need showcases future and on-demand events hosted by Chemical Processing. Located at www.chemicalprocessing.com/webinars, this page lists upcoming webinars (we do at least one webinar a month) and enables you to gain instant access to programs weve already done. So far, we have 17 on-demand events covering everything from the U.S.s Chemical Facilities Anti-Terrorism Standards (CFATS), and other government initiatives such as Registration, Evaluation, Authorization and Restriction of Chemicals (REACH) and Globally Harmonized System (GHS) for classification and labeling of chemicals to bulk solids cooling and heating, emissions, and energy efficiency. Again, registration is required. Webinars on the horizon include in-depth coverage of dust control, which will take place on July 21 at 2 p.m. ET. This discussion will examine the various regulations and standards that target dust and dust-collection systems and explore how to handle dusts that potentially pose risk of explosion and fire. Our Sept. 22 webinar (2 p.m. ET) will cover the topic of process safety. Panelists at this event will offer advice on how to successfully avoid or minimize risks associated with plant operations. These are just two areas of ChemicalProcessing.com that will make you feel like you have your own brain trust working for you. Be sure to poke around the rest of the site to find other answers. And if you need assistance, dont hesitate to drop me an e-mail at tpurdum@putman.net. If I dont know the answer, I bet I will know where to find it.
traCi PurduM, Senior Digital Editor tpurdum@putman.net.

Look to one of our myriad resources for expert advice.

Folio Editorial Excellence Award Winner

chemicalprocessing.com

July 2011

If youve paid for automatic control valves, none of your loops should have to be in manual mode. There must be a better way.

Loops in manual mode due to poor-performing rotary valves require constant operator attention. And they cost you process efciency. You can expect better control from the new Fisher Control-Disk valve from Emerson. The Control-Disk valve has double the control range of traditional buttery valves to allow control closer to the target set point, regardless of process disturbances. You can keep your loop in automatic mode. With low maintenance requirements and availability to ship in two weeks, its time to put a Control-Disk valve in your loop. Visit www.Fisher.com/ControlDisk to watch an animation video or download a brochure.

The Emerson logo is a trademark and service mark of Emerson Electric Co. 2011 Fisher Controls International LLC MV20-CD210

field notes

Survey the Sources of electrical risks

A walk-down helps determine the need for purged electrical boxes
My teaM was ready. We only had a week to define potential sources of hazards and complete a batterylimit Electrical Area Classification (EAC) drawing. We spent an hour walking down the unit. I completed the source spreadsheet in two hours. We reviewed the spreadsheet in another hour and then sent it to the designers. They finished the EAC drawing in two days. It took several months for us to become this proficient. An EAC drawing is crucial for reducing the risk of electricity igniting flammable, even explosive, chemicals. As my last two columns have pointed out, the effort starts with defining chemical risk (Dont Zone Out On Area Classifications, www.ChemicalProcessing.com/articles/2011/electrical-area-classification.html), followed by selecting zones around sources (Dont Push the Envelope, www.ChemicalProcessing.com/articles/2011/avoid-ignition-dangers. html). Here, Ill describe how sources demarcate the areas requiring purged electrical boxes. The walk-down team, at a minimum, should include a drawing designer, a unit operator and an engineer. Before venturing into the unit, collect current versions of plot plans, an elevation drawing if available, Process and Instrumentation Drawings (P&IDs), Process Flow Diagrams (PFDs), the equipment index, material safety data sheets and material balances. The purpose of this battery-limit survey is to identify clouds based on the worst-case sources. The walk-down may identify layout errors such as a source near a road or a walkway frequently used by operators. Developing an uncluttered EAC drawing requires care in source selection. You want a point source posing the greatest risk defined by NFPA 497 and API 500. But its not as simple as picking a Group B chemical over a Group D one. There are other factors e.g., the auto-ignition temperature (AIT), which define electrical risk. The most common Group B chemical is hydrogen, which is lighter than air. Lighter-than-air (LTA) materials have a smaller envelope. And hydrogen has a higher AIT than all Group D compounds; pure hydrogens AIT is 1,040F while, for example, naphthas is 450F. When both B and D chemicals are present, as in a knockout drum, define points by choosing a nozzle at the bottom for B (LTA) and an upper one for D. Use normal conditions if B wouldnt be at the drum bottom then, find a nozzle where it would appear. Consider high risk factors such as temperature, quantity and pressure. Pick points based on the greatest risk: temperatures, e.g., within 30F of flash point, sufficient to make a Class II or Class III compound a hazard (OSHA 1910.106(a)(18) (iii):Class II); flows greater than 500 gpm; and pressures exceeding 500 psig. Its best to select a number of points within 50 ft of the battery limit or 100 ft for high-risk sources. Other factors for example, tall (i.e., over 25 ft) or long vessels (including heat exchangers), distillation columns and reactors where composition varies, and banks of equipment can complicate selecting source points. With long or tall equipment choose a point every 50 ft for heavier-than-air (HTA) compounds and every 15 ft for LTA ones. For shorter vessels, use one nozzle near the battery limit. Pick an upper flange for an HTA compound and a low nozzle for an LTA one. For vessels with diameters larger than 50 ft, refer to API 500. You can consider a flange or nozzle as part of a vessel only if its within 10 ft. To measure the height of stacks and nozzles, I suggest a clinometer (see Strive for a Surveyors Eye, www. ChemicalProcessing.com/articles/2009/184.html). Source designations include: pumps measured from centerline or seal connection; compressors same as for pumps; control valves pipe centerline; condensers bottom of tubesheet or shell flange; vaporizers top of tubesheet or shell flange; miscellaneous heat exchangers top for liquids, bottom for vapors; vessels containing liquids top-most flange; vessels containing liquids and vapors topmost flange and bottom flange; and vessels containing vapor bottom-most flange. Also, of course, account for furnaces, diked areas, etc. Some surveys include flanges and manual valves but many restrict sources to automatic valves and control valves. The thought behind this is that staff will detect leaking manual valves. After completing the walk-down, prepare the source table based on the points collected and eliminate any redundant ones. Then, run material balances to evaluate compositions. Review the source table at least twice before handing it over to the designers.
dirk willard, Contributing Editor dwillard@putman.net

Consider high risk factors such as temperature, quantity and pressure.

11

chemicalprocessing.com

July 2011

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in process

Method Makes Z Alkenes

Catalyst reportedly provides unprecedented levels of reactivity and selectivity
A joint team of scientists from Boston College, Chestnut Hill, Mass., and Massachusetts Institute of Technology (MIT), Cambridge, Mass., have developed a new catalytic method for the synthesis of a large class of carbon-carbon double bonds. It enables production of the higher energy or Z isomer of alkenes. Amir Hoveyda, a professor of chemistry at Boston College, says these higher energy carbon-carbon double bonds are very important to organic synthesis and materials research. For instance, Z alkenes serve as starting materials for some common chemical transformations. Hoveyda and his team rely on a molybdenum-based catalyst to spur a Z-selective cross metathesis reaction in which two different alkene-containing molecules combine, with only ethylene as a byproduct. Removing the generated olefin by running the reactions in a vacuum significantly improves the desired process and yields unprecedented levels of reactivity and selectivity. Z isomers require a sufficiently active catalyst to prompt the chemical reaction while still maintaining the cis olefins U-shape geometry. The trick here was to come up with a catalyst that is active enough to promote Z-alkene formation but not too active to also want to react with the product. So, in a way, we had to walk on a very tight rope. Olefin metathesis is a reversible reaction and you always run the risk of going back and forth between product and starting material, which forces you to end up with a lower energy and less desirable isomer. What we have found are catalysts that are sufficiently active to promote this difficult reaction but are also discriminating enough not to go after the product and cause it to isomerize. The team demonstrated the catalytic method through synthesis of antioxidant plasmalogen phospholipids. Further details appear in an article in Nature. For future research, there are a number of possible steps to take, says Hoveyda, as well as other crossmetathesis processes that must be developed. We develop new methods based on their degree of relevance to facile and efficient preparation of various classes of important biologically active molecules. Like any highly active catalyst, the molybdenumbased catalyst is sensitive to air and moisture; the team is working towards designing air-stable variants. Once this phase of our research is completed, and considering the effectiveness of the catalysts that we have and the significance of cross-metathesis reactions, the technology will be a formidable force in chemical synthesis, he believes.
Catalytic Reaction

Such work could last several years, depending on what the researchers determine as the desired outcome. If the eventual goal is to develop an efficient version for all possible catalytic stereoselective crossmetathesis reactions, then we are looking at least at a decade. But we already have very promising leads on four new classes, Hoveyda adds. While all catalysts are designed and developed by the team at Boston College and MIT, Switzerland-based XiMo, AG, has licensed the technology and is working with the researchers to further develop the process. XiMo aims to use the available catalysts and technologies, as well as develop new ones for large-scale use.
Economic Snapshot
64,000 63,000 62,000 61,000 60,000 $ Million 59,000 58,000 57,000 56,000 55,000 54,000 53,000
May 10 June 10 July 10 Aug 10 Sep 10

Figure 1: Researchers designed an efficient process that favors formation of higherenergy carbon-carbon double bonds through a catalytic cross metathesis reaction. Source: Amir Hoveyda.

86.0 85.0 84.0 83.0 82.0 81.0 80.0 %

July 2011

79.0 78.0 77.0 76.0 75.0 74.0 73.0 72.0 71.0 70.0
Oct 10 Nov 10 Dec 10 Jan 11 Feb 11 Mar 11 Apr 11

Shipments (NAICS S325)

Capacity utilization

Shipments and capacity utilization both continued to rise. Source: American Chemistry Council.

13

chemicalprocessing.com

IN PROCESS

Energy Harvesting Gets Hot Option

How have your sites efforts for leak detection and repair changed over the past twelve months?
21.4% Modestly increased 28.6% Stayed the same

THE SURFACE temperature of heat exchangers, other process equipment and piping may serve to generate electricity a plant could use to recharge batteries of wireless devices, say researchers at the U.S. Department of Energys Oak Ridge National Laboratory (ORNL), Oak Ridge, Tenn. ey have developed tiny cantilevered structures that produce electricity when exposed to temperature gradients. ese micro-electro-mechanical 7.1% systems (MEMS) boast far higher eciencies than other Modestly decreased pyroelectric (heat-to-electricity) techniques likely to 28.6% reach 1030%, depending upon heat source, versus the Signicantly 0% increased Signicantly 15% of the others, contend the researchers. 14.3% decreased Not applicable e key dierence between our harvester and previous attempts is the fact that we use a MEMS Responses (%) device (bimaterial cantilever) that self-actuates when Half of respondents say efforts have increased. To participate exposed to a constant temperature dierence, notes in this months poll, go to ChemicalProcessing.com. Panos Datskos, a senior research scientist at ORNL. e tip of the hot cantilever comes into contact e cantilever is attached to an anchor axed to a substrate like a computer chip or equipment surface with a cold surface, the heat sink, where it rapidly (Figure 2). Heat from the substrate causes the cantilever loses its heat, causing the cantilever to move back and make contact with the hot surface, explains Scott to bend.

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ADT can help you cut the cost of CFATS compliance. Without cutting corners.

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IN PROCESS

Hunter, who leads the development team. e cantilever continues to oscillate between the heat source and heat sink as long as the temperature dierence is maintained between the hot and cold surfaces. e fast rate of exchange in the temperature across the pyroelectric material is the key to the energy con-

version eciency and high electrical power generation, Hunter notes. e technology will work with gradients from just a few degrees up to several hundred. e higher the temperature the more ecient the device, adds Datskos. Each cantilever structure is about 1 mm square about

Energy Harvester

A helping hand for heat transfer fluids.

Hard as it may seem to believe, your selection of heat transfer fluids can make your equipment operate substantially more efficiently, increasing process productivity. Your edge could just be a phone call away. Ask somebody who knows systems, not just fluids, and knows your industry and its equipment too. Consult with Paratherm about topics as simple as a fluid analysis, New data may change your mind. system cleaners, flow rates or film temperatures. Or maybe you have system questions about components or overall architecture. There are mountains of data available on the Paratherm web site about their full selection of low to high temperature fluids. Click on www.paratherm.com/chemicals for: case histories, fluid and property comparisons, users guides, Tip Sheets, technical reports, and safety info. Or call Paratherms Technical Specialists the SludgeBusters whose expertise in systems (not just fluids) can help you improve performance in a Facts can help you decide. wide range of applications. Let Paratherm take Experts are you to a new level. Call today. ready to help.
Listing and temperature range chart for all Paratherm heat transfer fluids.

