Chemical Engineering May 2015

This magazine is able to continue to bring you the same practical, relevant content that Chemical Engineering has been known for, for more than a century, in a new, modern format.


D orothy Lozowski


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Chemical Engineering

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  • D orothy Lozowski   
  • 110 Pages   
  • 05 May 2015
  • Page - 1

    www.chemengonline.com PL A N T ST A RT U PS • A SS ET RE LIA BIL ITY V O L. 12 2 N O . 5 M AY 20 15 05 May 2015 page 50 Managing Plant Startups Snapshot of U.S. Petroleum Refi ning Improving Particle- Size Analysis Asset Reliability Show Preview: ACHEMA 2015 Facts at Your Fingertips: Catalysis Flare-Gas Recovery Pressure- Relief read more..

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    Tel:+91.22.4073 6749 / 52 | Fax: +91.22. 4073 6737 Email: exports@dipeshengg.net | Website: www.dipeshengg.net Made in India. As a fast-growing economy with well-evolved legal system, matured financial system and strong laws that respect intellectual property, India has already emerged as a premier outsourcing destination read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 1 May 2015 Volume 122 | no. 5 Cover Story 50 Managing Large Chemical Plant Startups Prudent planning and scheduling during a project’s front end can lead to more expedient commissioning and startup activities In the News 7 Chementator New cryogenic technology for cooling superconducting cables; read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 2 78 Environmental Manager Optimizing Pressure-Relief Systems Alternative designs for pressure-relief systems may offer investment cost savings Equipment and Services 36 Focus Flowmeters Compact flowmeter manages up to six common plant gases; Use this flowmeter to create personalized gas compositions; Flowmeters are read more..

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    TRANSFER HEAT, NOT BLAME. In your line of work, you can’t afford downtime. You have to know that everything is doing its job so you can actually do yours. That’s why, at Eastman, we have you covered with a wide range of dependable Therminol heat transfer uids for some of the world’s most technical applications. And with our Total Lifecycle Care® Program, you can read more..

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    It’s time to LOOK AT PROJECTS DIFFERENTLY Looking for a way to avoid unforeseen and unrecoverable risks, budget overruns, schedule slippage, and unreliable partners? With Emerson’s global project services team providing guidance, you will reduce cost and schedule risk throughout the project. PROJECT SCHEDULE RISK 56% million AT RISK INEFFECTIVE communication For every $1 billion read more..

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    Editor s Page CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 5 If you’ve been noticing something different about your recent is- sues of Chemical Engineering — you are right. We have changed our look. With the February 2015 issue, we unveiled our newly redesigned print magazine. This May issue is our fourth, and big- gest-to-date issue that sports our new read more..

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    316 SS Construction IP66/68 a better way to view LEVEL viewing angle 140° orioninstruments.com High-visibility level indicators and transmitters from Orion Instruments are custom-engineered and built tough for the most demanding applications. Contact us to find out how personnel safety, cost of ownership, and reliability can all be improved over traditional sight glass read more..

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    Chementator Edited by: Gerald Ondrey CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 7 Industrial gases special- ist Messer Group GmbH (Bad Soden, Germany; www .messergr oup. com) has developed a new cryogenic technology that makes it possible to use liquid nitrogen (LN2) to cool high-temperature super- conducting (HTS) cables down to –209°C, read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 8 Carbon-negative technology being commercialized by Global Ther- mostat LLC (New York, N.Y.; www. globalthermostat.com) removes carbon dioxide directly from the atmosphere using low-cost waste process heat from in- dustrial processes. The technology works in a similar fashion to cogeneration approaches and could transform heavy read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 9 Circle 34 on p. 102 or go to adlinks.chemengonline.com/56197-34 read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 10 Construction to begin on biomass-to-fuels facility Construction is set to begin on a biorefinery in Oregon this summer that will manufacture bio-based jet fuel and diesel from forest and sawmill residues. When it begins producing biofuels at the end of 2016, it will be capable of con- verting read more..

