CEM - February 2008 PDF

February Pump
Hazardous
2008 Liquids Safely
PAGE 35
www.che.com
2
STEAM CHEMISTRY • PUMP HAZARDOUS LIQUIDS SAFELY
Tank Photons to
Coatings Electrons,
& Vice Versa
When it Becomes
Necessary Facts at Your
To Fire Fingertips:
An Employee Causes of
Overpressurization
Asset
Management Focus on
VOL. 115 NO. 2 FEBRUARY 2008
Flowmeters
Circle 01 on p. 62 or go to adlinks.che.com/7369-01
Cover 2 CHE 2-08.indd 2 1/15/08 4:21:47 PM

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1 CHE 2-08.indd 1 1/15/08 4:01:51 PM

2 CHE 2-08.indd 2 1/15/08 4:12:54 PM

FEBRUARY 2008 IN THIS ISSUE VOLUME 115, NO. 2
COVER STORY COMMENTARY

30 Cover Story 5 Editor’s Page
CPI Water and Steam Working Together
Chemistry Careful Toward Common
control of water and Goals With increas-
www.che.com steam chemistry at CPI ing project com-
facilities can pay off plexities, advanced
handsomely in reliable technologies and
operation globalization, the
need for cooperation
between companies
and across disciplines
is greater than ever
27 CE Community
This month we fea-
ture a crossword
NEWS EQUIPMENT & SERVICES puzzle on project
management and
11 Chementator New ceramic-membrane 24D-1 New Products & invite you to down-
system doubles rate and slashes cost for Services (Domestic Edi- load an article on
dehydrating ethanol; This platinum-free tion) This bearing protec- adhesives
fuel cell runs on hydrazine; Commercial tion ring lasts for the life
production and debut of a new solid-acid of the motor; Oils and DEPARTMENTS
catalyst for making biodiesel; One less step coolants will not affect Letters . . . . . . . . . . . 6
to make activated carbon with dispersed these rotary encoder col- Calendar . . . . . . . . . 8,9
metal nanoparticles; New solid-state heat lars; Create matte, satin and other fine Who’s Who . . . . . . . 28
engine cycles H2 through MEA like a fuel finishes on metals; This pressure sensor
cell; and more Reader
is ideal for high-purity applications; This
Service page . . . . . . 62
17 Newsfront Photons To Electrons, & Vice tubing is suitable for use with most harsh
chemicals; EtherNet/IP connectivity is fea- Economic
Versa Research in light-emitting diodes and
tured on this I/O module; This efficient Indicators . . . . . 63, 64
solar cells are boosting both technologies
chiller eliminates maintenance-related ADVERTISERS
21 Newsfront Making the Most of What downtime; and more Product
You've Got A proactive asset management
program helps processors get more from Showcase. . . . . . . 55–56
24I-1 New Products &
their facilities, despite obstacles. Services (International Classified
Edition) Measure material Advertising . . . . .57–60
ENGINEERING
stran with this laser-based Advertiser Index . . . 61
25 Facts At Your Fingertips Causes of
system; Efficient heating COMING IN MARCH
Overpressurization This one-page guide
for just about any size
describes several common causes of vessel Look for: Feature
flask; Extreme operating
and pipe overpressurization and ways to Reports on Column
conditions are no problem
avoid them Instrumentation Basics;
for these tiny pumps; Con-
36 Feature Report Pump Hazardous Liq- and Planning for REACH;
sider this valve when control is critical; Heat
uids Safely Reduce the problems associ- Engineering Practice ar-
exchangers can benefit from this fluoropoly-
ated with handling hazardous liquids by ticles on Plugging, Sleev-
mer tubing; A big valve for big applications;
following these guidelines ing and Ferruling Heat
Don't waste costly ingredients with this
Exchanger Tubes; Piping
45 Solids Processing Tank Coatings: Cover- granulator; Level control takes a completely
Design; and Sensing
ing the Basics of Selection and Specifica- new look; Take a close, accurate look at par-
Change in Batch Reac-
tion Good quality coatings can make all ticle size and shape; and more
tors; A Focus on Bulk
the difference where corrosion and chemi-
43 Focus Flowmeters A durable flowmeter for Solids Storage, Handling
cal compatibility are concerned
remote applications outdoors; This electronic & Packaging; News
49 Environmental Manager Caring for Cool- flowmeter is submersible; A way to measure articles on Engineering
ing Water Systems Hydrocarbon leaks can and Construction; and
corrosive fluids cost-effectively; An insertion
disrupt recirculated cooling-water systems. Fuel Cells; Facts at Your
vortex meter that is reliable in large pipes;
Here's an outline of effects and remedies Fingertips on Mem-
A flow-conditioning meter for easy retrofit-
51 You and Your Job When it Becomes ting; This device improves settling time and branes; Show Previews
Necessary to Fire An Employee These accuracy; This meter has low maintenance on Interphex; and the
guiding principles will help you prepare and costs; A compact, no-frills flow-measurement International Pump Users
properly avoid making this task more un- device; A large Coriolis mass flowmeter for Symposium; and more
pleasant than it has to be petrochemicals applications; and more Cover: David Whitcher
$)&.*$"-&/(*/&&3*/(888$)&$0.'&#36"3:3
4 CHE 2-08.indd 4 1/15/08 4:16:51 PM

Winner of Eight Jesse H. Neal
Awards for Editorial Excellence
Editor’s Page
Published since 1902

An Access Intelligence Publication Working together
PUBLISHER
NELLA VELDRAN
Vice President and Publisher
ART & DESIGN
DAVID WHITCHER
Art Director
toward common goals
T
nveldran@che.com dwhitcher@che.com
he chemical process industries (CPI) are united in many common goals.
LINDA LEE NIGRA
EDITORS
Editorial Production Manager Particularly in this age of fast global growth, it is difficult, if not impos-
REBEKKAH J. MARSHALL lnigra@che.com sible, for a company to achieve its targets by working independently.
Editor in Chief PRODUCTION
rmarshall@che.com A common theme circulating at this year’s DaratechPlant (Houston; Janu-
DOROTHY LOZOWSKI MICHAEL D. KRAUS ary 28–30; www.daratechplant.com), was that with increasing project com-
Managing Editor VP of Production & Manufacturing
dlozowski@che.com mkraus@accessintel.com plexities, advanced technologies and globalization, the need for coopera-
GERALD ONDREY STEVE OLSON tion between companies and across disciplines is greater than ever.
Director of Production &
(Frankfurt)
Senior Editor Manufacturing In fact, during the DaratechPlant Owner/Operator (O/O) Roundtable,
gondrey@che.com solson@accessintel.com Jerry Gipson, director of the Engineering Solutions Technology Center for
WILLIAM C. GRAHAM
MATTHEW PHELAN Ad Production Manager The Dow Chemical Co., cited collaboration as the one thing that is needed
Assistant Editor
mphelan@che.com
bgraham@che.com within the industry and hailed it as “the critical enabler of future success.”
KATE TORZEWSKI
MARKETING Gipson defined four areas of opportunity that we must address together:
Editorial Assistant HOLLY ROUNTREE 1) Developing winning opportunities, where the whole lifecycle of a project
ktorzewski@che.com Marketing Manager
hrountree@accessintel.com needs to be considered. Here, increased collaboration between the business
CORRESPONDENTS
AUDIENCE and technical communities is essential; 2) Managing projects effectively,
CHARLES BUTCHER (U.K.) DEVELOPMENT
cbutcher@che.com where it is critical to take the time in the beginning to define what suc-
SYLVIA SIERRA
PAUL S. GRAD (Australia) Senior Vice President, cess is, to identify risk and to get the right people and resources together;
pgrad@che.com Corporate Audience Development 3) Sourcing, retaining and developing people and knowledge resources
TAKESHI KAMIYA (Japan) ssierra@accessintel.com
tkamiya@che.com JOHN ROCKWELL — Gipson points out that relying on internal resources is not enough, but
JOY LEPREE (New Jersey) Vice President, collaboration and partnerships are needed; 4) Deploying competitive, sus-
Audience Development Chemical
jlepree@che.com
jrockwell@accessintel.com tainable technologies, where attention should be paid to defining what suc-
GERALD PARKINSON
(California) gparkinson@che.com
LAURIE HOFMANN cess is and what competition is.
Audience Marketing Director
lhofmann@Accessintel.com
On Gipson’s topic of sustainability, co-panelist Nick McKenna, manager
EDITORIAL
ADVISORY BOARD TERRY BEST of Quality and Management Systems, Project Services at ConocoPhillips,
JOHN CARSON
Audience Development Manager defined a three-part model, which includes environmental protection, so-
tbest@accessintel.com
Jenike & Johanson, Inc.
GEORGE SEVERINE cial improvement and economic growth. These principles are applied by in-
DAVID DICKEY
MixTech, Inc.
Fulfillment Manager corporating them into project planning, said McKenna, who participated in
gseverine@accessintel.com
MUKESH DOBLE
CHRISTIE LAMONT
the O/O roundtable for the first time this year. He and Gipson advised that
IIT Madras, India
List Sales, World Data 561-393-8200 while each company defines its own specific objectives within the model,
HENRY KISTER
Fluor Corp.
CONFERENCES the overall goal of sustainability is shared.
TREVOR KLETZ DANA D. CAREY Another well-known challenge shared by the CPI and Engineering,
Loughborough University, U.K. Director, Global Event Sponsorships
GERHARD KREYSA dcarey@chemweek.com Procurement and Construction (EPC) companies that serve them is
DECHEMA e.V. PECK SIM limited resources. Finding the right people and demographic issues are
RAM RAMACHANDRAN Senior Manager,
BOC Conference Programming particularly troublesome. During DaratechPlant’s EPC Roundtable,
INFORMATION SERVICES
psim@chemweek.com Karen Sobel, vice president, Engineering for SNC-Lavalin Inc., named
BEATRIZ SUAREZ
ROBERT PACIOREK Director of Conference Operations competition for resources and schedule pressures as the biggest chal-
Senior VP & Chief Information Officer bsuarez@chemweek.com lenges for 2008. Here again, collaboration comes up in the solution.
rpaciorek@accessintel.com
JOHN STRAZZA
CORPORATE One of Sobel’s co-panelists Jann Slettebakk, vice president Engineering
Director of eMedia STEVE BARBER Management at Aker Kvaerner, added that collaboration is especially
jstrazza@accessintel.com VP, Financial Planning & Internal Audit
sbarber@accessintel.com important now that projects have become so much more technologically
CHARLES SANDS
Senior Developer JOHN PEARSON complex. Slettebakk said that this is not the whole answer, noting that
Web/business Applications Architect Divisional President
csands@accessintel.com jpearson@accessintel.com
better tools (such as software) are also needed. But here too, he pointed
out, collaboration is needed in applying these tools from early on in a
HEADQUARTERS project.
110 William Street, 11th Floor, New York, NY 10038, U.S.
Tel: 212-621-4674 Fax: 212-621-4694 Perhaps the most concrete way to support a cooper-
EUROPEAN EDITORIAL OFFICES ative environment is to implement well-thought-out
Zeilweg 44, D-60439 Frankfurt am Main, Germany standards. Indeed, Gipson says that standards-based
Tel: 49-69-2547-2073 Fax: 49-69-5700-2484
integration is needed and that “we will ultimately
CIRCULATION REQUESTS:
Tel: 847-564-9290 Fax: 847-564-9453
require our suppliers to conform to applicable stan-
Fullfillment Manager; P.O. Box 3588, dards.” From the offerings described by many of the
Northbrook, IL 60065-3588 email: clientservices@che.com
DaratechPlant attendees, this is already well under-
ADVERTISING REQUESTS: see p. 62
For photocopy or reuse requests: 800-772-3350 or info@copyright.com
way. O
Dorothy Lozowski
$)&.*$"-&/(*/&&3*/(888$)&$0.'&#36"3:5
Letters
Another corrosion-resistant
material deserves a mention
In the December 2007 article, The Heat Is On (pp. 24–28)
I take issue with the statement next to the Pfaudler
photo, “Tantalum and glass-lined steel are the two most
corrosion resistant materials used in the chemical and
pharmaceutical industries.” They are two of the most
corrosion resistant materials, but our Hexoloy Sintered
Alpha SA silicon carbide SiC is also as corrosion resis-
tant as tantalum and glass-lined steel and is also used in
the chemical and pharmaceutical industries. Please see
our website www.hexoloy.com
James F. McMahon
Saint-Gobain Ceramics, Niagara Falls, N.Y.
Scholarship applications open