Figure 2. Cantilever cycles between heat source and sink, inducing an alternating current from pyroelectric material in the capacitor. Source: Oak Ridge National Laboratory.

HEAT TRANSFER FLUIDS

4 Portland Road West Conshohocken PA 19428 USA

800-222-3611
Copyright Paratherm Corporation 2011. SludgeBusters is a Trademark of Paratherm Corporation.

610-941-4900 Fax: 610-941-9191 info@paratherm.com

1,000 can t onto a 1-in. square surface. Although each device generates only a small amount of electricity, 110 mW, large arrays can provide sizable amounts, enough, for instance, to power remote sensor systems, the researchers note. e converters can be fabricated using standard semiconductor manufacturing technology. Hunter foresees initial use on high-performance computer chips with cooling rather than electricity generation the main driver. However, Datskos notes, Hot surfaces of equipment [such as] heat exchangers and pipes are also very good applications. e electricity generated could serve for recharging batteries of wireless devices, he adds. e harvester will need to be optimized for the particular application and set of conditions. For example, the temperature dierential and the duty cycle are important parameters, Datskos explains. So, if the conditions are determined, then my best guess is that in a year or two these devices can be ready for use.

www.paratherm.com/chemicals

Every single flowmeter I calibrate interrupts my process. There must be a way to verify meters without putting my plant and people at risk.

YOU CAN DO THAT

Verify flowmeter performance in place with Micro Motion Smart Meter Verification. Determining measurement integrity and performance of every meter in line means never stopping your process flow. Emersons Smart Meter Verification for Micro Motion Coriolis meters is the only automatic diagnostic tool that eliminates the need to break process seals, allowing you to avoid potential safety issues and costly process flow interruptions. So to keep your workers safe and your operation running, go to EmersonProcess.com/Verification

The Emerson logo is a trademark and a service mark of Emerson Electric Co. 2011 Emerson Electric Co.

What are the benefits of modernizing my APACS+ system to SIMATIC PCS 7?

Siemens has the expertise to maintain your APACS+ and PCS 7 systems, minimizing risk during your modernization.
Integrating PCS 7 with APACS+ provides you with enhanced alarm management, the latest cyber security, and integrated asset management. See other PCS 7 benefits and possibilities for your process by visiting us online at www.usa.siemens.com/apacs2020.

Answers for industry.

energy saVer

recover Low Level Heat, Part i

This two-part series highlights innovative concepts for recovering such heat
Most raw materials and final products usually are stored at ambient temperature. Because the driving force for heat transfer is the difference in temperature between hot and cold streams, it theoretically isnt possible to perfectly match heating and cooling loads. Hence, heating and cooling have become the two important steps carried out independently and heaters, boilers, cooling towers and air-fin coolers represent the most commonly used equipment. All modern process plants are designed with maximum possible heat integration between the heating and cooling streams. (Whats really operationally feasible depends upon more than heat transfer issues see, for example, Control Challenges Can Pinch Energy Savings, www. ChemicalProcessing.com/articles/2010/206.html.) But most plants designed prior to 1980 didnt consider heat recovery from process streams that were below 350F400F. Such process streams should include the f lue gas from heaters and boilers that are part of the process heating system. Flash steam near atmospheric pressure that is vented also is a common case of low level heat rejection. In recent years, low level heat recovery has gained more attention for three reasons: 1. Higher energy prices could justify the additional heat recovery equipment; 2. Improved heat recovery technologies have become commercially available; and 3. Innovative energy integration concepts could be developed into the processes. At current high energy prices, process engineers should consider opportunities to recover low level heat. Ill describe several. already been successfully implemented in some industries for low level heat recovery. For example, a pharmaceutical plant in North Carolina maintained a portion of its process area at a controlled humidity and temperature. The air circulated in that area was first dehumidified with chilled water and then reheated to the required temperature with steam. Because it was a critical process area, 100% fresh air was supplied. We recommended installing wrap-around heat pipes across the chilled water coil in the supply air duct. This heat pipe installation reduced the air temperature by 7F before entering the chilled water coil, and increased the air temperature by 6F before it entered the reheat coil. The plant engineers credited this as one of the best applications of low level heat recovery.
More Low LeveL Heat recovery aPPLications

Heat pipes used to preheat the combustion air are gaining interest.

At a Midwest refinery, product gasoline from a debutanizer column was cooled from 300F to 50F by an array of heat exchangers with cooling tower water. Very close to that location, a propane vaporizer was heated with steam to supply the fuel gas system. We proposed a new heat exchanger upstream of the existing propane vaporizer, in which the hot gasoline from the debutanizer passed through to vaporize the propane stream. This heat integration arrangement yielded both steam savings as well as a reduction in cooling tower load. Low level heat recovery applications such as this can save energy and improve efficiency. Another potential for low level heat recovery is the f lash steam vented from the blowdown water of the process-waste-heat steam generators. Although blowdown heat recovery systems are commonly installed at utility boiler houses, Heat PiPes Gain MoMentuM they usually are omitted at the process-waste-heat If the f lue gas from heaters and boilers is leavsteam generators. At a Midwest refinery, it was ing the stack at temperatures above 300F, then adding an air preheater to supply hot combustion observed that 3,000 lb/hr of additional low presair may make sense. In the past, conventional re- sure steam could be generated from the blowdown cuperators and regenerators were the only options water drained at its process-waste-heat boilers. More innovative concepts of low level heat for air preheaters. Now, heat pipes used to preheat recovery applications will be highlighted in part the combustion air are gaining more interest. II. Heat pipes use a low-boiling medium that results in better heat transfer efficiency and can operate at very low differential temperatures beven v. venkatesan, Energy Columnist tween the hot and cold streams. Heat pipes have VVenkatesan@putman.net
19 chemicalprocessing.com July 2011

L I Q U I D

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compliance advisor

U.s. Wants More Transparency in Trade

New memorandum focuses on encouraging trade, coordination and public participation
On May 19, 2011, the Office of the U.S. Trade Representative (USTR) and the Office of Information and Regulatory Affairs (OIRA) jointly issued a memorandum to U.S. departments and agencies highlighting the importance of regulatory transparency and openness to promoting international trade. The memorandum telegraphs the Administrations renewed emphasis on the significant role international collaboration has in domestic policy development. The communication builds upon President Obamas January 2009 Memorandum on Transparency and Open Government and the December 2009 Open Government Directive from the Office of Management and Budget (OMB). It describes several existing agency obligations that can reduce barriers to trade and contribute to economic objectives, such as economic growth, entrepreneurship, job creation and innovation. These obligations include: conducting robust regulatory analysis, avoiding the creation of unnecessary barriers to trade, providing domestic and foreign stakeholders a meaningful opportunity to participate in the rulemaking process, and encouraging international collaboration. The memorandum is available at www.ChemicalProcessing.com/trade_memo. The memorandum notes that Executive Order (EO) 13563, EO 12866, and OMB Circular A-4 all establish principles governing regulatory analysis. For economically significant rules, agencies are directed by these EOs to analyze and, to the extent feasible, quantify the costs and benefits of proposed regulatory actions. The memorandum states that, in some cases, such costs and benefits can impact productivity, employment, and the ability of small- and medium-sized enterprises (SME) to participate and compete in the global economy. Where any such effects are reasonably anticipated, agencies should provide a publicly accessible assessment. The memorandum also reminds agencies that, under the Trade Agreements Act of 1979, they are prohibited from engaging in any standards-related activity that creates unnecessary obstacles to the foreign commerce of the United States. One way to avoid creating such unnecessary obstacles is to consider relevant international standards. Consistent with EO 13563, federal agencies should provide the public with timely access to regulatory analyses and supporting documents, as well as opportunities to comment. To that end, the memorandum states agencies should provide a description of the methods used in their analysis; publish information online; and, to the extent feasible, provide the underlying data in downloadable format. Public access via the Internet ensures that rules, analyses, and supporting documents are available to, and allow comment by, both domestic and foreign stakeholders, thus promoting exports and trade. In addition, the memorandum notes the World Trade Organization (WTO) Agreement on Technical Barriers to Trade (TBT Agreement) requires the U.S. and other member states to notify the WTO of certain draft product standards and related procedures for comment by other members. To fulfill this requirement, the U.S. TBT Inquiry Point, which is housed in the National Institute of Standards and Technology, undertakes the day-to-day notification functions of the U.S. To implement these existing requirements, and help ensure regulatory actions dont create unnecessary barriers to exports and trade, agencies have adopted, in certain cases, collaborative practices to discuss and evaluate potential trade implications. These include information exchanges, dialogues, meetings with other governments and stakeholders, and coordination of regulatory activities with other governments. The goal is to share best practices and harmonize relevant regulatory approaches, standards, and related procedures, and that these efforts contribute to the development of regulatory measures. These practices can help reduce regulatory costs while also promoting U.S. exports and trade by decreasing unnecessary regulatory divergences, which impose costs on U.S. exporters especially SMEs. This can help promote job creation and support export goals. These collaborative efforts could have many domestic benefits, including increasing the safety and quality of other countries exports to the U.S. and thus helping to protect U.S. consumers. Long-pending trade agreements are being addressed and approved in the current Congress, in contrast to languishing during the first two years of the Obama Administration. The memorandum is, in part, a response to the desire by all in Congress to focus on jobs, while allowing the Administration to improve environmental and labor protection provisions.
Lynn BergesOn, Regulatory Editor lbergeson@putman.net
Lynn is managing director of Bergeson & Campbell, P.C., a Washington, D.C.-based law firm that concentrates on chemical industry issues. The views expressed herein are solely those of the author.

Better agency collaboration could help promote job creation and support export goals.

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respondents select technology leaders in more than 40 categories.

By amanda Joshi, managing editor

ChemiCal ProCessings 2011 Readers Choice Awards survey, which is now in its eighth year, continues to generate strong response from readers. But for many of the 1,000 respondents this year, picking a favorite technology provider in 47 different categories wasnt always easy. In all categories I found more than one excellent supplier, explains one participant. As in past surveys, some vendors remain strong favorites in certain categories, while in others several suppliers garner substantial votes. The winners in some categories differ from last year. This may ref lect increased awareness of a particular vendors offerings or improved products. For instance, one reader noted a category that has enhanced its offerings. Process simulation software has greatly improved lately and is much more of a help now, he says. People also used the survey to express their desires. I wish there were more automation vendors; every year we need more control of the system, notes one respondent. Readers recognized that, in the past several years, many companies have merged or consolidated to help expand or improve their product offerings. With all the mergers and consolidations during the last 20 years, those companies that remain should be embraced, as they have been through a very rough economic time period, says one reader.
July 2011 chemicalprocessing.com 22

23

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Past Contenders remain strong

CrunChing the numbers

Many technology leaders held their ground, maintaining their high rankings from previous years. Emerson Process Management, a strong favorite from year-to-year, took top honors in seven categories, and placed in six other categories. Of all the dealings I have had with Emerson, they always are willing to come by my office and work with me and my colleagues to find a solution. They also have such a wide variety of products that are time tested that we can always find what were looking for, says one participant. Emerson is the best in my opinion because they have been more than willing to work with customers to resolve any issues even if it takes a couple of months to actually figure out the root cause of the problem, adds another reader. Honeywell, another strong performer, received top honors in two categories and placed in four others. Readers also gave accolades to AspenTech, Alfa Laval and GE (Bently Neveda) each gained two first place finishes. In addition, ABB, Rockwell Automation, Siemens, Flowserve and SPX all garnered multiple mentions in several categories. A few contenders moved up the ranks in their categories to earn top honors this year from readers. These include Cleaver Brooks, Flexicon, MAC Equipment and Chicago Bridge & Iron (CBI). Further details about the winning companies in each category are included on the following pages. For additional information about any of the vendors or products listed, we encourage you to visit www. ChemicalProcessing.com and search for bearings, pumps or any other category that interests you. Results from previous Readers Choice Awards also are available online: 2010 www.ChemicalProcessing.com/ articles/2010/127.html 2009 www.ChemicalProcessing.com/ articles/2009/133.html 2008 www.ChemicalProcessing.com/ articles/2008/112.html 2007 www.ChemicalProcessing.com/ articles/2007/108.html 2006 www.ChemicalProcessing.com/ articles/2006/111.html 2005 www.ChemicalProcessing.com/ articles/2005/523.html 2004 www.ChemicalProcessing.com/ articles/2005/363.html
July 2011 chemicalprocessing.com 24