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    a highly reactive oxygen plasma that etches away at the graphene’s carbon atoms, until holes are formed in the layer. The pores themselves are punc- tuated with silicon atoms — not oxygen or carbon — a noteworthy phenomenon that the researchers attribute to the silicon’s potential stabilizing effect on the pores. The size of the read more..

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    Smart Valve Positioner Control. Manage. Optimize. The NEW Research Control® SRD positioner does everything you expect any valve positioner to do, plus more. The SRD’s comprehensive diagnostics tool continuously monitors for fugitive emissions, delivers real-time performance statistics, and facilitates both proactive and reactive process management. Available with integrated network read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 13 Introducing the Z Series Metering Pumps Hayward is a registered trademark of Hayward Industries, Inc. © 2015 Hayward Industries, Inc. Thermoplastic Valves | Actuation & Controls | Strainers | Filters | Bulkhead Fittings & Tank Accessories | Pumps Bring simplicity and ease to your solenoid diaphragm read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 14 The major drawback of existing mem- branes for desalination plants is that the membranes are not tolerant of oxidizing agents, such as chlorine. To overcome this drawback, a team of re- searchers from the University of Melbourne (www.unimelb.edu.au) and CSIRO (Mel- bourne, Australia; www.csiro.au), led by pro- fessors read more..

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    discover more For more information, visit www.hwll.co/UltimateOperator ©2015 Honeywell International, Inc. All rights r eserved. Improve Process Performance with Operator Competency Management. Honeywell’s UniSim® Competency Suite improves process plant safety, reliability and performance. Our software tools support console and field operator training and competency management, helping to read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 16 www.SRR-IBS.com • Rental Inventory Consisting of Over 12,000 Intrinsically Safe Motorola Radios • Custom Mobile Communications Centers • National Motorola Authorized FM Approved Radio Repair Facility • Customized Communications Systems • Nation’s Largest Industrial Blinds Rental Inventory • Innovative Industrial Blinds read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 17 How can we perform for you? diamondrefractory.com emcor_info@emcor.net 866.890.7794 CritiCal ProjeCt exeCution for the refinery and PetroChemiCal industries 85% of Diamond clients turnaround. And come back. as specialists in all manner of temperature/erosion/corrosion resistance services, diamond is self-suicient, read more..

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    Business News CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 18 LINEUP A. SCHULMAN AKZONOBEL ASAHI GLASS CEPSA DOW EXXONMOBIL RESEARCH AND ENGINEERING FERROSTAAL FLUOR HALDOR TOPSØE INDORAMA KURARAY LANXESS LYONDELLBASELL MAIRE TECNIMONT OLIN PPG ROQUETTE SHIN-ETSU SINOPEC SIPCHEM SOCAR THYSSENKRUPP INDUSTRIAL SOLUTIONS Plant Watch Roquette launches isosorbide production unit in France April 10, read more..

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    World Premier. Experience the new LEWA triplex® G3M. ACHEMA 2015 – Hall 8.0, Booth C62. You’ve never seen the LEWA triplex® like this before. The power of innovation. Made by LEWA: The innovative G3M process diaphragm pump offers high effi ciency while taking up 30 % less space. It is ideal for the challenging conditions in chemical plants or offshore. Discover read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 20 Sinopec and EMRE to develop fluidized-bed MTG technology April 1, 2015 — Sinopec Engineering (Group) Co. (Beijing, China; www. sinopecgroup.com) and ExxonMobil Research and Engineering C o . ( E M R E ) a re p a r t i c i p a t i n g in a cooperative development agreement for read more..

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    As the global leader in catalysis, BASF draws on the talent and expertise of more than 1,100 researchers working in close partnership with our customers. This collaboration results in innovations that drive new levels of performance and achievement, today and over the long term. When global catalyst innovations help our customers become more successful, it’s because at BASF, we read more..

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    Newsfront CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 22 Newsfront On a broad level, the outlook for the U.S. petroleum-refining industry remains bright, despite a recent decline in crude oil prices. Dra- matic gains in the production of crude oil and natural gas in North America have given U.S. refiners access to low-cost energy read more..