Chemical Engineering has established a scholarship
program in the name of former Editor-in-Chief Nicholas
P. Chopey, to assist students who plan to continue their
education in college programs.
Applicants to the program must be current third-year
students who are enrolled in a full-time* undergraduate
course of study in Chemical Engineering at one of the fol-
lowing four-year colleges or universities:
• Columbia University,
• Rutgers University,
• SUNY Buffalo,
• University of Kansas,
• University of Virginia
If selected as a recipient, the student will receive a one-time
only award that may be used for undergraduate study.
Application details. Interested students must complete
the application and mail it along with a current, com-
plete transcript of grades to Scholarship Management
Services postmarked no later than April 1. Applications
and guidelines can be found at www.che.com by clicking
on Events and Announcements.
Questions regarding the scholarship program should
be addressed to:
Nicholas Chopey Scholarship Program
Scholarship Management Services
One Scholarship Way, P.O. Box 297
Saint Peter, MN 56082
Telephone: (507) 931-1682
Selection of recipients. Scholarship recipients are
selected on the basis of academic record, demonstrated
leadership and participation in school and community ac-
tivities, honors, work experience, statement of goals and
aspirations, unusual personal or family circumstances,
and an outside appraisal. Financial need is not consid-
ered.
Selection of recipients is made by Scholarship Manage-
ment Services, a division of Scholarship America. In no
instance does any officer or employee of Chemical Engi-
neering Magazine play a part in the selection. Applicants
will be notified in early June. ■
*Full-time study is defined as full-time enrollment for the entire upcom-
ing academic year.
Chemical Engineering www.che.com February 2008
8 CHE 2-08.indd 6 1/29/08 6:24:42 PM

7 CHE 2-08.indd 7 1/15/08 3:59:01 PM

www.pneumaticproducts-spx.com
Calendar
NORTH AMERICA
Pittcon 2008. The Pittsburgh Conference (Pittsburgh,
Pa.). Phone: 412-825-3220; Web: pittcon.org
New Orleans, La. Mar. 1–7
SPAR 2008. Spar Point Research LLC (Danvers, Mass.).

Phone: 978-774-1102; Fax: 978-774-4841; Web: sparllc.com
Houston, Tex. Mar. 3–5
Conexpo-Con/AGG 2008. Association of Equipment

Manufacturers (Milwaukee, Wis.). Phone: 414-272-0943;
Fax: 414-272-1170; Web: conexpoconagg.com
Las Vegas, Nev. Mar. 11–15
Interphex 2008. Reed Exhibitions (Milwaukee, Wis).

Phone: 203-840-5533; Fax: 203-840-9533; Web:
interphex.com
Philadelphia, Pa. Mar. 26–28
Residuals and Biofuels 2008. Water Environment

Federation (Alexandria, Va.). Phone: 800-666-0206; Fax:
703-684-2492; Web: wef.org/residualsbiofuels
Pneumatic Products Doesn’t Play Philadelphia, Pa. Mar. 30–Apr. 2
Games with the Quality of Your
Compressed Air or Gas! Techtextil North America. messe frankfurt (Frankfurt,
Germany). Phone: 770-984-8015; Fax: 770-984-8023; Web:
Engineers inherit air systems where reliability, integrity techtextilna.com
and countless devices determine the fate of productivity. Atlanta, Ga. Apr. 1–3
The wrong moves can result in product rejects or
Odors and Air Emissions 2008. Water Environment
costly downtime. The right moves keep production, Federation (Alexandria, Va.). Phone: 800-666-0206; Fax:
profit and your career advancing. Since 1946, 703-684-2492; Web: wef.org/OAE
generations of engineers have avoided checkmate by Phoenix, Ariz. Apr. 6–9
insisting upon legendary Pneumatic Products brand air
Reach USA 2008. Smithers Rapra (Shrewsbury, U.K.).
and gas treatment systems for their toughest Phone: +44 (0) 1939 250383; Fax: +44 (0) 1939 251118;
applications in the nastiest of environments — Web: rapra.net
because, there’s no substitute Boston, Mass. Apr. 15–17
for the right strategy.
CANECT 2008. Envirogate Event Management Inc. (To-
• Flows to 20,000 scfm ronto, Ontario, Canada). Phone: 905-727-4666; Fax: 905-
841-7271; Web: esemag.com
• Pressures to 5,000 psig Toronto, Ontario, Canada Apr. 21–22
• Dew Points to -100°F
• Specialty Metals The World Congress on Industrial Biotechnology
• Standard Designs or
and Bioprocessing. Biotechnology Industry Organization
Built to Specifications (Washington, D.C.). Phone: 202-962-6630; Web: bio.com
Chicago, Ill. Apr. 27–30
europe
Nanofair 2008. VDI Wissensforum GmbH (Dusseldorf,
Germany). Phone: +49 (0) 211 62 14-4 26; Fax: +49 (0) 211
62 14-1 54; Web: nanofair.com
Dresden, Germany Mar. 11–12
Silicone Elastomers 2008. Smithers Rapra Technology

Email: pneumatic.products.sales@dehydration.spx.com • Phone: 352-873-5793 (Shropshire, U.K.). Phone: +44 (0) 1939 250383; Fax: +44
(0) 1939 252416; Web: rapra.net
Munich, Germany Mar. 12–13
8-9 CHE 2-08.indd 8 1/29/08 5:57:46 PM

Detergency & Cosmetics. C.E.D. (Barcelona, Spain).
Phone: +34 93 204 02 12; Fax: +34 93 280 53 00;
Web: cedmeeting.com
Barcelona, Spain Apr. 2–3
European Thermoforming Conference 2008. Soci-

ety of Plastics Engineers Europe (Antwerpen, Belgium).
Phone: +32 3 541 77 55; Fax: +32 3 341 84 25;
Web: e-t-d.org
Berlin, Germany Apr. 3–5
Advances in Synthetic Chemistry. Select Biosciences

(Sudbury, U.K.). Phone: +44 (0) 1787 315110; Fax: +44 (0)
1787 315111; Web: advsynchem.com
Frankfurt, Germany Apr. 8–9
Hazards XX. IChemE (Cumbria, U.K.). Phone: +44 (0)

1539 732845; Fax: +44 (0) 1539 732845; Web:
icheme.org/hazardsxx
Manchester, U.K. Apr. 14–17
ERTC Coking and Gasification Conference. ERTC

(Surrey, U.K.). Phone: +44 1737 365100; Fax: +44 1737
365101; Web: gtforum.com
Paris, France Apr. 16
asia and elsewhere

Middle East Fertilizer Symposium 2008. World Re-
fining Association (Gloucestershire, U.K.). Phone: +44 (0)
1242 529 090; Fax: +44 (0) 1242 529 060;
Web: wraconferences.com
Abu Dhabi, U.A.E. Mar. 3–4
GEO 2008. Kuwait Oil Company (Ahmadi, Kuwait).

Phone: +44 (0) 20 7451 4700; Fax: +44 (0) 17 8441 9257;
Web: geobahrain.org
Manama, Bahrain Mar. 4–6
PIA Vietnam 2008. Bangkok Exhibition Services Ltd.

(Phyathai, Bangkok). Phone: +66 02 615 1255; Fax: +66 02
615 2991; Web: piavietnam.com
Ho Chi Minh City, Vietnam Mar. 5–8
P-MEC Japan. CMP Information (London, U.K.). Phone:

+81 3 5296 1020; Fax: +81 3 5296 1018;
Web: pmec-japan.com
Tokyo, Japan Apr. 9–11
Base Oils and Lubricants in Russia and the CIS

2008. World Refining Association (Gloucestershire, U.K.).
Phone: +44 (0) 1242 529 090; Fax: +44 (0) 1242 529 060;
Web: wraconferences.com
Moscow, Russia Apr. 16–17
PETnology Europe 2008. PETnology GmbH (Regens-

burg, Germany). Phone: +49(0) 941 870 2374; Fax: +49 (0)
941 870 2373; Web: petnology.com
Duesseldorf, Germany Apr. 22–23 n
Kate Torzewski
8-9 CHE 2-08.indd 9 1/29/08 5:58:34 PM

10 CHE 2-08.indd 10 1/15/08 4:06:23 PM

Edited by Gerald Ondrey February 2008
New ceramic-membrane system doubles 0WFSIFBEWBQPS

MCI
rate and slashes cost for dehydrating ethanol XU MCI )JU[[FPMJUF
NFNCSBOF
H itachi Zosen Corp. (Hitz; Tokyo, Japan;

edlinks.che.com/7369-531) is commer-
cializing a new membrane for a hybrid-dis- 3FGMVY
MCI
tillation system (HDS) that is especially
suitable for dehydrating ethanol and iso-
propanol. The HDS can produce 99.7 vol.% 1SFTTVSF 1SPEVDU
QTJB 3FCPJMFS $POEFOTFS
ethanol from ethanol-water mixtures with "OIZESPVT
FUIBOPM
10 vol.% H2O at a dehydration rate of 50 8BTUFXBUFS
NJMMJPOHBMZS
kg/m2/h/atm (at 130°C), which is more than MCI Y#UVI 1FSNFBUF
XU MCI
MCI WPM
two times higher than conventional ceramic- XU
membrane processes, says the firm.
The membrane element consists of a 3BXNBUFSJBM XUXBUFSXUFUIBOPM
porous alumina tube that is closed at one 'FFE