Readers received e-mail notices, electronic newsletters, used a link posted on www.ChemicalProcessing.com or responded to Twitter and Facebook postings to complete the questionnaire. A total of exactly 1,000 readers cast their votes about which vendors they consider technology leaders in 47 different categories. Categories were listed, but respondents had to enter the name of the technology provider in a blank text box. By not providing a pre-selected list of companies in each category, the survey avoided bias. The rankings show the percentage of total responses in each category that a particular company received. We only list firms that got at least 5% of the votes in a category. Scores within 3% of each other should be considered a statistical tie.
AlArm mAnAgement SoftwAre Honeywell (Matrikon) Emerson PAS Yokogawa BeAringS SKF Timken BoilerS/SteAm SyStemS Cleaver Brooks Babcock & Wilcox Thermax Spirax Sarco cAtAlyStS BASF (Engelhard) Johnson Matthey Honeywell (UOP) Haldor Topsoe Criterion centrifugAl PumPS ITT (Goulds) Flowserve Sulzer KSB centrifugeS Alfa Laval GEA Westfalia Andritz Bird Beckman
Percent

26% 16% 10% 7%

51% 11%

14% 11% 8% 5%

13% 12% 11% 6% 5%

31% 12% 7% 5%

21% 12% 7% 5%

Providing higher yields and greater safety. Achieving increased regulatory compliance. Eliminating all those trips up the ladder. Amazing what the right level instrumentation could do.
Its Emerson products and the people that make all the difference. Our portfolio of Rosemount level instrumentation covers the breadth of todays leading technologies as well as tomorrows ground-breaking ones. We then augment your level technologies further with our new Smart Wireless solutions and advanced diagnostics. And finally, top-tier Emerson application specialists and tools are at your disposal to help squeeze the absolute most from your process. So start climbing less and achieving more, go to Rosemount.com/Level
Differential Pressure and Hydrostatic Guided Wave Radar Non-contacting Radar Point Level Detection Ultrasonic Electromechanical

The Emerson logo is a trademark and service mark of Emerson Electric Co. 2008 Emerson Electric Co. Rosemount and the Rosemount logotype are registered trademarks of Rosemount, Inc.

Compressors Ingersol Rand Atlas Copco Computerized maintenanCe management software (Cmms) SAP Maximo Condition monitoring GE (Bently Nevada) Emerson Process Management Rockwell Automation Conveying (meChaniCal) Flexicon Hapman Conveying (pneumatiC) MAC Equipment Dynamic Air Vac-U-Max Cooling towers SPX (Marley) Paharpur Baltimore Aircoil distillation equipment Koch-Glitsch Sulzer dryers GEA Niro dust-Control systems Donaldson Torit explosion proteCtion systems Fike Fenwall fans & Blowers New York Blower Howden Buffalo Dresser Roots Chicago Blower feeders K-Tron Schenck Accurate Acrison Siemens
July 2011 chemicalprocessing.com

32% 18%

filtration systems Pall Millipore Siemens flow instrumentation Emerson Process Management Endress+Hauser heat exChangers Alfa Laval heat transfer fluids Dow Solutia infrared thermography equipment FLIR (Extech) Fluke instrument CaliBration systems Fluke Emerson Process Management level instrumentation Emerson Process Management Endress+Hauser Magnetrol luBriCants ExxonMobil Shell Royal Purple Lubrizol mixing systems SPX Chemineer motors ABB (Baldor Reliance) Siemens GE Emerson paCkings and gaskets Garlock John Crane Flexitallic pipe/tuBing/fittings Swagelok Parker Hannifin

14% 7% 6%

25% 19%

51% 11%

27% 16% 8%

24%

44% 18%

9% 8%

41% 36%

11% 8% 8%

25% 15%

36% 11% 10%

41% 13% 5%

28% 24%

12%

28% 18% 7% 5%

22%

30% 12%

26% 15%

15% 10% 8% 6%

50% 11% 7% 7%

15% 11% 10%

28% 16% 9% 5%
26

31% 10%

When the right reaction matters ...

Trust BASF Process Catalysts and Technologies

At crucial moments, the right reaction matters. When you are looking for the right reaction from your process catalyst, turn to BASF. Our technical experts will recommend the right catalyst from our innovative product line that will achieve the desired reaction. The end results may also include greater yield and better end product properties. When the catalyst is right, the reaction will be right. Trust BASF. Adsorbents Chemical catalysts Custom catalysts Polyolen catalysts Rening catalysts For more information, please visit www.catalysts.basf.com/process

Plant Design software AspenTech Autodesk Intergraph Honeywell Positive DisPlacement PumPs IDEX (Viking) SPX Moyno Pressure instrumentation Emerson Process Management Yokogawa Endress+Hauser Process analyzers Emerson Process Management Siemens ABB Yokogawa Process automation systems Emerson Process Management Honeywell Rockwell Automation Yokogawa Siemens ABB Process simulation software AspenTech Honeywell Chemstations Emerson Process Management seals (mechanical) John Crane Flowserve Eagle Burgmann Chesterton security equiPment anD services Honeywell ADT

24% 15% 14% 8%

sPray nozzles Spraying Systems Bete Lechler Betz tanks & vessels CBI Pfaudler temPerature instrumentation Emerson Process Management Omega Endress+Hauser vacuum systems Gardner Denver Nash Busch Sihi Graham valves & actuators Emerson Process Management Flowserve Metso (Neles-Jamesbury) variable sPeeD Drives Rockwell Automation ABB Siemens Toshiba Yaskawa vibration monitoring equiPment GE (Bently Nevada) Emerson Process Management Rockwell Automation water treatment systems Nalco GE (Betz) Siemens (U.S. Filter) weighing systems Mettler Toledo Rice Lake

37% 14% 6% 5%

18% 8% 5%

7% 6%

50% 7% 7%

41% 6% 5%

30% 12% 9% 6%

14% 14% 12% 10%

31% 13% 12% 11% 10% 7%

32% 8% 6%

32% 20% 7% 5%

25% 21% 17% 5% 5%

53% 8% 6%

42% 17% 9% 8%

23% 15% 12%

12% 10%

56% 5%

congratulations to
randy rutledge is the recipient of the 8gB apple ipod Touch, which was offered as an incentive to participate in the readers choice awards survey. his name was randomly selected by computer from all of the respondents.

July 2011

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Properly Assess Compressed Air Demand

A careful analysis can lead to substantial savings and more
By William Scales, Scales Industrial Technologies Inc.

MOST COMPRESSED air systems at process plants oer signicant opportunities for improvement. A rigorous evaluation of an existing or new system can establish sustainable best practices for maximizing reliability and performance and minimizing lifecycle costs. In addition, it can forestall product contamination and scrap as well as the possibility of environmental damage. The same optimization strategies and techniques apply to new systems and improvement of existing ones. They ref lect a key common denominator: energy costs alone generally exceed the purchase price of a compressor in its first year of operation. Often, addressing the inappropriate application of compressed air and the proper control of the compressed air system provide the greatest savings.

Eorts must begin with analysis of demand. Every new plant will have specic initial requirements while an existing plant has established consumers. However, both of these likely will change over time, so always consider anticipated growth.
HOW MUCH AIR IS NEEDED?

Start by creating a demand pro le form and listing each steady demand, based on manufacturers specications, including the required pressure and operating ow rates at minimum, average and peak conditions. Identify and separately list all intermittent demands with compressed air on/o cycle times in seconds or minutes. Include the number of shifts and resulting variations and potential future additions. Indicate whether the air is for process or general plant use or serves as breathing air.
29 CHEMICALPROCESSING.COM JULY 2011

Industrial Compressed Air Quality

Class maximum particulate size, micron maximum particulate concentration, mg/m3 oil aerosol and vapor, mg/m
3

1 0.1 0.01 0.01 -94

2 1 1 0.1 -40

3 5 5 1 -4

4 15 8 5 37.4

5 40 10 25 44.6

6 50

Water vapor pressure dew point, F

Table 1. International Standard ISO 8573 defines different classes of compressed air quality.

Typical Components of Demand

Leaks - 10-20% Inappropriate Uses 15-25% Articial Demand 10-15%

Production - 50%

Figure 1. Leaks and inappropriate uses usually amount to at least a quarter of demand.

Costs Over Ten Years

Maintenance - 12% Equipment - 12%

Electricity - 76%

Figure 2. Electricity generally accounts for more than three quarters of overall expenses.

The type and size of compressors needed and the air quality necessary for the applications are very important factors. Consider the air quality requirement for the applications in selecting the compressors and the air treatment. While a specific process or plant standard may call for an oil-free air compressor, some sites have successfully installed lubricated compressors with proper filtration and excellent maintenance to provide oil-free air. In other cases, where a plant requires some oil-free air but has an almost equal demand in other applications that can tolerate a given lubricant level, two separate systems may make sense. International Organization for Standardization (ISO) standards classify the level of particulates, degree of dryness and amount of lubricant in the air. Operating at the lowest possible system pressure allows for the most efficient operation. For example, in many compressors, reducing the compressor discharge pressure 10 psi can cut specific power by 5%. Many plants supply compressed air to the main distribution system at a pressure that is at least 5 psi above the required minimum, which is determined either by the most significant uses or one most sensitive to lower pressure. Figure 1 shows components of demand and their typical levels. Artificial Demand relates to increased air consumption required by any unregulated uses due to system pressure in excess of what actually is necessary. Inappropriate Uses refers to applications where replacing compressed air with other options potentially can improve effectiveness or efficiency. Leaks covers unintended losses. Leaks typically represent 1020% of total demand. In the past, recommendations were to maintain the leakage rate below 10%. However, compressed air now is recognized as a very expensive utility and standards at many plants call for holding leaks to less than 5% of peak flow. A corollary is to provide automated equipment to shut off air to applications when not in use. A few end uses requiring higher pressure can lead to maintaining the entire system pressure at an

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GET MORE DETAILS

The subjects covered in this article are discussed in much greater detail in Best Practices for Compressed Air Systems, which is available via www.compressedairchallenge.org. The 325-page manual addresses topics such as distribution piping systems, specic end uses, measuring and estimating the cost of leaks, monitoring systems for optimum performance, and self-auditing opportunities.

articially elevated level, resulting in increased energy consumption. In some plants, its possible to modify end uses to operate at a lower pressure. In other cases, a motor-driven booster can handle continuous demands for higher pressures and an air amplier can take care of intermittent ones. Sometimes a low-pressure blower can replace compressed air. ere are many examples of such switches for sparging processes for aerating or agitating liquid. Depending on the height of the column and specic gravity of the liquid, the design blower discharge pressure usually runs 415 psig. For a 15-psig design pressure, the energy saving is approximately 60%. Before making such a move, check for any adverse eects on the process and necessary changes to the distribution piping. Electric motors often can replace air motors, reducing energy consumption by 80%. Similarly, where applicable, swap out double-diaphragm pumps with electric-motor-driven pumps. Another often very worthwhile move is to create vacuum for continuous applications with a vacuum pump rather than compressed air venturi methods.
COMPRESSED AIR QUALITY

Compressed air must meet the requirements of the process equipment it serves. A minimum pressure dew point of 3539F, supplied by a refrigerated air dryer, may not always suce. A regenerative desiccant dryer to provide a substantially lower dew point may be necessary but will consume more energy. e requirements of the air consumer also may demand greater ltration. You can locate these additional lters centrally at the compressors or at points of use. Packaging and instrument air. Most plants de ne packaging air as air used in packaging lines that does not come in contact with the product in any way. Instrument air is de ned as air used for instrumentation and controls. Most instrumentation

For most industrial applications, ISO 8573.1:2009, the international standard for compressed air quality, denes the level of contamination permissible (Table 1). e standard identies three primary forms of contamination: solid particles, water (vapor) and oil. It classies contaminants and assigns an air quality level ranging from Class 1, the highest purity level, to Class 9. A user or supplier can specify an evenmore-stringent requirement, Class 0. ere also are other possible gaseous contaminants. eir acceptable level depends on the application; the purication methods will depend on the specic requirements. Compressed air users must understand what are considered potential contaminants in their applications, the eects of these gases, and the methods to achieve successful and sustainable contamination control. Process and laboratory air. Process air sometimes is de ned as air that comes in contact with the product or has incidental product contact.