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    ChemiCal engineering www.Chemengonline.Com may 2015 23 Eng. May 2014, pp.17–20). Since the rapid uptick in the production of light, tight oils, there has been a lingering concern that U.S. petro- leum refiners lacked sufficient capacity to process the vol- ume of LTO that has been observed and projected. This idea is a misconception, read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 24 A separate study, conducted by the consulting firm Baker & O’Brien Inc. (Dallas, Tex.; www.bakerobrien. com), came to a similar conclusion. Their study concluded that the U.S. refining fleet could technically pro- cess all available domestic crude with a combination of four strate- gies: 1) Increase processing read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 25 Circle 9 on p. 102 or go to adlinks.chemengonline.com/56197-09 read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 26 recovery in FCC units through op- erational modifications (such as run- ning at higher reactor temperature and higher catalyst circulation) and by increasing use of ZSM-5 additives to crack gasoline-range olefins into liquefied petroleum gas (LPG)-range olefins. ZSM-5 is a widely used alu- read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 27 new strategies for increasing gaso- line quality, in terms of sulfur content and research octane number (RON). RON attempts to quantify the degree of compression that a fuel can with- stand before igniting. Higher-RON fuels exhibit higher performance and less engine knocking in vehicle en- gines. Among the strategies read more..

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    Newsfront CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 28 Particle-size analysis plays an im- portant role in many chemical pro- cesses that involve dry powders and granules, fibers, suspensions, emulsions, gels, sprays, inhalants and the like. Processors rely heavily upon particle- size analysis to improve the quality of the product, reduce rework and increase yield. As read more..

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    ing from 20 to 4,750 m. The system employs a pneumatic sieving principle that enables accurate and repeatable particle-size analysis. Features, such as an integrated analysis computer with touchscreen control, user-friendly software with step-by-step instruc- tions, a built-in automatic pressure differential gage and automatic data recording and storage read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 to-day measurement. For example, the software in- cludes an optical property opti- mizer that makes it easy to check the sensitivity of a measurement to analysis parameters during method development, and a data-quality assessment tool that warns the op- erator if there is anything about the read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 31 Delivering the best technology for your needs. Endress+Hauser’s line of 2-wire instruments provide our customers with the opportunity to replace aging or substandard components of their installed base with modern technologies that can bring about significant gains in read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 32 rate characterization of the particles throughout the entire process. But possibly the most significant gain experienced through in-situ analysis is the ability to achieve feed- back in real time, says Jason Noga, product marketing specialist, with Microtrac (Montgomeryville, Pa.; www.microtrac.com). “Many of our customers read more..

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    Downtime. A word often associated with high cost and low production. Team has been helping companies minimize downtime for over 40 years with our global online inspection, mechanical, and heat treating services. We’re here to help you repair, maintain, and ensure the integrity of your equipment to keep your facility up and operational. Visit us at CORROSION read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 34 As a result, remote control and auto- matic data transfer are possible. Noga, at Microtrac, says his com- pany also eases the transition to on- line measurements using laboratory instrumentation adapted for use in- situ. The company’s PartAn 3D labo- ratory analyzer is now available as the PartAn 3D PRO read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 35 Your one-stop resource from drop in spray lances to tank washing nozzles Retractable Spray Lances MaxiPass® Nozzles HydroWhirl® Orbitor TF Spiral Nozzles Allow you to remove a nozzle for inspection or service without taking your process ofline The ultimate in clog-resistance with the largest free passage in a read more..

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    Focus CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 36 Compact flowmeter manages up to six common plant gases The ZFM Mass Flow Meters (photo) provides multigas, multirange func- tionality to 8 bars. This device cur- rently handles up to six gases: nitro- gen, air, oxygen, argon, helium and carbon dioxide). When the instru- ment is connected to the RS-232/ RS-485 read more..

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    Manage Your Steam Trap Population with TLV’s is the first diagnostic instrument to test a steam trap AND make an automatic judgment of its operating condition. ’s intrinsically safe design records both temperature and ultrasonic levels to identify dangerous blocked steam read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 38 Coriolis fl owmeter aims to give users greater process insight This company’s Micro Motion Model 5700 Transmitter (photo) is a Corio- lis flow transmitter that is designed to translate measurement data into meaningful insight and instruction. It does this by translating measure- ment data into, for instance, time- read more..

