CHE y Satis www.cheme Instrument Calibration Cele UI Eetir-coya) Controlling HS Mathematical Modeling Facts at Your Fingertips: ental 1eelA) Focus on Gas Detection : eoeeelelln cle juctionrersro1e June 2019 WV ieee Unload, Convey, Mm _ Less degradation Sixteen concepts Move your dry granular Each Dynamic Air system materials genily, reliably js custom designed and with significant from one of our sixteen reductions in product different conveying, degradation and /or concepts. So you geta system wear conveying solution that fits your process perfectly, Breven copebtnry without compromis Dynamic Air dense phase [ pneumatic conveying, Cost effective systems have been proven Qur high material-to- Dense Phase Transpertes, in over 15,000 installations air ratios reduce energy _Serles worldwide. They handle and compressed ait a wide range of materials fequirements, Our low and bulk densities at conveying velocities rates from afew hundred provide significant pounds to 4001tons per process savings in hour, over distances both operation and » exceeding 5,000 feet, ‘maintenance. \ Conveying Systems Dynamic Air Ine, + St, Poul, MN * Phone +1 651 484-2900 Gyro ex Bin Activating eta Twn Shot Email info@dynomicaizcom + www.dynamicalrcom Feeder Faiized Zone Mixer For details visit adlinks.chemengontine.comy738: hitps:vew iminus.com1S!documer13160/1 2183rersro1e June 2019 CHEMICAL 3 ENGINEERING ESSENTIALS FOR THE CPI PROFESSIONAL = www.chemengoniine.com June 2019 Volume 126|no. 6 Cover Story 30 Part? Efficiency in Pneumatic Conveying Air Filters Paying closer attention to the ai-fitration systems of pneumatic conveying (Operations can avoid losses in effcency in compressed-air usage during, fiter cleaning 34 Part 2 Minimizing Risk for Combustible Dust Explosions By focusing on ignition sources, such as static cscharges, and housekeeping, facies hancling sokds can ‘minim their risk for comoustble dust explosions In the News 7 Chementator Isobutane sythess end exracton process could ee energy compared to ateratves; Eecrochemica separation and comoression of hydrogen, High-tength A alley for 3D pining fe moving into commerce production: Nogen eatin under ambient condton| and more 42 Business News Porstorp wil construct new pant for sodium formate daioer product Linde ster up air separation unit at Samsung facility; Pinke to construct ric ‘acid plant in India; Covestto to expand production of polycarbonate fs in Dormagen; Sulzer acquires GTC Technology; and more 14 Newsfront Modularization Finds New Roles As berelts become apparent, the acceptance of modular process systems grows, a/1d the concept finds new cpportunties Technical and Practical 26. Facts at your Fingertips Fermentation i Considerations and Economics This one pig2 reference ollrs 7 anit dscusson of how process considerations anc escroms der between Se fermentation based procasses and conventional chomial processes 28 Technology Profile Polybutadiene Production This column outines a production process for polyutacione, a major component of vehiale tres 42 Feature Report Professional Calibration Supports Operational Excellence “pari fom ensuring the conformity of the process and the qually ofthe product, professional calibration frst and foremost, improves the quality ofthe process 49° Environmental Manager Technologies for Controlling H2S Thee ae many Industral technologies for removing HES from process gas, and each brings with i ferent benefits with regard to cst, effciency and equipment layout CHEMICALENGINEERING WWHCHEMENGONLINECOM JUNE 2019 hitps:vew iminus.com1S!documer13160/1 isaperero1e hitps:vew iminus.com1S!documer13160/1 5a 9 59 68 438 OG June 2019 Engineering Practice Improving Mathematical Model Development This arcle provides practical guidance for enginears and righights the importance of combining mathematical skits, domain expertise and proper communications. Equipment and Services Focus on Gas Detection Hania camera detect ftv var lc; Tis dovice monitors erisions at andi; WrelessHART gas-detecion device adds capabiies; This sensor [ovis ood dtecion of tre gases Infeod ine-oF-sght dette mortars Combate gece; Minimize worker posure dung ld uvoys of YOO, ad more New Products New contol sytem for mut-burnerenpkcatons; Gey feed fee-owing «gander ret. Custom soding sppicatone for hyper aatone, Te erable carer inode thermal maging enayss; Chemica meting pumps Terremete and mobie appicators are moe Show Preview Valve World Americas 2019 ‘have Word Exposton and Conference wt ako lace Houston on June 19-20, Hees a smal sample ofthe products bang speyed there Departments Editor's Page The 2019 Kirkpatrick Award The finalists are announced for the 2019 Kirkoatrick Chemical Engineering ‘Achievement Award Economic Indicators Advertisers Solids Processing Special Advertising Section Hot Products Classified Subscription and Sales Representative Information Ad Index Chemical Connections Follow @ChemEngMag on Twitter Join the Chemical Engineering Magazine Linkedin Group Visit us on www.chemengonline.com for more articles, Latest News, Webinars, Test your Knowledge Quizzes, Bookshelf and more Coming in July ibacter Feature Reports on Packagng and Handing of Mazarious tera and te Tectrical Warkoce; A Focus on Pures: A Facts at your Fingertips on Catats; News Articles on Fe‘oming anc Temperature Measurment and Conta: New Products; and much oo Cover design: Rob Hudgins CHEMOALENGINEERNG WWWCHEVENGONLNE.COM JUNE 2019 isarerero1g June 2019 MANAGE LARGE-SCALE BULK HANDLING PROJECTS with control and efficiency unique to Flexicon Project Managers Dedicated To Your Success + The Lead Fescon Project Manager supervising your system eff you 8 Single pinto contact though every phase of development, sreamining Your communications + Strietachorence to your unique standare, documentatonrequvements aa timelines + Commitment tothe suecesstul performance fand cot eflectvanes af your projet by Seving as your deleted advocate Engineering Teams Ensure Smooth Integration + Engineering teams on four continents rele your stat of overoacing + Over 22,000 bulk handling nstaliations worldwide provide the breadth and depth of experience esata or seamless Integration with your upstream ana Adownsveam processes + Ault to work with the engineering rn ‘managing your entie project, or rect usa seles@eon cam 1/888 FLERIGON Effectiveness Only a Major Manufacturer Can Provide “As one ofthe word's largest manufacturers of bulk handing systems, Flexion ean proide the engineering, matali, futsourcing, ntgration, programming ad Validation ef your prject~elminaing the "rk of coordinating multiple suppliers + Greater efciensy ant conto than avalbe trough diversified engineering ems, sedieated equipment makers o i-hawse fenginering departments with ited time ‘anal Suk hancling experince Flexrcon ENGINEERING DIVISION CHILE +85.2 2415 1286 TUK #44 (0)1227 374710 GERMANY 49 170818 76.13 Fleicn's Projet Engineering Dvn ean esse single source responsibility for enginesring, integrin, evtometing ‘ond supporting your forge scale bulk handing projet while becking al Fexiconcomponens wih a ietine Feefomence Guarentee 'FRANCE +33 (0)? 61.3686 12 SPAIN +34 930 020 500 AUSTRALIA +61 (0)? 3879 4180 SINGAPORE +65 5776 9225 INDONESIA +62 81.1103 2400 flexicon.com ‘SOUTH AFRICA +27 (0}41 453 1871 ©2018 Pesce Cpr. Fen Cert has aon ae ei aan te vam PLENCON eo wn i For details visit adlinks.chemengonline.com/73855-18 hitps:vew iminus.com1S!documer13160/1 9183June 2019 Manage Your Steam Trap Population with TrapMan. ee OURS Pe nee end make an automatic judgment ofits Ces ea eee ei ear eeaey Cee ee Ae ed Coen a te ak ccd Pneee oerecay ager aes leer emery rs reenenes Doe eaueie toa Peco eT Uo XN Sees b b NY ree ee od eae eal sents eet eed A ee A ence . es bf Seas Weer cnr) eet io cis AWC eee Pete eee en eer ee a ere euecued Pee eee x orem D \ TLV. CORPORATION 13001 South Lakas Drive, Charlotte, NC 28273-8780 Tol: 708-507-9070 Fax: 704-583-1610 E-mail t@rvengineering.com For techneal Sewice 1200-TLV TRAP EP htps:imwtv.com hitpsview imirus.com1Sidocument*3160/1rersro1e nor separ scromcmwon ‘byt feagwosimen Benne ee Soenmgeneion erwtatrntton —— smoovores pokocienertmcee eae aTHEH Gav Sanaa an SUZANNE 4. SHELLEY noe oa a anspor euaacen eae magenonne Se. | meee cormeee — sruerenn = pT Seta Hessen pases booty Sinkireeterscen ene are a aes. aes — fea bute Se) Creech ceaLD S40 fe 0 smawescre, hm CHEVICALENGNEERING WWW.CHEVENGONLNECOM JUNE2019 hitps:vew iminus.com1S!documer13160/1 June 2019 Editor's Page 2019 Kirkpatrick Award Finalists ‘vary two years, Chemical Engineering honors an innovative ‘technology that has been commercialized with the Kirkpat- rick Chemical Engineering Achievement Award, This year, we have six finalists who wi have the opportunity to present their technologies at the Chem Show in New York City (October 22-24), ater which the winner willbe announced. Here isa brief surnmary of the six finalist technologies: Braskem — Renewable EVA. Aparialy renewable ethylene viny\ ac: elate EVA) was co-developed wath Allrds fa shoe company), where sugarcane, instead of oll was used as a raw material. A process was developed to produce a wide range of EVA and EVA-rubber products Using 2 potymer plant that was designed to produce polyethylene. A commercial product using the new EVA was launched in 2018. Dow Packaging and Specialty Plastics — Symbiex adhesive tech- ‘nology. Tha traciemarkod Symbiex technology crates mutter pack- aging for foods and moee by gluing together ayers of cterent plastics, to create a laminate. Developed together with Nordmeccanica this a new lamination concept where the two parts are not mixed peor to pplication, but are applied independently. The cure starts vinen the {two coated fms are rough! together to form the mulaye im. Johnson Matthey — Catacel SSA Structured Steam Reforming Catalyst. An increased demand for hydrogen has operators of steam methane reformers (SMRs) pushing their systems to maximum ca- pacttes and experiencing tations in temoeretue, pressure and food flows, The patented Catacel SSR is a catayst-coated metal fl atema- tive to catastioreqnated pallets that can decrease pressure ckop, andinozease heat transfer and catalytic actvy. Qvral plant throughout can be nereased up to 20% without capital investment fora new plant LanzatTech — Gas Fermentation Technology. This process converts carbon-ch gas steams to products using proprietary microbes thet feed on gases rather than sugars, 2s in tractonal fermentation, The ‘0urce ofthe gases can include industrial emissions and more, Lanza Tects process takes waste carbon and produces chemicals thal seve 2s bulng blocks for products such as rubber, pastics and fuels. Tied- party assessments have shown greenhouse-gas-emissions reductions by over 70% compared to equivalent products from fossi carbon. Reliance Industries — Simultaneous Production of Benzene and Gasoline trom 0-6 Heart Cut of FCC Gasoline. To mest the low levels of benzone allowed in gasoline, Reliance Industries and the in dln institute of Petroleum joint developed technology for process ing the CB heart out of FCC (hud catalytic cracking) gasoline based on the principles of extractive dition without the requirement of a pre-processing stop. Said to be the fist ofits kind, this technology produces gasoline that meets U.S. benzene limits, while also recover ing bigh-purty benzene. TechnipFMC — Direct Heating Unit (Flameless Combustion). Tis, technology, jointly developed with support from Total Petrochemical and Shell Oi, s said to be a groundbreaking tech- ology for adding heat to high-temperature pro- ccess08. Unike conventional furnace burnocs whore fuel and air are combined at a single point, in this process, fuel is added incrementally to a high-ve- J Tociy air stream via. multiple injections over an ex- fended reaction zone. As a result the fuel reacts in 2 conirlled manner at signiicantly lower tempera tures than classic combustion. . ‘Dorothy Lozowsk, Editorial Director d 183rersro1g June 2019 Dispersion Genius The ROSS Solid/Liquid injection Manifold (SLIM) system saves time and money on your bottom line. Engineered to accelerate mixing in challenging applications, the SLIM instantly disperses hard-to-mix powders like furned silica, CMC and titanium dioxide into a liquid stream. Directly induct powders at rates up to 700 Ibs/min and cut processing times by 80% or more, By preventing the formation of agglomerates, the SLIM helps ensure the maximum yield of solid. No pump, eductor or clogging. In-line and batch models are portable to serve multiple process lines, Try our free online Knowledge Base & Product Selector ‘web app at mixers. com/web-app. ROSS rscnetherossiivios — wwwimixers.com/SLIM + 1-800-243-ROSS For details visit adlinks.chemengonline.com/73855-08 hitps:vew iminus.com1S!documer13160/1 aisrersro1e Chementator June 2019 Isobutanol synthesis and extraction process could reduce energy compared to alternatives io-based isobutanol is altractive. asa renow- jable_blendstock for ‘gasaline because it has higher energy density than bio- ethanol, and does not impose vehicle-rango penaltes as a fuel additive, but thus far, processes to synthesize and isolate iso- butanol have required a sizable fraction ofthe energy embodied in te fual. Now, a collaborative team of re- ‘searchers from Worcester Polytechnic insti tute (WPI; Worcester, Mass.; www.wpl edu) and the Massachusetts Institute of Technol- ay (Mf; Comixidge, Mass.; wiww.mit.edu) have devised a process for making and ex- tracting isobutanol that could cut energy re- {uirements by as much as a factor of fv “The biosynthesis of isobutanol is carried cut by a genetcaly engineered microbe iso- late from rock samples at a geological car- bon dioxide resenot. The MIT group, led by Kris Prather, Janele Thompson and Jason Boock, introduced genes for isobutanol bio- synthesis into the mirobe (GacHlus mega- {erum), which can surive in high-pressure (005 evironmants. The ability t0 survive in these conditions is cial to the extraction ‘process, which elias on supercritical CO> WP! charical engineer Mike Temko lod the team that developed the extraction techriave. IF the supetoiica-CO,-toleant. microbe is coupled to-an aqueous femmentation process, the GO, can be used as an extraction sokent “Supercitical CO> alows us to preferentally ‘extract isobutanal rom the fermentation step with more favorable thermodynamics than ‘conventional iscbutanal processes,” he says, “Then, by partial reducing the COp pressure, \we can separate product at low energies, In earlier research on isobutanol ‘pro- cesses, product yields have been low, and energy ‘costs high, because isobutanol 1s toxic to microbes at only 2 wi.%, and meth- ‘ds to extractit, such as gas stripping, have ‘consumed tao much energy, The WPL-MIT project has calculated that itis possible to generate and extract isobutanol using its System at 2 Mu/kg, Timko says. ‘The team has completed proot-of-principle stucls for both the biosynthesis and the ex- traction process, and is now working on a complete integrated process and a better un- derstanding of microbial growth. Timko is also thinking about how to apply the extraction technique to other mic-polar compounds, These ‘imprinted’ resin beads selectively recover gold from leachi ‘early Apri, 6th Wave Innovations Corp. (Salt Lake City, Utah; wn.6wie.com) and CyPlus GmbH (Hanau-Woligang, Ger many; vraw.cyplus.com) signed a sales ‘and marketing representative agreement for IXOS nanotech gold extraction resin for the mining industry. CyPlus will represent 6th Wave in Europe, Mexico, Turkey and Egypt 6th Wave estimates that its molecularly i printed polymer IXOS resin can increase gold mining profits by approximately $100 per ounce in process savings and extra gold recovered in direct comparison and as a re- placement for activated carbon, the most ‘widely used extraction medium today. The patented [KOS resins are “imprinted at the molecular level to selectively attract gold and ignore the other elements from Cyanide leach solutions in mining operations. ig processes. Unlike conventional. ion-exchange resins, the DKOS resin has a long life (more than 50 loacing/unioading cycles), and high capac ity (-30 g/kg) and Selectivity for gold (over 95%). The unloading (elution) process is sim- ple, straightforward and inexnensive when ‘compared to activated carbon. The beads requite no activalion step for re-use. The resin is supplied ready-to-use, with a renge Of parlcle sizes avaiable to accommodate heap leach and resin-in-leach/pulp circus. Inlaboratory and field trials conducted over the past three years, KOS has consistently ‘and thoroughiy outperformed acivated car- bon and conventional ion-exchange resins, ‘says the company. 