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sociation (CGA) Commodity Specification for air ANSI/CGA-G7.1. The OSHA standard references this specification and is essentially consistent with ANSI. Breathing air also must be tested for contaminants such as methane, nitrogen oxide, nitrous oxide, halogenated hydrocarbons and other hydrocarbons. Grossly contaminated or oxygen deficient air may not be able to be purified to levels acceptable for breathing. The CGA Standard Commodity Specification G7.1, Grade D, commonly is specified for plant breathing air systems. At a minimum, this air must conform to OSHA standard 1910.134 (revision effective April 1998) or, in Canada, Canadian Standards Association standard CAN3-Z180.1-M85. Check to ensure compliance with all local standards.
COMPRESSOR CONSIDERATIONS

Many companies use lifecycle costing derived from compressed air data and bid response forms. These forms help in judging among possible options, including air-cooled, water-cooled and various engineers specify oil-free air compressors. Where types of compressors and ancillary equipment. The specifications just require oil-free air, proper filtradata forms could include: package power, pressure, tion often may suffice. The pressure dew point of flow, inlet conditions, dew point for dryers, cooling compressed air used inside a building should be at least 18F below the buildings minimum tempera- water or ventilating requirements, service life and necessary maintenance. Purchase decisions often ture. For instruments used outside, the pressure consider actual energy and maintenance costs for dew point should be at least 18F below the lowest a 10-year period (Figure 2) as well as equipment ambient temperature. Monitor these temperatures reliability. and install an alarm to alert operators of a possible For more information on the types of compresproblem. sors, see Dont Err with Air Compressors, www. Where a single system must provide process, packaging and instrument air, use the highest qual- ChemicalProcessing.com/articles/2008/050.html ity air required. Many process plants instead rely on and Dare to Compare Air Compressors, www. PlantServices.com/articles/2008/013.html. two systems one for plant air, which may not The inlet air to the compressor should be as cool, be dried, and the other, generally at a much higher quality, for instrument air or some processes. Many dry and clean as possible. Clean is defined as a minimum amount of dust and foreign matter. The air plants will use dry nitrogen as a backup for the cannot contain contaminating gases such as ammoinstrument air system. This is especially important nia, chlorine, sulfur, carbon monoxide, etc., that can when short-duration power interruptions occur and minimum pressures must be maintained for all affect the compressor, piping, process or pneumatic system components. Compressed air must be free of instruments and valve actuators. Breathing air. Air supplied to respirators, hoods corrosive contaminants and hazardous gases. For lubricant-free positive-displacement-type and helmets and to special breathing air systems compressors (screw and reciprocating), lowering the must satisfy U.S. Occupational Safety and Health inlet air temperature 5F will improve compressor Administration (OSHA) standard 1910:13d. It performance approximately 1%. Where practical, requires drying, filtration and treatment to meet specific levels, including for carbon monoxide, with consider outside air for many applications. If the inlet piping takes air from a remote location, such an alarm system. Compressed breathing air must as outdoors or from conditioned plant air, increase comply with the requirements for Type 1 Grade D breathing air as described in American National the pipe one size for every ten feet of length. Do not place the intake point near cooling tower or Standards Institute (ANSI) Compressed Gas AsFigure 3. Software for optimizing system performance and energy consumption provides many screens such as this.
July 2011 chemicalprocessing.com 32

exhaust fan discharge, as this could contaminate the inlet air to the compressor. If not supplied with the compressor, install an inlet vacuum gauge to monitor the condition of the intake lter. Adequate compressor room ventilation is essential for heat rejection. Usually, however, it is not cost eective to air condition the area. If the compressor ventilation air is ducted out of the room, the total static pressure of the combined inlet and outlet ductwork generally should not exceed 0.12 in. of H 2O. You many need to install a ventilation fan in the ducting for heat recovery or to address large ducting losses. It may be possible to recover almost all the heat generated by the air compressors to signicantly reduce your plants total energy consumption. For more on heat recovery, see: Air Compressor Heat Recovery Is a Hot Topic, www.PlantServices.com/ articles/2003/103.html.

RELATED CONTENT ON CHEMICALPROCESSING.COM

Cut the Cost of Compressed Air, www. ChemicalProcessing.com/articles/2009/204.html Dont Err with Air Compressors, www. ChemicalProcessing.com/articles/2008/050.html Energy Savings Are Often Disguised as Problems, www.ChemicalProcessing.com/articles/2006/107.html Compressed Air Systems: The Secret is in the Pipe, www.ChemicalProcessing.com/articles/2005/12.html

Eective control strategies require documented data to monitor: ows (use mass ow meters that compensate for pressure and temperature); power and energy consumption; pressure and pressure drop (P) before and after major components such as dryers and lters; OPTIMIZATION AND CONTROL temperatures (sensors often come with the A control strategy should strive to match system equipment); and demand with compressors operated at or near pressure dew point of the system. their maximum eciency levels. is should result Another optimization strategy relies on a presin compressors running at their lowest possible sure/ow controller. is is a device that serves to input power and total energy consumption for all separate the supply side of a compressor system demand conditions. Excessive part-load or no-load from the demand side of a compressed air distribuoperation is wasteful avoid it where practical. tion system. e controller maintains a constant Some examples of multiple compressor sequencing demand-side pressure with varying demand loads. are cascading systems and rate-of-change systems. For this controller to work properly, the A cascading system overlaps the pressure setting supply-side pressure generally must exceed the in the compressors installed so that an increase or demand-side requirement by a minimum of 10 psi. decrease in pressure starts or stops the approprie compressors operate at an elevated pressure ate compressor, loaded or unloaded. is type of system generally requires a large pressure band and and increased horsepower, but pressure on the demand side can be maintained at a lower stable considerable storage volume. level to minimize actual compressed air consumpToday, modern multiple-compressor systems tion. Storage, sized to meet anticipated uctuacan benet from sophisticated controls, like Smart Sequencers (Figure 3), to eciently match compres- tions in demand, is an essential part of the control sor operation and air delivery to the system require- strategy. Using a pressure/ow controller may not be ments at the lowest energy consumption. is type necessary in all cases. Each compressed air system of sequencer can be used with any combination of compressor types and manufacturers. For addition- diers in supply, distribution and demand aspects. So, its essential to properly evaluate the benets of al information, see: Taming Multiple Compressors, www.PlantServices.com/articles/2010/01Tam such a controller for the particular system. Additional primary and secondary air receivers often ingMultipleCompressors.html. may serve as an alternative to, or in conjunction Reducing compressor discharge pressure 2 with, a pressure/ow controller. psi will cut input power 1% for many types of compressors. Proper sequencing controls should consider uctuations in demand, available storage WILLIAM SCALES, P.E., is CEO of Scales Industrial and the characteristics of the equipment supplying Technologies Inc., Carle Place, N.Y. Email him at bscales@ and treating the compressed air. scalesair.com.
33 CHEMICALPROCESSING.COM JULY 2011

PVDF Conveyor

Pneumatic Conveying
Keeps Moving Ahead
Technical developments enhance performance and economics
By Sen Ottewell, Editor at Large
Figure1. Pneumatic line connects to hopper through a valve receiver. Source: Air-Tec.

CHEMICAL COMPANIES demands for conveying solutions that increase throughput, shorten lead times, handle vastly diering solids, reduce costs and simplify maintenance all while ensuring worker and plant safety are spurring suppliers to develop innovative solutions. At dense-phase pneumatic conveying specialist Air-Tec, Calderara di Reno, Italy, for example, customers desire to handle products with vastly dierent levels of abrasiveness is driving developments. e company has installed conveyors at many chemical plants. e most common challenge that we have to face is the abrasiveness of the product, says marketing and communication manager Fulvia Lombardo. Abrasive materials can wear the conveying line and be damaged by high-velocity transportation; thus we nd the lower conveying velocity of a dense-phase system best. is lower speed, combined with a reduced amount of compressed air or other gases, avoids pipe wear, preserves the integrity of the product and contributes greatly to reduced maintenance costs, she adds.
JULY 2011 CHEMICALPROCESSING.COM 34

e company uses air boosters to introduce gas into the conveying systems to reduce friction inside the pipes, and relies on anti-wear cast iron elbows to extend downtime intervals. Air-Tec has just completed a project at the research center of a major European-based supplier of specialty cross-linkage compounds. e challenge here was to convey one metric ton of polyvinylidene uoride (PVDF) powder per hour over a distance of 30 meters. e conveyor also had to be usable with materials both more abrasive and fragile than PVDF, and ensure the quality of all products during handling procedures. To achieve this, the company installed a TPA (AirTec Pneumatic Transport) system, its most advanced oering, which provides greater exibility and control of transport cycles. Material is discharged into the TPA from bags and conveyed the 30 meters to two hoppers with load cells connected to gravimetric feeders. Valves allow PVDF into the hopper; they close when the target weight has been reached (Figure 1).

Impact of Properties property Particle shape has impact on Discharge from hoppers Flowability and compressibility Abrasiveness on equipment and particle fragility Size of storage vessels and compressibility of material Cohesive strength and arching ability of bulk materials Tendency to pack in a feeder hopper Minimum outlet diameter for bins, hoppers, and outlets Sizing of filter receivers and bin vent filters Saltation velocity Ability to flood Table 1. A wide variety of properties affect conveying. Source: K-Tron.

This solution has also met the requirement for flexibility and can be used to convey other materials with different levels of abrasiveness and fragility that might be present in the client laboratory, says Lombardo. In a sign of whats to come, Air-Tecs research and development department is working on combining different ratios of air and inert gases to boost conveying efficiencies and save energy. In collaboration with engineers at the University of Bologna, Italy, the company has developed a mathematical model that enables plants to drastically reduce energy consumption during transport of any product, says Lombardo.
FLOWABILITY

Particle size and particle size distribution Particle hardness Bulk density (loose and compact) Moisture content Compressibility Cohesiveness Can velocity Conveying velocity Permeability

MiniVacs ease of cleaning was a key plus for a pharmaceutical application requiring a cleaning system that Speaking at a bulk solids conference in Guangzhou, totally eliminated any possibility of cross-contamination China, on May 20th, Jaime A Gmez, global business development manager for K-Tron, Pitman, N.J., point- during product changeovers. Hapman engineered the system with individued out that many variables must be considered when deciding how best to implement a pneumatic conveying ally controlled spray-wash ports placed throughout strategy. However, he emphasized that the first priority the interior of the conveyor. This self-contained design reliably cleans and sanitizes the conveyors stainless steel is to address material flowability (Figure 2). interior without the need for time-consuming external Flowability is a function of the material, flow procedures. The system also boasts quick filter cartridge rates, and the equipment used. Thus, we need to understand a bit about each one of these factors. Material change-outs; a clean-in-place rotary valve that allows disassembly, cleaning and reassembly within minutes; characterization allows us to understand the material we are dealing with. We need to understand the mate- and sealed motors and controls rated for explosive-atmosphere and washdown applications. rial behavior at the micro level (that is, particles) and The pneumatic conveyor not only met all of the the macro level (that is, in bulk quantities). Material pharmaceutical makers requirements but led to inparticles interact with each other (particle/particle interactions), with the equipment (particle/equipment creases in efficiency and processing rates, says Hapman. To cut maintenance downtime, the company has interactions) and with the environment (particle/environment interactions). The ability to flow also depends launched a managed maintenance program (MMP). on the throughput (Kg/hr) and velocity (Km/hr). The This involves regularly scheduled inspections to spot last factor to be considered is the handling equipment. potential wear and tear before it becomes an issue. The Geometry, distances, angles, surface finish, and agita- MMP also offers customized training to improve equipment uptime, performance and longevity. tion all influence flow behavior or flowability. Meanwhile, Flexicon, Bethlehem, Pa., is taking Gmez went on to highlight other variables that deal more with transport of bulk materials such as can conveying to higher levels, quite literally. One of the companys latest successes is a project and conveying velocities (Table 1). for Oplex, Mexico City, one of Mexicos largest plastics Only when these are fully understood can facprocessors. Installing a bulk bag unloading system for tors such as method of pneumatic conveying for example, pressure or vacuum, and closed-loop nitrogen polyvinyl chloride (PVC) resin that combines both systems together with weighing and scaling systems pneumatic and flexible screw conveying has streamlined materials handling, created a safer work environment and vacuum sequencing be implemented successfully. and improved worker efficiency. The two separate pneumatic conveying lines prevent cross-contamination OPERATIONAL ISSUES when running different products. One topic that certainly commands plant attention Flexicon had to adjust its Pneumati-con dilute-phase is reducing operating and maintenance costs, notes pneumatic conveying system to maintain performance Hapman, Kalamazoo, Mich. Its MiniVac range of pneumatic conveyors are designed for installation flex- at Mexico Citys high altitude 7,349 ft above sea level. This primarily involved ensuring that the fans cooling ibility and do away with the need for expensive plant the motors generated enough air flow to be effective. air or separate compressors, says the company.
35

chemicalprocessing.com

July 2011

Slide Angle

Figure 2. One measure of owability is the minimum slope at which a powder will move down an incline. Source: K-tron.