MCI
end. A thin zeolite film is synthesized onto
the tube, and the pore size is precisely the energy required to dehydrate ethanol,
Pumping hot oil
controlled by proprietary technology to be and the required installation space for the PCM (Paris, France; edlinks.
che.com/7369-541) has intro-
around 10Å, which enables the element to membrane unit is about half that needed
duced what is claimed to be the
act as a molecular sieve for the two alcohols. for a pressure-swing-absorption unit.
world’s first all-metal progress-
In the HDS, the mixture is fed to the out- Hitz has demonstrated the technology in ing cavity pump (PCP). PCM
side of the tubes and the dehydrated water a test plant with the capacity to produce Vulcain is capable of pumping
is removed from the inner side of the tubes. 30 kL/d of ethanol, and plans to expand the extremely hot (350°C) and
The membrane is able to dehydrate etha- production capacity (for the membranes) to viscous fluids, making it par-
nol-water mixtures with less than 30-wt.% 750,000 m.t./yr this year. The firm has also ticularly suitable for the thermal
water and, when combined with distilla- designed an HDS for producing 99.7 vol.% recovery of heavy oil. Half of
tion, covers a wider range of mixtures. Hitz ethanol from a 10 vol.% ethanol feed, with a the world’s known oil reserves
estimates that HDS can save up to 30% of capacity of 50-million gal/yr. are said to be made up of un-
conventional oil, ranging from
viscous heavy oil to nearly
This platinum-free fuel cell runs on hydrazine solid bitumen. Such oils cannot
flow unless they are heated by
D aihatsu Motor Co., Ltd. (Osaka, Japan;

edlinks.che.com/7369-532) has designed
a fuel cell for powering automobiles, using
F
steam injection; as a result, the
recovered oil is extremely hot.
PCPs are said to be more
nickel and cobalt for the electrodes (instead /) 0 energy efficient that other pump
of conventional platinum and carbon), and technologies, but standard
)0 )0
hydrazine hydrate (N2H4.H2O) as its fuel 0)m PCPs are limited in terms of
(instead of hydrogen). Although hydrazine is maximum operating tempera-
ture. The rotary action of the
a hazardous material, the company says the
Vulcain outperforms beam
hazard level is about the same as gasoline. /
pumps in overall system ef-
And unlike H2, which requires high (700 )0 ficiency, and is less fragile than
bar) pressures or low (–253°C) tempera- "OJPOFYDIBOHF electric submersible pumps,
tures for storage, hydrazine hydrate is easy &MFDUSPEFT NFNCSBOF says the manufacturer.
to store and transport by conventional tanks
and trucks. dized at the anode (diagram) to form N2 and Bio-based succinic acid
Daihatsu’s fuel cell is composed of an anode an electron, while O2 (from air) is reduced
Royal DSM N.V. (Heerlen,
made of Ni nanoparticles, a cathode made of with water at the cathode, releasing hydrox- Netherlands; edlinks.che.
carbon-cobalt (polypyrrole-modified) com- ide ions. The OH– ion migrates through the com/7369-542) and the French
posite, and an anion-exchange membrane as membrane to the anode. starch and starch-derivatives
its solid electrolyte. The hydrazine hydrate A prototype of the new fuel cell has a company Roquette (Lestrem,
is stored as hydrazone, which is bound to the power output of 0.50 W/cm2, which is compa- France; edlinks.che.com/7369-
carbonyl groups of polymer particles within rable with existing H2-based cells, says the 543) have joined forces to im-
the fuel tank. To liberate hydrazine hydrate, firm. Daihatsu aims to install the new fuel plement and commercialize the
water at 60°C is passed through the fuel cell battery for its lightweight cars in the fu- fermentive production of biore-
newable succinic acid. A dem-
tank, where it reacts to form an aqueous hy- ture, and is seeking partners from other car
drazine solution. The hydrazine is then oxi- manufacturers around the world. (Continues on p. 12)
Note: For more information, circle the 3-digit number
on p. 62, or use the website designation. Chemical Engineering www.che.com February 2008 11
11-16 CHE 2-08.indd 11 1/29/08 6:00:15 PM

C hementato R
&MJNJOBUF
Commercial production and debut of a new solid-acid 8BTUFXBUFS
catalyst for making biodiesel .FUIBOPM

$BVTUJD
OFVUSBMJ[BUJPO
L ast month, Benefuel, Inc. (Mt. Prospect, "MDPIPM SFDPWFSZ

.FUIBOPM 'VFMXBTIJOH 'VFMQPMJTIJOH
Ill.; edlinks.che.com/7369-533) established &UIBOPM 4PMJEBDJE (MZDFSJO BOEGJMUFS
an exclusive global agreement with Süd- DBUBMZTU TFQBSBUJPO
'FFETUPDL SFBDUPS
Chemie India Pvt. Ltd. (SCIL; New Delhi) 6OSFGJOFEPJMT '".&
&MJNJOBUF
whereby SCIL will manufacture proprietary "OJNBMGBUT
(MZDFSJO
8BTUFWFHFUBCMF
solid-acid catalysts for Benefuel’s biodiesel PJMT EJTUJMMBUJPO
production facilities around the world. The &MJNJOBUF
patent-pending catalysts — developed by "45.BOE&/
-JRVJEDBUBMZTU
1VSJGJFE
Benefuel in collaboration with the National HMZDFSJO #JPEJFTFM
Chemical Laboratory (Pune, India; edlinks.
che.com/7369-534) — are based on an iron- 'VFM
zinc double-metal cyanide (DMC) complex, PYZHFOBUF (Continued from p. 11)
and can turn most vegetable oils, animal fats onstration plant with a capacity
or waste cooking oils directly into fatty acid in batch or semi-continuous processes, Ensel of several hundred metric tons
methyl esters (FAME). Unlike other solid- does not require a number of post-reactor per year is targeted for opera-
acid catalysts, the DMC is highly active even purification steps (diagram) to wash catalyst tion by the end of 2009. Two
for the simultaneous transesterification of from the FAME, and directly produces pure years later, after a successful
triglycerides and esterification of the free- (≥98%) glycerin. This means Ensel oper- trial, the new technology will
be transferred to large-scale
fatty acids (FFAs), which are present in un- ates water-free; conventional routes require
production, says DSM.
refined and waste cooking oils and non-edible about 3–5 gallons of water for each gallon of Used for pharmaceutical,
oils, says William Summers, Benefuel’s chief biodiesel produced, which can be problematic food and automotive applica-
science officer. The new catalyst is also insen- in regions where water is scarce, says Sum- tions, succinic acid is currently
sitive to the presence of water (even 20 wt.% mers. Depending on the feed, Ensel has a produced by hydrogenation
H2O), whereas alternative solid catalysts cost advantage over conventional processes of maleic anhydride followed
can’t tolerate a water content above 0.2 wt.% of 40–90¢/gal of biodiesel produced, he says. by the hydration of succinic
or less, he adds. The first commercial application of the anhydride. The fermentation
The catalysts are the key feature of Bene- Ensel process will be in a biodiesel plant process instead uses both
fuel’s Ensel process whereby FAME and by- currently being constructed for Seymour sustainable feedstocks, such
as plant carbohydrates, and
product glycerin are continuously produced Biofuels, LLC (Seymour, Ill.). When the
carbon dioxide, and is esti-
in a fixed-bed reactor. In contrast to con- plant starts up later this fall, it will have the mated to save 30–40% of the
ventional biodiesel routes that use a liquid capacity to produce 10-million gal/yr biodie- energy compared to chemical-
catalyst (typically aqueous NaOH solutions) sel from unrefined soy oil and chicken fat. base routes.
One less step to make activated carbon Algae-based biodiesel

Valencent Products, Inc.
with dispersed metal nanoparticles (El Paso, Tex.; edlinks.che.
com/7369-544) and Global
N anostructured microporous carbons con-

taining well-dispersed metal nanopar-
ticles have the potential to improve the
carbon precursor. Paul Webley, group leader
and associate dean (research) at the univer-
sity’s faculty of engineering, says presently
Green Solutions, Inc. (Van-
couver, B.C., Canada; edlinks.
che.com/7369-545) are in the
performance of fuel cells or catalysis. How- a simpler, single-step approach is being de- final stages of commercial-
ever, traditional techniques for embedding veloped, which involves direct CVD using izing their patented Vertigro
metal particles in porous carbons (post- acetylene as a precursor. The new process process, which includes the
synthesis treatment either by impregna- produces fully ordered microporous carbon growing and harvesting of
algae, and extraction of oil
tion, adsorption, or ion exchange) can lead molecular sieves of extremely high micropo-
from algae for biodiesel pro-
to uncontrolled growth of metal particle rosity that also contain well-dispersed tran- duction. Key to the process is
size, shape and aggregation, which can sition-metal nanoparticles. a continuous, closed-loop bio-
cause the pores to be blocked. The one-step process produces Ir-C, for reactor constructed by Gray-
Last year, researchers from the dept. of example, with excellent dispersion of the ling Industries (Atlanta, Ga.;
chemical engineering at Monash Univer- loaded iridium and a fairly uniform par- edlinks.che.com/7369-546).
sity (Melbourne, Australia; edlinks.che. ticle-size distribution of around 2–5 nm. In the bioreactor, algae
com/7369-535) successfully synthesized Iridium metal loading was 20 wt.%, and in water circulates through
transition-metal-doped microporous carbons surface area of this carbon was about 1,880 10-ft high, UV-stable plastic
from impregnated zeolite Y templates by a m2/g, which is higher than commercial ac- tubes, in which the algae are
exposed to sunlight. The key
two-step chemical-vapor deposition (CVD) tivated carbons and may therefore be suit-
using furfural alcohol and propylene as a able in fuel cell applications. (Continues on p. 14)
12 Chemical Engineering www.che.com February 2008
11-16 CHE 2-08.indd 12 1/29/08 6:00:50 PM

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13 CHE 2-08.indd 13 1/15/08 3:54:43 PM

C hementato R
New solid-state heat engine cycles H2

through MEA like a fuel cell
J ohnson ElectroMechanical Sys-
tems, Inc. (Atlanta, Ga.; edlinks.
che.com/7369-536) in conjunction with +
2-
)
2)
+
P ) ) 2 2 ) ) P
professor Heshmat Aglan of Tuskegee
University (Tuskegee, Ala.; edlinks.che. - ) -
com/7369-537) has received a $75,000 2- 2)
grant from the U.S. Dept. of Energy
(DOE; Washington, D.C.) to further de- &SJDTTPODZDMF
velop the firm’s solid-state heat engine tech- and above 1,200ºC. According to the
5FNQFSBUVSF
5)
nology. The device operates like a fuel cell to device’s inventor and namesake, Lonnie
generate electricity by catalytically splitting Johnson, the firm has already “produced
hydrogen molecules on one side of a mem- proof-of-concept demonstrators for power
brane-electrode assembly (MEA). Unlike a scavenging applications, fuel cell appli- 5-

fuel cell, however, the protons and electrons cations (operating at the highly sought
recombine into H2 on the other side of the after intermediate temperature ranges of
MEA (diagram). Dubbed the Johnson Ther- 200 to 400ºC) and thermal to electric con- &OUSPQZ
moelectric Converter (JTEC), the engine is verters.” To adapt JTEC technology for
effectively cheaper than a fuel cell because use in solar thermal conversion systems, (Continued from p. 12)
only a consistent external heat source and Johnson and Aglan have been testing advantages of the bioreactor
not a continuous supply of H2 is required. novel ceramic membranes with the goal over open ponds, are that a
It also promises improvement over compet- of a system capable of handling tempera- much higher surface area is
ing thermoelectric conversion devices, such tures up to 600ºC. (At present, solar concen- exposed to sunlight and no
as molten sodium, which operates at 1,200– tration via parabolic mirrors can surpass water is lost through evapo-
1,500 K and gradually plugs the porous elec- 800ºC.) At 600ºC, the JTEC’s theoretical ef- ration, explains Glen Kertz,
trodes required to pass its Na+ ions. ficiency rate, based on its approximation of president and CEO of Val-
With the wide range of proton-conductive the Ericsson thermodynamic cycle (graph) cent Products. Algae can be
harvested after 25–30 d, and
materials currently used in MEA, versions approaches 60% — twice that of current
contains about 50 wt.% oil.
of the engine would be capable of generat- solar Stirling engines. The technology is With the Vertigral process, the
ing electricity at operating temperatures patented by Johnson under U.S. patents biodiesel production volume
anywhere from room temperature to up 6,686,076 and 6,709,778. can be 20 times more than
that produced from traditional
Maintain pH, even at cyrogenic crops, with only 5% of the