6th Wave is operating pilot plant at a major U.S, gold producer, and thas pending projects with other mines and Canadian F8D entities. CHEMICAL ENGINEERING WWWICHEMENGONLINECOM JUNE 2019 hitps:vew iminus.com1S!documer13160/1 East by: Gerald Ondrey SULFUR CONTROL Prolernt Osdation Co tals — a new cate sotion fom Hatr Ton 08 A/S [Lyn Denmark ‘wnutopeoecam) — as ben indus proven 15 ecto removoundosied hyctogen sulle i ean of ‘goss fom vecoos reckc- ton at a signfeanty lover cost than Weatonal seo: bers The new techogy os boan ” domonstrated to selectively teat offre slur compounds in erder to moe effcenty roravs HiS ftom emissions, wale retaning he vauable car bon dist thal reused in tho precuton. ty asd tion, une Yacional seu tong, Prterora Oxdation Cetayoa does notoonsuana cost sodium hycrxide or produve wattewaer, which Intoubleometo dispose ot “Te tecioloay was deve pee andtestea nthe abo fal) anc sta smakscae industial pla calabor= tonwith Bila Clsose oho ‘Aaiyabiie Gree, eleacing ‘estes manufac he nex stp is bung a large-scale demonstration Pantin China togothor wih ‘hong Group in comer tin wih a viscose pent in the Xinjang province, The ernorstaton plat wl te commesionadttarn 2079, NEW NH PROCESS KBR, nc Houston; ew oncom) as. successily evoped Ammar 6000, ‘ic set on thon anys proces Punter famvreria process. The Am rmonia 6000 prooess. n= bles expanding srge-tan capacty up 196,000 metic tonsperdayni/djtoespit economies tna, nee marae ncdreae cost pet tonotammena rocuced. Tho Armonia 6000 fx ology iB said to provid eomaceens 8 9183perero1g yr bath tholowest capiaoxpon. ures (espn ae the lowest operating expences (ope) at meine ton of amnona Produoed 1 comparison to ‘competitive oerns. The “Ammen 6000 design avis txparsho at-soparation act nrogen-nash unis 6nd Ut ta2s an eligent squpment layout wih optimize and laces equipment count het sizes, alo ich hab oleer- ‘age economies of sale ant contra o ecko capo, SS KBR, NEW MEMBRANE ecearoners fem te Massa chats Isitte of Total. gy MT, vmod) Have Gereopeda row ype ot poy ror memrane ~ cctbed fra recon esuo ol Avance Materia ~ atc “eer aly’ improve tne etcency ot natures purca. Ex: hg momtrares ae yicaly made using Inesrsterds of panes, says Zachary Sith tho dosoph R. Marae Carer Doveloprent Proesior of (Chemica Engnaerng at MT, sho bh resoare ft These sre bong-chan poy rer, which look cooks paghett Poodles at a molec- Ut evel he says “You can race these eaoses spaghat noodes more rig and nso ding you crate epaces be teeentreraodlesthatorange the packing stuctute and ho spaong though which mole foues tan parnaat, Howe aon tes ae rot suticey porous akon (G0, moecube to pomeate trough om ot aie ocoegh Fats fo compete win exstng purfeaton rocesos. stead Of using long chan of ony mar, theresaachars nave signedmemtreresh wncnine farce ok ike aioe, wary basen cach to “These besos alow the 93 es to separate gases much morse Inlabortay experimen, the memerane ws abe 10 wi- Sand CO, feed pressures of Upto bas witout stern Dlestczaticn, the research teport Thscomparestoaroure ‘Roar for the best performing maids, Tre marbrane Goin. June 2019 Electrochemical separation and compression of hydrogen ydrogen gas is used widely in in- dustry, including in metal anneal~ ing, float-glass production and sii- ‘con wafer manufacturing, among others, but greater than 80% of the H used for these processes is typically vented or flared as waste. A new electrochemical sys- tem allows facilities that use Hz to recover the gas by separating and purifying it froma waste gas stream, while also compressing the gas for re-use. ‘Skyte Inc. (East Hartford, Conn.; www. skyre-ine.com) has developed a propri etary high-pressure electrochemical mod- tle, modeled after proton-exchange-mem- brane (PEM) fuel cells, to separate pure hydrogen from Hp-containing mixed-gas waste streams. Known as HaRenew, the device works by introducing & mixed gas stream to one side of a cation-exchange membrane and applying an electric poten- tial. When Hp contacts a piatinum-group metal catalyst in the membrane, it sepa- Fates into protons (which pass through the the electrochemical circu). As protons ‘and electrons recombine on the other side Of the cell, pure Hp builds up and is com- ‘ressad to high pressure. “The system works tke an electrochemi- cal iter that effectively separates rydragen ‘fom other gases and impurities, and is able to compress the gas simultaneously without ‘any moving parts," says Skyre CEO Trent Moiter, Recovering fycrogen that would have been wasted can reduce the costs of Ho by one half compared to purchasing new Cinders or tubes of Ha, or generating the ‘gas onsite, Molter says. HoRienew can produce H with purities up to 99.999% and pressures up to 13,000 's. In addition to Hp-recyciing applications, HeRenew can also be used for compression applications and for separating H. from he- lium, which has become expensive recently ue to a shortage of supply. Based on similar technology, Skyre has also developed an electrochemical cell for converting carbon dioxide into valuable fuels and chemicals. membrane) and electrons (which complete High-strength Al alloy for 3-D printing is moving into commercial production first high-strength, wrought-alu- minum alloy powder’ designed for use in additive manufacturing (3-D printing) applications is moving into ‘commercial production. The powder was developed by HAL Laboratories (Malibu, Cali; vawiznt.com) for use in laser pow der-bed fusion 3-D printers. The company recently announced that the material has been registered by the Aluminum Asso- ition (Arington, Va. waw.aluminum org). The alloy material was originally described in a 2017 Nature paper. High-strength wrought alurrinum alloys in the 7000 and 2000 series have been used for decades bacause of their strength and low-cost alloying additives (Zn, Mg and Cu}, ‘explains HAL's Zak Eckel. These alloys are Used widely from aireraft components and industrial equipment to sporting goods, but they have not been successtully 3-0- printed before, The main bartier to 3-D-printing of high- strength AI alloys from metal powder is that rapd melting and solticaton of the feed material in 3-D printing gives rise to subop- timal crystal structure in the metal product. Because aluminum’s coeficient of thermal expansion and other properties strain the crystal structure, cracks develop easiy in the solitied aluminum, Grain refinement in metal alloys refers to strategies to contro! the nucleation and. growth of crystal siructures with desired Properties. With its Al 7A77.60L alloy, HL has developed a targeted grain-refinement ‘method that controls the solfcation of the ‘metal in additive manufacturing to avoid the cracking phenornenon in the end product. "We have developed an inoculant selec- tion method, based on matched lattices, 10 grow aluminum grains in a way that wall generate the sirength and other required properties in the product,” says HRL met- Blurgist Hunter Martin. By functionalizing the melt poal from which sold Al can grow when solicfying in 3-D printers, we avoid large, columnar grains, Martin explains. Using zirconium, we create many points for aluminum crystal growth to occur in the desired way, HAL is hoping to use the commercial pow= der to attract strategic customers looking for the performance and cost benefits of high- strength AL-alloy systems combined with the freedom of addiive manufacturing. Among the intial applications of 3-D-printed Atalay parts is replacement parts in aging, high value equipment for which tooling for com- ponents no longer exists. CHEMOALENGINEERNG WWWCHEVENGONLNE.COM JUNE 2019 hitps:vew iminus.com1S!documer13160/1 10183rersro1e June 2019 Nitrogen fixation under ambient conditions stion- metal: ion of ritrogen is an alter: native to the traditional energy intensive Haber-Bosch process for producing ammonia. In these tion systems, metallocenes or potas- sium graphite are typically used as the reducing reagent, and conjugate acid of pyridines or related compounds are ised as a proton source. To develop next-generation system, these reagert cost, readily tally 'riendly, Back in 2010, professor Yoshiaki Nishibayshi and colleagues at the University of Tokyo {wwnt.ustokyo. ‘acip/soe/index.htm) developed a mo: iybdenum-nitrogen complex. catalyst having @ PNP’ (phosphorus-ritrogen: phasphorus)-type. pincer ligand that produces 23 molecules of NH3 pe catalyst molecule. But the catalytic tivity was rather low due to the decors postion of the catalyst system during the reaction, Now, the research teams of Nishibayshi and Kazunari Yoshizaw nitrogen-fixation ‘at Kyushu University have designed ‘a new PNP-type pincer ligand, which Combines samarium (I) diodide (Smig) with alcohols or water. This new cat alyst system enables the fixation of nitrogen by molybdenum complexes under ambient conditions. Up to 4,350 equivalents of ammonia can be produced (based on the molybdenum Catalyst), with a turnover frequency of around 117 per minute, The amount of ammonia produced and its rate of formation are one and two orders of magnitude larger, respectively, than those achieved in artificial reaction systems reported so far, and the for- ‘mation rate approaches that observed with nitrogenase enzymes, The high reactivity 1s achieved by a pro! Coupled electron-transfer process that is enabled by weakening of the O-H bonds of alcohols and water coordi nated to Smlp. Although the current reaction is nol suitable for use on an industrial scale, this work demon: strates an opportunity for further re: Into catalytic nitrogen fixation rmeatia thantactonalmembrenss accatng loth cam, PACATALYST (wine, Garmany; wlan ‘comets ecu anced he SvCcOEs star of se” highield OxyMax PA 620 cata yal at Petowicice’s wri sox hale antyace (PA) lar in Gresik. Eas! Java, noosa. Ar > high oars Ine of 100 Ninf, te. producton fect re ors sinaeanty lee Wel! for he fret rine monte of apart, ‘Thehghytavrate resus demon thet the une ceogn and ate rs englosesin thon cat, (OwMax PA 690s a shalt calahat which = procucad using Garant propria hid bed ‘Coating echnologyn he prot he cataicaly actve meters an doce ondvaradu pan. CHEMCAD Pelee ee Lela) Polak eta brew the perfect beverage. ere) For details vi iw mirus.comyS1Sidocument¥3160/t Biaisereo ny 1159perero1g yr se coated a thin shat oto June 2019 ceramic ngs. The thn, po tous sal esaves mais" et heattranspon challenges ‘rng sdlctve cxdaton of ‘oan to PA, Henao, cv fxn © reds, and ‘astman Chemical Co. (Kingsport, Tenn; waw.eastman.com) is ready to commercialize a new chemical: recycling technology that can handle Tnwanted Dyprducts, seen a WiGO varioty of mixad plastic waste, includ sr carn onde and alee 9 plastic materials that cannot be hancled ‘nineda,eremrimsad Tre by conventional recycing processes. "We shall, combined with en im are modifying the front end of the existing proved calayst compestion production stream that manufactures. col ‘ondoptinizedmasssneper \ulosics and acetyls to accept mixed plastic Properties resutsinexcdlent waste. We will convert those materials into Seecivty cupto 116 ¥7% the same basic building blocks that are used reactor cult PA yield pertmance tat iS unpre: ® for products like methyl acetate and acetic veontod by pradauy camer annycride,” says Tim Dell, vice president of generators, 58/5 Clarant ‘corporate innovation at Eastman, ‘What sats this tachnology apart from other PRODUCTDEVELOPMENT chemical-recycing processes is the rapid Lamess AG (Coleg, Ger many; yaw eres om) hes feted no soso eoleor. ten wih. Cite ntomaties (Recixood Ciy, Galt hive:/ ‘ina, company epoca ting in dta-sven merase ‘eecpmert. The two com cientists at the Chinese Academy of Sciences (Baling; wwww.cas.cn) Jand Yangzhou University (Jangsu, (China; ywrw.yzu.edu.cn) have de- anias have launched @ pot veloped a technique for purifying water by bole eres @ gr Me Using graphite carbon rivide shoots. They Gtr gestes pedsten, claim their technique purifies water in 30 Gt Basis Poe anutes,kalog more than 99:9900% of bac- Pegustoma tomes (aia. Tadiona cabor-based.calalss, ties or erivery many Such as carbon nanotubes end grephens Is tivowomarc pes Onde, are not eflecive enough because Shute toetorce te _they flo produce enough reactive oxyeen performance of hemateas ‘Gass fbrs that ae m6 to overcome pathogens. ‘The Chinese scientists managed to over- wa the pases ‘0 e882 come thase problems with a unique catalytic ther mechanical pecormanee fe sirourded wth 2 5209, “This helps the gs fers fo Cesign, They used nanoshests of graphitic carbon nitride, an ultra-thin. two-dimen- ood more sreagy wit te sional material with the right properties to asic mats urate en- absorb light and generate reactive oxygen. fang the pooettes cured This material generates sufficient hydrogen ‘of high-porxmanc plastics, peroxide to effectively kil bacteria. Unlike lemon) Imetal-based photocatalytic. cisinfectants, Large-scale recycling of mixed plastics ‘commerciaization enabled by essentially ing on” the new technology to Eastman’ existing units and targeting specific areas of Eastman's value chain, “We processed, under Controlled conditions, truckload cuantitios of mixed plastics into the commercial operation, 0 we've proven it at scale. Ful commercia ization is expected by the end of 2019," adds Del, Also in the works at Eastman is a new ‘world-scale plant to recycle waste polyester materials using methanoiysis. The plant, ex- ected to begin commercal operations in the next 2-8 years, wil break down polyester ‘waste into viron-queity dimethy! terephthel- ate and mono-ethylene glycol, both of which are important building blocks for Eastman's specially plastics busness. Disinfecting water with photocatalytic nanosheets the scientists’ technique achieves a high level of water purification without leaving behind secondary pollution or heavy metal resides, offering a promising alternative to less eco-friendly technologies. Professor Dan Wang of ‘the Chinese Academy of Sciences, one of the scien- tists involved, says the technique should bbe easy to develop on a larger scale. The Construction of this material is completely metal-free, he says ‘The scientists plan to improve the tech- nigue's efficiency by expanding the materi- al8 abilty to absorb photons, developing an- tibacteral fibers, and refining the nanashest preparation process. Wang says the tech- nique is not intended to purify water single- handedly. “Purification needs other devices for removing heavy metal ions, adjusting pH and removing residue, We need to combine ‘our system with others to mest water-purif- cation requirements,” he ads. Aone-step route to bioplastic monomers erobic oxidation of a biomass- derived roxymethybfurtural; HME) in produces monomers MFOC — the ‘methyl ester of furan-2,5-dicarboxyic cannot be produced efficient. acid (FOCA) — and HEFDC — the ethylene glycol ester of FDCA, These monomers are recognized as crucial for the manufacture of polyethylene furanoate (PEF) — a promising 100% renewables-based polymer that can replace polyethylene (PET). However, MFDC production 10 Nom, the two monomers can be: has so far been exclusively studied searchers previously developed a sta- substrate [S-(hy- for dilute HMF soluions, and more ble compound called HMF-acetal, and desirable routes for the’ production have now shown that 80-95% of