e accuracy of the now-automated systems loading, weighing and mixing operations has improved overall product quality and repeatability. In addition, using bulk bags in place of 25-kg sacks of PVC has reduced the amount of oor space needed for materials storage. Flexibility is another advantage. A single conveyor can handle powders with a wide range of bulk densities, as well as akes, pellets, capsules, tablets and other friable materials. Because the Pneumati-con system fully evacuates the vessel being discharged and the conveyor line itself, cross-contamination of multi-ingredient systems is minimized. e system also boasts easy-to-maintain lter receivers and rotary airlock valves.
PRESSURE BALANCE

One of the secrets of a successful and highly efcient pneumatic conveying system, whether a

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high-pressure dense-phase system or a low-pressure dilute-phase, is achieving an optimum pressure balance, notes Dynamic Air, St. Paul, Minn. Many systems operate in an unstable or unbalanced pressure condition, says the company. This means the conveying system can be using either too much or not enough compressed air, both of which are undesirable. To effectively counterbalance all the friction factors normally inherent in a pneumatic conveying system, Dynamic Air has developed DC-5 Air Saver technology, which accurately controls and pressure balances the pneumatic conveying system. It achieves the proper pressure balance by automatically sensing system conditions and reacting instantaneously and accurately without overcompensation. So material is conveyed through the line in a smooth, controlled manner and at the desired velocity, to optimize the conveying process for higher performance and reliability. DC-5 Air Saver cuts energy consumption, improves system reliability, allows highly abrasive materials to be transported, reduces dust handling requirements, and decreases the dynamic loading experienced at pipe bends by controlling the conveying velocity, says the company.

JULY 2011

CHEMICALPROCESSING.COM

36

make the most of

radar
By Sarah Parker, Emerson Process Management

Following some best practices can ensure accurate level measurement

The emergence of radar has significantly advanced level monitoring. Radar provides cost-effective and accurate measurements that are immune to density and other process fluid changes, as well as most vapor-space conditions. Radar level measurement systems come in contacting and non-contacting versions, both of which are widely applied in the process industries. Contacting generally is a good fit for small spaces; it easily replaces older technologies such as displacers and capacitance probes. Non-contacting usually is better for dirty, viscous or corrosive applications and when agitators are present. Currently, contacting devices called guidedwave radar (GWR) are slightly more prevalent, primarily because they can measure interface level (e.g., oil and water) as well as standard direct level (Figure 1). There are some important considerations when applying both types of radar technology. For example, getting accurate measurements in steam applications of more than 400500 psi (3035 bar) requires GWR systems that have dynamic vapor compensation. Similarly, in applications where signal reflection is weak, you must select a device with technology that

minimizes losses in the returned signal. In cases including some solids applications and those with low dielectric fluids and turbulence due to boiling or entrained air where the return signal is so weak that it occasionally disappears, the device should be able to provide a level measurement via alternative methods such as probe end projection (which uses a combination of the known length of the probe and an online reading of dielectric to calculate level). While GWR works in many conditions and doesnt depend on reflecting a signal off a flat surface, probe choice requires care. Probes come in several styles the application, length and mounting restrictions influence the correct choice. Unless coax-style units are used, probes should not directly contact a metallic object because that will impact the signal. Twin and coaxial probes are susceptible to clogging and build up. If the application involves liquids that tend to be dirty, sticky or can coat, then only use single-lead probes. For such applications, devices offering signal quality diagnostics can help determine if the probe needs cleaning and allow scheduling of maintenance only when needed.
37 chemicalprocessing.com July 2011

Guide Wave Radar

Figure 1. This contacting device can detect interface level as well as overall level.

In general, GWR doesnt suit extremely viscous products where fluid flow is minimal. If GWR is used with very viscous fluids and installed in a bypass chamber, heat-trace and insulate the chamber to ensure fluidity. In addition, check that the connections from the tank to the chamber and the chambers diameter are large enough to allow good fluid flow. For applications such as asphalt where heavy coating is likely, go with non-contacting radar and mount directly on the vessel, not in a chamber. Non-contacting radar (Figure 2) demands careful consideration of process conditions and installation constraints. It requires a clear unobstructed view of a liquid surface. An unrestricted mounting nozzle also is important. The measured surface must be relatively flat, not slanted. Non-contacting radar gauges can handle agitation but success depends on the fluid properties and the amount of turbulence not limiting the return signal too much. Low dielectric fluids reflect very little radiated energy back to
38

the gauge. Additional signal loss occurs if the liquid surface is turbulent, whether from agitation, product blending or splashing. To overcome this, you can use bypass pipes including self-contained chambers or stilling wells to isolate the surface from turbulence. Such bypass pipes (Figure 3) provide a calmer surface in case of turbulence. They offer external mounting with valves, allow for easier servicing of level devices and enable radar measurement in tanks such as towers that only offer side connections. Always provide multiple holes or slots on one side of the pipe to ensure good fluid flow-through. Both GWR and non-contacting radar work well for pipe or stilling well applications, but GWR is far simpler to install and maintains accuracy and sensitivity independently of the pipe. For these types of applications, correctly dimensioning the chamber and selecting the appropriate probe are essential. Choose 75-mm or 100-mm chambers. Smaller ones raise risks of build-up and flow-through problems, and increase the chances of the probe contacting the chamber wall. Select a single probe, as it is less susceptible to build-up. Most chamber installations rely on rigid probes but flexible ones also may also be used. Ensure the probe is suspended vertically and does not touch the pipe wall. A centring disk can keep the probe properly positioned away from the wall. For shorter pipes, use GWR with rigid probes. GWR with flexible probes can work in long pipes, but the probes must remain taut and away from the wall. A combination of weights and centring disks can achieve this. For longer pipes or when head space for installing probes is limited, opt for non-contacting radar.
SPECIAL CHALLENGES

Several types of applications raise particular issues. High temperature and pressure. Applications with extreme temperature and pressure conditions demand a heavy-duty process seal with multiple layers of protection and a flexible assembly to handle the stresses and the forces induced. This is to prevent leakages and ensure the safety and efficiency of your plant. When measuring liquids at very high temperatures in a chamber, you must insulate and heat-trace the chamber. Fluctuations in temperatures alter the density and volume of the liquid, which then affect the level in the chamber. Maintaining the temperature of dirty liquids such as heavy oil also helps avoid clogging and sticking within the chamber and enables adequate flow-through.

July 2011

chemicalprocessing.com

Although radar technology is not affected by density changes, dielectric variations can have an impact. For boiler and feed-water systems where boiling water and high-pressure saturated steam vapors are present, the returned signal from the surface becomes weaker as water temperature increases. In addition, the saturated steam alters the propagation velocity of the radar signal and generates an error in the level reading proportional to the measured distance. Dynamic vapor compensation can address the changes in the vapor-space dielectric and reduce the incorrect distance caused by varying pressure or temperature to less than 2%. Interfaces. The fluid with the lower dielectric must always be on top and you must know its dielectric value. The two liquids must differ in dielectric value by at least around ten. Effective measurement requires certain thicknesses of layers. Typical successful applications have a hydrocarbonbased fluid with a dielectric around two as the top layer and water-based fluid with a dielectric over 40 at the bottom. Applications where the densities of the two fluids are very close or where emulsifiers are used can produce fairly large emulsion between the liquids. This may make the interface indistinct. Heavy and thick emulsion layers or liquid layers with similar dielectrics can pose a problem for GWR because it requires a distinct dielectric difference to detect
Non-contacting Radar

the interface. GWR devices have proven to work in interfaces with emulsions but success is difficult to predict. The interface threshold on the radar device may require manual adjustment. In applications with large emulsions, a displacer device (which relies on a buoyancy effect rather than any dielectric value) can track the midpoint of an emulsion layer and, so, may provide a better solution. However, that technology relies on moving parts that require frequent cleaning and replacement, thereby reducing the reliability of the measurement and incurring greater maintenance costs. Open air and non-metal tanks. Radar often works well in such applications. In some cases, though, outside disturbances may interfere with the radar signal and you must select a device, such as a GWR with a smart galvanic interface, with high resistance to electromagnetic interference. For most open sump and well installations, an ultrasonic meter is a morecost-effective solution. However, should vapors be present, choose a low-frequency radar device instead. Overfill protection. In critical applications, you must install a minimum of two level technologies or devices; if several measurements rely on the same technology, you must employ a voting scheme. Using technologies less influenced by process conditions, such as radar in combination with vibrating fork switches, is a good step to more accurate and reliable measurements. For radar, most failure modes relate to a loss

Figure 2. Measurements require a clear unobstructed view of liquid surface.

39

chemicalprocessing.com

July 2011

Bypass Pipes

probe gets coated, providing the opportunity to schedule proactive maintenance. Today, vibrating fork switches continuously monitor corrosion of the forks, external damage to the sensor, internal wire disconnect or breakage, and over-temperature. is results in a fault indication and fail-safe operation of the switch output.
INSTALLATION PITFALLS

Figure 3. Using external chambers for level measurement can cope with turbulence and enable easier servicing of device.

of signal. High sensitivity normally results in high availabilities. High sensitivity is achieved by increasing the signal-to-noise ratio, e.g., via Dual Port and Direct Switch Technology. Enhanced echologics the ability to ignore false echoes and smart software functions also improve radar performance. Some GWR devices incorporate SARAH PARKER is level application manager for Emerson software that improves measurements in the near Process Management, Chanhassen, Minn. Email her at Sarah. zone (high level areas), especially for low ref lecParker@emerson.com. tive targets. However, above a certain level the surface RELATED CONTENT ON echo may not appear at all in the waveform. Using CHEMICALPROCESSING.COM echologics to monitor signal changes as the level Dont Impair Level Measurements, www. gets close to the top adds an extra layer of protecChemicalProcessing.com/articles/2010/177.html tion. is supports the basic level signal and gives Dont Underestimate Overllings informative warnings that the tank is full, even if the Risks, www.ChemicalProcessing.com/arlevel signal is lost. ticles/2010/143.html Advanced diagnostics is another step in the right Keep Measurements on the Level, www. direction for safe measurement. For example, some ChemicalProcessing.com/articles/2006/165.html GWR devices provide real-time notication if the
40

A good installation is key to success with radar. A new radar device usually is installed on an existing nozzle. is nozzle sometimes may be too tall or narrow for the instrument. Try to minimize the height of the nozzle used. Ideally, nozzles should be at least two inches in diameter but no more than six inches high for GWR. For non-contacting radar, the end of the antenna should extend slightly beyond the nozzle. High-frequency noncontact radar can use longer nozzles but they must be smooth and clear of obstructions. Positioning the nozzle directly over a pipe, bae or other obstruction can cause problems. e obstruction interferes with the radar beam and it, rather than the process medium in the vessel, becomes the level measurement. Similarly, a uid stream coming into the tank that falls into the path of the radar beam or on the probe will impact the reliability of the measurement. As with all instrumentation, you must correctly congure radar devices in accordance with application needs. Take special care when inputting thresholds for the radar signal these will change depending on the medium being measured. For example, oil appears very dierent to a radar device than water and, therefore, requires very dierent threshold settings. However, today good set-up guides and functions in most cases enable easy conguration in just a few steps.

JULY 2011

CHEMICALPROCESSING.COM

making it work
Split Seal

Figure 1. Dry-running unit coupled with perfluoroalkoxy sleeve bearing prevents leakage of TiCl4.