water requirements, he says.
temperatures, with this buffer A push for Jatropha
B iotechnology samples, such as proteins,
nucleic acids, biological specimens and
pharmaceuticals, are typically stored frozen
alkaline (pH increases by 1.5) as the tem-
perature falls from ambient to –180°C; and
potassium phosphate, which becomes acidic
Archer Daniels Midland Co.
(ADM; Decatur, Ill.; edlinks.
che.com/7369-547), Bayer
to extend their shelf life. However, a prob- (pH decreases by 0.5) over the same tem- CropScience AG (BCS;
lem that has plagued researchers for de- perature range. By adjusting the ratio of the Leverkusen, Germany;
cades is that the buffers used to maintain two components in the mixture, a TIP buffer edlinks.che.com/7369-548)
the pH of the samples lose their efficacy as is formed that shows only a 0.2 variation in and Daimler AG (Stuttgart,
Germany) have signed a
samples are cooled. Low-temperature bio- pH during cooling.
memorandum of understand-
physical and bioanalytical techniques can To demonstrate the need for, and efficacy ing to explore the potential for
also be affected by pH variations caused of the TIP buffer, the pharmaceutical (peni- a biodiesel industry based on
by the temperature dependency of buffers. cillin analog) oxacillin was stored at –20°C Jatropha curcas L., a tropical
These problems can now be avoided with a in TIP and other common buffers. After 144 plant that is seen as a promis-
temperature-independent pH (TIP) buffer h, only about 4% of the drug remained ac- ing alternative-energy feed-
developed by researchers at the University tive when stored in HEPES alone, but 96% stock. The wild plant requires
of Illinois at Urbana-Champaign (UIUC; of the oxacillin “survived” in the TIP buffer, very little water or fertilizer
edlinks.che.com/7369-538). says UIUC chemistry professor Yi Lu, who’s and can be cultivated on
The buffer is made by simply combin- group reported the results in a recent issue barren land. BCS plans to de-
velop and register herbicides,
ing two commonly used buffers that were of Chemical Communications. Lu says a pat-
soil insecticides and fungi-
shown to have opposite temperature depen- ent has been filed for the methodology, and cides for disease and pest
dence: HEPES [4-(2-hydroxyethyl)-1-piper- he is amenable to licensing the technology to control of Jatropha plants.
azineethanesulfonic acid], which becomes commercial buffer suppliers.
1 4
+
11-16 CHE 2-08.indd 14 1/29/08 6:01:31 PM

Sensor uses microfluidics to sniff
for airborne contaminants
A irborne contaminants can be identi-
fied within 2–3 s with a new sensor
developed by researchers at the Uni-
Desalination barges based on reverse osmosis
5SBOTGJFME4FSWJDFT-UE FEMJOLTDIFDPN
BOE8PSMFZ1BSTPOT-UE CPUI
/PSUI4ZEOFZ "VTUSBMJBFEMJOLTDIFDPN
IBWFCFFOTFMFDUFEUPDPOTUSVDU
versity of California-Santa Barbara UXPNPCJMFEFTBMJOBUJPOVOJUT .%6
GPSDPOUJOHFODZVTFJOUIF#SJTCBOF3JWFS5IFQSPK
and Stanford University (Calif.). The FDUJTFYQFDUFEUPQSPWJEFNJMMJPO-EPGQPUBCMFXBUFSBUBUPUBMDPOTUSVDUJPODPTUPG
researchers have founded a company, "NJMMJPO*UTFTUJNBUFEUIBUUIFCBSHFTDPVMECFCSPVHIUPOMJOFCZMBUF
SpectraFluidics, Inc. (Santa Barbara; 8IJMFBNJMMJPO-E OVDMFBSQPXFSFE MPXUFNQFSBUVSFUIFSNBM.%6IBTCFFOPQ
edlinks.che.com/7369-539) to commer- FSBUJOHJO5VUJDPSJO *OEJB TJODFMBTU"QSJM UIFOFXCBSHFTXPVMECFUIFXPSMETMBSHFTU
cialize the detector. BOEUIFGJSTUCBTFEPOSFWFSTFPTNPTJT 30
*GTVDDFTTGVM UIFQSPKFDUXJMMTFSWFBTB
The instrument employs free-surface NPEFMGPSESPVHIUFNFSHFODJFTXIFSFMPOHFSUFSNTPMVUJPOTMJLFEBNT BOEMBOECPVOE
microfluidics to absorb molecules di- EFTBMJOBUJPOQMBOUTQSPWFGJOBODJBMMZJNQSBDUJDBM"SPVOEPG"VTUSBMJBTQPQVMBUJPO
rectly from the air, then identifies them SFTJEFTOFBSUIFDPBTU TPUIFQPUFOUJBMGPSTIBSJOHCBSHFTCFUXFFOTUBUFTDPVME
by surface-enhanced Raman spectros- TBWFUIFDPVOUSZCJMMJPOTJOTUSBOEFEBTTFUT P
copy (SERS), says Carl Meinhart, presi-
dent of SpectraFluidics and a professor hanced using SERS, in which the water molecules, says Meinhart. “Essentially
of mechanical engineering at UC Santa is seeded with silver nanoparticles that the sensor is an optical nose,” he says.
Barbara. The molecules are absorbed adsorb the contaminants, thereby am- “Light is used to smell things that only
into flowing water that is pumped by plifying the Raman signal by up to 10 a dog can smell.” At present the device
surface tension through a 1.5-µm-deep orders of magnitude. is interfaced to a desktop spectrometer,
by 15-µm-wide open microchannel, The present unit can detect hydro- but the firm plans to make the system
etched into a 1-cm2 square silicon chip. philic aromatic molecules, including cer- portable by combining it with an off-the-
The sensitivity of the instrument is en- tain types of explosive or carcinogenic shelf, hand-held Raman spectrometer.
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Super-oleophobic materials promise 0 3G 0
revolutionary membranes 0 4J 0
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0
A team of researchers from MIT’s
(Cambridge, Mass.; edlinks.che.
com/7369-540) chemical and mechani-
hedral oligomeric silsesquioxane mol-
ecules (POSS; diagram) with a moder-
ately hydrophilic polymer, poly(methyl
3G
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cal engineering departments, in associ- methacrylate) (PMMA). This low-en- 3G$)$) $'
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ation with the U.S. Air Force Research ergy blend was then electrospun for
Laboratory (Edwards Air Force Base, increased and scalable roughness. The in the non-wettability of the surface.
Calif.), has developed oil-repellent team also determined a new param- While the intended use of these ma-
surfaces with likely separations and eter affecting the liquid repellency: terials has been as a coating on sur-
safety applications for the chemical re-entrant surface curvature. To verify faces that absorb hydrocarbons, some
process industries. Due to the high- its applicability, a model material with of the low-POSS microfiber non-woven
surface-tension of water (lv = 72.1 re-entrant curvature was fabricated mats electrospun by the researchers
mN/m), super-hydrophobic surfaces from the reactive ion etching of a 300- proved ideal for separating disper-
are relatively common in nature and nm top-layer of SiO2 and subsequent sions of octane and water. “We hope to
industry, while surfaces resistant to isotropic etching of a flat Si bottom- continue along these lines to develop
liquids like decane (lv = 23.8 mN/m) or layer using vapor-phase XeF2. These separation schemes for the more chal-
octane (lv = 21.6 mN/m) are extremely so-called “hoodoo structures” were lenging case of hydrocarbon mixtures,”
rare. To fabricate a super-oleophobic then treated with 1H,1H,2H,2H-per- said MIT’s Anish Tuteja. If success-
material based on the traditionally un- fluorodecyltrichlorosilane to chemi- ful, this further research suggests the
derstood factors of surface energy and cally lower sv. Whether the curva- possibility of low-energy membranes
roughness, the surface energy of the ture was convex (as with the team’s replacing energy-intensive processes
solid (sv) would have to be lower than electrospun polymer microfibers) or like distillation in certain liquid-liquid
that of any known material. concave (as with its SiO2 “micro-hoo- separations. The technology is patent
The researchers blended several doos” produced through photo-lithog- pending under application serial num-
kinds of fluorinated, hydrophobic, poly- raphy), the result was an increase ber U.S. 60/917012. ■
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Circle 15 on p. 62 or go to adlinks.che.com/7369-15 Circle 16 on p. 62 or go to adlinks.che.com/7369-16
11-16 CHE 2-08.indd 16 1/29/08 6:02:36 PM

Newsfront
PHOTONS TO
ELECTRONS,
& VICE VERSA
Advances in
light-emitting diodes
,POBSLBhT1PXFS1MBTUJD
and solar cells are PSHBOJDTPMBSDFMMUFDIOPMPHZ
XJMMTPPOCFVTFEJOB
boosting both technologies TPMBSFOFSHZDPMMFDUJOHXJOEPX
DPNBOVGBDUVSFECZ"JS1SPEVDUT
T
echnical innovations in light ment of Energy’s (DOE; Washington, OLEDs can be made as broad lumi-
emitting diodes (LEDs) and pho- D.C.) Commercially Available LED nescent surfaces that are transparent
tovoltaics have consistently rere- Product Evaluation and Reporting (or when inactive, flexible and lightweight.
flected the similarities between CALiPER) Program (www.netl.doe. These features lend them well to back-
the two technologies. In fact, research gov/ssl/comm_testing.htm). Tasked lighting for displays, ePaper applica-
groups at many universities, such with providing “unbiased product per- tions, and architecturally integrated
as the University of Michigan (Ann formance information,” CALiPER has lighting such as windows that shine
Arbor, Mich.; www.umich.edu) and developed standards for accurately in the evening. In an early application,
the University of Southern California gauging luminous flux from LEDs, as General Electric’s GELcore subsidiary,
(USC; Los Angeles, Calif.; www.usc. well as accounting for ambient tem- which is now known as Lumination
edu), are studying both simultane- perature changes and thermal effects (Valley View, Ohio), marketed its OLED
ously. With pressing consumer inter- specific to the device in which the bulb materials as self-lighting displays for
est in affordable, energy-efficient and is installed. As can be seen from its museum artifacts. Apple’s recent pat-
environmentally sustainable lighting, most recent round of product testing, ent for an OLED keyboard promises
displays and energy sources, market white LEDs have made prodigious keys that change to suit different al-
demand is now leading industry to- leaps over the past year in recessed phabets, characters and application
ward synergistic breakthroughs. downlight applications (graph, p. 18). shortcuts. The same properties that
According to research firm Nano- allow for transparent OLEDs also facil-
Lighting and displays Markets LC (Glen Allen, Va. www. itates sharper image quality in OLED
In some ways, as Brian D’Andrade nanomarkets.net), new developments displays, because red, blue and green
of Universal Display Corp. (Ewing, in silicon nanocrystals and printed diodes can be stacked on top of one an-
N.J.) points out, commercial advances silicon are expected to challenge the other instead of clustered side by side.
in white LEDs and OLEDs “can’t be role of organic materials in flexible Although the first stacked RGB OLED
slowed down” and are, in fact, “already optoelectronics and photovoltaics. But node was patented by USC’s Thomp-
here.” Firms like Guangzhou Bright industry experts are doubtful in the son group in the mid-90’s, a flat-panel
Lighting LED (Vancouver, Canada) case of OLEDs. “OLED technology is OLED TV (photo, p. 20) only hit the
are currently offering ‘omni-direc- already very mature,” says Ansgar market this past year. One barrier to
tional’ 9-W LED bulbs with the com- Werner, senior manager in Novaled’s market has been that, while blue phos-
parable output of a 50-W incandescent (Dresden, Germany) OLED R&D phorescents had proven themselves to
bulb, available in color temperatures group. “Solution-processed or printed be theoretically 100% light-emission
between 3,000K (incandescent) and silicon is certainly no material for LED efficient compared to blue fluorescent’s
6,000K (cool daylight). Others are of- (too-low band-gap, hardly emissive, 25%, they tended to degrade quickly
fering equally competitive, recessed and so on).” In addition, many familiar over time. Konica Minolta (Tokyo) re-
downlights, which in the case of LED with the two technologies also foresee solved this issue in June 2006, with
Light Fixtures, Inc. (Morrisville, N.C.) OLEDs and ‘regular’ inorganic-LEDs the development of a phosphorescent
are dimmable like conventional units. etching out their own separate and lu- blue that gave the firm’s white-OLEDs
Rapid improvements in those LED crative niches in the marketplace, due a 10,000-h lifetime and a luminous ef-
technologies brought to market has to their divergent form factors and ficiency to rival compact fluorescent
led to the necessity of the U.S. Depart- relative strengths. bulbs (64 lm/W compared to an average
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Newsfront *ODBOEFTDFOU3BOHF
-JHIUPVUQVU MVNFOT