HMF- ethanol and ethylene glycol of HEFDC is currently impractical cause a high-yield of the monomer solution can be efficiently converted bbe- acetal in a concentrated (10-20 w.5) to MFDC and HEFDC with a gold [pro- nanoparticle catalyst. The researchers duced by a one-step, energy-efficient note that this method has fewer re process developed by the research action steps and requires less energy teams of Kiyotaka Naakajma al Hok- than conventional processes. kaido University (Hokkaido, Japan; wiwglobalhokudel 2c jp) and Emiel with Mitsubishi Chemical Corp, This. study was conducted jointly terephthalate Hensen of Eindhoven University of (Tokyo) and findings were published in ‘CHEMIOAL ENGINES hitps:vew iminus.com1S!documer13160/1 ‘Technology (the Netherlands). The re- the journal ACS Catalysis RING WWWCHEVENGONLNE.COM JUNE 2019 rasrersro1e Ultrafine dust has a June 2019 big impact on the environment nintemationel study has found that coalred power stations ‘emit more ultfine dust par- icles than road traffic and that those dust particles can modiy rainfall pattems and can, in general, have con- siderable imoact on the climate. The study found that fitration systems of ex haust gas on modem coal-fired power stations are the main source of ultrafine particles. Ammonia is added to the ox faust gases to convert oxides of nitro ‘gen into water and ritrogen. However, ‘ammonia is availabe at the right mixing ratio for particle formation. “The study was led by professor Wo ‘gang Junkermann from the Karlsruhe Inatitute of Technology (Germany; wv. kitted) and professor Jorg Hacker from Airbome Research Australia (Adelaide; ‘wurwairborneresearch.org.au) — a part of Flinders University (Adelaide; www: finders.edu.au) ‘The study's key findings ere: Modern coal-fired power stations emit more Ul ttefine particles than urban road traf- fic; ultrafine particles can harm human health; ultrafine particles can affect rainfall distribution by increasing the ‘condensation nuclel count; ultrafine Particles can be transported in layers with high Concentrations for hundreds of kilometers and then lead to local ized particle events, The study also found that ultrafine ‘particle concen: trations have increased continuously since modern coal-fired power sta tions were commissioned. The study involved measurement fights throughout the world in small research aircraft equipped with highly sensitive instruments measuring dust Particles, trace gases, temperature, hu: ‘misty, wing and energy balarice. “By redistributing rainfall events, the Lltrafine particles from fossil power sta- tions can lead to drier-than-usual condi tions in some places and to unusually heavy rainfall elsewhere,” Hacker says. With diameters of less than 100 nm, Ultrafine dust particles have a huge ef fect on environmental processes. Ml The prscest of ontiniang glass ‘ber sang is corps, Sboroue andiine-consuring “Weexpect Al ‘cut the deve tine eco ‘imzed formulations by more than a” says Axa Tucan, ad of Glcha Proauct an Applicaton De \eleprentin tho Lanwoes Hoh Per ‘omance Matera buses it In fredonal product develo ment tie complex composiion of (Gass toe sings and the nue: fue variables when manfactonng higrpedermance patios reasee entensne tosing, the resus of ‘nich can be hard to rect A fan make an meortant cook: tioninthiseasebyaettanthne most fut ofthe avaiable deta, Svaied ‘rom thousands of measurement ‘aus fam prevcus omulation, ‘avmatera information andartt Of aditionl aaa, A agorthos ‘abut foconet meee orf roves test confusions ad pe Fame, ennance these modo ‘nthe basis ot the messuoment rests frm each idk tet and rely propose: an optimum ‘oxmulaton. Ths procedure makes protct davolopment much fater ‘han ational methods. For Your Next Clean Air Project Go Modular Get the cost, sourcing and labor saving benefits our ScrubPac” Fully Engineered, “Packaged” Emission Control Systems can deliver Available ScrubPac™ System applications include; —, + Gas and Fume Scrubbing + Particulate Removal + Rerosol, Mist and NO, Removal = Odor Control ‘© Ammonia and Acid Reconcentration + Chemical y-Prodct and Waste Heat Recovery f With over 40 Years of application expertise... Ifit can be scrubbed, well scrub it! BIONOMIC Tears ite For details vi hitps:vew iminus.com1S!documer13160/1 a =! i Peer ee eee eS links.chemengonline.com/73855-07 13158perero1g June 2019 Business News LINEUP. ‘CLARIANT covestro BXKONMOBIL GTC TECHNOLOGY HONEYWELL UOP LINDE LORD CORP, METS ourorec PARKER HANNIFIN PERSTOR? PUNKE PUMP SOLUTIONS GrOUP SSTANIGARBON suizen TESCO CONTROLS ‘TAMAX SYSTEMS WUXtIVUAN O Look for more latest news on Plant Watch Perstorp will construct new plant for sodium formate deicer product May 8, 2019 — Perstorp AB (Perstorp, Swe- den; wr: perstorp.com) plans to construct ‘anew plant in Perstorp, Swoden. Tho plant ‘wlincrease capacity for Pergrp Fun NF. the sodium-formate deicer product for airport runways. The plant will have a nemepiate ca- pacity of 12,000 metric tons per year (m.t/ yf) and is due to begin opereting ahead of ‘the coming winter season (2019-2020), Stamicarbon signs contract for urea melt and granulation plant in Russia May 7, 2019 — Stamicarbon BY (Sittard, the Nethetlands; ww.stamicaroon.com) ‘has signed a contract for icense, process design package (PDP) and proprietary equipment ‘supply for a grassroots urea melt and gran- Uation plant for ShchekinaAzot, to be bull in Pervomaysky, Tula region, Russia. The scope of work for Stamicarbon is the com- plete license and POP for a 2,000 metric ton per day (m.t/d) melt and granulation plant including supply of proprietary equipment Clariant Catalysts and Wuxi Xiyuan win contracts for formaldehyde production May 7, 2019 — Ciariant Catalysts (Munich, Gormany; www clariant.com) wil be collabo" rating with its engineering pertner, Wuxi X- ‘yuan, on two new projects to supply ther joint formaldehyde production technology. The new contracts were awarded by Shandong ‘Yushiu Chemical, one of the largest Chinese producers of phenol formaldehyde resins, ‘and Shandong Sunny Wealth New Matori- as, a leacing antioxidant producer in China. ‘The producers formaldehyde capacity is ex- pected to be 180,000 and 180,000 tony, respectively, with operations starting in 2019, ExxonMobil proceeds with $2: Baytown expansion project May 2,2019 — ExxonMobil Corp. (rvng, Tex: vwevinexxonmobiicom) wil proceed with a $2-blion investment to expand its Baytown, Texas chemical plant. The expansion, expected to start up in 2022, includes a new Vistamanx performance polymer unit, which wal procuce _250ut 400,000 tony of Vietamaxcx polymers. ‘The project wil also inchude @ 360,000-ton/y pant to produce near alpha olins Covestro to expand production of polycarbonate films in Dormagen ion ‘chemengoniinecom May 2, 2019 — At its Dormagen site, 2 ‘CHEMIOAL ENGINES hitps:vew iminus.com1S!documer13160/1 Covestio (Leverkusen, Germany; wwew. covestro.com ) has started bulking add ‘ional production lines for high-qualty poly carbonate fims. The new co-extrusion lines ate scheduled for completion by the end of 2020 and will cover the increasing demand. Linde starts up air separation unit at ‘Samsung facility May 2, 2019 — Linde (wwwiinde.com) has started up a new air separation unit (ASU) 0 ‘supply 700 tondd of gaseous nitrogen to sup- port Samsung in Tangisong, South Korea ‘Thisis the company’s fourth ASU at the faci, Ma‘aden selects Outotec for gold- processing plant May 1, 2019 — The Saudi Arabian Mining Co. (Ma'aden) has awarded the consortium ‘f Outotec Oy) Espoo, Finland: wwn.outotec. ‘com) and Larsen & Toubro with an engineer- ing, procurement and construction contract 10 buid a greenfield mineral concentrator and ‘gold processing piantin the Kingdom of Saudi Arabia. Outotec's share of the €540-million project is over €140 millon. Qutotec’s delivery includas basic and detail engineering, pro- ‘curement and deivery of process equipment, ‘commissioning, star-up assistance and tain ing services. The new gold processing plant is ‘dup to be completed in 2022. Plinke to construct nitric acid plantin India Apil 80, 2019 — KBR, Inc. (Houston; ww koc.com) announced that its subsidiary Pinks ‘GmbH has been awarded a contract by Guje- rat Narmada Valley Fertiizers & Chemicais to. (GNF) of India to build a concentrated nitic ‘acid plant (CNA) at Bharuch, Gujarat. Under the terms of the contract, Pinko will provide the license and engineering, as wel as supply the proprietary equipment for the new plant ‘that will produce 98.5% CNA mainly forthe In- ‘an market. The plant, which is designed for a throughput capacity of 160 m.t/d of CNA, is due to come on stream in 2021. Honeywell UOP licenses ionic-liquids alkylation technology in China ‘Api 26 — Honeywell UOP (Des Plaines, tl; ‘wwewuop.com) announced that Sinochem Hongrun Petrochemical Co., Ltd, wil use UOPS. looky ionictiquids “(Ls) alkylation ‘technology to produce cleaner-burring motor fds at its refinery compiex in China. Devel- ‘oped with Chevon U.S.A. Ine. in 2016, the Isoalky technology isthe fest successful quid RING WWWCHEVENGONLNE.COM JUNE 2019 saisrersro1e June 2019 aliyiation technology to be introduced production of aromatics and other www.lord.com) for approximately inmore than 75 years. The technology petrochemicals. The enterprise value $3.675 billion in cash. The trans Uses ILs instead of conventional HF or _ is $39 milion (CHF 89 milion, action has been approved by the HSOq acids as a catalyst to produce board of directors of each company aikylat crical component for mak- Parker Hannifin acquires ‘and is subject to customary closing ing bigh-octane motor fuels LORD Corporation conditions, including receipt of ap- April 29, 2019 — Parker Hanni- plicable regulatory approvals. Upon Mergers & Acquisitions fin Corp, (Cleveland, Ohio; www, closing ofthe transaction, LORD will Dover acquires pparkercom) announced that it has be combined with Parker's. Engi ‘All-Flo Pump Company entered into @ defitive agreement neered Materials Group, 7 May 8, 2019 ~ Dover Corp. [Down- {0 acquire LORD Corp. (Cary, NC:s erat Onciey ers Grove, ll; wwew.dovervorpora~ tion.com) has completed the aoqui: is'ouras avo eee’ | Dependable seals wihich is now part of the Pump So- lutions Group (PSG; wwaw.psqdover t rt ith D WAL =aarc => || Start with De’ turer of specialty airoperated dou- ble-ciaphragm (ADD) pumps, ‘Seals, gaskets and diaphragms can ail leak, so DeWAL Industries has developed a broad range of durabl ‘Trimax Systems joins forces with bondable PTFE and UHMW film and tape compositions Taso Controls that creale dependable seals despite abrasion, harsh May 8, 2019 — Tesco Contr, Inc. (Sacramento, Calif; wwwtescocon- trols. com), @ conttsystem solutions Provider forthe water and wastewater industry, has acquired Tmax Systems, Ino, (Brea, Calf) for an uncsclosod sum, Timex is a systems integrator sening the water and wastewater marke, and is aso a leader in the ut- ity, solar and renewable envionmen- tal energy industries. The transaction coed river ehza2 More than a dozen DeWAL PTFE and UHMW fms and Maio wdeasanqaaienat tapes are designed specifically for gaskets, expansion HighService Service in Chile joints, valve seals and diaphragms. May 6, 2018 — Metso Corp. (Hel sink, Finland; wwnw.metso.com) has Completed its acquistion of Higher vice Service, the service division of the mining engineering, construction and technology company Higher Ps vice Corp. Gantiago, Chile; ww. highservice.com), HighSenvice Ser vice offers its customers a varity of servioes from maintenance to com- rmissioning and remote monitoring. ‘chemicals, high temperatures or imegular surfaces. Let DewaL engineering Sulzer acquires ‘help you with your most GTC Technology diffi chatlonges. May 3, 2010 — Sulzer Lid, (Wintec the, Staaten waresuercom) wrens has aoqured GTC Technodgy LLC eerie (Houston; www.gtctech.com), a iil technology compary ofeng proot- etary processes and systems forthe For details visit adinks.chemengontine.com7658-44 hitps:vew iminus.com1S!documer13160/1 19189perero1g Newsfront June 2019 Modularization Finds New Roles As benefits become apparent, the acceptance of modular process systems grows and the concept finds new opportunities rile providers of modu lar “process systems ‘and facies wil tell you modular builds were once a hard sell, modularzation is Row sought after for both traditional process systems, as well as new and novel appications. What is the reason? Aside from its many inher- ent benefits, including reduced eosis and significant schedule reductions, the modular concept lends itself to a variety of applications across many processes (Figure 1). struction continues to expand,” says Thomas Schafer, vice president of Koch Modular Process Systems (Paramus, Ni; www kochmoduta. com). "When we frst got into the modular business, we had to over- come objections that modular con- struction was diferent and potentially would be crowded and dificult to maintain. But now we're finding that ‘most of our clients don't have to be convinosd about the benefits and ‘qualty of modular construction, as it has been widely proven, which is ex- Panding modular opportunities.” Not only are previously conserva~ tive companies embracing modular builds, but the scope of projects is growing as well. "in more recent projects, the scope has expanded 0 that instead of supplying only dis tiation equipment, we are supplying reactors, as well as fers, compres- sors and other equipment modiular- ized," Schafer continues. “So, the ‘rend is that we are expanding the Lnit operations going into these sys- tems" (Figure 2) The big drivers for the increased interest in modular construction, ac- cording to David Funderburg, global technology manager with ABB (Cary, 4 hitps:vew iminus.com1S!documer13160/1 FGURE 1. cdlrztion sno sought te froth atonal process ysis, s wel as new ap- ications becase he macula canopt easy lens sl oa ary of apacaos acess many o> esses, Shon hres cans soda evapretr shia N.C; wwaw.abb.com), are the reduc tion of costs, schedules and risks. “Costs are reduced because you can buld off site, and risk is reduced ‘because you can pre-test and pre- document the systems, which in turn improves schedules because late changes can be managed due to the LLego-lke approach of modular con- struction versus having a big projact where any change has a ripple effect (on the schedule for the entire proj- fect,” explains Funderturg. ‘Modularization benefits ‘Modblar construction is known tore duce costs dus to the assembly-tne- like bulling concept. In addition, the controled workshop environment also reduces schedules, improves uaity of the finished product ang increases safety, which directy leact to adtional benefits for owners. of ‘modular process skids (Figure 3), Costs savings often result fom labor savings, according to Ken Sipes, direcior of engineering for the process and mechanical group with EPIC Modular Process Systems (St. Louis, Mo.; www.epicmodularpro cess.com). “Especially on large pro}- fects in an area where construction 's usually porformed by union cratts- ‘men, modular projects often provide an opportunity to realize labor sav- ings while stil providing quality work performed by talented craftsmen ‘who build to the same specifications ‘as unionized labor forces, just under diferent labor agreement.” ‘ditional savings can be found ‘on very large jobs where *a massive labor force would be required," Sipes ‘adds. "in some geographical loca tions, a labor force of this size might bbe almost impossible to deive,” he ‘says. “When labor is a limiting fac tor, you're let with the sarne amount (of work to be done with a smaller ‘orew. That orew has to work more, which means paying premium over- time wages, as wallas per diems and travel expenses. However, taking @ ‘modular approach can spread the ‘work out geographically to where the worklorce is raacily avaiable, lesson- ing the impact of those cost.” Elizabeth Manning, manager of ‘sales with Koch Modular, says sav ings are also discovered because project owners don't have to em- oy 2 