Mixer Seal Gets Major Makeover

Novel retrofit prevents leaks and offers other benefits
By Vic Lundberg, Quadna

SealinG the agitator shaft entry point in a tank used for high temperature mixing of titanium tetrachloride (TiCl4) at its Henderson, Nev., plant was a crucial worker-safety issue for Titanium Metals Corp. (Timet). TiCl4 is an aggressive chemical that has a tendency to flash off to form a potentially noxious vapor and toxic white cloud. In addition, when the chemical comes into contact with water, it can become hazardous. In late 2010, Timet sought out Quadnas advice on the best way to seal the mixer shaft entry point. We faced two major challenges in developing an effective solution. The first was to determine how to maintain a strong positive seal. The seal design was of paramount importance and there were critical metallurgy issues as well. Previously, the system employed a double mechanical seal with a mineral-oil barrier fluid that provided lubrication between the inboard and outboard faces. Timet wanted to use a split mechanical seal instead because its installation and eventual replacement take far less time. However, to enhance the operation, a dry seal was needed. The problem? At that point in time, no manufacturer was producing a dry-running split seal. The second obstacle was the length of the shaft.

The mixing operation uses a long unsupported shaft, which commonly leads to excessive shaft run-out at the mechanical seal. We recommended installing a sleeve bearing made of DuPont Vespel CR6100, a perflouroalkoxy. The additional sleeve would help the long shaft run true and minimize shaft run-out. The typical total clearance for a steady bearing for a shaft of the diameter used for this mixer (3 in. to 5 in.) is 0.020 in. The Vespel sleeve bearing was machined for a total clearance of 0.0070.010 in. This dramatic reduction in clearance between the bearing and shaft allowed the Vespel sleeve bearing to act as a primary seal, as well as to keep shaft run-out well below maximum acceptable levels. The reduction in clearance was possible because of the unique coefficient-of-thermal-expansion properties of Vespel. Thermal growth is largely confined to the Z direction (along the shaft) growth in the X and the Y directions is extremely small. In addition, the material is chemically inert to TiCl4 and can operate without lubrication because of its very low coefficient of friction. Quadna redesigned the mixer stuffing box for a John Crane Type 3740D cartridge split seal using the Vespel sleeve bearing this represented one of the first
41 chemicalprocessing.com July 2011

MAKING IT WORK

John Crane dry-running beta split seal installations.

IMPRESSIVE RESULTS

During nal assembly of the bearing and split-seal system, a slight dimensional issue prevented installation of the John Crane seal. Because time was running short,

the mixer had to be placed back into service. During subsequent operation the Vespel sleeve bearing alone sealed nearly 100% of the vapor and also demonstrated its eectiveness in reducing run-out. So, Quadna and plant ocials decided to continue operating the unit without the seal while the

minor dimensional issue was addressed. en, at the rst opportunity, we put in the dry-running seal to ensure complete containment of vapor. e split seal took only hours to install during a brief outage (versus the days required for a double seal) and has operated without a hitch. Several vessels in the plant that were experiencing similar problems now have received John Crane Type 3740D dry-running split seals as well as Dupont Vespel 6100 sleeve bearings for their mixer shafts, resulting in the containment of all TiCl4 vapor. ese enhancements have provided other benets too. Signicant savings come from eliminating the mineral-oil barrier uid and specialized seal-support equipment to regulate ow and pressure required by double mechanical seals. In addition, seal replacement in the future will take much less time. Quadna team members are incorporating all the modications as standard oerings for new mixers that Timet is purchasing for the plant. Installation of these mixers should be completed by the end of 2011.
VIC LUNDBERG is a Las Vegas, Nev.based process engineer for Quadna, a DXP company. Email him at vlundberg@ dxpe.com.

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process puzzler

prevent pump problems

Readers suggest possible root causes and ways to improve performance

tHIS mONtHS pUZZLer

reDUCe tHe SHAFt SpeeD in our gas plant we pump natural gas liquids (ngl) with a double-suction high-speed centrifugal pump. it runs with a discharge pressure of 60 Barg at 6,700 rpm, and is designed for a flow rate of 670 m3/hr. a booster pump discharges at 20 Barg to the ngl pump suction. The ngl, which has a specific gravity of 0.52, then travels about 400 km to our refinery for fractionation. about 3540% of the pumped fluid recycles into the surge bullet via a recycle valve, wasting energy. There are other problems: vibration trips in low flow due to shaft deflections, seal leaks, etc. so, were planning to buy a new pump, preferably one that will allow us to save energy and avoid such problems. What type of pump do you consider the best choice for this application? DeSIGN FOr eNerGY eFFICIeNCY

The booster pump and the export pump should have their own minimum-flow recycle valves. These minimum flows need to be maintained at all times either by a flow control valve or a restrictive orifice (RO). An RO is simpler; however, it will waste energy. I suggest flow control loops so that the flow is recycled only when needed. If flow above the minimum rate is required and the economics allow, use variable speed drives to reduce energy consumption. The problems may be due to low seal pressure. Double mechanical seals require pressure above the pump discharge pressure. Otherwise, hydrocarbon will migrate to the seal system. Another symptom, pump vibration at low flow, may be due to improper alignment and cavitation. The same problems will appear with the new pump if the cause is not clearly established. Sameer Chawla, lead process engineer Another response appears online at www.ChemicalProcessing.com/ WorleyParsons, Kuala Lumpur, Malaysia voices/process_puzzler.html

I think the problems can be divided into two categories design and operational. The high rotational speed of these pumps causes overheating at the seal faces and seal failure. The high peripheral velocities are too close to the manufacturers design limits. Another design problem is shaft deflection, which is highest at low flow. Under these conditions, high radial forces, created by the high pressure in the pump casing, act on the shaft and impeller. The pumps double volutes are ineffective. As a result, the pumps vibrate severely, enough to cause tripping. Operationally, the pump wastes energy because of the high recycle flow. I suggest exploring: 1. A lower capacity impeller. Design for the identical head with increased shaft stiffness and reduced throat bushing clearances. The material of construction may need to be changed. These modifications should reduce low-flow vibration. 2. A two-pole motor, constant speed direct-drive. 3. A multi-stage pump. It offers many advantages over a single-stage pump, including: a lower shaft speed, resulting in increased life of bearings and seals; reduced shaft deflection; elimination of a speed-increaser gear box, reducing energy consumption; and less motor horsepower. Although the NGL pump will still be operating well below its best efficiency point (BEP), the energy losses will be reduced. As a last resort, another option could be a variable speed drive. Sakrapani Amirthalingam, shutdown engineer Gasco/Asab, Abu Dhabi

SeptemberS pUZZLer
We used an old welded stainless steel silo at our missouri site to store dried brewers grain. During a september shutdown, we installed a new bagger and weigh scale. This prevented us from loading railcars for several days. so, to keep the dryer running during the outage, we cut its output to a rate that would only fill up the silo. The weather was hot but a rainstorm swept through with a cold front. after the storm, we noticed a seam on the silo had split apart, dumping several hundred tons of dried brewers grain. now, corporate managers, concerned because another plant is planning a similar shutdown and bagger installation soon, want to know why the silo failed. What do you think caused the accident? What should we tell management? send us your comments, suggestions or solutions for this question by august 12, 2011. Well include as many of them as possible in the september 2011 issue and all on cp.com. send visuals a sketch is fine. e-mail us at processpuzzler@putman.net or mail to process puzzler, Chemical Processing, 555 W. pierce road, suite 301, itasca, il 60143. Fax: (630) 467-1120. please include your name, title, location and company affiliation in the response. and, of course, if you have a process problem youd like to pose to our readers, send it along and well be pleased to consider it for publication.

43

chemicalprocessing.com

July 2011

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plant insites

Pick the Proper Centrifugal Pump

Consider the impact of startup conditions and prospective operating points
Centrifugal PumPs impart velocity to a f luid and then recover the velocity as pressure head. Performance curves depict the total dynamic head generated at a given f low rate for a specific impeller and rotational speed (Figure 1). They typically show total dynamic head in feet, not psi, unless the curves are for a defined liquid. You can convert pressure rise from feet to psi via: P = H/144 (1) where P is pressure rise in psi, is density in lb/ ft 3, and H is dynamic head in feet. Pump work applied to the f luid is: W = QP/1,714 (2) where W is work in hp, Q is f low in gpm, and is pump efficiency, as a fraction of one. Both P and W vary with liquid density. So, you must know the density to convert from a dynamic pump performance curve to the physical pressure rise or power required. Pump efficiency varies with f low rate. In addition, the efficiencies of the drive system (belts, gears, couplings, etc.) and driver come into play. For an electrically driven pump, the driver efficiency is the motor efficiency. This can vary as a function of total load. Motor efficiencies drop at low loads. Dynamic head in feet doesnt change as density changes. Imposed pressure in psi and power demand will vary as liquid density varies. For many processes and conditions, the density is well understood and known in advance. However, densities can vary dramatically in some common situations. For instance, at startup many units are cold, so densities are higher, increasing power demands. Lets look at a situation where startup density differences created motor problems. Figure 2 shows the bottoms of a high temperature distillation tower. The startup procedure required circulating cold tower bottoms to the fired heater reboiler. Limits on both the pump (suction specific speed) and the fired heater (minimum safe firing with air control) restricted f low rate to 1,500 gpm for starting conditions. The design operation was 2,250 gpm. Obviously, the pump can handle the lower f low rate. However, startup usually was a hit-or-miss affair because the pump motors thermal protection system was near its trip point, a power draw equivalent to 300 hp. Table 1 illustrates the normal and startup conditions; efficiency takes into account the pump, driver and coupling, as well as an allowance for efficiency changes due to high viscosity at the startup condition. Designers should have factored in the need for some extra startup power. Good practice requires thinking about different operating points. Consider, for instance, startup at cold conditions, higher viscosity operation, pumping heavier f luids, and installing larger diameter impellers in the future. Many companies, as standard practice, buy pumps with some room to increase impeller size later to boost capacity. Greater throughput plus higher discharge head from a larger impeller rapidly raises the pump power required. Prudent engineering practice is to select a motor sized for the maximum impeller that fits in the casing. In the end, economics sets the best motor
Pump Curve
0.8

Select a motor sized for the maximum impeller that fits in the casing.

Dynamic head
550

Net Positive Suction Head required, ft

0.6 15

500

450

400

Net Positive Suction Head

0.4

10

350

0.2

300

250 0 500 1,000 1,500 2,000 2,500 3,000

0.0

Flow, gpm at conditions Figure 1. Dynamic head in feet doesnt directly give pump power required.

startup Versus normal Operation Condition Startup Normal Flow, gpm 1,500 2,250 Head, ft 550 460 Head, psi 191 111 Density, lb/ft3 50.0 34.9

Overall Efficiency, fraction 0.57 0.67

Power, hp 294 218

Table 1. Startup requires power draw close to thermal protection trip point.

45

chemicalprocessing.com

July 2011

Efciency, fraction

Dynamic head, ft

Efciency

PLANT INSITES

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Product Figure 2. Circulation of cold viscous bottoms at startup posed motor cutoff risk.