$'-3BOHF

compact fluorescent’s 60-100 lm/W).
Traditional inorganic-LEDs, by con-
trast, deliver sharper less-diffused -&%EPXOMJHIUGJYUVSFT
beams of light, making them ideal for -&%EPXOMJHIUGJYUVSFT
44-T
point-lighting applications like street *ODBOEFTDFOUEPXOMJHIUT
lamps and automotive headlights. This $'-EPXOMJHIUMBNQTGJYUVSFT
year, three major automobiles will hit

the market featuring full LED head- &GGJDBDZ -VNFOT8BUUT
lamps: the Audi R8, the Lexus LS600h

* Values for SSL downlights are from CALiPER testing.
and the Cadillac Escalade Platinum. ** Values for CFL and incandescents are assembled from CALiPER testing, earlier photometric testing and
In anticipation of the growing demand, product catalogs (of 45W-65W incandescent products and CFL equivalents).
*** A fixture efficiency of 0.9 is applied to all replacement lamps unless tested inside a fixture.
Showa Denko K.K. (Tokyo) is investing
Source: DOE SSL CALiPER Program, Round 3, October 2007
$10.6 million to scale up the produc-
tion of its aluminum-gallium-indium- The downlight results from the U.S. Department of Energy’s Commercially Available
phosphide (AlGaInP) ultrabright LED LED Product Evaluation and Reporting (or CALiPER) Program underscore the tech-
nology's maturation
chips from 100 to 200 million units-
per-month by the end of 2008. In street Inc. (Menlo Park, Calif.) has noted, “a (QD) lumiphores. First developed by
lamps, LEDs would replace high-pres- lot of smart people are worrying” about Vladimir Bulovic at MIT (Cambridge,
sure sodium lamps approximately the thermal management problems. Mass.), “Quantum dots (as emitter)
quadrupling the time between replace- LEDs smaller size relative to are the inorganic components closest
ments to an amount in excess of 50,000 OLEDs also makes them likely candi- to application” in hybrid displays, ac-
hours (or 10 years). LED street lights dates for retrofitting into ‘Edison bulb’ cording to Novaled’s Werner. QD Vision
would also contain no environmentally sockets, thus competing directly with (Watertown, Mass.), a firm developing
hazardous mercury and could help to incandescent and compact fluorescent the technology with Bulovic on its Sci-
reduce light pollution as a consequence bulbs — a fact not lost on large players entific Advisory Board, estimates that
of the sharp, focused quality of their in the lighting industry. In 2007 alone, it could produce a marketable QD-
beams. Controlled dimming of street- Royal Philips Electronics (Amster- LED cell phone display within three
lights has also been considered since dam, Netherlands) spent $4.3 billion years, promising more vivid colors and
LEDs warm-up radically faster than in the purchasing of five LED lighting greater energy efficiency than OLED
high-pressure sodium lamps. companies (including Genlyte Group displays. While “hybrid structures are
There are thermal and electrical ob- Inc. and TIR Systems Ltd.), surpass- realistic,” Werner emphasizes that,
stacles to be overcome before the wide ing General Electric as the largest “today many printed inorganic materi-
adoption of LEDs takes place in these supplier of lighting to the U.S. market. als need high temperature annealing,
high luminosity (<12,000 lm) contexts, The Netherlands-based firm supplied rendering them incompatible with or-
however. Though LEDs produce more Times Square with a 9,000-bulb LED ganic layers and flexible substrates.”
light-per-unit energy than traditional ball for its 2008 New Year’s celebra- The sentiment is common among
bulbs, their waste heat is highly local- tion and was also competing to sup- other OLED researchers as well. Due
ized around the miniscule semiconduc- ply color-tuning LEDs for the top of to the required high-temperature an-
tor components that convert electricity the Empire State Building. (The firm nealing, inorganics must be deposited
to photons. Due to that concentration, was competing against Color Kinetics, first in any hybrid process, affecting
it is not as easily transferred as the which it also bought in 2007.) the cost, the flexibility of the manufac-
heat radiating off a traditional lamp’s Adding to these high-profile PR- turing sequence and what substrates
large exposed surface. These thermal spectacles, Philips has been vocal in can be used.
issues evolve into environmental chal- its call to institute a federally legis- These are the kind of obstacles that
lenges when the devices are intended lated phase-out of incandescent bulbs. have encouraged OLED research-
for outdoor use — where something With plans to develop and market ers to pursue fully organic methods.
like the possibility of a bird nesting new generations of energy-efficient While the prospect of paper-thin, flex-
over a vital heat exhaust can threaten incandescent bulbs, GE has publicly ible monitors, self-illuminating plastic
to permanently damage an LED fix- been advocating a more free-market surfaces and wearable solar cells all
ture. Recently, Gordon Routledge of approach to such a phase-out. As one have an obvious marketing appeal,
Dialight Lumidrives (York, U.K.) and researcher phrased it, it would seem the real benefit of flexible electronics
Roger Shuttleworth of the University that emerging LED technologies are from an industrial standpoint has con-
of Manchester’s (www.manchester. “more competing with the incumbent” sistently been roll-to-roll processing.
ac.uk) electrical engineering depart- than with OLEDs. Traditionally, when indium tin oxide
ment have partnered to address these With respect to monitors and dis- (ITO) is used as an electrode in OLED
challenges. As Paul Drzaic president- plays, however, other emerging tech- devices or photovoltaic cells, the place-
elect of the Society for Information Dis- nologies are vying with OLEDs for ment of the material on glass or plas-
play (San Jose, Calif., www.sid.org) and position, namely hybrid organic/inor- tic requires a vacuum chamber, sput-
chief technology officer for Unidym, ganic LEDs featuring quantum dot tering tools, and roughly a 1-ft/min
07_CHE_021508_NF1.indd 18 1/30/08 2:23:03 PM

Companies Lighting the Way
Nichia edlinks.che.com/7369-561
Lumination edlinks.che.com/7369-562
Cree edlinks.che.com/7369-563
Philips edlinks.che.com/7369-564
Lumileds edlinks.che.com/7369-565
Novaled edlinks.che.com/7369-566 ible spectrum of light, but the material semiconducting polymers and fuller-
Universal Display edlinks.che.com/7369-567 translates them all into red wavelength, ene derivatives via all-solution pro-
Unidym edlinks.che.com/7369-568 lower energy photons. This energy is cessing. Though only power-conversion
Osram edlinks.che.com/7369-569
effectively lost as heat in the cell. efficiencies of over 6% were achieved
Dupont Displays edlinks.che.com/7369-570
Konarka edlinks.che.com/7369-571 The breakthrough development in at illuminations of 200 mW/cm2, each
Air Products edlinks.che.com/7369-572 stacked OPV research came from a tandem cell was absorbing more en-
GBL LED edlinks.che.com/7369-573 team lead by Kwanghee Lee and Alan ergy from photons within its respec-
Applied Materials edlinks.che.com/7369-574 J. Heeger
COAP who were able to fabricate tive wavelength
0243-11_3pcbv_CE:U9840td_COAP024304_PE range.5:20
1/16/08 The team also 1
PM Page
QD Vision edlinks.che.com/7369-575 a two-layer OPV system composed of noted that the OPV materials could “be
Q-Cells edlinks.che.com/7369-576
LED Light Fixtures, Inc.edlinks.che.com/7369-577
Dialight Lumidrives edlinks.che.com/7369-578
Konica Minolta edlinks.che.com/7369-579
Showa Denko K.K. edlinks.che.com/7369-580 ONLY FROM APOLLO : FULLY-RATED ANSI CLASS 600
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100% American-Made B A L L VA LV E S
processing speed. In effect, the slow Fully rated Class 600 in every size: 3/8", through 2" Carbon steel,
processing requirements and the ex- stainless steel, nickel and alloy bodies
pense of the equipment itself combine
to significantly lower the amortization Gland plate adjustable without removing actuator
rate on the equipment and reduce the
Meets all latest industrial codes and standards
return on investment. Flexible elec-
trode alternatives like carbon nano- NPT, socket weld and buttweld end connections
tubes (CNT) can be deposited at room
temperature, with faster and cheaper Rugged RPTFE spiral wound body seals
printing techniques akin to conven- Fully machined ISO 5211 mounting
tional newspaper publishing.
Cast purge and drain bosses
Organic and inorganic solar cells
Two-position locking device
In 1997, phosphorescent OLED tech-
nology had not developed efficiencies
that were comparable to those of fluo-
rescents, though many paths toward
improvement had been proven at a re-
search level. Within three years, rapid
advances in new materials were facili-
American-made Apollo®
tating innovative design architectures
for OLED devices. According to USC’s Class 600 three-piece,
Mark Thompson, “where we are in or- full-port ball valves give you
ganic photovoltaics, today, in terms of superior quality, performance
intellectual development is not far off and long, reliable life for the
from where we were with OLEDs ten lowest cost of ownership in
years ago.”
tough applications like power,
Currently, organic photovoltaic
pulp and paper, oil field, refin-
(OPV) cells operate at efficiencies be-
tween 2/3 and 1/2 of dye-sensitized ery and chemical processing.
or Grätzel solar cells and about 1/3 to For real lasting value, turn
COAP 0243-11_HP
1/4 the efficiency of the average, com- to Apollo Valves.

mercially available silicon-based solar
panel. However, OPVs carry with them
the promise of simple and cost-effec-
tive tandem-polymer solar cells. Tan-
dem solar cells are a series of linked You can afford AMERICAN-MADE.
solar cells, each with different absorp- You can afford APOLLO.
tion characteristics capable of collect-
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Silicon-based solar cells can absorb a
wide range of photons within the vis-
Chemical Engineering www.che.com February 2008 19
07_CHE_021508_NF1.indd 19 1/30/08 2:23:47 PM