large project engineering statf CHEMICALENGINEERING WWWICHEMENGONLNECOM JUNE 2019 16189rersro1e FGURE 2. This complete mod cones proces plant was desing and ultra outa US. seca hema produ. was alae a ‘ono ioe rot ht was eld conse ae the seeds was steal teat upto te tance a pn to overses the project. “They can issue a single purchase order and Uimately, we are responsible for all Of the vendors’ building equipment fabricating piping and doing electrical work, This alows the project owner torunaleaner staf than ifthey had to manage a feld-erected plant. ‘The workshop environment also lends itself to reduced project schedules, as craftsmen can work Indoors in'a controlled environment June 2019 without weather or other interfer ence while site permits are obtained and the sita is prepped. And, since skids are always pre-tested parior to livery, it reduces installation time. ‘We pretest the systems and ensure that all instruments are wired cor- rectly, calibrated and configured, all motors turn on and off and all valves are actuated to verify functionality, says Doug Comwell, controls engi- neering manager, with Bamum Mi FGURE 3. The contd workshop enorenmont edie scotia, mproves {lt of te tistesprogut an eas Stet Me arecty lado ‘Son orf orownarsl medoar rats ses chanical, Inc. (Loomis, Cali; www. boarnummech.com). “More often than not, customers raquest modi: fications ‘or additional features dur ing installation. This means that the inetallation may require more time than anticipated, but the owner's startup date isn't going to move. However, because we do testing in ‘our shop, we are able to reduce VO Cchack out, commissioning and vai- dation time during installation and ay EKLEEN. Automatic Filters Inc. WE WON’T LEAVE YOU HANGING!! + No Flow Interruption + No Bags “No Cleanup «No Downtime «No Kidding Filtration Down to 2y 100% AUTOMATIC SELF CLEANING WATER FILTRATION SYSTEMS hitps:vew iminus.com1S!documer13160/1 7153perero1g yr June 2019 AWORD ABOUT CONTROLS ‘Curent, corr of modular proces kids anton ons oft ‘ways, depend von tho needs of ie owner Aozora to Dou ‘Cemel nity Barnum he kc can De designed ih he program ‘able ogi coil (F.C) crboard anda sal-contanes program. ‘Ths B ofen te toute selected whon the en user docon have ‘man PLC a the pant or wnen they dont want to Fear the Pro- ‘ess skid eto the main con system. The sé cpr vais om ‘canto pant and operstor nario erin. “he second method cf canto us employed wien the end ser Pasa PLC and they want to conta he ska wa te ma contol method, “th these cogs, we supply the isrumeraton anc nat! ‘utput iOjnareware escoxdrg tte specteations. We puta pare! ‘on ho 8 ith aarouted UO modules at mateh the rand Oe PLC nthe pan he exons, We pre-test io hat isiouied VO pane, do all he protasing, cc, 60 that whan we fal ho id he pl, we ust Deng powor tothe dstbuted UO panel and @ Communion newark cab an integrate our program fom he ‘kno tho owners easing PLC progam.” For compan th ae balding orn the gression, sid burs ‘en hep them sect epcrooriestumantaton and PLCs to mest ‘th eoods anc intogtate tho ks tho samo wa. ini skid manuactaers oe vey flexble now the skids re ‘ontoled he canta and automaton neki nok or ‘ote integration stendards, says ABS's Dai Fundarburg, “The NAMURied Modular Auematon inate adseton the nad 10 ‘chin an open standard interac o kd equement he says “Tis ‘means tat ene vrs ov ot be forced ta use One sid von oF ‘ne automation suppie, hus achieve We teoperaDity” He suggaete thrving about slanconseng shed auzeraton tke Dinter ver, dofnod by NAMUR edule Automston as an Module often can reduce the on-site com- missioning portion of the project from two weeks to ten days. Pre- testing allows us to absorb some of the schedule hits that sometimes ‘occur during installation.” Experts estimate that the con- trolled workshop environment, con current building and pre-testing es- sociated with modular construction ‘can shave anywhere from a quarter ‘to haif the time from schedules when Compared to the same project when traditionally fabricated ‘As a side benefit, compressed schedules help companies get their URE 4 When astm suit na cna enutonmer ox shop thx is bere Safe tan dongs work on 3b ste ‘wor work ay cing ard wear 2 sono ara atk ‘reas sal pret execute staegy 16 hitps:vew iminus.com1S!documer13160/1 Products to market faster, says Schafer. "Some clients come to us because they are in a time crunch ‘and need to save time in orcer to get to market faster and satisfy oftake ‘contracts,’ he says, “They know that if they build the plant modulary, in some cases, they can be up and running six months to a year ear- ler than they would be if they had a large engineering company site con struct the same facility. This is important evan where cus- tomer contracts aren't an issue, he adds. “Once the owners have made the decision to spend the capital, they don’t want to wait ‘any longer then neces- sary for a project 10 be ‘completed. The faster the project is Gone, the faster they realize profits from it” explains Schafer ‘And, in existing facil- ties, the modular concept helps reduce downtime, says Gregory Sandel, senior process engineer with Bamum, [ot of work in existing faciities and because they're currently operat- “ype Packago MTP), “You buy a ki hat asa corer or PLC on iy a8 wal as en inerace vert, MTP) ha you lust impor into your sutoratin sytem. The brand went matter because the MTP ind pre-cniguad ata connectors, inludng proces repos fang sores, which kos ea ta mpoM” lau). Stancarization, whon achieved wil bereft sk Builders, 9s wot OEM skid suppers can supply th skid with tok on inatoctual propery in ther peter plato and the Interface tot wll be fan open standard. This means they are forced to change ther sotare or architecture fo mae! thal ofa project-specific souton,* Says Funosroug, ‘Curanty, shoddy chemical and paranoia processors aro saokng hs yp of standariatonbecauso& proves Hey alow ing thom to buy skal equpment 'o mate one pred, then rearange the skid fo malo a deren proc in a plg-ans-prodee fshion sneut omyng aoa corto ra trace comes, Ne Sa, ‘Stenderdzaton woud seo bane tector! ol, G&= ano chem tal plant hat ravo alt of etegratn aqupnent. Wel, cys Funder Ussoly thee alot of YO ard enginsag ivoNed on rjects orgs magnitude," he says. “But stendardzaton wou re Suce the angneemng and alow uses to plug maid ard have cata ht ave vatnou te era voriead of xstomirg iniriages to get the det fem tha venders PLE" ‘Whi i make macssrtion mere cenit, tandaraton sila werk progress duet the consort rats ae comely four rusty, tes Furdattara. ‘To dlandarla Pave boon ransod and hero are ts taking lace Europe, but hore ag between the pio bing compete anc wascaeacopton, We ae between the choges bang pron tpt sca anid xg faites bora \wocan sia socingitasa stanéa speatcatonforskintegaton” Ing, downtime is lost revenue,” he says. "Many customers in this situ- ation find that if they go modular when they need to replace an older systom with a better performing one Or one that meets current standards, ittean reduce the financial impact on their production schedules.” EPIC Modular Process Systems’ Sipes agrees: "Think of instaling processes within existing chemical plants lke open-heart surgery. The heart and soul of that plant is tun- ning and has wires, power, com- ‘munication and utlties connected to it and i's making product. The moment you tum off the flow to the: process and start tearing it apart is the moment you stop making money,” he explains. “With moduiar, you can do 75 to 90% of the work in the shop, bring it to the site, turn off the existing equipment, remove it, drop in the new skid, reconnect it faster because i's been pre-tested and be up and running again rela- tively quickiy.” Additonal perks of modular con- struction include increased safety ‘and consistency, according to the experts. "Safety i the number one priority with our customers and this "We do CHEMOALENGINEERNG WWWCHEVENGONLNE.COM JUNE 2019 181892218/2019 June 2019 remains true when they are execut- venient for a manufacturer to reduce: ing projects," says Sipes. "Modular their environmental impact by not construction lessens the amount of using potable water to flush toilets or ‘work done at a customer's property irrigate landscaping," he says. 80 their exposure goes down. Ad- Solvent recoveryis another oro08ss itionally, when a system is bult in employing modular skids with more ‘a controlled ervironment on a shop frequency. “Everyone who manufac- fioor, its inherently safer than doing turers paint, adhesives or resins uses. this work on ajob site where they are solvents. and most of them want to cimbing and weather and elements recover these solvents at the end of are a factor. It creates a safer project the process and recycle them back to execution strategy” Figure 4). the front of the process,” says Rocky ‘And, for processors for whom Costello, president of F.C. Costello ‘consistency across locations is key, ‘modular builds often provide the so- lution, "Some customers have facil- ties throughout the U.S. or globally aie they wan fo deploy now sect radogies waitin multe pats, but CHem | Oo fer eave te-caen texlmobar ‘and the same equipment not only to provide consistent quality of the finished product, but also so that in- ventory and training, operations and Looking for that dream maintenance are the Same at each in of those plants," says Sipes. “This chemical process fean only happen when the. same equipment Is bul to the proper Post your resume and codes, using consistent craftsman- dhemengotne.cm /chenply today ship, workmanship, techniques and - ‘equipment and delivered to each of > Chemploy job center focuses exclusively on. those plants in a modular fashion.” jobs in the CP For these and other reasons, modu- lar technologies are being employed innew applications. Te Receive jobralerts ieclly to your emi of es ‘any new jobs posted pelea, search & Associates, Inc. (Redondo Beach, Calf; wanw.rccosteto.com), “This is bbeing accomplished with modular batch or modular continuous distlla- tion equioment.” Creating feriizer trom wastewater treatment is another new application for modular skids, Barnum worked with a large municipalty to help de- velop 2 modular, low-temperature, commercial-scale, _skid-mounted thermal hydrolysis processing unit. The mobile process was developed prelerences New opportunities » Access the Careers Resources library which One of the newest trends is using ‘tlre you volute eonching and sree eae H5 N modular skids for sustainable initia- tives that reduce waste or environ- ‘mental impact. “One of the hottest ——— ‘markels for modular skiis ight now is ‘water recovery or water harvesting,” says Tony Salomi, product manager with Chicago Plastic Systems (Orys- tal Lake, I; www.cpstab.com). “The skids recover gray or runoff water and ‘neat and recycle it for use in flushing atl employ Cie on SST ‘onew epparuniy tolets or for imgating lendsce ees The skis inchde be fitaion mecher Let Chemploy work for you >)! ts ot nisms, utravolst (UV) or chlorne- chemengonline.com/chemploy gos ne treatment equipment, pumps and other necessary components, ‘Wie the process isnot new, mod- wanting it onto sks makos # con el venient to go green. “Ifa company ream ert ‘wants to do this, they just order the equipment. Is delivered as a. skid and installed in about a day. Then they simply collect the water and turn it on. It makes it very easy and con- CHEMICALENGINEERING WWHCHEMENGONLINECOM JUNE 2019 hitps:vew iminus.com1S!documer13160/1 Ce ee eee eee 19189perero1g fehatsioie Seeney roxtens “nie i] FGURES, Sunéarding si autorton cn be ough hea pine dv: Get NAR Moda Asai as Male Package OTP) in response to increasing demand {or practical resource-recovery solu tions, particularly from smaller-scale solid-waste treatment plant opera- tors, allowing end users to create Class A bio-ferlizer product during the waste treatment process. ‘Another new area for modulariza- tion isin specialty and pharmaceuti- cal processing, where the switch is being made from batch processing to continuous flow chemistry, be- cause they are starting to realize June 2019 that cost benefits can be achieved bby moving from batch to continuous processing, says Costello. Often, ‘when making the switch, these pro” ‘cessors take a modular approach. "The cost and size of the plant is much smaller when employing con- tinuous processing in these typos of facilties andl winen you have smaller plants, as compared to batch pro- ‘cessing, it's very amenable to do so in a modular fashion.” Besides reducing cost and size it increases their flecilty. “if possible, ‘we buld the plant with modules that ‘can move around. You may have a reactor here, a crystalizer there, a filter undar 4 crystalizer, and £0 on, ‘And, if modules are built correctly, ‘owners can move them around into & new configuration if products change,” explains Costello. ‘Another new market cludes bio- derived chemicals and tues, says Koch's Schaler. “Many of these prod Uucts are beng created by start-up ‘companies with a great idea for anew route to a product, but who need to hire a company with chemical process lengneering expertise 10 get them to 2 ful-plant-constructed solution that 's economical, fexble and sale. AS 2 result, we've gotten involved in as- sisting several such companies with the development of these processes. ‘And, because they want 10 get this new product to market as quickly as possible, modular construction makes ‘sense as itis inherently faster’ Case in point, Koch Modular re- cently worked ‘with New Jersey- based start up Primus Green Energy On its natural gas-to-liquids technol- ogy, specifically their processes for converting natural gas to crop-in gasoline and methanol via reform- Ing, reaction and cistilation unit op- erations. Koch assisted Primus with lengineoring services supporting the process conceptualzation and pilot- testing phase and, later, the develop- ‘ment of the process design package ‘and the forthcoming detailed engi- ‘neering and construction of is frst commercial-scale system. . soylerree Other Valves Up to6 Million Cycles ‘Unlike other valves that seal with friction, PosF-flate’s Unique butterfly valve uses an inflatable seat to seal ‘with air pressure. Thus Ftrequines les torque and smaller actuator resulting Fnower cost Plus, the sent automatically compensates for ‘wear, providing longer life. Some tsers have reported ‘over 6 million cycles and the valves are stil going strong. * Less Friction Low Torque For dtails visit adinks.chemongonlineom/73855-33. hitps:vew iminus.com1S!documer13160/1 Bata ere econ We Designed It ut zune posiflate (CHEMOAL ENGINEERING Riemer PRING LOADED! Mists: une eariuoee en Gece: VERY! aoe Ce For dotalis visit ainks.chomengontine.com73855-09 WAWW.CHEMENGONLNE.COM JUNE 2019 20059rerero1g New Products June 2019 hitps:vew iminus.com1S!documer13160/1 New control system for multi-burner applications ‘The Kromschrdder BCU 4 Series con- ‘rol platform (photo) for multiburner applications is dasigned for directly ignited oF piovmain bumers of un- limited capacity in intermittent or con- {tinuous operation, and for modulated ‘oF step-controlled gas burners, The seties consists of three new models. ‘The BOU 460 controls, ignites and monitors modulating or stage-con- ‘rolled gas burners for intermittent or ‘continuous operation, making it sult= able for frequent cycling operations. The BCU 465 incomporates airflow monitoring and pre- and post-vent- lation for use with recuperative bum- ‘rs. The BCU 480 can monitor pit and main burners independently. The BCU 4 Series comes equipped with ‘an ignition transformer, burner control ‘and an embedded human-machine intetace (HMI), all arranged within a ‘compact housing. The fourdigit dis- play shows vital information, such as program status, unit parameters and flame signals. All models possess a manual mode to adjust the bumer ‘and its diagnostics. — Honeywot Process Solutions, Houston ‘wwihoneywellpracess.com ‘Custom sealing solutions for hygienic applications