CAS-195C.indd 1

Material Handling Equipment 1/28/11

10:35 AM

Drum Discharger Lift & Dump Container Discharger

Container Discharger

sizing choice. Higher investment now for a larger motor saves money in both the motor, electrical systems and, perhaps, foundation later. It also enhances pump reliability. Power consumption costs really dont change a lot with larger motors. Of course, this logic only goes so far. Multiple margins for cold startup conditions with larger impellers may lead to drastic oversizing. Motors that run at small fractions of their design load have lower efficiency. Use engineering judgment to choose the right motor size. Large motors with significant capital costs may require a true lifecycle analysis of total system cost.
ANDREW SLOLEY, Contributing Editor ASloley@putman.net

GET MORE PUMP INSITES

Lift & Dump Drum Discharger Bulk Bag Filler Bulk Bag Discharger

Call: 800.836.7068 www.materialtransfer.com

Previous columns include: Properly Trigger Standby Pumps, www.chemicalprocessing.com/ articles/2010/095.html and Cut Pump Speed to Cut Problems, www.chemicalprocessing.com/ articles/2009/167.html.

equipment & services

Conductivity Sensor Resists Corrosion

The TCS3020 Toroidal noncontacting inductive sensor is designed for performance from 01,000 mS and long-term deployment with no maintenance. Its resistant to corrosion, coating and fouling and constructed from Noryl. The TCS3020 reportedly has a wide solvent tolerance and temperature stability to 105C. It operates up to 150 psig. The sensor is either submersible or can be installed in-line. It includes a standard style ATC measuring element and a 20-ft (6 meter) cable. The TCS3020, when combined with the TCSMA or TCSTX toroidal transmitter, is said to offer a complete conductivity measurement system.
Sensorex 714-895-4344 www.sensorex.com

inputs in two-, three- and four-wire connections, as well as display the current primary temperature measurement and indicate alarms. It reportedly enables cost savings by sending alarms to trigger predictive maintenance scenarios. The transmitter is capable of automatically switching to a back-up sensor and then notifying the control room that the primary sensor has gone bad, which could prevent loss and improve productivity.
Invensys Operations Management www.iom.invensys.com

Pumps Handle LowPressure Applications

The 2000 Model WA and WB positive-displacement pumps feature a compact, closecoupled configuration. They are designed for low-pressure, low-f low applications that do not require the full features of a 2000 G1 pump. The models are claimed to be ideal for industrial and municipal applications that require the transfer of highly viscous f luids and solids where a close-coupled configuration is preferred, but the robustness of a gear joint is desired.
Moyno, Inc. 937-327-3017 www.moyno.com

low-profile unit reduces agglomerates and friable materials being discharged from process equipment, storage vessels and shipping containers. Material entering the 15-in. (381-mm) square inlet is reduced in size by dual rotors with three-point single-piece stainless-steel breaking heads rotating with minimum clearance inside a curved, perforated bedscreen. On-size material exits through apertures in twin bed screens ranging from 1 32 - to 2-in. (25 to 64 mm) in / diameter. At 11-in. (279 mm) high, the unit is designed to fit in restricted spaces.
Munson Machinery Company, Inc. 800-944-6644 www.munsonmachinery.com

Drum Dumper Rotates 180 Degrees

The 180 rotation drum dumper accepts 55-gallon drums of non-free-f lowing powders and discharges the contents into a vibratory feeder at 83 in. above f loor level. The unit boasts dust-tight operation and 304

Temperature Transmitter Offers Flexibility

The Foxboro RTT30 Foundation Fieldbus two-wire temperature transmitter receives input signals from thermocouples, RTDs, resistance (ohm) and voltage (mV) sources. The RTT30 also can measure two

Sanitary Lump Breaker Fits Tight Spaces

Model RDC1515-SS sanitary lump breaker features side removal bed screens for washdown applications. The all-stainless,
47 chemicalprocessing.com July 2011

equipment & services

stainless steel product contact surfaces. Its available with discharge heights up to 40 ft for any size drum or container, and units can be custom designed for any application.
Material Transfer 800-836-7068 www.materialtransfer.com

less steel bar stock and designed to withstand repeated open and close cycles. Suited to control oil, water, toxic fluids, chemicals, air and steam, the two-valve block manifold has one isolate and one vent valve. Each valve stem is precision machined with hard seats to reduce operating torque, the company says.
Dwyer Instruments, Inc. 800-872-9141 www.dwyer-inst.com

Module Monitors Gas Turbine Performance

The Envision Gas Turbine (GT) performance module can help assist operators and field service personnel in their day-to-day operation of General Electric aero-derivative gas turbines. The module gathers and analyzes real-time data to calculate thermodynamic performance. Its outputs are ISO-reference and humidity corrected, specifically for the General Electric LM series gas turbines. Its open architecture supports OPC and DDE servers. The module is f lexible and can monitor multiple trains simultaneously, even when controlled by different processors and control systems. Users also can select from multiple graph formats or create trends from stored data.
Dresser-Rand 713-354-6100 www.dresser-rand.com

radio. The camera is said to be capable of transmitting over 30 frames per second of video in 1,280 1,024 resolution. Its IR illuminator provides high-resolution images from over 200 ft in complete darkness. The system connects wirelessly to an IP network for remote viewing and recording. Its clasping hooks can attach to rails and walls up to 1-in. thick. The antenna is mounted on an ultra-high-pull encased neodymium-iron-boron rare-earth magnetic base for secure mounting to sites that may move or vibrate.
Industrial Video & Control 617-467-3059 www.ivcco.com

Compressor Boasts Energy Efficiency

The ZH 350+ three-stage turbo oil-free air compressor is designed for use in industries that rely on 100% oil-free air. The compressors three-stage design helps it achieve compression between 100 and 160 psi while minimizing power use, says the company. The ZH 350+ has no gearbox thus eliminating transmission losses that can reportedly reduce energy efficiency by up to 9% in compressors in the 350-kW range. Its titanium impellers are said to permit faster load/unload cycles, allowing for rapid speed changes which cut power loss during times of low-air demand. The compressor features optimally sized coolers that can help reduce pressure drop.
Atlas Copco 866-546-3588 www.atlascopco.com

Video System Boasts High Resolution Monitoring

The RD-MZ-3630-01 rapid-deploy wireless video system consists of a high-definition color camera and an internal wireless
July 2011 chemicalprocessing.com

Valve Block Reduces Operating Torque

The Series BBV-0 two-valve block manifold is considered suitable for use over a broad range of processing applications. The Series BBV-0 is forged from 316 stain48

Vent Heads Recover Condensate

VHT vent heads can help safely discharge dry steam to

equipment & services

the atmosphere at low velocity, protecting personnel from injury, buildings from damage and minimizing the nuisance of water spray on the surroundings. The internal drain recovers condensate that would have otherwise been directed to an external drain and removes the possibility of hot condensate exceeding temperature limitations of local drainage. Suitable for vertical open-ended steam vent pipes, the vent heads are manufactured from austenitic stainless steel and should provide life-long, trouble-free operation. They also are considered well-suited for blowdown vessels, feed tanks and condensate receivers.
Spirax Sarco, Inc. 803-714-2000 www.spirax.com

monitoring, device diagnostics and control applications. The devices are designed to run on explosion-proof batteries that can easily be replaced in hazardous locations.
Yokogawa Corporation of America 800-888-6400 www.yokogawa.com/us

Flow Meter Suits Tubing

The Traceable ultra-low-flow meter features a simple four-button operation (flow/total, units, zero and power) and an LCD display that shows the current and total accumulated flow. Accuracy is 2% full scale with liquid temperatures of 20 to 30C, and 4% full scale for all other temperatures ranging from 32 to 122F (0 to 50C). User may adjust a viscosity compensation correction. Chemically resistant nylon barbed inlet/outlet connectors are compatible with all types of tubing. Housing is constructed of chemical-resistant ABS plastic. The meter is 6- 4- 4- inches and weighs 1 lb.
Control Company 281-482-1714 www.control3.com

signed and now offers both a hydraulic cutting head option (JR360H) and the previously available pneumatic cutting head (JR360P). Enhanced features include a hydraulically assisted sectional boom that adapts to different size vessels; cutting heads featuring interchangeable blades, f lails, or chain cutters engineered to safely remove a wide variety of materials; and a new chain cutter or whip mounts, which swivel into the compact hydraulic cutting head. The 5-in. diameter hydraulic cutting head is said to fit into extremely small f low channels or ratholes without losing any power or cleaning capacity.
Mole Master 800-322-6653 www.molemaster.com

Field Wireless Devices Follow ISA Standard

Devices based on the ISA100.11a industrial wireless communications standard include an EJX-B series differential pressure and pressure transmitter, a YTA series temperature transmitter, and an integrated field wireless gateway for field sensor networks. With the ISA100.11a standard, the production, device diagnostic and parameter data transferred between a control system and field devices are securely encrypted. This wireless technology is said to be ideal for status

Heat Transfer System Cuts Down Degradation

The MOS mid-size hot-oil heat transfer system is said to assure responsive and precise electronic process temperature control in a space-saving design. Its considered ideal for applications in reactors, evaporators, dryers, platen pareses, heat exchangers, roll heating or jacketed kettles,
chemicalprocessing.com July 2011

Cleaning System Reaches Small Spaces

The Junior 360 silo and bin cleaning system has been rede49

equipment & services

vessels and tanks. The system provides heat transfer capabilities to 600F or, optionally, 650F at atmospheric pressure. Available for operation from 50150 kW, the MOS offers SCR electronic solid state power control. The unit operates in a closed-loop system using an optional cold expansion tank, reducing the degradation of heat transfer fluids and removing the need for a nitrogen purge.
Chromalox 800-443-2640 www.chromalox.com

included. The company offers thermocouple grounded or ungrounded elements in types J, K, or T. Thin film or wire-wound type RTDs in Class A or B and two-, three-, and four-wire models are available. offer improved pumping speeds at deeper vacuum levels. These single-stage pumps provide end vacuum levels comparable to most two-stage designs, the company says. All Dolphin LX series vacuum pumps are compact, feature a motor-mounted design and considered ideal for a wide range of wet or corrosive applications. Standard construction includes cast iron housing, a 316 stainless steel impeller, replaceable port plate and mechanical seal. The company notes these rugged pumps can replace traditional close-coupled, separate-drive or base-mounted liquid ring configurations.
Busch USA 800-872-7867 www.buschusa.com Palmer Wahl Instrumentation Group, Inc. 800-421-2853 www.palmerwahl.com

Regulators Feature Domeloaded Design

RHPS series domeloaded regulators permit high f lows and reportedly exhibit less droop than spring-loaded designs in controlling the pressure of liquids and gases. The domeloaded design relies on a pressurized chamber above an elastomeric diaphragm in place of a spring to operate the regulator. Depending on regulator size and configuration, inlet pressures can range to 5,800 psig (400 bar). Regulated pressures span 1.4 to 29 psig (0.10 to 2.0 bar), 0 to 1,000 psig (0 to 70 bar), 0 to 2,900 psig (0 to 200 bar), and 0 to 5,800 psig (0 to 400 bar). Regulators are available for pipe sizes ranging from to 4 in. with corresponding Cv values ranging from 0.1 to 73.
Swagelok 440-349-5934 www.swagelok.com

Coriolis Flow Meter Offers High Accuracy

With its 14-inch diameter and accuracy up to 0.05%, the Promass 83X/84X four-tube Coriolis mass flowmeter is claimed to be ideal for pipeline custody transfer and other high-flow-rate applications requiring reliability and low maintenance. The unit can measure the mass flow, density and temperature of oil, gas and other fluids at rates up to 4,100 tons/hr. For both models, accuracy of the density measurement is 0.01 g/cm3 (0.001 g/cm3 optional), while accuracy of the temperature measurement is 0.5 C. They also have a balanced measuring system with high immunity to external pipe vibrations and process influences, and work in applications with entrained air.
Endress+Hauser, Inc. 317-535-7138 www.us.endress.com

Temperature Sensors Come In Many Versions

A line of RTD and thermocouple sensor assemblies come in a wide variety of configurations to meet an assortment of application requirements. The line includes sensor heads in aluminum, stainless steel, cast iron, polypropylene and explosion-proof models. Terminal blocks and transmitters for data transfer, including HART protocol transmitters, are also
50

Vacuum Pumps Maintain Higher Speeds

The Dolphin LX B series liquidring vacuum pumps reportedly
July 2011 chemicalprocessing.com

Meter Measures Bi-directional Flow

The RS Series helical-screw flow meter is based on a low-mass rotor

equipment & services

design that is said to increase accuracy and reduce pressure drop and response time. The double sensor electronics allow bi-directional flow measurement with user-selectable resolution and signal filtering. These features provide an accuracy of 0.3% of measured value and a repeatability of 0.05% with viscosities from 1.2 to 1,000,000 cSt. Stainless steel or cast iron construction is available with standard pressure ratings of 450 bar (6,500 psi). The meter comes in three sizes, for flow range from 0.5 to 1,000 liters per minute.
IC Flow Controls, Inc. 309-862-1800 www.icflow.com

control helps ease operation. The devices large color display, with multicolor traffic-light guidance, reportedly simplifies operations and system maintenance. The unit also separates fiscal and maintenance data, permitting remote maintenance without compromising security and data integrity.
Krohne 978-535-6060 www.Krohne.com/northamerica

Software Upgrade Eases Navigation

An upgrade to the Enterprise Performance Management (EPM) suite of business intelligence and analytic solutions improves visibility into business operations. The upgrade enables users to open dashboards with or without data, includes a new documents tab, and is said to ease navigation with fewer clicks. It also includes Sentinels functionality to the web client, which provides predictive analysis based on a companys key performance indicators (KPIs). The EPM suite includes four modules: sales analytics, manufacturing, inventory, and accounts payable/accounts receivable (AP/AR) analytics. Customizable management dashboards, pre-built reports and proactive alerts reportedly allow enterprise users to easily monitor KPIs in real time.