Newsfront
fabricated to extend over large areas by uct more valuable than just the power
means of low-cost printing and coating it produces.”
technologies that can simultaneously This past October, Konarka also en-
pattern the active materials on light- tered into licensing agreements with
weight flexible substrates.” Dupont Displays (Wilmington, Del.)
The Lee/Seeger technology is now for the sole rights within the OPV field
one of the key patents for Konarka to use key patents that Dupont and Sony's 11-in. OLED HDTV, the XEL-1,
(Lowell, Mass.), which his begun en- the University of California at Santa offers a 1,000,000:1 contrast ratio, 1080p
tering into deals with other firms to Barbara (www.ucsb.edu) had devel- resolution and >100% NTSC color
reproduction
market its flexible OPV cell technology oped for OLED displays. The patent
(photo, p. 17). Having been awarded a licensing is reminiscent of a decision has forecast that the thin-film PV mar-
grant from the National Institute of made that same month by Applied ket will grow from $1 billion in 2007 to
Standards and Technology (Gaith- Materials (Santa Clara, Calif.) to con- $7.2 billion in 2015, with 75% of that
ersburg, Md., www.nist.gov), the firm vert its LCD-display processing equip- total attributed to large projects and
joined with Air Products (Allentown, ment for the processing of amorphous utilities, commercial and industrial
Pa.) in October to create a translu- silicon solar cells, selling equipment facilities, and residential buildings.
cent OPV window — seen more as to solar industry giant Q-Cell (Bitter- These figures are echoed by Pho-
competition with ordinary windows feld-Wolfen, Germany). ton Research Associates (San Diego,
than with lower cost-per-watt cells. Though OPV technology promises Calif.), which estimates that thin-film
“We’re not selling high efficiency and economical manufacturing, thin-film PV will have a 63% compound annual
not lower prices,” Konarka’s chairman techniques for traditional crystalline growth rate into 2010.
and cofounder Howard Berke told the silicon and amorphous-silicon PV cells Last summer a consortium headed
Lux Research conference on nanotech- still hold major energy conversion re- by DuPont and the University of Dela-
nology. “It’s the patterns, colors, the cords and are the most mature tech- ware (Newark, Del.; www.udel.edu)
aesthetic attributes that make a prod- nologies on the market. Nanomarkets developed a silicon PV with a record
efficiency of 42.8% by optically sepa-
rating the light into three groupings of
similar photons before being absorbed
by the cell. The technique, funded
under DARPA’s Very High Efficiency
Solar Cell (VHESC) program, would
allow silicon cells to compete in poten-
tial future efficiency with OPVs, be-
cause the novel optical design circum-
vents the need to mechanically stack
a Si PV to fully absorb energy from a
range of photons.
R&D synergies
Optoelectronic materials, whether they
are emitting light or absorbing light,
find themselves in a highly competitive
field today with many promising new
technologies. Research into new mate-
rials has created more efficient designs
for existing technologies like solar cells,
LEDs and displays. Furthermore, the
structural similarities between these
display, energy-collecting and lighting
devices have facilitated a ‘cross-pol-
lination’ of technical innovations and
unexpected economies of scale. While
other factors such as resource markets
will be a determining factor in how the
field develops, the scope of research
interest in academia and industry sug-
gests a high potential for many signifi-
cant breakthroughs to come. ■
Matthew Phelan
07_CHE_021508_NF1.indd 20 1/30/08 2:24:30 PM

Newsfront
MAKING THE MOST

OF WHAT YOU’VE GOT
A proactive asset-management program helps processors
get more from their facilities, despite obstacles
A
sset management means differ- are making asset management a vital walk into the plant and keep it going.”
ent things to different people in tool for survival. On the bright side, companies that
the chemical process industries The high cost of energy and the in- take asset management seriously, en-
(CPI). Some take a holistic view creasing price of raw materials have grain it into the workplace culture
in which equipment operations and created a difficult working environ- and link it to their business practices
maintenance, planning and schedul- ment for chemical companies. “Mak- can not only survive these threats,
ing and all other processing proce- ing it more challenging is the fact that but prosper despite them. The most
dures fall under the asset manage- processors can’t increase their fin- obvious benefit is greater availabil-
ment umbrella. Others focus solely on ished product prices to customers as ity of equipment and labor. While
physical equipment and assets. quickly as they have experienced their the narrow view of this is increased
To make it more diverse, asset own price increases,” says Gary Tray- uptime, it actually has far greater
management needs differ according lor, senior vice president and head of implications. More available and pro-
to facility type. For instance, brown- chemical practices at Celerant (Lex- ductive uptime often has a positive
fields should use asset management ington, Mass.). “Difficulties maintain- influence on unit costs, which lowers
programs to increase efficiency and ing a margin have forced processors to per-pound production costs and ulti-
provide the ability to react to the very intensely focus on efficiency and mately allows these cost decreases to
market, despite existing constraints. cost management.” be passed onto the customer in the
“In other words, existing facilities Another factor is the labor situa- form of lower product pricing. This, in
need asset management programs tion. During the downsizing of the turn, increases the company’s market
to help them become more agile in 1990s, chemical companies trimmed share, according to Traylor.
the face of obstacles,” explains Elinor away younger talent and kept senior “It’s critical to think of the strategic
Price, director of product marketing workers due to union requirements. implications of asset management,”
for chemicals with AspenTech (Bur- As a result, the chemical industry is notes Traylor. “I see chemical proces-
lington, Mass.). While new plants, faced with a demographic profile that sors out there who are aggressive in
which tend to be large, high-capacity includes 20% of the workforce retir- asset management taking market
facilities designed to be reactive, need ing each year so that in the next three share away from those who are less
to utilize their assets to make more years, 50 to 60% of the workforce will aggressive. There really is a linkage
pounds of product in the most cost be replaced with younger, inexperi- of how important asset management
effective manner. “This approach re- enced people. is to overall business, sustainability
quires a different type of asset man- “If you talk to folks in management, and growth.”
agement,” notes Price. they are really concerned about the However to carry out an asset
ability of this younger set to main- management program to this level
A tool for survival tain the integrity of the plant,” says of success, visibility of equipment
Whatever the asset management Traylor. “They worry that if they don’t information and performance data,
needs of a company, the current eco- create an asset management plan and some type of standardization
nomic and labor conditions in the CPI now, the ‘newbies’ won’t be able to are mandatory.
$)&.*$"-&/(*/&&3*/(888$)&$0.'&#36"3:21
Newsfront
Data + visibility = knowledge

Collecting, studying and providing ac-
cess to information about equipment
is vital to any asset management pro-
gram for two reasons. First visibility
of diagnostic information allows tech-
nicians to make better decisions about
when and where to apply predictive
and preventive maintenance. Second,
performing these tasks ultimately
helps avoid unplanned downtime and
increases equipment availability.
“Technicians in chemical processing
facilities need access to information
about everything equipment related,”
says Moin Shaikh, an automation and
asset management expert at Siemens
(New York, N.Y.). “All of this informa-
tion has to be logged into the system also tries to provide visualization and for further investigation of a system’s
and then studied over time in order for integration to the end user, but in a reliability, explains Stearns. How-
technicians to use it for the ultimate mobile fashion. “We are big on mobil- ever, David Ochoa, director of stra-
goal of improving overall efficiency ity solutions that allow field opera- tegic planning with Emerson’s Asset
and utilization of assets.” tors to interact with automated pro- Optimization division (Austin, Tex.),
Jeffrey Vasel, global asset optimiza- cedures, collect data and bring it back warns that diagnostic, visibility and
tion manager for ABB’s Process Au- into the asset management solution integration tools are just that — tools.
tomation Division (Wickliffe, Ohio), easily,” he says. “We find with our customers that just
agrees that visibility of information Honeywell’s Mobile PKS technol- having the tools isn’t sufficient. Many
is critical and adds that integration of ogy offers a wireless mobile produc- customers purchased diagnostic tech-
this information is also necessary. tivity solution that extends access to nologies and programs for visibility as
“Because many chemical processors critical process information, historical part of a system but they aren’t actu-
have a variety of vintages of equip- data, graphics and other key func- ally using it,” he says. “In facilities like
ment, as well as equipment from mul- tions beyond the control room. Mobile this they need to make a business case
tiple manufacturers, it is important PKS technology allows engineering, for rewriting the maintenance proce-
for them to have a way to integrate all operations and maintenance person- dures to include use of the technology
the information collected from these nel to capture process data directly so someone gets a work order telling
various assets into one view for opera- from field devices, as well as validate them to look at the information before
tors, maintenance, production and en- and share information at the point of heading into the field.”
gineering people,” notes Vasel. collection. Combined with other Mo- Experts agree that this type of
He explains how one customer uses bile PKS solutions, such as IntelaTrac preparation helps on several levels.
integration to combine three different PKS — an integrated software and Obviously necessary, and only nec-
maintenance systems into one. The hardware solution for wireless field essary, repairs are tackled before
firm has a vibration analysis system, data collection and asset manage- catastrophic, productivity-stopping
a route-based maintenance program ment that enables users to integrate breakdown occurs, but on a more ad-
that uses handheld thermography field data with data from multiple vanced level it helps with the labor
equipment and a data-collection sys- other sources, including production, issues plaguing the industry. Because
tem that gathers realtime information process control and work manage- there are fewer technicians in the
about different devices throughout ment systems — the handheld access plant, having a system that provides
the facility. ABB’s 800xA asset-opti- to process data allows users in the information on a timely basis about
mization product is used to integrate field to view the latest plant informa- what actually needs to be done allows
information collected from the three tion while on the move, enhancing op- better management of the resources
disparate programs into one view. On erational performance, says Stearns. that are available.
a daily basis, the maintenance techni- Making information available “We hear all the time how guys hate
cians look at the information collected throughout a facility and integrat- it when they get a work order and don’t
and integrated by the system to drive ing process information into plant have all the information about the
their maintenance schedules. systems and applications, helps give tools necessary for the job,” says Marc
Chris Stearns, who is responsible field users the tools and information Carlson, industry principal with SAP
for operator effectiveness and main- necessary to identify failures and (Newtown Square, Pa.). “This means
tenance effectiveness with Honeywell causes that may previously have gone they have to waste time going back to
(Morristown, N.J.), says Honeywell unrecorded. It can also open the door the shop for a different part or a piece
21-24 CHE 2-08.indd 22 1/29/08 6:27:23 PM

Traylor. “Even within a plant, there He says this causes a lot of variabil-
A sample of Equipment may be differences from line to line, ity, which leads to poor performance
and Service Providers operator to operator and maintenance of equipment. If an operator on one
ABB edlinks.che.com/7369-600 tech to maintenance tech. Operators shift sets parameters differently than
AspenTech edlinks.che.com/7369-601 may interpret parameters differently the person on the next shift and if one
and maintenance technicians may pri- parameter is incorrect, the equipment
Celerant edlinks.che.com/7369-602
oritize tasks differently. Simply put, will trip or fail and then the technicians
Emerson Process there’s an utter lack of standardization repair the equipment subjectively or
Management edlinks.che.com/7369-603 in many facilities and companies.” with the wrong components. “Not hav-
Honeywell edlinks.che.com/7369-604
Invensys edlinks.che.com/7369-605
www.woodgroup-esp.com
Rockwell
Automation edlinks.che.com/7369-606
SAP edlinks.che.com/7369-607
Siemens edlinks.che.com/7369-608
Yokogawa edlinks.che.com/7369-609
of personal protective equipment. But,

if the system in place provides the in-
formation in a coordinated and inte-
grated environment where all the data
and requirements are included in the
maintenance plan, the guy who is turn-
ing the bolts knows what he needs and
can get the job done efficiently. The
machine will be available when needed
and is repaired in a timely fashion,
which helps reduce costs.”
Low tolerance for pump problems?
Actually applying data collection No problem.
tools and asset optimization products
can also help gather workforce knowl-
edge and prepare chemical proces- Pressure to lower ever-increasing maintenance
sors for the future. “As the workforce costs and reduce environmental impact has paved
the way to better surface pumping solutions. SPS APPLICATIONS:
is heading for retirement, capturing 0 Booster
their expert knowledge is crucial to Our multi-stage centrifugal SPS™ Surface Pump- 0 Transfer
ing Systems provide versatile, low-maintenance 0 Circulation
survival,” says Vasel. “Smart proces- alternatives to many split-case centrifugal, 0 Injection
sors are beginning to have these guys positive-displacement and vertical-turbine pump
program information about when applications. The SPS is a cost-effective solution
equipment breaks down, what situ- for processing, petroleum, mining, water and other
ations occur that make an asset go industries that require high-volume movement of SP1000: rated 100 to 1000 HP
bad and how or when to correct the fluids. Proven benefits include: (SP2000: rated 1000 to 2500 HP
also available)
situation into an asset management • Lower initial and whole-life cost
system. Basically it gets important • Short construction lead-time
• Increased reliability and runtime
information out of their heads into a
• Low noise and vibration levels
working program where other, new • Remote monitoring and control
technicians can share it.” • Worldwide support.
Call this number: 281.492.5160.
Standardization growing Or e-mail sps @woodgroup.com.
While obtaining and actually employ-
ing technology for data collection, vis-
ibility and integration is a step in the
right direction. Experts say the differ-
ence between the leaders and everyone
else is how comprehensive and consis- Wood Group
tent the definitions and processes are. Surface Pumps
“It’s common to go from plant to
plant within a company and find their
strategies are very different,” says
WG SPS ad_CE_half_1-08.indd 1 1/7/08 10:38:14 AM
21-24 CHE 2-08.indd 23 1/29/08 6:27:47 PM