This companys family of high-oer- formance seals (photo) are designed speciicaly for applications. inthe pharmaceutical manufacturing, ana- IMtcal instrumentation and nygienic, tid handling sectors. The seals are ‘manufactured with chemical-resistant materials to meet or exceed quality requirements, intuding United States Phermecooeia (USP), FDA and ISO product standards. With low leach- able profies, these specialty com- pounds meintain their inert nature in Highly “demanding conditions. The ‘company’s Metal Spring Energized {MSE} ne of seals croates a loak- roe seal without excessive friction and ‘wear by applying calculated spring force directly over sealing lios. MSE ‘seals operate from cryogenic temoer= alures up to 625°F (828°O) and are available in custom sizes. — Greene, Tweed & Co., Kupsvite, Pa ‘wvwngtweed.com Gently feed free-flowing granular media The K-ML-BSP-150-S Buk Solids Pump (BSP) feeder (photo) provides. gentle feeding of free-flowing granular materials without using screws, au- 90's, batts or vibratory trays to convey the materal, Instead, it utlizes posi tive-displacement action to feed free- ‘lowing materials, offering uniform dis- charge, consistent volume and gentle handing. The BSP feeder has vert Cal rotating discs that create feeding ducts. Material moves smoothly from the storage hopper to discharge out- let through a “product lockup zone, achieving linear mass flow, With no pockets or screws and only ane mav- ing part, the feeder is cleaned quick'y, ‘making it ideal for applications with frequent material changes. The BSP- 180-$ foods at rates from 1.2 to 237 £87 using fve feeding discs to create four feeding ducts, It features a stain- less:stoe! feeder body and uses a stepper motor. Two additional models. are available for smaller feed rates. — Coperion GmbH, Stuttgart, Germany wwnw.coperion.com thermal-imaging analysis Jn collaboration with ecom, this company has launched the Onsight Cube-Ex wearable camera (photo) for asset analys's and safety inspec tions in hazardous areas. By pairing the Cube-Ex with ecom’s intrinsically safe AG/LTE Smart-Ex smartphone + Tab-Ex tablet, users can remotely control the camera, view high-def- inition video and thermal imaging, or caoture and annotate pictures or recordings trom a sate distance. The versatile design of the Cube-Ex pro vides feibility for workers to wear securely on a harchat for hands-free inspections, attach to @ monopod for harc-to-teach locations, or mount to equipment to view from afar. Bul-in ilumination provides. high-quality ve suais in low-light environments. Also cffered are optional cloud storage and remote expert collaboration and digital work instruction through the Onsight eugmenied-realty piattorn — Librestream Technologies inc., Winnipeg, Manitoba, Canada wwwlibrestream.com VAWW.CHEMENGONLNE.COM JUNE 2010 2159rersro1e TCT Series centrifugal pumps (photo) feature an open and rear-mounted Impaler, internal anti-abrasive coat- ing and low rotational speed (rpm), ‘making tham suitable for applications ‘where pumps may be exposed to high levels of abrasion, such as ceramics ‘manufacturing or cstileies. Addition aly, TCT pumps feature a vortex im: pelle design thet, compared to the traditional closed impeller, reduces the ‘energy of the sold particles impacting the intemal surfaces. — Pompetravaini S.p.a., Castano Primo, italy ‘www.pompetravaini.com ‘This company has introduced a naw Jow-temperature sealing option for its RHPS Series of pressure regulators (photo). Composed of low-temper: ature-esistant tile material, these new seals are designed to maintain & strong seal in cold climates and appl- cations where significant cooling oc June 2019 cours due to high pressure drop, even in environments with extensive pres ence of hydrocarbons, where cimate Control may not be an option. The new sealing options fave minimum tem- perature ratings of: ~49°F (45°C) for Configurations rated up to 70.0 bars; 40°F (-40°C) for configurations rated up to 400 bars; and ~4°F (-20°C) for configurations rated above 400 bars, = Swagelok Co., Sofon, Ohio wunw.sevagelok.com The Qdos serias of chemical-metering pumps (photo, p. 24) now includes a ‘madel for mobile and remote applica tions — with no practical access to Grid electricity — that can be powered bya 12-24 V dc. power supply. Sut, able for both remote static and mobile battery-powered applications, typical ses of the new Qdos model include remote water treatment and sampling, potable water refining and on-truck pumping operations, For very remote applications, the pump is able to run hhorgrove-epc.com / 877.388.8356 / WF For details visit adlinks.chomengonline.com/73885-22 hitps:vew iminus.com1S!documer13160/1 2289rerero1g yr " 0 hitps:vew iminus.com1S!documer13160/1 June 2019 from batteries that can be recharged via solar cells, other renewable en- ‘ergy Sources or spit charge relays, says the manulacturer. The product is self-contained and does not re- ‘quire any additional components. — Watson-Marlow Fiuid Technology Group (WMFTG), Comwall, UK. ‘wwwawmftg.com Safe, hygienic, in-line powder testing ‘This company’s auger and vacuum ‘samplers (photo) provide a reiable way to accurately take povider samples safely and hygisnicaly while ensuring that the powder is not contaminated ‘oF damagad in the process. The auger ‘samplor uses technology that dolvers accurately controlled powder samples. ‘Tha auger sampler is recommended for applications where the sampling point is near the sample destination. By contrast, the vacuum sampler is best used when the sample point is further away from the testing location. The model complies with the latest relevant global requrements and pro- vides either a two-pot oF spot di- verting head for maximum fxbity. — GEA Group AG, Ditssolcort, Germany www.gea.com This app puts a digital twin ‘on your device With the new Version 2.0 of this ‘company’s ProcessApp for buk- materials processing equipment, users have a digital twin of their ma~ chine virtually in their pocket. Opera- {ors can request soare parts directly from their machine or contact the manufacturer. ProcessApp can also bbe used to measure motion curves fon the TSM/tsi tumbler screening machine. In adcition to the tumbler screening machine, the app is now available for other machine types, such as the VRS vibration screening machine and the MSizer compact. Each new machine is equipped with its own QR code. The machine can be uniquely identiied immediately by scanning the code. An embed- ded digital twin of the machine and ‘an interactive drawing guide Proces- sApp users to appropiate spare paris selection. — Allgaier Group, Uningen, Germany ‘wwwwallgaier-group.com New shaft seals for screw conveyors ‘The AM CEMA shalt seal (photo) has. been designed speciically for Con- vveyor Equipment Manufacturers. As- sociation (CEMA) screw conveyors. The AM CEMA shaft seal utiizes a postive air or inert-gas- purge to cre- ‘ata a barrier between the shaft and seal, eiminating product leakage and process contamination. Due to its noncontacting design, the AM CEMA shaft seal has no weering paris, re- {quiring minimal maintenance or need for rebuild kits. To accommodate shaft movement, the AM CEMA shaft seal fully articulates to alow for radial run- ‘out and anguiar msaignmant simulta- neously. — InproySeal, Rock island, ‘www.inpro-seal.com ‘Simulation software speeds development of digital twins ‘A new release ofthis company’s Mimic ‘Simuiation Software (ghoto) makes it easier for plants to develop a more acourate digital twin, New modeling ‘capabilties, usabilty enhancements, ‘and tuning options will hep engineers more easiy create, modify and inte- ‘grate dynamic simulations for process: improvements across the plant ifecy- ‘de, New online streamflow views in the latest release of Mimic significantly speed engineering changes. Users ‘can quicley see all process etements ina singe table with changeable pa- rameters, making it possible to view ‘and tune entre processes from front to back ~ all while keeping the simu- lated processes online. — Emerson, St Louis, Mo. ‘wonw.emerson.com/mimic Ensure complete discharge from hoppers with this vibrator The new Vibration Bottom system (photo, p. 25) enabies sale discharge ‘of powdery, crystaline, fatty and granu- lar buk materials from hoppers. The lateral, imbalance vibrator sets the vi- bration bottom in horizontal, circular vibration, Vibrations are tranemitted 10 tha materais column via the simulta- neously vibrating reliving cone inside the vibcation bottom, This sets the buk materials in motion and the level crops ‘eveniy without resulting funnel low or bridging. Buk materials reach the out- let safely through the annuler gap. Hop CHEMOALENGINEERNG WWWCHEVENGONLNE.COM JUNE 2019 259rersro1e June 2019 ers are discharged completely without any fluid, Units ere programmable w leaving residue, Funnel formation and to provide alarm status for high and bridging n the hopper are prevented. low rates both visually and aud. — ‘The system can be sed for vitualy all AW-Lake Co,, Oak Creek, Wis bulk materials, even those that ypicaly _ wwwaw-lake.com flow poorly, — Azo GmbH & Co. KG, i storburken, Garmary Pelletizers for high productivity wuwazo.com and product quality Baol-8 cry-cut polelizers are designed Process-control functionality for for processing both hard and soft ma thermal mass flowmeters terals. As with previous Beol genera The new PCU Series of controlers tons the automated cuting chamber -_ (ohoto) connect to thermal mass lockng system enables fast handing ‘foumeters to provide a local display while supporing operator safety, The Of ow output. Serving as @ single- or company also offers the Pesaro uncer- ‘multi-channel _mass-fow controller water peltzing system forthe produc- with up to four channels, the PCU tion of sphercal pelets with through Controller supports muiipie-unit net- puts of up to 36,000 kg/h. Compact ‘worked operations. “4 large, high- and modula structured, f requires Contrast backit display offers easy-_onlya vey smal footprint n procuction. to-read views of process variables Electronical contrlad EAC tachno! | {and programmed selpoints for each ogy guarantees precise feed o the pet Connected device on one soreen. The letzng knives dixing operation, thereby POU Series offers. process-control enabling long runtimes ‘ree of interup- ‘unctionalities for batching, setpoint tions with consistent pelet qually. — anus Control, resettable dual totalzer and Maag, Obergltt, Swizertana valve-override control. Gas-factor_ www.maag.com desing slows veee 1 ee uso Mary Page Daly and Gerald ncrey Need a Hand With Your Bulk Solids? Innovating, modeling, and designing, We have been your bulk material solution provider from concept to commercialization for 50 years Solids \ Powders \ Conveying \ Processing \ Storage [736493300 \ ee com\ ekecon For details visit adlinks.chemengonline.com/79055-26 CHEMICALENGINEERING WWHCHEMENGONLINECOM JUNE 2019 4 hitps:vew iminus.com1S!documer13160/1 241592218/2019 June 2019 Facts At Your Fingertips Fermentation Considerat Department Editor: Scott Jenkins roducing chemicals and fuels oy fermentation of renewable feadstocks can offer improved sustainabilty, lower costs and great- fr safety compared to conventional thermal processes. But realizing these benefits depends on a care- ful assessment of the process eco- ‘nomics, and an understanding of the differences between. fermentation- based processes and alternatives. ‘This one-page reference offers a brief discussion. Process considerations Key considerations for fermentation processes ciffer from those using petroleum-based feedstock Impurities. Chemicals from fossil feodstocks have characteristic im- puries that oiler from those derived biclogicaly, even if both technologies offer end products at the same purity level. For example, the feedstock for bio-based processes is often carbo- hydrates. These can lead to product- ‘quality issuos, such as color and ‘oof not addressed curing process design. Engineers for fermentation: based processes must be familar with carbohydrate, and protein and amino acid chemistries, as well as ‘methods for separating color end ‘odor-causing compounds. ‘Separations. Separating the desired ‘chemical product trom the fermen- tation broth often requires iflerent techniques and equipment than what ‘might be found for a conventional process. Effective handing and pu- ification of aqueous streams often dictates specialized unit operations. ‘Key concams include energy-efficient techniques to remove water and the ability to recycle and reuse water. Feedstock variations. Desigring a process that can handle varying inputs '5 2 fundamental task for process on ‘gheers that impacts both capital and ‘operating costs. The techniques for ‘managing variations in feedstocks for bbo-besed processes are different than for conventional processes, and may Include feedstock testing to determine attrbutes), colaboration wih feedsiook supplies to optinize consistency ver- hitps:vew iminus.com1S!documer13160/1 ns and Economics caccapianneavein See Te eatin) handle greater variation in oe it feedstock properties, and ‘adjusting fermentation or ‘ther operating parameters, eget —| ‘Sterility requirements. as wi —| Contamination is acon: ccem in any production pant, but the manner in eer" { ‘which itis eatzed fora BO Se based process, and the gor with which it must b= maintained, are ciferent. In particular, lis necessary to design, buld and operate ‘a bio-based process to exclude vis ‘able foreign microbes. This is particu ley citical in fermenters and associ- aied systems, and, depending on the product, can extend inte downstream Processing as wel, Preventing con- {amination of fermentation systems is (of pararmount importance, ‘Managing weather. Large-scale fer- rmertations can be senetive to the ef- {fect of outside temperatures on cool ing-tower capacity. Insulficent cooing capacity can nun a fermentation batch due to temperature ruvup, wth con- ‘Sequences that can extend into down ‘Steam processing. This isk can be ad- ‘essed through operating procedures that adjust process parameters to siow down the fermentation rate to maintain ‘temperature control ofthe fermentation process, Fermentation plants are offen constructed with minimal enclosure and exposed piping. Given their lower ‘Operating temperatures and aqueous sSveams, it may be necessary to ac count forthe possibilty of eezing, Economics of fermentation In bio-based processes, a single unit ‘operation (fermentation) requentiy replaces mutiple unit operations for ‘a conventional chemical process (diagram), 50 the capital cost per ton may be significantly lower (6ome- times 20-40%) for bio-hased process technologies than for conventional processes using fossil feedstocks — especialy for mid-sized plants. ‘Additionally, capital equipment for bio-based processes may be less ex- ppansive because they are run at near- ambient temperature and pressure ‘and neer-neutral pH, versus the more ‘challenging conditions often required ina conventional process. Inconsidering capital and operating ‘costs in fermentation processes, the ‘questions of whether itis better to use ‘a smaller number of large fermenta- tion tanks (for example, one 1,000- tank) or alargor number of smallor tanks (100 me) should be asked. Oth- ‘er questions also must be addressed, including whether the process wil use ‘aerobic oF anaerobic microorganisms; ‘whether fo control temperature with a ‘cooling jacket, internat cal or external loop; and whether the process willbe unas a batch or continuous process, For separation and purifcation after the fermentation step, considerations include feedstock quaity (more impu- fies at the start tkely mean more ef fort and cost iter}; handling of solids, both upstream {for example, biomass pretreatment and sucrose handing) ‘and downstream (erystalization and ‘drying; and the properties ofthe tar- get chemical (such as solubility, vola ‘ity, permeabalty and target purty). ‘The nat effect of these factors