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    ©2015 C leaver-Brooks, Inc. Circle 43 on p. 102 or go to adlinks.chemengonline.com/56197-43 read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 40 flows for saturated and supersatu- rated steam and hot water, and heat-metering applications. In ad- dition to gross heat calculation for steam, the Optiswirl 4200 (photo) now includes net heat calculation for steam and condensate, as well. With one temperature sensor inte- grated as read more..

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    Circle 46 on p. 102 or go to adlinks.chemengonline.com/56197-46 read more..

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    If interested in posting a job, please contact DIANE BURLESON | Direct: 512-337-7890 | dburleson@accessintel.com Looking for that dream job in the chemical process industries? Don’t let the competition score that perfect position you deserve. Let Chemploy work for you. chemengonline.com/chemploy Chemploy job center focuses exclusively on jobs in the CPI. Post your resume and cover read more..

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    New Products CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 41 This remote user interface is now hazardous-location certified The EZ-Zone EZK (photo), a remote user interface (RUI) that can also be used as a communication gateway, is now available with an option for Class 1, Division 2, temperature class T4A, for use in hazardous read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 42 footprint, and features high switching cycles, extended operating life and high-speed load switching. Common uses of the RV8S include general load switching in control systems for as- sembly machines, solenoids, mold- ing machines and other applications requiring a high repetition rate. The read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 A high-pressure microreactor for small-batch chemistry The HPR-Micro Reactor (photo) is a high-pressure reactor specifically designed for small-batch reaction chemistry, and is well suited for re- search, process-development and screening applications when re- agents, catalysts or other essential materials are read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 44 sors That Learn. New ISM algorithms allow pH sensors to actually learn from the conditions in a process. Sensors That Learn delivers more accurate sensor-health diagnostics more quickly than previous versions, and enhances the consistency of sensor-lifetime information. When an read more..

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    Circle 45 on p. 102 or go to adlinks.chemengonline.com/56197-45 read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 46 compliant with the temperatures and conditions specified in API Standard 607 6th Edition — 2010 and ISO 10497:2010. The tests verified that, in the event of a fire, the hardware will continue to function and the in- tegrity of the locking mechanism will be maintained. read more..

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    Facts At Your Fingertips CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 47 Catalysis is among the most im- portant chemical phenomena in industrial chemistry, as well as in many biological and research fields. This one-page reference pro- vides a review of several of the funda- mental concepts underlying catalysis. Catalyst basics A catalyst interacts with read more..

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    Technology Profile CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 48 Hydrogen Production from Natural Gas By Intratec Solutions Hydrogen (H2) is an important chemical feedstock, mainly applied in the manufacture of ammonia and methanol, and for hydroprocessing operations in petroleum refineries. Also, since H2 is an energy carrier, it has been consid- ered for stationary read more..