Newsfront
Improving Safety and Operational Performance
W
hen a process is disrupted at a facility, it costs money • Early detection, according to the consortium, alerts operators
and time. When a process goes out of control it can to possible abnormal situations. Research into the effectiveness of
harm people, the environment and company’s repu- various advanced techniques for detection of the onset of abnor-
tation and profits. For this reason, Honeywell helped mal situations has led Honeywell to deploy solutions that send the
form the Abnormal Situation Management (ASM) Consortium. operator an alert well before an alarm would have occurred. This
The team of 12 companies and universities has conducted re- type of early warning can be crucial in allowing the operator to
search at member sites into root causes of incidents and ways to investigate and take pre-emptive action to avert a problem
detect precursors of abnormal situations, prevent incidents and • Tools, procedures and training to help operators take swift and
more effectively manage assets. appropriate action, defined as mitigation by the consortium, is the
The ASM consortium has pinpointed three key asset-man- third area of attention. It is important to provide quick and easy
agement areas: prevention, early detection and mitigation of access to information needed by operators in the control room as
abnormal situations. they try to mitigate abnormal situations. However, according to
• According to the consortium, prevention includes proactive the consortium, this is often lacking, leaving operators ill equipped
maintenance of equipment and process tools, procedures and to diagnose and manage major problems and emergencies. These
training to prevent human error. The consortium has researched findings led to recommendations about when, where and how to
how operators interact and communicate with one another. Studies present information on schematic displays, how to link displays
show that in many cases, written procedures for activities such as and how to sensibly arrange a hierarchy of displays to avoid
startup are out of date or incomplete. Research also demonstrates excessive display call ups. The consortium has developed more
that many companies are having difficulty hiring new operators than 80 guidelines for this issue. On-site research has demon-
to replace the older workforce. Based on this information, Honey- strated that when operators follow the guidelines, they perform
well suggests use of better operator training tools and software, tasks much more quickly and complete some tasks that otherwise
such as simulation technology, which allows operators to practice would not be completed. The end results, according to consortium
managing abnormal and infrequent situations, which is the way literature, often have a positive financial impact. More information
airline pilots are trained can be found at www.asmconsortium.com ❏
ing standard operating procedures of pumps to learn how to fix and if of the plant can be used for decid-
or maintenance techniques creates a there is only one procedure used to fix ing which feedstocks can and should
huge amount of disparity throughout them,” says SAP’s Carlson. An added be selected because the models help
an organization, which leads to vari- bonus is that if there’s just one set of users understand how equipment
ability in performance and poor asset parameters when operating a piece of will react to a certain feedstock.
management,” explains Traylor. processing equipment, production rate They can also use models for sched-
Instead, he says, leaders standardize and quality should remain consistent, uling to understand what is the best
all their approaches in the plant. This he adds. “When there are standard- sequence to optimize the yield of fin-
means they have common definitions ized, set procedures for everything in ished product.
of critical assets and how to operate the plant and visibility and access to “It used to be that the engineering
and repair them, as well as common those procedures are provided, things models were put on a shelf, but now
strategies for the purchase and pro- run smoothly and assets perform at they are taking them and using them
curement of what is considered across their peak,” says Carlson. to optimize the planning and sched-
the board to be critical equipment. uling or the realtime optimization of
“There’s a host of asset management Reaching a new level a control system. This type of activ-
strategies related to standardization, While many of the above-mentioned ity shows that asset optimization is
including how to organize support re- tips will help get existing plants into reaching a whole new level.”
sources, health and safety and supply shape, planning for asset manage- Other experts agree. “Asset man-
chain. And the more standardization ment when a facility or line is being agement has taken on a new role in
within the plant and across the com- built is a new way to manage assets chemical processing. It’s no longer just
pany, the better your technical re- that many processors are only now be- about maintaining a critical piece of
sources can support the plant organi- ginning to take. equipment,” says Carlson from SAP.
zation and create more leverage out of “Our engineering and design prod- “It’s about using the available tools,
the available talent and equipment,” ucts have long been used during the whether they are CAD drawings, di-
stresses Traylor. “There are a lot of design of a processing plant, but it agnostic technologies, or software for
benefits if you tackle asset manage- wasn’t until recently that customers in visibility and integration, to become
ment in a way that standardizes true the chemical industry began request- more proactive in your approaches to
best practices and focuses on gaining ing that the models created during the equipment availability and process
leverage from the commonalities.” design of the plant be made available planning. For new and existing plants,
Standardization can also sim- as part of the deliverable package so asset management is all about being
plify things for a less experienced they can be used during the produc- more proactive and getting the most
workforce. “It’s easier and faster to tion process,” says AspenTech’s Price. from what you have available.” ■
train people if there are fewer types She says the very detailed models Joy LePree
21-24 CHE 2-08.indd 24 1/29/08 6:28:09 PM

Stafford Manufacturing
FEBRUARY
This bearing protection ring lasts

for the life of the motor
A split-ring version (photo) of the
Aegis SGR Bearing Protection Ring
comes in halves for easy installation.
For variable frequency drive controlled
a.c. and d.c. motors, the SGR split ring
protects bearings from electrical dam-
age caused by circulating or shaft cur-
rents. This maintenance-free ring lasts
for the life of the motor, independent
American Sensor
of speed. Its conductive microfibers Technologies
work with virtually no friction or wear Electro Static Technology
and are unaffected by dirt, grease and
other contaminants. It is available
with mounting hardware in sizes to
accommodate motor shafts with di-
ameters up to 6-in. By shunting shaft
currents to ground, the SGR prevents
“bearing least resistance” and reduces
noise, vibration, bearing failure and
motor failure. — Electro Static Tech-
nology, Mechanic Falls, Maine
edlinks.che.com/7369-331
Oils and coolants will not affect

these rotary encoder collars
This standard line of rotary encoder
collars (photo) can be mounted on vir- CS Unitec Parker Hannifin
tually any shaft to provide speed-sens- torque and electronic speed control. It rity applications. Krystal Bond Tech-
ing capability from their outer diame- produces matte, satin and other fine nology eliminates the need for oil-fill,
ter or face using a variable reluctance surfaces up to a mirror finish on steel, welds and internal O-rings to avoid
sensor. Made of anodized aluminum, stainless steel and nonferrous metals. contamination, and the sensing ele-
these fully-split, two-piece designs The PTX is also suitable for coarse ment is made of electropolished 316L
come in 11 standard sizes from ½-in. grinding jobs such as removing welds, stainless steel. Available in ¼-in. NPT
I.D. by 2-in. O.D. or 3-in. I.D. by 4.5-in. deep scratches, oxidation, rust and male and ¼-in. VCR male fittings, the
O.D., and either 12, 20 or 24 steel tar- paint, as well as for polishing inside AST4900 can be scaled with pressure
gets. Unaffected by oils and coolants, corners. It has an abrasive mounting ranges of 0–25 psi to 0–10,000 psi. In
these encoder collars are suitable for system that eliminates vibration, and addition to high-level voltage, current
a wide range of new and retrofit ap- the grinding and polishing wheels can and frequency output signals, the
plications. Special bore configurations, be changed in seconds. The finned- unit can be packaged with cable, DIN
target locations and custom sizes are shaft design of this finisher makes it 43650 and Bendix electrical connec-
also offered. — Stafford Manufactur- vibration-free during operation and tions. Able to withstand over 100 mil-
ing Corp., North Reading, Mass. ensures 100% concentricity. — CS lion pressure cycles, the AST4900 is
edlinks.che.com/7369-332 Unitec, Norwalk, Conn. suitable for test stands, semiconduc-
edlinks.che.com/7369-333 tor-processing equipment, gas-pipe-
Create matte, satin and other fine line instrumentation, data loggers,
finishes on metals This pressure sensor is ideal panels and manifolds. — American
For finishing surfaces, the PTX Eco for high-purity applications Sensor Technologies, Inc., Mount
Smart finishing machine (photo) has The AST4900 (photo) measures pres- Olive, N.J.
balanced straight-line handling, high sure in gases and liquids in high-pu- edlinks.che.com/7369-334
Note: For more information, circle the 3-digit number
on p. 62, or use the website designation. $)&.*$"-&/(*/&&3*/(888$)&$0.'&#36"3:24D-1
New Products
This tubing is suitable for use