can be significant, potentially shifting the balance of capital and operating ex- panses. One process design might bbe botter at larger scale while another isbetter at smaller scale, 7 dts nth coret ys cum was Fontetaburg sess 8 Hares Boer ‘apy APaea Gabe Oar A206 S25 an ve 8, fy nd oro Lae ‘San tasratn See pn Don Pet (om By, Nowe 208,68 39-05, (CHEMOALENGINEERNG WWW.CHEVENGONLNE.COM JUNE 2019 25159perero1g June 2019 or GO HOME! High Flow High Performance [¥| Corrosion Resistant [V|Ultra-pure Mate: Bi BORE Ca ECU Creme C ee Teeter hy Fora cee ac] Cnt aetna orion Po PLAST-@ Seana 7 LVS re Eo aU Pe Ce ee eee eee’ hitps:vew iminus.com1S!documer13160/1 261592218/2019 June 2019 Technology Profile Polybutadiene Production via a Solution Process By Intratec Solutions foloutaciene (also known Jas butadiene nibban is pro- duced from the polymer leation of 1,3-butadione. In terms of production volume, polybur taciene is among the largest synthetic rubbers produced. This elastomeric polymer can have a variety of ciferent properties depending on the ratio of its microstructural units and its tactc- ity. Most polybutaaiane is consumed in the production of vehiole tires. Its also used to improve the mechanical propertes of plastics. The process ‘The production process ciscussed here is similar to the CB! Lummus Catadiene process, integrated with & 'ypical solution process. The process comprises four major sections: (1) = butane dehydrogenation; (2) 1,3-bu- tadiene puriication; (3) polymerize tion; and (4) rubber molding. Figure 1 presents a simpliied flow diagram. n-butane dehydrogenation. Ini- tially, fresh butane, recovered butane ‘and mixed butenes are heated to de- hydrogenation temperature. These components then pass through fixed beds of chromia-alumina catalysts in the reactors, where they ase con- verted into butadiene, 1,3-butadiene purification. The reactor product ' quenched for re- moval of polymeric compounds. The quenched gas is compressed and partally condensed. The guid con- dJensate, containing butadiene, is foc! toa series of dtilaton columns, from ‘which a butadiene-rich C4 stream is ‘obtained. This stream is then subrrit- {ght hyrosarbons — = | aH a aes oe mM sara ‘Cian tay Mange! ‘2 dtm pypusene radios thwaysdopend on the sare tons ted io exracive dilaton in the pres- ent sources cr the butadiene used. ence of A-methypytoidnane (NMP), In this contest, the most typical pro- Used as a soNent. Ths step yields duction routes are based on butadi- high-purty butacione. Recovered bu- ene produced from isolation of 4 tane and butenes are recycled to the steam-cracker fractions and dehy- be generated i factors such as blowdown at the end Of @ dense-phase batch transfer oocurs. Under such circumstances, the fiter area may be found to be in. adequate if this effect of increased air volume has not ‘been fully taken into accaunt when the ‘iter system ‘was designed and specified. Shifts in particle-size dis. {tfoution can also be an outcome of the use of exces- sive ir velocities ina pipeline (Figure 3) . Exited by Scott! Jenkins Author ctr Faris ser caning ema athe Sn oer fu Sond nag ec Ue ‘erty tenn Chaban, Kerk MEE AT Uk: Pe: "4438 a onal Fanshawe. Tne mriy is et The Wetson Centers et bruhing esas awe anc aes isa ests ey some (Padua cts cc ahr nts ay Are Forno ewok eve ote Dok sae Foca fata unpetereg sera oqupnan ca asc rot any pct bey agplmeran atten ‘Ealing yan ss Fat ht oa a he oto Cet ce 96 Nearer means egret sta amb of be son o& Mtn Ere hE ‘hens ne UR CHEMICALENGINEERING _ WWHNICHEWENGONLINE.COM hitps:vew iminus.com1S!documer13160/1 June 2019 0) BEUMERGROUP 0 Sea SS Ty tsa 5 PN Steve A COMPROMISE THROUGHPUT, TSE Ce asda ee ee ge ee See ee Com ero eee nC ares rink hoodings stil fommon, BEUMER stretch hood uses ee eee ee or Or een eer an ere oes Beste rota MADE GEN 2289perero1e June 2019 OTN ORS elo SNe Come hs Solutions IN BRIEF DUST PENTAGON [AREAS OF ISK PARTICLE SE PRMARY AND ‘SECONDARY EXPLOSIONS IMPERIAL SUGAR EXPLOSON PREVENTING STATIC DISCHARGE PREVENTION CONG 1S isk for gmbustible dust explosions attest — unfortunately, fatalities. A US. Chemical Safety end Hazard investiga tion Board (CSB; Washington, D.C.; www. cab. gov) report conducted in 2008 identifiad 281 combustible dust incidents between 41980 and 2005 that killed 119 workers with injuries sustained to 718 others, along with several damaged faciltios. In the U.K. the government agency Health and Safety Exec- tive (Mersoyside, U.K; wwwhse.gov uk) re corded 803 dust explosions over a nine-year period, and German records demonstrate 426 similar incidents over a 20-year petiod. Unfortunately, tragic incidents lke these con- tinue to cause significant business interrup- tions and loss of Fves, Given that such hazards exist within in- dustry today, itis ertical for plants to focus Con areas where they signticantly reduce the risk of dust explosions. These include close attention to good housekeeping practices, strict adherence to maintenance practices, {and the identification and elimination of ign tion risks for combustible dusts, This artcle provides information on the potential causes Of dust explosions and on methods to mini= mize the risk of such incidents occurring, Dust ‘pentagon’ Dust explosions within hazarcous-area pro- ccassing environments are not a new danger, ror is static charge being a potential source Of ignition. The earliest recorded dust ex- plosion was at Giacomeliis Bakery in Turin, Ntaly in 1785, where flour dust generated uring normal operations came into contact, with @ mounted lamp, Flour can become FHGUREt. Contnement nd esperion arene two ee- mani spect expose ta make up te cst fre estan Combustible if it is too dry and builds up a static charge, The bakery owner was re- corded as saying that the flour was the cii- ‘st sean in the bakery that year. A cispersed cloud of flour originated when flour from the upper portion of the warehouse dropped to the confined warehouse below. The result- ing explosion that followed injured both the worker shoveling flour into an open flame ‘and a boy who fell from scaffolding, as a re- sult of the flames blowing out windows onto the street. What this incident inadvertently demonstrated, apart from the violent and volatie nature of a dust explosion, was an archetypal insight into the “dust explosion pentagon." Five elements are required to intate a dust explosion. Beyond the fie triangle (fuel, oxy: gen, heat source), @ dust explosion requires ‘wo additional elements, in the form of dis persion of dust particles in the right con- CHEMOALENGINEERNG WWWCHEVENGONLNE.COM JUNE 2019 hitps:vew iminus.com1S!documer13160/1 259rersro1e June 2019 Cover Story centration and the confinement of the dust Cloud itselt (Figure 1). Dispersed airborne dust burns more rapidly, and confinement in ‘ae alows for pressure build up. Having these ‘wo additional elements in place, along with remons the three elements of the original fre tangle, a increases the ikenoad of a dust explosion By definition, a combustibledustis any fine matoral that has the abiity to catch fre anderen ‘explode when dispersed in er. By ther very nature, dust explosions emt an energetic force, creating powertul pressure waves that ‘can cause signifcant harm to personnel and ‘damage to fact structures and equipment. Dust explosions can also generate intense heat inside the dust cloud and cen cause structures to fal, creating addtional risk for piant personne Ape eatin arf wt im S020 Areas of risk Dust is a hazardous byproduct in many in- cdustries in which handling powders is in- * Coal ume 2. A wide range of volved. This includes companies engaged in * Wood Ign source ext dst alwide range of sophisticated manufacturing * Waste recycling (paper) ‘nob recat processes. Dust explosions can occurin any © Agriculture industry handing combustible dusts, includ: * Chemicals ing (but not imited to} the following: + Metal processing PROTECT PUMPS DRY RUNNING * CAVITATION * BEARING FAILURE + OVERLOAD sii cansaneresnie pr posta ats Sata erat © ‘Wo ADJUSTABLE SET POTS Raceway : hn ae sence oer neon PETS nn nee @ 4-20 MILLIAMP ANALOG OUTPUT: aati een, i MTR POWER TAD OF St a? ve rowea A. dee’, oe Retseeesieny Swine, ecrome = pean LOAD CONTROLS INCORPORATED CALL NOW FOR YOUR FREE 30-DAY TRIAL 888-600-3247 WHW.LOADCONTROLS.COM For details visit adlinks.chemengonline.com/73855-25 CHEMICALENGINEERING WWHCHEMENGONLINECOM JUNE 2019 4 hitps:vew iminus.com1S!documer13160/1 30159perero1e June 2019 FIGURE 3. Dust exptsions often nae pinay expos, tie eer in canfan eo- ess eaupmen, and secaed- sy expos sh ante Ima disperse te inal xpsin| FIGURE 4. Dust xs, ‘chaste on shown ee Prt ener, Gera can (Geta devastating cestuston ‘Over half of dust explosion incidents can be attributed to one of these four industry sectors: food products, wood products, chemicals and metals. The average dolar loss per explosion incident in a typical year is $3.4 milion ‘The National Fre Protection Associa- tion (NFPA; Quincy, Mass; wwe nfpa.or3) Standard 654 (Standard for the Preven- tion of Fire and Dust Explosions from the Manufacturing, Processing, and Handling of Combustible Particulate Solids) defines dust as "A combustible particulate solid thal presents a fire or deflagration hazard vshen suspended in air or some other ox: dizing medium over a range of concentra. tions, regardless of particle size or shape.” Many organizations are uninformed and un- aware that their processes can produce an atmesphero that can be explosive, and as a result, dust can be produced by a seem- ingly imocuous consequence oftheir usual manufacturing process. “There are @ number of primary ignition sources that can trigger @ dust explosion (Plaue 2, inciuding the folowing + Electrostatic ignition Friction Electrical arcing Hot suraces Open fame = Satrigntion hitps:vew iminus.com1S!documer13160/1 TABLE. MINIMUM IGUTION ENERGIES, JOULES os 200 Wat our 0 Petre 0 suger 0 Mages 20 sutur 16 Aerio 10 509 080 9 acer 5 Particle size Dust explosions occur when 2 dispersed combustible material is present ina suf ficiently high concentration. Therefore, an ‘explosion hazard oxists whenever dusts are produced, stored or processed, and when- ‘ver these matarials bacome airborne. When the product being processed is considered ‘combustible and has an appreciable portion Cf fine material, the potential for having an ex- plosion increases dramatically. Fine powders with low minimum ignition energies (MIE) wall regularly reach the minimum explosive con- ‘centration (MEC) along conveying systems ‘and may be at risk of combustion by several ‘sources of ignition. One such ignition source: 's electrostatic discharge. ‘The MIE required to ignite any given pow- dor depends on the fineness of particles, with the lowest MIE velues tending to relate to very fine particles (Table 1). In situations where the MIE for a dust material s above 10 Jouies, and no flammable gases or va- ors are present, taking special measures fo minimize static electricity is usually not necessary. However, precautions could sill bbe necessary with conductive piant equip- ‘ment capable of storing high levels of static charge, to minimize oloctrc-shock risks for ‘operators, In the chemical and pharma- ‘ceutical industries, MIE valves required for ignition are often relatively low (especially in flammable dust-vapor hybrid almospheres), while in the food industry, MIES are usvaly somewhat higher “The ease of igntion and severity of com: bustible dust explosions are typically inlu- ‘enced by panicle size, Finer particles are more explosive than coarse particles be- ‘cause they have larger surface areas relative to their weight, lowing them to rapialy react with oxygen when dispersed in air and ignite (Table 2) In NFPA Standard 654, dusts are defined as solid particies with particle diameters of 420 microns (im) or smaller. For perspec- 3559rersro1e tive, the particle size of table salt is ‘around 100 microns, Primary and secondary explosions (One of the main dangers of a dust ex- plosion occurs when combustible dust ignite and cause a chain reaction with ‘other dusts. Dust explosions create their own self-sustaining domino effect, hich continues as long as uel exists. A ‘secondary explosion ocours when dust ‘accumulated on loors or other surfaces is ted into the air and ignited by the pri mary explosion. The primary explosion liberates dust from surrounding surfaces {including beams and ledges), causing them to be suspended in air and ois- parsed. The secondary explosion prop: ‘agates from the resulting dust cloud. ‘Secondary explosions occurring when the structural integity of the faciity may already be compromised can result in catastrophic results. Primary and secondary explosions ‘often occur together, alowing for tran sitions from fre to multiple explosions ‘and vice versa, In many cases, a pri- June 2019 Sore e erry Te ee “lam por bed els estore Sto 10 Pali cae st 44 97 Tate sat 10510149 ‘arch fon Fort Wentworth ty storage so 10 Poorer prod fo he Fat Weta ity 23 altos aga prod Hon te Porter ty 286, mary explosion occurs inside a process vessel, such as a sieve, dryer, mixer, conveying system or silo (Figure 2). tis within these confined environments that the five elements of the dust explosion pentagon are met. The resulting impact Of the frst explosion usually ignites the second. Unburned fuel from the primary ‘explosion is ejected by the blast outside the enclosure, causing dust to become airborne, where itis susceptible to ign tion and is capable of triggering a sec ondary explosion. ‘A secondary explosion can be more destructive than the primary due to the increased concentration of dispersed Bisa trenton Ate Dati) wunupauloabbe.com 955-789-0027 sales@pauloabbe.com hitps:vew iminus.com1S!documer13160/1 ed MA i "allperero1e June 2019 FOURE 5. Tempera Sar combustible dust and stronger _ ignition ‘oleon ested i 14 fatale, mostt whic cc ‘i ring be sezondry ‘ples ad Te source. The resulting shockwave of an initial ‘explosion will damage and often rupture the self-contained vessel where the initial blast ‘occurred, allowing the explosion to propa- {gate through the plant. Imperial Sugar explosion The explosion at the imperial Sugar refinery in Por Wentworth, Georgia in 2008 provides and ilustrtive example of a dust expiosion and highlights the devastating affects that ‘any dust explosion can have on people, busi esses, communities and the economic cli imate (Figures 4 and 5), The incident claimed the lives of 14 workers and critically injured 36 others. A year before the blast, in 2007, the company had produced 1.3 milion tons of sugar, making it one of the largest sugar refinerias in the U.S. A series of violent sugar Gust explosions obliterated the site, with 12% of the 160-acre facilty completely de- stroyed. According to the subsequent CSB investigation, all 14 casualties from the blast were “most likely the result of the secondary explosions and fres.” Prior to this destructive incident, the Port Wentworth faciity had operated for more than 80 years without experiencing a dev- astating dust explosion. However, the plant had a history of long-standing problems of suger dust and spied suger in the packing buldings and silo penthouse botween 1970 ‘and 2007. It is likely that, although condi- tions suggested that an incident should ‘occur, the sugar dust never accumulated to levels above the MEC before the event, It Seems to have been just fortune that dust from spilled sugar never reached levels where the concentration was high enough for an explosion to propagate through a hitps:vew iminus.com1S!documer13160/1 plant until the incident, Internal correspon: ence documented the amount of spiled sugar as “knes deep” in some areas of the lant. Two months prior to the incident, ‘an internal ingpaction showed that tons of sugar were accumulating on the floor of the: faclity. This provided much of the fuel for the secondary explosions. ‘At the Port Wentworth site, granulated sugar was stored in three 100+ sios and then conveyed into packing buildings, where it