quiring a square explosion vent. Its high-vacuum rating (-12 psig/24.4 inHg) helps extend the life of the vent. The MV-RDs lower burst pressures give users the ability to reach required relief area without increasing vent size. The vent operates in temperatures up to 450F.
Oseco 800-395-3475 www.oseco.com

Ball Valve Includes Actuation-Ready Features

Digital Flow Computer Offers Improved Security

The Summit 8800 Digital Flow Computer for metering, data handling and system maintenance is claimed to be ideal for a variety of custody and process applications. The unit contains a dedicated microprocessor with a -second processing cycle for each input/output (I/O) board rather than using one shared processor. A removable memory card stores data with enough capacity for several years of flow information. Scroll-andclick navigation and touch-screen

The large diameter TB Series true union ball valve incorporates an actuation mounting pad per ISO5211 and an integral panel mount foot pad. Sizes range from 2-in. (DN63) to 6 in. (DN150). Available materials include PVC and CPVC. The valve is pressure rated at 235 psi non-shock. It features low torque ratings, a full port design, FPM or Ross Systems EDPM seals, reversible PTFE seats www.rossinc.com and double O-ring stem seals. The valve is interchangeable with earlier Vent Prevents Potential TB Series valves of the same diamDust Explosions eter and end connections. TB Series The MV-RD explosion vent protects personnel and equipment dur- true union ball valves are NSF and ANSI 61 listed. ing deflagrations in high-cycling or high-vacuum applications. The Hayward Flow Control vent mounts on enclosures where 888-429-4635 dust explosions may occur, and ac- www.haywardflowcontrol.com tivates to safely relieve pressure in the event of a deflagration, thereby Kink-Resistant Hose preventing a large explosion. The Extends Service Life MV-RD can also be used on bulk The Chemfluor Convoflex WCSR storage units and in ductwork remultipurpose chemical trans51 chemicalprocessing.com July 2011

equipment & services

ment, helping reduce maintenance costs. ChemSeals are available in a variety of materials to meet critical temperature and pressure ratings.
Chemineer, Inc. 937-454-3200 www.chemineer.com

fer hose reportedly is designed to prevent corrosive chemicals such as acids from damaging the stainless steel braid commonly used on hoses for bulk chemical transfer. The Chemfluor hose is claimed to provide longer service life while enhancing plant and worker safety. Its low profile, helical convoluted inner core design provides flexibility, while preventing kinking a common cause of downtime. An acid-resistant EPDM outer cover protects the hose when acid or other corrosive chemicals are accidentally exposed to the outer surface.
Saint-Gobain Performance Plastics www.plastics.saint-gobain.com

Tank Cleaner Handles Small Tanks and Totes

The TankJet 75 fluid-driven tank cleaner reportedly provides thorough impingement cleaning of small tanks without the expense of high impact tank cleaners. The unit uses external gears to reduce nozzle speed for improved impact and cleaning efficiency. Claimed ideal for medium-impact cleaning of tanks, totes and intermediate bulk containers, the unit cleans tanks up to 30 ft (9.1 m) in diameter. Its rotating solid stream nozzles complete a 360 indexing pattern every 45 revolutions for full tank coverage. The units self-cleaning, flowthrough design is said to enable easy maintenance and requires approximately five minutes for rebuilding.
Spraying Systems Co. 630-665-5000 www.tankjet.com

centrifuges, providing the desired result at lower cost, the company says. Hydrocyclones are supplied in either an open-manifold or a packed-vessel configuration. Both configurations can process feed rates from 10 to 3,000 gallons per minute, depending on the size and number of hydrocyclones installed in the system.
Sweco 859-371-4360 www.sweco.com

Plant Design Software Adds New Features

The CADWorx 2012 Plant Design Suite for AutoCAD-based projects and workgroups includes a new discontinuity palette for showing component discontinuities and overlaps in the model, with full reporting capabilities. The software also is compatible with AutoCAD 2012, the latest release from Autodesk. An improved pipe support module provides more flexibility in pipe support placement and extends bills of material capabilities to pipe support subassemblies. The CADWorx Plant Professional equipment module includes a new center-of-gravity calculator for modeling equipment and for vessels and exchangers. Designers can also add stiffening rings internally and orient rings around their primary axes.
Intergraph CADWorx & Analysis Solutions www.coade.com

Seal Design Speeds Up Replacement

The ChemSeal line of mechanical seals is designed specifically for agitator service. The agitator seal features high runout, reverse rotation and reverse pressure capability. The line includes both single and double cartridge configurations for easy installation and maintenance. The seals reportedly can be readily removed from the agitator as a complete assembly and quickly repaired on the workbench before re-installation, saving maintenance time and effort. The swing-out agitator seal change design also is said to speed up seal replaceJuly 2011 chemicalprocessing.com

Hydrocylcone System Suits Slurries

Hydrocyclone systems reportedly provide an economical and effective method for removing solid particles in the 4 to 100+ micron range from slurries. Hydrocyclones typically make finer separations than are practical with screening separators and at significantly higher capacities. In many applications, cyclones can be used in place of decanting
52

Register now! 2011 CP PANEL DISCUSSION WEBCAST SERIES!

Join Chemical Processing editors and industry experts as we engage in lively discussions about strategies, industry challenges and solutions during our CP Panel Discussion Webcasts. Each 60 minute Webcast features experts on the topic being discussed and will also include a Q&A session with all attendees. Register now for the remaining CP Panel Discussion Webcasts at www.ChemicalProcessing.com/cpseries

Next up! CFATS & MTSA Security: Tips & Regulatory Updates Date: Thursday, August 18, 2011 Time: 1 - 2 pm, EST
Many petrochemical companies are faced with the challenge of managing security compliance programs including CFATS and MTSA. Join us for a NEW 60-minute panel discussion regarding these regulations. Speakers will discuss MTSA II & Harmonization with CFATS, as well as recent Personnel Surety updates and more. Learn about the latest legislative updates and their impact on manufacturing, storage and the use of Chemicals of Interest (COIs) plus practical tips for compliance. Hear from industry professionals who have assisted companies with compliance at many Tier 1-4 CFATS sites, as well as MTSA sites. Register now!

Additional 2011 CP Panel Discussion topics include: Process Safety Sept. Energy Efciency Oct. Dry Materials Handling Nov. Dust Control Dec. CP Discussions Now Available On-Demand: Dust Control Alarm Management Emissions Condition Monitoring Energy Efciency

Asset Management Comprehensive Asset Management Makes Wireless Easy Date: Thursday, August 25, 2011 Time: 2 - 3 pm, EST
Getting the most out of equipment for efcient and economic plant operations is a goal for every facility. In an ever-evolving competitive industry, asset management often is the one factor that sets companies apart. This discussion will provide practical pointers for optimizing asset use, improving efciency and lowering maintenance costs. Learn best practices for planning and implementing your wireless network to shift from reactive and preventive to predictive and proactive maintenance. Also learn the benets of wirelessly monitoring vibration of any mechanical assetcompressors, motors, pumps, fans, gearboxesto detect typical machine problems. Identify developing problems before they become signicant and cause plant upsets.

For more information on each of these exciting 60-minute Webcasts, to watch on demand Webcasts and to register, go to:

www.ChemicalProcessing.com/cpseries

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Product Spotlight

Saflex 2000 tube bundle cleaning system

The Saflex 2000 from NLB cleans twice as fast as manual water jetting, operating at pressures up to 40,000 psi (2,800 bar). An operator feeds the lances in and out with push-button controls, or from a distance with an optional X-Y positioner and wireless controls. The system is adjustable for tube diameters from 4mm to 15mm. NLB Corp. (248) 624-5555 www.nlbcorp.com
PumP load control

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The PMP-25 pump load control guards against dry running, cavitation and overload. It monitors true pump power for maximum sensitivity. The display shows pump load, trip points and delays. Its NEMA 4X enclosure is small enough to fit on Size 1 starters and can be door-, panel- or wall-mounted. Load Controls Inc., (888) 600-3247, www.loadcontrols.com.

atomizing SPray nozzlE for HigH ViScoSity fluidS

The XAER air atomizing spray nozzle provides a full cone round spray pattern that is especially suited for liquids with a high viscosity. It operates with an external mix, which means the atomization of the fluid takes place outside the nozzle. As the XAER is an external mix, (as opposed to an internal mix), the flow rate is not dependent on the air pressure, which results in easier control. BETE Fog Nozzle, Inc., 50 Greenfield Street, Greenfield, MA 01301, T (413)772-2166, F (413)772-6729, www.bete.com, sales@bete.com

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JULY 2011

enD poinT

Energy Policies threaten U.K. Chemical Firms

Government plans call for a 60% reduction in emissions by 2030
U.K. EnErgy Secretary Chris Huhne has been warned that his blinkered and dogmatic energy policies pose a threat to the countrys 60 billion ($98 billion) chemical industry and its 600,000 jobs. The charge is made in Chain Reactions: How the Chemical Industry Can Shrink Our Carbon Footprint, a report compiled by independent civil policy think tank Civitas, London. The author, Civitas research fellow David Merlin-Jones, argues that by pricing energy-intensive industries out of the U.K. via green levies and taxes, the greenest government ever is actually smothering the emerging low-carbon economy. Huhne proposes plans for a 60% reduction in emissions by 2030, which Merlin-Jones says is too much, too soon. A better way to tackle climate change is not through the hasty decimation of industry, but the long-term nurturing of existing low-carbon innovation as found in the chemical sector, he writes. In the reports foreword, Brendan Barber, general secretary of the Trades Union Congress, London, notes that at this crucial moment in energy policy making, the government must strike the right balance between its climate change and industrial polices. Merlin-Jones reports that, on average, for every metric ton of carbon dioxide used in the chemicals industry, two metric tons are saved down the line. This ratio could double to 4:1, provided that the government policy fostered rather than punished the sector. However, short-term green policies have failed to take into account long-term emission reductions offered by the chemicals industry, he notes. For instance, insulating materials have an emissions saving ratio of 233:1. At the heart of the problem is the U.K.s 2011 budget, which promises a carbon price floor. Current plans are set to push the price to 30/mt ($49/mt) of carbon dioxide by 2020. This doesnt take into account other levies such as the Renewable Obligation (see, http://docs.wind-watch.org/ renewables-obligation-paper.pdf). When all of these are pooled together, Merlin-Jones says the average energy-intensive companys utility bill is set to rise from 3 million ($4.9 million) to 17.5 million ($28.7 million) by 2020. Meanwhile, Huhne argues that his plan for a
58

New carbon budget could smother emerging green companies.

60% reduction in carbon dioxide emissions by 2020 (versus a1990 reference point) 14% higher than the European Unions goal is necessary for our sheer economic self interest precisely because it will send out clearer carbon price signals and allow us to develop more rapidly across all those lowcarbon sectors. Not so, contends Merlin-Jones: Theres no economic benefit to pricing ourselves above competitors. Moreover, unrealistic goals have created an approach that relies on forcing out the chemicals sector, despite the fact that its developments are the only way to reach the long-term target of an 80% reduction by 2050 let alone the huge leap of an extra 40% cut in ten years from 202030. However, the author also points out that all is not yet lost: Huhnes 60% plans are not yet enshrined in law, nor is the carbon price floor. There is no reason Britain cant maintain parity with European energy costs. Image is not everything and green policies should not be driven to the point where they undermine actual emission reduction. Its not an either/or situation: there is no reason Britain cant support industry and reduce its carbon emissions. If energy costs are kept competitive, the U.K. will create the fertile environment required to produce a low-carbon industrial renaissance. For its part, the Chemical Industries Association (CIA), London, recognizes that the sector faces a new competitiveness challenge. Reacting to Huhnes announcement, CIA boss Steve Elliott acknowledges the governments acceptance of the need for transition measures, but cautions that unless these measures are effective, energy-related costs (already the highest in Europe) could rise from 10% to over 100% of profits turning successful green product companies into loss-making concerns. Elliott notes the chemical and other industries want to work with government to make sure the green future can be delivered. However, if measures are half-hearted, manufacturing jobs and companies delivering low carbon solutions will be ripped out of the industrial heartlands of the U.K. with very little prospect of new businesses willing to invest.
SEn ottEwEll, Editor at Large sottewell@putman.net

July 2011

chemicalprocessing.com

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