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    THE SIMPLEST IDEAS ARE OFTEN THE BEST. THE ALL-NEW FLASHMIX. UNBELIEVABLY FAST, UNEXPECTEDLY SIMPLE. Stop wishing for a simpler more powerful powder/liquid mixer, and get one today. Call us at 413.525.4825, email us at sales@silverson.com or visit us online at Silverson.com/Flashmix 413.525.4825 | read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 50 IN BRIEF FRONT-END PLANNING OWNER-CONTROLLED COSTS JUSTIFYING STAFFING RESOURCES OWNER TASK-FORCE FUNCTIONS CLARIFY CONTRACTOR RESPONSIBILITY PRE-COMMISSIONING ACTIVITIES OBTAINING ADEQUATE RESOURCES TIMING STAFF BUILDUP DETAILED PLANS AND SCHEDULES MONITORING PROGRESS CULTURE AND MORALE Prudent planning and scheduling during a project’s front read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 51 as follows: Identifying the resources that are • needed from the owner’s company in terms of financial and human-resourc- es contributions in order to make the efforts for pre-commissioning through startup a success Defining the focus of the owner’s • task force during the design phase to ensure successful read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 52 cause major difficulties in accomplishing pre-commissioning work in time for a successful startup. It is normally up to the project manager or operations manager who is involved in the front-end planning to make the case for adequate staffing prior to project au- thorization. read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 53 zation holds approval rights where owner approval is to be required in these activities Thoroughly review the design stan- 3. dards that the contractor will use, and confirm that those standards will be used by subcontractors and all equipment suppliers as part of their bid packages Come to an agreement on which read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 54 taining each. Although environmen- tal permits are the major permitting issue, it is not unusual for construc- tion of a new facility to require 20–30 other permits from regulatory agen- cies, some requiring many months to obtain. If any of these are not ob- tained in a timely manner, it can im- pact read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 55 chasing and logistics. Some of these pre-commissioning activities involve interaction with the contractor, such as witnessing se- lected construction quality-assurance activities or accepting custody of equipment as construction is com- pleted. Most activities, however, pro- ceed independently of the read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 56 will be fully committed to training, then to the formal process of ac- cepting systems from construc- tion, and then to commissioning these systems. If the bulk of the pre-commissioning work for these four groups is not completed prior to final training, they will be faced with read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 57 pre-commissioning activities well ahead of staffing the hourly posi- tions. This enables all new hires to immediately begin working on spe- cific tasks by being equipped with the tools and guidance necessary to progress efficiently. Some good examples of prudent early planning are as read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 58 with expectations based on the cul- tures at their previous workplaces. There may be an unresolved culture clash among employees if managers do not provide leadership in establish- ing the desired cultural elements for a new site. The human-resources leader can pro- mote the development of, read more..

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    Feature Report CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 59 IN BRIEF OPERATIONS OWNERSHIP THE PATH FORWARD DEVELOPING THE VALUE PROPOSITION ESTABLISHING METRICS CHANGING THE EQUIPMENT-CONDITION MINDSET TRAINING AND TROUBLESHOOTING INTEGRATING MAINTENANCE WORK PROCESSES PERFORMING EQUIPMENT ROUNDS AUTONOMOUS MAINTENANCE Seven methodologies are described to help operations staff take read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 60 but also understood how to maintain the function of all of the assets under their command. Historically, opera- tors relied on using their four senses (hearing, seeing, touching and smell- ing) to keep close track of how the equipment was operating during their shift. They read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 61 couraged and allowed to return to performing basic and simple repairs (so-called autonomous maintenance). This approach will allow maintenance personnel to focus on performing proactive, strategic care tasks that are designed to move the facility away from reliance on reactive read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 62 CPI operations. These words — and concepts — should be constantly reinforced at all levels of supervision, and should appear on information boards throughout the facility and be stressed at daily meetings. A small portion of the operations group will already understand the message, while another portion of the read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 63 erators, maintenance or reliability en- gineers and maintenance personnel. One attendee is assigned to be the scribe to record what is found and set the priorities for the work. After the audit, the list is converted to work-order requests. These au- dits should be more than just a “fix-it” tour . They should read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 64 maintenance personnel should seek out the specific operations personnel with the work-order response to ac- knowledge their submission and en- sure their satisfaction with the work and the condition of the area after the work was performed. 6. Performing equipment rounds. A widely held belief in industry is hat read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 65 operators offers one solution. Unfor- tunately, industry’s history with uti- lizing operators for these tasks has not always yielded a success story. Site-specific work rules, lack of train- ing, lack of a value proposition, and “perhaps exaggerated” concerns for safety tend to keep operators from being allowed to read more..