was packaged for distribution. The primary dust explosion occurred inside the enclosed steel conveyor belt used to transport gran- lated suger under sios 1 and 2. Airbome combustible sugar dust accumulated above the minimum explosibie concentration in- side the unit, and this triggered huge soc- ondary explosions and fire throughout the packing buildings. In the aftermath of the incident, the CSB reported that for many years, granulated sugar on these convey- ‘rs was exposed to possible contamination ‘rom debris that could fall nto the sugar. As a result, Imperial Sugar instaled a stainless- sleel frame to enclose each belt assembly to protect granviated sugar from debris and ‘contamination. These panels were able to be removed for cleaning operations, but were rot equipped with a dust-removal or explo: sion-venting eystem, The stainless-stee! en- Closures essentially confined the sugar such that sugar dust was able to accumulate to a potentially explosive concentration above the MEC within the conveyor. An overheated Deering was determined to be the likely ign tion source, and the explosion was triggered in that way. In action, multiple other poten- tial dust-ignition sources were identified in- side the enclosure, Imperial Sugar CEO John Sheptor stated at the time that “accumulated sugar likoly ‘acted like gun powder,” and called com- bustible dust “a silent risk that needs to be ‘addressed.” In the 1925 book "The Dust Hazard in Industy,” author Wiliam Gibbs ‘concluded that “Sugar, dextrin, starch and ‘cocoa are the most dangerous,” in terms of dust explosions in industrial facilities, with sugar being exceptionally so. "Sugar ignites when projected as a cloud against a surface heated to below red heat, and when ignition has taken place, the fame travels throughout the dust-cloud with great rapidity," Gibbs wrote. In the wake Of the Imperial Sugar explosion, The Oc: ‘cupational Safely and Health Administra- tion (OSHA; Washington, D.C.; wwwosha. ov) cited the company for 108 instances RING WWWCHEVENGONLNE.COM JUNE 2019 a7is32218/2019 ‘of “wilful violations related to the combustible dust hazerd, including the failure to clean up spilled dust and not using appropriate equipment or safeguards ‘where combustible cust is present.” At the time, the proposed fine of $8.7 milion for the sugar refinery explosion was the third largest in history for an indus trial gafety incident. Preventing static discharge Ih manufacturing end handing process industries in- volving flammable and combustible atmospheres, the thyeat of static electricity is ever present. There are cer- tain types of dust-handing plant equipment in which sate electricity Is readily generated. These include mils, conveyor belts and pneumatic conveying sys- tems. In potentialy explosive atmospheres, the amount ‘of eneray contained in spark discharges ftom plant ‘equipment, and ven trom people, may be sufficient to ignite mary fine dusts produced during handing cf loose solids, such as powder, granules, poets and flakes. Electrostatic charging of isolated lant equip- ment or material is ikely when moving dusty materials in quantity It's fundamentaly ortical to take necessary ‘precautions to prevent cischarges that are powerful to ‘cause ignition of a dust cloud ‘Al potential sources of internal and external static ois- ‘charges from process equipment situated in zoned and 5,000+ CPI PROFESSIONALS > 35+ FREE SEMINARS For details vist adlinks.chomengonline.com/73855-23 hitps:vew iminus.com1S!documer13160/1 40159perero1e June 2019 Feature Report Professional Calibration Supports Operational Excellence Apart from ensuring the conformity of the process and the quality ofthe product, professional calibration, first and foremost, improves the quality ofthe process Dimitri Vaissiere and Pia Héflin Endess+Hauser IN BRIEF WHY CALIBRATE ‘ASOUND APPROACHTO CCALIRATION CALIBRATION INTERVALS INTERVAL OP THMZATION DEVIATION MANAGEMENT PERFORMING (CALIBRATIONS BENERTS OF ACCREDITATION TIME SAVING METHODS TOWARO INTEGRATED INTELLIGENCE PUTTING IT ALL TOGETHER tmany plants inthe chemi- cal process industries (CPI, measurement instrumentation is usually calibrated during scheduled maintenance down: times. This basically means that metro logical requirements are regarded as sec- ondary to operational =a = (aR Serine aes needs. The objective RGURET. Avatabity peromance ane culty ae the twee quantile components the saoms to be to pro: duce a complete set of calibration certificates to pass the next aucit again. Although this approach seems tobe practical, in fact, it misses the point: professional calibration management is aimed at safe and efficient production pro- cesses and optimal product quality. Why calibrate? Calibration should rot be considered pr- marily as @ means to obtain a certificate for regulatory reasons. Calibration is much more than just @ question of compliance. Rather, it affects the overall equipment effectiveness (CEE), and lacking or inadequate caltration right resuit in increased expenditures ‘Avalabilty, performance and quality are the quantficble components of OEE (Figure 1). Al ofthese three can be affected by in- conect measurements. Avalabity may be impacted where taling devices might rauit in shutdowns. Performance suffers. when iifing measurements call for corecve ec- tions time after time. In addition, incorrect measurements may be responsible for waste in raw materia or production loss. Of course, proves instrumentation does eral equipment teens (OEE) not come for free. There are the inevitable direct costs of maintenance and calibration, for example (Figure 2). But on the other hand, apart from the above-mentioned is- sues’ arising from poor measurements, ‘working with inaccurate readings can cause unnecessaniy high consumption of eneray and raw materials, To avoid the numerous details of common, textbook knowledge we would ike to sim- ply summarize the purpose of calibration as follows, just to provide an operational deft nition: those who calibrate a measurement instrument ae determining whether and to ‘what extend the measured value deviate ‘rom the reference value given by a mea- surement standard. If the deviation exceeds the tolerance — gonerally cae maximum, penmissible error (MPE) — the instrument likely needs to be adjusted, repaired or ra- placed. This apples to all types of measur- ing devices, whether they measure physical ‘quantities, such as flow, pressure and tem: perature, oF chemical parameters, such as pH, conductivity, dissolved oxygen and so (on. The calipration method for both of these CHEMOALENGINEERNG WWWCHEVENGONLNE.COM JUNE 2019 hitps:vew iminus.com1S!documer13160/1 4159rersro1e June 2019 emootvruming proces, ey rorgy coreuepton ane proget aisle, he aio apples wher en ecevale, anaes tobe "ud Cause a voile produc batch To fe dasudea ‘nother mporant consteraton we “Guat on hone biotre fafough tore a0 moastorent Pecengdipretlbect pte Sand au aorey teh ifaw ee ottere whore te fel thecane, Th presen io aressed threughinespectceton of he MPE that Shou be deted wi eopect {ote rove rehome ih nat caioe the talcrin- ton ofthe MBE oes compan tot cteoneleratone, which tam ‘wears at cannot be slay re Fo, Sa el GSE VERON rescore tte ralaenence «youps and even or each ndvcual cal. shoud supper the wey to exper 80 well suc ao fctory Tessa nooe Sailer ht hoopla GEE reasorae an. snpenino, "qual asturance, eo eeondeyeopect What presthtocoleraton'eivoratesin Soe and‘s0°'on i fs assent anions tae conrad, Fore fier ba'rsttonatce mune 3 Wiel our bo egerdecae Ne scual Ne most decehe aspect of a winoever doo oversee te cols: Gpecive cf cabraton ke ha we proper allyson Srateay ithe Yan"or rcatoraon, mveWes the fates ceive fat frat mae: Scale exch qrasetoneet roses Gamer or plat Soeur tig ‘nctumeri| coring ft. Gon tho’ reeponable persone, Monet to neomprat thar cow feocierinor pupact a'portS0) ey aurce Stictune & nok Kav and srpeiete omeang he soora018 6718 (Grance managers row tesa protons, ually marornens oan Seal des ymahcnon peed ass rikie a veunie toma Asoundapproach to calibration requte? thay shoud poy espe. cha cone basis Al fs arondy Saled, caoraon not Galy cose etenon to eseue- calation an important pa of Preven abel ebianing a oR ort pots ia ar Gila! ra Guay eaturnce Neto De els Mele ime eC MCL may dirty Lo valving Giemueiae tama ethene eee hitps:vew iminus.com1S!documer13160/1 42892218/2019 June 2019 yr Grom Tene Teuishaeot “Onan creat, ~ nana ano, Senet Sheet “Meaceomeie’ Mcrmort waa Str Sirois Mowat satan ame seh ‘mortomie” atte’ acesin “km "sbscomne ea FIGURE 3, An approach to calraton scutine hae Calibration intervals that put a heavy strain on the instru- will be selected? Which reference In many instances, maintenance ments, for example, when they are instruments will be used? Which manager's, when inquiring about the highly corrosive. This clearly shows requirements regarding conformity appropiate calioraton intervals, ex- that only dynamic intervals can factor should be considered? Within the ect a standard answer that applies in all those aspects. In that respect, entire calibration process, there is. equally to every instrument in the in- meastrod values during calibration often a lot of hidden potential for stalled base, While this corresponds shall be taken into consideration and increasing efficiency. The logistics woll to the scheduled maintenance not only the conformity stalement, as. and the workflow management re- and service downtimes, it does not they reflect the behavior of the mea- lated to calibration should not be support the overall goals of ealiora- surement inetrument. underestimated. Furthermore, cali- tion, Even the relevant standards do Setting the calibration frequency bration managers must make sure Not specily exact intervals. Instead, for each measuring device is a that the employees who will be car~ they merely suggest, in the words of matter of risk management in find- rying out the actual calibration are ISO 9004, that “measuring equip- ing the optimal balance between thoroughly trained ment shall be calibrated or verified, cost and risk. Calioration is there- Calibration managers who are or both, at specified intervals, or prior fore not a pure burden, as itis per- not only able to provide the aucitor to use, against measurement stan- celved by many plant operators. with a thick stack of certficates, dards traceable to international or Instead, it represents more of an but have also understood why raational measurement standards.” opportunity, because at the end of they chose specific instruments, Consequentiy, the organization is re- day it leads to improved and more calibration intervals and calibration sponsible for determining and estab- reliable processes, methods, will be well-prepared for lishing suitable calioration intervals. Performing calibrations depends on) the next audit. They can thus avoid When determining the appropri- an even deeper understanding of the embarrassing scenes like this: The ate calibration intervals, it's very im- installed base. Although that should auditor asks @ question about the Portant to realize that a ‘one fits all” be obvious, i's often not the case. calibration of a specific instru- strategy does not work. To deter- ment, after which the calibration mine the adequate interval for each Interval optimization manager begins to feverishly look instrument, the following aspects Keeping a comprehensive inven- for the corresponding certificate must be considered: tory and descrigtion of each and in the hope of finding the answer. ‘Device type and its sonstivty to drift every instrument and measurement However, those who have pursued + Citicaty of the measuring point point is the first stage of the pro- these tasks with a high level of ex- + MPE cess. Once the installed base of pertise in the field of measurement + Aging of instrument instruments has been inventoried technology and metrology and ‘Individual process and envion- and documented, including the taken the aforementioned recom- mental characteristics required calibration intervals, it is mendations to heart, will not have Consequently, calibration intervals stil too early to begin the calibra~ to hesitate to provide the auditor a cannot be the same for all cases tion itself. Of major significance for competent answer. and cannot be static over the instru- proper calibration processes are mont’sifetime. the standard operating procedures Deviation management Indeed, tis not uncommon for okier (SOPs), which must be created, re- Deviation management means instruments to tend more towards viewed and if necessary, modified. triggering a response in cases dfiting. Also, process conditions, such This is not only important for the where calibration indicates that as @ high-temperaiire environment audits. What must be determined the measurements are out of tol- that impacts electronic components, is the number of respective caliora-erance or thal significant dnit is can also cause the measurements to tion points, 2s well as the measure- occurring. At a minimum, the af- be less stable. In chemical processes, ment uncertainty that can be tol- fected instrument needs to be re- it's often the products themselves erated. Which calibration method adjusted and recalibrated, Under CHEMICALENGINEERING WWWICHEMENGONLNECOM JUNE 2019 hitps:vew iminus.com1S!documer13160/1 42592218/2019 June 2019 URE 4, & standard operating procedure SOP) for caltatio an speci the need or earcem catons certain circumstances, an impact analysis must be carried out to examine the quality deviations of the product or the environmen- tal requirements. This task is too often neglected. As per experi- fence, we observe that almost ‘only the pharmaceutical industry addresses these issues properly. Performing calibrations Performing calibration is not a trivial task (Figure 4). One path to professionalizing calibration man- agement, and the calibration pro- cose itself, can lie in enlisting the support of calibration service provider. This can be a reasonable approach, especially if the metrol ‘ogy competence is not available in house. The ideal situation is when the company has a specially ‘rained, experienced calibration ‘manager, but its by no means the standard in industries such as the chemical industry, Considering the complexity of calibration management and tho calibration process itsef, many pro- cass owners choose to go with an ‘external calibration service provider Service providers can do more than carry out the calibration, however. They can support the calibration ‘management process by becoming involved in the development of the SOPs as an example (Figure 4). Or they can provide essential help with the definition of proper calibration intervals. Providers of the relevant services can become an important partner. Acting as a trusted advisor, they provide measurement tech- nology expertise that operators tre- ‘quently lack. They can translate the requirements of the process, which only the operator is fully aware of, into the requirements of the mea- surement technology and the cal bration process. Benefits of accreditation When selecting a service provider, itis essential to keep one thing in mind: the calibration technician wall have an influence nat only on the ‘calibration of the instrumentation, but at the end of the day on the production process itself. Only the right partner wil carry out this task in a responsible manner. While it may sound trial, the most impor- tant characteristic properties of a ‘service provider in this field are ex- perise and proficiency, Those who ‘want to be sure that the calibration service provider knows what they ‘are doing should pay attention to the accreditation, in fine with ISO IEC 17025, which is furnished by third-party ‘organizations such as DAKkS (Germany), SCS Gwitzer CHEVICALENGNEERING WWWICHEMENGONLINE.COM JUNE 2010 hitps:vew iminus.com1S!documer13160/1 @DMOLLER" a retest eS Pre eee a | 4059perero1e yr GURE 5. Carat of free Instruments must cares out wih aresity eins land), AZLA and