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    Engineering Practice CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 66 Although gas flaring is neces- sary at some chemical pro- cess industries (CPI) plants or facilities, more and more efforts are underway to reduce flaring, not only to help reduce emissions of air pollutants, noise and light, but also to save both energy and raw mate- read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 67 amounts of CO2, carbon monoxide, oxides of nitrogen (NOx), hydrocar- bons and other volatile organic com- pounds (VOCs) and others. Besides emissions to the atmosphere, simple flaring is a loss of both energy and raw materials. For instance, an ethylene plant with a production capacity of 1.2 bil- lion lb/yr of read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 68 simpler components Regardless of which method is used, the recovery of some or all of the flare gases will decrease combus- tion products and the release of pol- lutants into the atmosphere, reduce fuel requirements and minimize flare- tip maintenance, as well as reduce thermal radiation, light, read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 69 initial design stage for a new plant, so that the design of the refrigeration cycle can include enough cooling to supply the FGRU. In this way, we can recover valuable gases and reduce emissions form gas flaring. Generally, all of the quench towers in an olefin plant read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 70 and (4) give 59,800 kJ/s or about 60 MW of power released by the flare. This value drops to about 40 MW with the introduction of a FGRU that reduces the volume of gas flared by about 40% (35.9 m.t./h). For the same 40% reduction in flare gas being flared, Equation (4) shows a reduction in sound emis- read more..

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    Engineering Practice CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 71 Forced outage of a direct-fired heater is the worst nightmare for any operator in a petro- leum-refining or petrochemi- cal plant. Since fired heaters are not replaceable by spares, forced outage in many cases means emergency shutdown of the entire plant. In most read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 72 triggered an alarm, which led to the shutdown of the heater for mainte- nance and hanger repair. A good troubleshooting guide can demonstrate the fact that failed roof hangers are caused by overheating in the convection section. In this vein, by monitoring burner flame read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 73 A Hotspots on tubes can be the result of internal or external problems. First check external problems which are mainly caused by faulty burner performances. Do you experience flame impingement on tubes ? Caution: Since the flame of fuel gas is hardly visible, flame impingement can be easily ignored by the read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 74 B Internal fouling may be caused by coke formation or other material sediments (usually minerals salts dissolved in crude oil). Follow the questions below to be able to differentiate between the two phenomena. The fouling is 90% caused by mineral sediments. Fouling is 90% caused by mineral sediments or even small read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 75 C There are two types of external fouling, metallic oxides and external scaling. Follow the questions below to be able to differentiate between the two. The particles are metallic oxides (MOs). Proceed to point MO. In case of gas firing, external scales (other than oxides) are caused by complex heat transfer read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 76 D Internal corrosion is mainly influenced by the chemical composition of the process fluid. Do you have sulfur compounds present in your process fluid composition? End troubleshooting procedure. Seek engineering consultancy. Do you experience localized or general tube-wall thinning? Its possible that the inlet process read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 77 future internal-fouling problems, as for the case history shown in Figure 1. Surveying the operating history of the heater proved that long-time local flame impingement was the main cause of this event, and tuning the draft and excess-air amounts could have solved read more..

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    Environmental Manager CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 78 Pressure relief systems for the chemi- cal process industries (CPI) are es- sential to prevent a process system, or any of its components, from being subjected to pressures that exceed the maxi- mum allowable accumulated pressure, by emergency venting to a closed relief system. read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 79 using combustion gas or nitrogen from the upstream end toward the KO drums to avoid ingress of air into the system. Optimized closed systems The calculation criteria for sizing the flare KO drums and process-unit KO drums result in very large vessels. This implies the need to install the collection headers very read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 80 At the flare unit, the KO drum is even larger than the process unit drums, and as a result, the main flare header at the inlet to the vessel is very high, as can be seen in Figure 3. Consequently, the main flare header at the flare-unit battery limits (BL) is also very high. Since the flare header read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 81 carryover is not in question. How- ever, the designer should avoid very large droplet carryover, which results in vessels with a smaller length-to- diameter ratio than usual for vertical gas-liquid separation vessels. The reason to remove very large drop- lets in the process units is not to overload, with liquid, the read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 82 can be done in two steps — the first of which is to reduce the header height at the flare unit battery limits. This may be done by a simple al- teration of the header’s inlet piping arrangement to the very large, hori- zontal flare-unit KO drum — which can be over 8-m dia. — by changing the read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 83 Taking this into consideration, this profile permits that the process units nearest to the flare unit can re- duce the diameter of the ISBL flare headers until the maximum permit- ted back pressure is reached for the most critical pressure-safety valve (PSV). Normally the most critical PSV is the valve with the read more..