NVLAP (U.S) or ahvays related CNAS (China). This is not to be con- surement pa libration ly verifes the existence temperature i fused with ISO 9001 certification, of ually managernent system. refers ISO/IEC 17025 accreditation is and to specific: mee: trumentation. It also procedures and shows the suitabilty up to a small ‘est measurable uncertainty, What important is that it verte the nec: essary traceability, as well as the expertise of the service provider. During an ISO 17025 audit, one of the auditors examines the quality management systern (QMS). Ar ther technical specialist assesses the professionel skills of the em ployees responsible for performing the calibrations. The accreditation process is extraordinarily precise, and ultimately conveys trust in the expertise of the service provider's employees. If a service provider is Unable to provide the relevant a¢ crreditation, it becomes the raspor sibllty of the organization to per for their awn aut to ensure that the service provider's employees do possess the necessary expertise and follow best practices for cal bation in line with ISO 17026. The calibration service provider must be focused on the techni cal conditions and the pl rs eel ea in cA tps: ow mirus.com1Sidocument13160!1 45159,perero1e June 2019 dividual requirements. Apart from providing trace- Saberndorf able calibration forthe installed base, the calbration oT partner also supplies precise and comprehensive Calibration certificates, “raceabilty in accordance with intmational stan- dard isa requirement from !SO 9001, applicable in the chemical industry. This is set out in section 7.1.5 (monitoring and measuring resources) of the sian- ard. Calibration of the reterence instruments must be carried out with traceabilty in mind (Figue 5). ifthe service partner is {SO 17025 acoredited, the traceability of the calibration is guaranteed. Without accreditation however, the calibration partner has to separately demonstrate proof of traceability. That means frst and foremost being able to provide the Calibration certiicates for the reference Instruments Lsed. in adtton, not ont the reference device must be traceable, but also comprise documentation of hitps:vew iminus.com1S!documer13160/1 46592218/2019 June 2019 EA — FIGURE 6. On-site density aration can save time by eliminating the ned or Sonig an stument to ‘cairn fay analysis instruments, like pH sen- sors, that operate with “smart” technologies. The sensor can be precalibrated under laboratory con- ditions using traceable butfer solu tions, The existing sensor is then swapped out for a newly calibrated sensor, which saves time as well ‘Toward integrated intelligence While integrated systems that in- ‘crease measurement reliability are hitps:vew iminus.com1S!documer13160/1 extend, the calibration cycles. It is also advisable to combine these types of diagnostic technologies with the opportunities that artfi- ial inteligence and the industrial internet of things (loT) offer. This increases reliability, which can then bbe used to predict when a calibra- tion is required or potential instru- ‘ment damage. Putting it all together the necessary measured values in the appropriate quality. If you opti- mize your existing calibration inter- vals keeping the above in mind it ‘may lead to significantly increased calibration intervals for certain it struments and reduced intervals for others. But even if it leads to more frequent calibration, you will ultimately achieve an optimum with the least possible use of resources = which basically means that your installed base will gain a higher de- gree of reliability. Furthermore, those who under- stand how to utiize the opportuni- ties that (self) diagnostics and digi- talization offer with regard to quality and calibration management are in a better position to design their production systems for the future. The extensive basis of data that the intelligent measurement instru- ‘ments provide, combined with ar- tificial inteligence and lloT, helps to provide operators with support ‘over the long-term. This will even- tually not only drive down costs, but also allow for proactive man- agement of deviations and coun- termeasures as well as optimizing the instrumentation, thus making significant progress toward opera- tional excellence. . cited by Gerald Ondey 471832218/2019 June 2019 Environmental Manager Technologies for Controlling HoS There are many industrial technologies for removing HS from process gas, and each brings with it different benefits with regard to costs, efficiency and equipment layout Christopher Risteveki and Rosanna Kron Macrotek Inc. yorogen sulfide (H,S) is a toxic and corrosive gas that occurs naturally, but can also be produced through many industrial processes, In action, HeS has an odor thresh- ‘old of 0.01-6.15 parts per milion opm), according to the Occupa- tional ‘Safety and Health Adminis: tration (OSHA, Washington, .C.; worw.osha.gov), Due to the very Yow odor ‘threshold, in_countries where nuisance odor is regulated, HyS removal from process gas or off-gas is required. Since HyS is produced through engerobic diges- tion, itis prevalent where organic matter and sufates are present, As a result, pipeline gas specications ‘exist to ensure gas quality: Further- more, when natural gas, synthesis ‘gas (syngas) or biogas is used in turbines or engines for power gen- eration, H2S concentrations cannot exceed the engine manufacturer's ‘specifications, due to corasion concerns. During combustion, HS 's oxidized to suifur dhoxide’ —~a highly regulated ar pollutant — ‘which necessitates its removal be- fore combustion itis clear that HS removel is imporiant forthe environ- ment, industrial equipment integrity {and human heath HS can be removed from pro- ‘cess. gas through various. tech- nologies, depending on the ap- plication, process conditions and removal’ requirements. This er- ticle describes selected proven technologes for controling HS in small to medium-sized ap- plications, including natural gas production, landtil gas recovery, waste-to-energy systems, _bio- gas. production and. wastewater {treatment plant. = FIGURE 1. atypia sav redox system, a cata ply chelate an converts HS ans nto su nan aquenus system Liquid redox guid redox refers to technologies that absorb HS and oxidize it to sulfur in an aqueous system using a catalyst (most commonly chelated iron). The chelated iron converts HoS {gas into solid sulfur, a8 shown in the below chemical reactions: HS + 2FeS = 8 + DF? + 2H (Reduction of ron) 2Fe2* +1409+HO—>2Fe% + 20H (Oxidation of ion) HS +O)» $ + HzO (Overall reaction) As can be seen, only oxygen is consumed in the reaction. The che- lating reagent is not consumed, be- cause itis continually regenerated by forced oxidation using air. Although the reagent is not consumed in the process, a small amount of loss is typically experienced, mainly due to chelate degradation overtime. Since solid sulfur is produced, tration can bbe used to remove the sulfur and re- ‘oye the reagent back into the pro- CHEMICALENGINEERING WWHCHEMENGONLINECOM JUNE 2019 hitps:vew iminus.com1S!documer13160/1 cess, This eliminates or significantly reduces the production of wastewa- ter and the associated costs. The sulfur that is produced can also po- tentially be sold as a product ‘The main vassels ina liquid redox system include an absorber and. an oxidation vessel (Figure 1). In the absorber, HS is absorbed into the liquid and converted into sulfuc The spent recirculating liquid is sent to the oxidation vassel wheres contact with air regenerates the solution into its active form. The regenerated so: lution is re-crculated back to the ab- ‘sorber to complete another reaction oycle, Some systems use a setting tank to concentrate the sulfur be- fore sending it to a fitration system for removal from the process. Typi- cally, 316L stainless stool is used as the material of construction for the ‘process equipment. Overal, liquid redox systems re quire minimal water and chemi ‘cal addition and produce minimal waste. This results in very low operating costs compared to al- ternative technologies. The sys- tems are also capable of handing wall 40592218/2019 June 2019 ‘aos Trott we sn ‘ate Ey ‘avo oun tiee — = = FIGURE 2.8 chemical ciation system neutatoes HS gassing FIGURE. licking processes se autotoplc microbes to cansume ard tase bc sd yon ttn he large fluctuations in init compost: HS + 2NaCH + 44:02 tion, but the reaction products can tion and gas flow while maintain- “+ NagS0,-+ 2H6 cause scaing inthe packing. Care jing high HS removal efficiencies ‘must be taken during the equipment of greater than 99.0%. The sys (Overall eaction with NaOHandH,0,) design and selection of process set- tom are, however, higher incepta Ponts to ensure OO interference ‘costs due to the increased control Packed-bed scrubbers are the is minimized, Sophistication that is required. Al- most common process equipment Chemical oxidation _scrub- though most liquid redox systems used for chemical oxidation (Figure bers are compact and low in cost. hhave very similar overall chemis- 2). Vertical countercurrent packed- They are also capable of handing ‘ry, diferent suppliers use different bed scrubbers are generally pre- large fluctuations in inlet compos- chelating agents to keep the iron ferred due to their high efciency. tion and gas flow while maintain- jn solution. Some of the chelat- Compared to a spray tower, tower ing high HS removal efficiencies jing agents, such as nitiotiacetic packing provides addtional mass of greater than 99.9%. The chemi- ‘acid (NTA), are hazardous. Recent transfer and therefore smaller equip- cals that are used are commodity advancements in this technology ment size and pumping costs for the chemicals, and therefore, avalabi- have helped drive down the operat same performance. ity is rarely a concern. The rate of ing costs through the development In the vertical countercurrent de- chemical consumption can be high ‘of innovative chemical reagents sign, gas flows upward while scruo- relative to the amount of HS that that reduce chemical consumption bing’ liquid flows down through is treated. For example, for every rates. Similarly, the equipment and spray nozzles or a liquid distributor 1 mole of HS, 2 moles of NaOH instalation costs are being reduced above the random packing section. and 4 males of HQ are required, ‘due to modularization and skid- The absorption of gases occurs in as shown in the overall reaction: packaged offerings. the packing section. A mist elimi- Furthermore, handling the sulfate- ator inside the vessel removes en- containing wastewater stream adds Chemical oxidation scrubber _ trained liquids from the gas before _significanlly to the operating cost of Ina chemical oxidation scrubber, exiting the scrubber. A regulated the scrubber. 4388, typical sodium hydroxide amount of the reagents is added 10 (NaOH), is used to neutralize HS the re-circulating liquid to maintain Biological processes {gas aller absorption into the scrub- setpoint pH and oxidation-reduc- There are several types of H,S r bing liquid. The absorbed HS is tion potential (ORP) levels. Fiver- moval technologies that use bi then oxidized using a chemical oxi- reinforced plastic (FRP) is typically logical or biochemical processes. izing agent, typically hydrogen per- the material of choice for the pro- This aticle focuses on biatricking ‘oxide (H20,) or sodium hypochiorte cess vessels, particularly if sodium filters, which use autotrophic mi- (NaOC),. to form soluble sodium hypochlorite is used as the oxidiz- crobes to consume HS and con- suifate (NaSO,), as shown in the ing agent vert it into sulfuric acid. Biotrickling ‘overall equation ‘below. NazSO, is One of the disadvantages of filters consist of a vessel with a removed from the system through a chemical oxidation is that caustic packed or porous media section lowdown stream, This sufate-con- is not selective to H,S in the pres- (Figure 3), The media provides a taining wastewater (blowdown) must ence of other contaminants, such a8 large surface area for the microbes be treated or sent for disposal carbon dioxide (CO,). Not only does to grow on. Makeup water is re (CO, increase chemical consump- quired to maintain the pH, and a 80 CHEMCALENGINEERING WWW.CHEVENGONLNE.COM JUNE 2010 hitps:vew iminus.com1S!documer13160/1 49592218/2019 June 2019 ‘aes Ad 4 [RQURE 4. scavenger system inves the nection ogi or od chemical tees react wins blowdown stream of dilute acid is removed from the system. NPK (nitrogen, phosphorus and potas- sium) fertiizers or other mixtures (such as unchlorinated raw water) ‘are used to provide the nutrients that are required by the microbes. Nutrient addition can be done manually or can be mixed at a fixed ratio with the makeup water. When FIGURE 5. Adsorption of Sung a feed Seta eaten abiotricking fiter is installed, it may take several days for the biofilm 10 develop on the media, and during this phase, the removal efficiency Ne PVE CT ee he ae Vil ty hitps:vew iminus.com1S!documer13160/1 Colins plastic contol valves are highly responsive control valves designed for use with corosive ‘media andlor corrosive atmos heres. Cling vals faatiraalllastic. 501532ovzore ara 019 over, the deacatage is hat most ‘Process Features: ‘Liquid | Chemical | Biotrickling | Scavengers | Carbon | SCavengers can be sensitive to high el Kees sen a" | SSrpottre and tocure ges wa rng ee ry vo ie Fixed-bed activated carbon sepeaton | nage | % id ‘Adsorption of His a physical pro meio" | pega ‘cess where HS is captured onto Ey “ te eros of Stated cabo ‘The ahs lo spect sue a = = area due to its inner pore structure, Regenerate reagent 7 which provides a large adsorptive ‘Non-hazardous reagent Varies: « ‘Varies: v rok Carbon beds - parte 7 7 Suitable when very tow (od = concentrations are required. In ad- Usable byproduct generation a ition to the physical process, some a 7 ||| sched cotera, fave camps ane ee SJ Broertes that onic nes to wa: fereaue slur somprds: Ts re) eS 7 7 - allows the carbon to be washed for ee Le zZ jgrecicn wil oper ot a oro n ZT] Peet depvod rose Tanne 7 = SSince the process does not occur in the liquid phase, liquid recircuta- will be low. Concrete structures are often used for large gas-flow sys- tems, while FRP can be used for smaller units. ‘The bacteria are sensitive to hu- rmidity, temperature and_ fluctuat- ing H,S inlet loading. Recircuiat- ing liquid supplied by a pump, or ‘once-through water, is required 10 keep the packing or media wet. If hitps:vew iminus.com1S!documer13160/1 molecular sieves and so on) are not discussed here, as they do not ‘liminate the HS. Instead, a waste ‘gas with a high HS concentration is produced during the scavenger- regeneration process, which must be ‘treated or sent for disposal Uke other HS-removal technolo- ies, most scavengers require dedi- ‘cated process equipment (Figure 4). tion, chemical addition and the as- sociated controls are not required, resulting in relatively simple process ‘equipment and operation. A carbon- bed vessel is typicaly sized based Con the carbon usage rate and super- ficial gas velocity. The vessel contig ration is typically vertical, with gas flowing up through the fixed-carbon bed (Figure 5). When the activated ‘carbon is spent, the media must be S1592218/2019 sorbed. The most common mater als of construction for carbon beds include coated carbon steel, FRP {and other plastics. Technology selection Selection of the appropriate HpS- removal technology is mainly gov- femed by cost and technical sutabi- ity, Table 1 provides a summary of hitps:vew iminus.com1S!documer13160/1 June 2019 ‘and carbon beds are typically used for low-HS-loading applications or ‘as a polishing stage to avoid fre- ‘quent change-out. In the past, liquid redox systems ‘were best suited for applications with very high HS loadings, par- ticularly for natural gas and landfil ‘gas processing. The high capital ‘cost of a liquid redox system re- 52592218/2019 June 2019 rr... hitps:vew iminus.com1S!documer13160/1 sais