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    Show Preview CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 84 Achema 2015 — the 31st world forum for the chemi- cal process industries (CPI) — will be held June 15–19 in Frankfurt am Main, Germany. Or- ganized by Dechema e.V. (Frankfurt; www.dechema.de), this year’s event features 11 exhibition halls, which will provide a platform for over 3,600 reg- read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 85 This system performs non-destructive sealing analysis The Induction Integrity Verification Sys- tem (I2VS; photo) provides analysis of induction-sealing integrity for bottles without causing packaging-line slow- down. Inspection is performed through the closed cap, without physical con- tact, in an entirely read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 86 steel and bronze bodies are among the available options, and many ac- cessories can be added to further optimize the product. The motorized version (photo) is designed for appli- cations where electrical actuation is required. This lightweight valve has a low power consumption of read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 87 can be analyzed) or polymerization. Based on sonic-velocity measurement, the analyzers provide high precision and stability with minimal maintenance requirements, says the company. Hall 11.1, Stand F75 — SensoTech GmbH, Barleben, Germany www.sensotech.com A versatile pipette designed with ergonomics in mind Bravo pipettes read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 88 tings, the ICD can protect containers used for carrying gases and liquids, complying with several international standards relating to the transporta- tion of hazardous materials. The disc can also be used in conjunction with traditional safety-relief valves. Hall 9.0, Stand B45 — read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 89 PHO TO: HTR I Badger Meter BETE Fog Nozzle Carver Pump Company Charles Ross & So n Cleaver-Brooks Collins Instrument Delta Screens Dipesh Engineering Works Eastman Chemical Co. Emerson Process Management Endress+Hauser Hayward Flow Control HTRI John Zink Hamworthy Combustion Orion Instruments RedGuard Service Radio-Industrial Blind read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 90 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 Gulf Coast 2015 Special Advertising Section In a landscape of increasing technical complexity and fewer expe- rienced resources, process industries are challenged to success- fully execute projects. The impacts of missed deadlines, budget overruns, and unexpected read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 93 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 Gulf Coast 2015 Special Advertising Section For decades, refineries and chemical plants have counted on BETE Fog Nozzle to supply complete fabricated assemblies that can be custom designed starting with the spray nozzle. Beginning with the pro- cess conditions, read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 94 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 Gulf Coast 2015 Special Advertising Section Steam is invaluable in a chemical plant. From cleaning to fermentation to chemical re- covery, steam is incredibly versatile, and de- pending on the plant, large quantities may be required. The problem is that, when read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 95 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 Gulf Coast 2015 Special Advertising Section Wood Group Mustang is a recognized leader in engineering, procurement, and construction management for the refining, chemicals, and polymers industries. The company’s process en- gineers and project managers average more read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 96 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 Gulf Coast 2015 Special Advertising Section A lot of myths still surround the use of blast-resistant buildings (BRBs) as tra- ditional building replacements, writes Tim Taton, North American Sales Manager with RedGuard. Understanding these myths could save many read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 97 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 Gulf Coast 2015 Special Advertising Section Increasing efficiency in the boiler room Cleaver-Brooks is a complete boiler room solutions provider that helps businesses run better every day Cleaver-Brooks offers a fully integrated boiler room solution for any size read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 98 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 Gulf Coast 2015 Special Advertising Section Delta Screens brings deep experience and manufacturing excellence to critical filtration and media retention applications. Headquartered in Houston, Delta Screens provides custom and standardized screen solutions for a read more..

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    CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 99 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 Gulf Coast 2015 Special Advertising Section Turnarounds allow for necessary maintenance and upkeep of operating units and are needed to maintain safe and efficient operations. Founded in 1973, Team Industrial Services is the worldwide leader in minimizing read more..

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    Economic Indicators CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM MAY 2015 104 CURRENT BUSINESS INDICATORS LATEST PREVIOUS YEAR AGO CPI output index (2000 = 100) ____________________________________________________ Mar.'15 = 91.8 Feb.'15 = 92.4 Jan.'15 = 92.7 Mar.'14 = 90.0 CPI value of output, $ billions _____________________________________________________ Feb.'15 = 1,887.9 Jan.'15 = 1,834.4 Dec.'14 = read more..

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