with most harsh chemicals
This fluoropolymer FEP and PFA tub-
ing (photo, p.24D-1) can be formed and
welded into heat exchanger transport
lines that offer a non-stick, bac- Rockwell Automation
teria-free transport of deion-
ized water and other cor-
rosive media. With less
than 0.01% moisture
absorption, this tub-
ing can withstand
most harsh chemi-
cals. The FEP and
PFA tubing can op--
erate in tempera--
tures up to 260°C
and has the lowest
coefficient of fric-
tion of any tube
available, accord-
ing to the manufac- Thermo Fisher Scientific
turer. Product sizes
range from 1/8- to 4-in. inner diamdiam- tration and visual fluid-level inin-
eter. — Parker Hannifin Corp., Forth dication. For easy maintenance,
Worth, Tex. the air and fluid filters on Ther-
edlinks.che.com/7369-335 moFlex units can be changed
while the equipment is running
EtherNet/IP connectivity is to eliminate downtime. Accord-
featured on this I/O module ing to the manufacturer, efficien- Rex-Cut Products
The CompactBlock Guard I/O on cies achieved with the new plat-
EtherNet/IP (photo) is said to be the form design provide up to 20% more Diagnose machine failure early
industry’s first safety I/O module to cooling than units of similar size and with this analyzer
feature EtherNet/IP connectivity. power. The chillers can maintain tem- The Datastick VSA-1225 Vibration
The CompactBlock Guard allows the peratures from 5º to 40ºC. — Thermo Spectrum Analyzer enables facilities
use of the industry standard Ether- Fisher Scientific, Newington, N.H. to use vibration analysis in predic-
Net/IP protocol in conjunction with edlinks.che.com/7369-337 tive maintenance, allowing for the
safety PLCs that incorporate the CIP early diagnosis of potential machine
safety protocol over EtherNet/IP. It Grind, finish, blend and remove failures. Based on the Windows Mo-
detects failures at the I/O and field- scratches from stainless steel bile/Pocket PC platform, this vibration
device level, while enhancing opera- This company offers a full line of cot- analyzer and data collector includes
tor protection in many applications, ton fiber mounted points for remov- the new Version 1.8 of the Datastick
including robotic, point-of-operation, ing slag and splatter from welds on Spectrum software suite. The software
guard-monitoring and remote-control stainless steel and aluminum fabrica- records and displays vibration FFT
applications. — Rockwell Automation, tions. With a blend of aluminum oxide spectra in acceleration, velocity and
Milwaukee, Wis. abrasives, the MS Plus line (photo) displacement displays, and now in
edlinks.che.com/7369-336 are suitable for light grinding, finish- a new vibration decibel display. The
ing and blending stainless steel up to VSA-1225 hardware module attaches
This efficient chiller eliminates a finish of 32 RMS. The units come in firmly to a HP iPAQ hx2400-series or
maintenance-related downtime coarse, medium and fine grits, and in hx2700-series handheld, combining
With continuous cooling capacities of sizes of 3/8- to 2-in. dia. and 3/8- to 2- computer power and 128 MB of data
2500 W, this recirculating chiller is in. length. In addition to basic finish- storage with sensor power, Datastick
ideal for diverse applications, including, the MS Plus line is effective for electronics, and interface. — Datastick
ing semiconductor, packaging, analyti- removing scratches caused by carbide Systems, Inc., Santa Clara, Calif.
cal instrumentation, laser, laboratory, burrs, deburring holes, blending cor- edlinks.che.com/7369-339
medical and research applications. The ner welds, and breaking edges without
Neslab ThermoFlex 2500 unit (photo) removing the base metal. — Rex-Cut This screen handles separations
incorporates a recirulation system Products, Fall River, Mass. from ¼ to 100 mesh
with an integrated funnel, full flow fil- edlinks.che.com/7369-338 The Megatex XD is the newest ad-
24D-2$)&.*$"-&/(*/&&3*/(888$)&$0.'&#36"3:
prepare the chromatography vials Perform these tests to ensure
required for the analysis of extracted earplug effectiveness
analytes, while delivering any dilu- VeriPRO technology allows safety
tion required, sealing the vials and managers to ensure employees are
providing the option to load samples getting the most out of their hear-
directly from the workbench through ing protection devices by measuring
an injection port. — Zinsser Analytic real-world attenuation of unmodified
GmbH, Frankfurt, Germany earplugs. Consisting of software and
edlinks.che.com/7369-341 an optimized headset, VeriPRO de-
Zinsser Analytic
dition to this company’s line of dry

separation equipment, specifically
designed to meet the screening re-
quirements of high-volume applica-
tions. The unit features a high capac-
ity per square foot of screen cloth, a
screen deck slope of six degrees, and
an external drive cartridge. A quick
opening discharge door provides ac-
cess to each individual screen deck for
inspection and quick change-out. The
stacked multiple-deck track-access de-
sign allows access to these individual
screens without requiring all decks to
be removed at once. With the ability
to handle separations from ¼ to 100
mesh, the Megatex XD houses a single
reaction cartridge with two spherical
roller bearings designed for 200 h of
service, a support shaft suspension
system with industrial U-joint bear-
ings, and low torsion center springs. —
Rotex Global, LLC, Cincinnati, Ohio
Liquid-liquid and solid-phase

extraction in one system
The Speedy system (photo) can fully
automate solid-phase extraction
(SPE) and liquid-liquid extraction
(LLE) processes on one platform.
Speedy provides state-of-the-art
hardware tools for SPE, such as digi-
tally controlled elution rates using
positive or negative pressure, flow-
rate measurement and the ability to
handle all types of SPE hardware.
LLE with various solvents is also
available on Speedy using either a
single tube vortexer for large volume
extractions, or a multiposition vor-
texer for smaller volumes. It can also
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Union Process
New Products
termines the effectiveness of an ear- commodate different sizes

plug fit over a range of frequencies. of grinding media. The drive
The result, known as the Personal system allows the user to
Attenuation Rating (PAR), identifies switch easily between the
the actual protection an employee re- high speed HAS system
ceives from his or her earplug in each (1,700 rpm) with a side dis-
ear. The device offers two test proto- charge and the conventional
cols. The Complete Check runs testers 1-S system (350 rpm) with a
through five frequencies to determine bottom discharge. The vari-
PAR. The Quick Check is a simplified able frequency controller
test of earplug fit at one frequency, includes an LCD operator
used as an easy pass/fail check for interface module and is pro-
more frequent use. VeriPRO includes grammed to display agitator rpm, and batch processes. Included in the re-
short training videos on proper fitting motor current and power for the close lease are the Tabular Recipe Editor,
of earplugs. — Spherian Hearing Pro- monitoring of processing conditions. ActiveX Controls, integration with
tection, LLC, San Diego, Calif. — Union Process, Akron, Ohio the Proficy Process Systems, per-
edlinks.che.com/7369-342 edlinks.che.com/7369-343 formance enhancements and ease-
of-use features. The new ActiveX
The features of two attritors are This updated software version Control simplifies batch operation
combined in this combination mill improves batch process design by allowing users to view the active
The HAS-1/1-S combination attritor The latest version of Proficy Batch phases of the recipes being executed,
with vertical shaft adjustment (photo) Execution, Version 5.1 (photo, p. along with the key parameters that
combines the features of two of this 24D-5), introduces a variety of fea- are being collected for each phase.
company’s attritors. The vertical shaft tures to simplify and improve the de- — GE Fanuc, Charlottesville, Va.
adjustment feature is designed to ac- sign, maintenance and operation of edlinks.che.com/7369-344
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24D- Chemical Engineering www.che.com February 2008
#%7EB(OUSE!DINDD !-
24D1-7 CHE 2-08.indd 4 1/29/08 6:32:49 PM

GE Fanuc
JM Science
Measure moisture in difficult-to- It features a unique algorithm to im-

analyze materials prove accuracy when defining the
For the analysis of moisture, the length and shape of fibers. With this
Aquacounter AQL-2320 Automated algorithm, it separates crossing fibers
Oil Evaporator Karl Fischer Titration as individual particles and assigns
System (photo) is designed to accu- each one accurate size and shape pa-
rately take measurements in difficult rameters. The PSA300 also has a new
samples like oil, grease, peanut butter, automated sample disperser for dry,
pain, resins, bonding agents and more. free-flowing powder by breaking up
Using an azeotropic distillation solvent agglomerates and providing a homo-
such as toluene or xylene, moisture is geneous spread of sample across the
evaporated at a lower temperature to slide. The disperser utilizes a vacuum,
save money on Karl Fischer reagents. ensuring that individual particles are
Samples are heated to 200ºC, and sol- not damaged and that samples are not
vent is automatically added. Up to 20 contaminated. — Horiba, Irvine, Calif.
samples can be held in the sample tray edlinks.che.com/7369-346
at once. — JM Science, Inc., Grand Is-
land, N.Y. Harsh conditions will not stop
edlinks.che.com/7369-345 this PLC from ideal performance
The HEC-2000 PLC is the newest
This particle characterizer addition to the HEC family of Harsh
utilizes a unique algorithm Environment Controllers. It allows
In conjunction with Clemex (Lon- for programmable intelligence under
gueuil, Canada), this firm has created less-than-ideal conditions, thanks to
an improved PSA300 image-analysis a sealed, watertight enclosure with
system for particle characterization. pluggable connectors, and is submers- Circle 30 on p. 62 or go to
adlinks.che.com/7369-30
Chemical Engineering www.che.com February 2008 24D-
24D1-7 CHE 2-08.indd 5 1/29/08 6:33:33 PM

New Products
Pepperl+Fuchs Dampney
ible to three feet. The HEC-2000 is Expand segments without and caulking tubes. — Dampney Com-
programmed using this company’s disturbing trunks pany, Inc., Everett, Mass.
EQ Ladder software, which supports The R2 RieldConnex Segment Pro- edlinks.che.com/7369-350
ladder diagram with function block tectors (photo) can be disconnected
programming. Eight to 32 Vd.c. input while leaving trunk communications Achieve low-concentration gas
power is standard, and I/O includes uninterrupted. Moreover, these mod- mixtures with permeation tubes
eight 8–32 Vd.c. inputs, two 40 kHz ules inherently prevent over-termi- The Trace Source Permeation Tubes
high-speed counters and eight digital/ nation that can cause start-up and are small Teflon tubes filled with pure
pulse-width modulation outputs rated commissioning problems. Providing component compound that emit a
to 3 A with automatic over-current IP20 protection with DIN rail mount- small, stable flow of pure component
safety and programmable-status mon- ing, offered in 4-, 6-, 8-, 10- and 12- for making low-concentration (parts-
itoring for each. Network communica- spur configurations, the R2 Segment per-million to parts-per-billion) gas
tion is accomplished via a standard Protectors feature removable termi- mixtures. Flow is measured in nano-
CAN port or an optional second se- nals with retaining screws, as well grams or nanoliters per minute and is
rial communication port. — Divelbiss as bright LEDs for power, communi- varied by changing the temperature of
Corp., Fredericktown, Ohio cation and short circuit status indi- the tube. Permeation tubes are avail-
edlinks.che.com/7369-347 cation. Built-in test lead connections able for over 400 chemical compounds.
for the company's Mobile Advanced Multiple forms of Trace Source are
These epoxy tougheners will not Diagnostics Module on each spur offered, including disposable perme-
sacrifice material performance and trunk connector eliminate the ation tubs, refillable permeation tubes,
The Fortegra Epoxy Tougheners are risk of shorting as a result of incor- refillable gas-fed tubes, and extended
low viscosity materials for use in rect wiring. life permeation tubes. — KIN-TEK
amine, DICY, anhydride and phenolic- — Pepperl+Fuchs, Twinsburg, Ohio Laboratories, Inc., La Marque, Tex.
cured epoxy systems. They are suitable edlinks.che.com/7369-349 edlinks.che.com/7369-351
for any applications where properties
of epoxies, such as adhesion, corrosion Repair metal with this Perfectly pair servo drives and
and chemical resistance are needed, compound prior to finishing motors with this software
but greater performance is required. A single-component metal repair and MotionMatch software (photo, p. 24D-
Based on a specially-designed self-as- patching compound is now available 7) has recently been released for this
sembling block co-polymer that cre- from this company. Lab-Metal Repair company’s servo drives and motors.
ates the particles needed for toughen- (photo) requires no mixing and ap- The combination of MotionMatch
ing the cured epoxy, Fortegra will not plies easily. This compound repairs motor-sizing software and MotionView
result in big changes to other proper- dents and voids, smooths weld beads, drive-configuration software is a pow-
ties, including viscosity, cure speed or and hides cracks and other surface erful solution to motion-control man-
chemical resistance. The material is blemishes to make cosmetic repairs agement. MotionMatch simplifies the
offered in four forms, based on a blend prior to metal finishing. After harden- process of pairing a servo drive and a
of one of two epoxy resins and the ing, it can be milled, drilled, tapped, motor, allowing the user to configure
toughening material. — Dow Epoxy, machined, sanded, coated and baked. the drive easily. — Lenze-AC Tech, Ux-
Hong Kong, China Lab-Metal Repair is offered in 6-, 12-, bridge, Mass.
edlinks.che.com/7369-348 24- and 48-oz. cans, 1- and 5-gal pails, edlinks.che.com/7369-352
24D- Chemical Engineering www.che.com February 2008
24D1-7 CHE 2-08.indd 6 1/29/08 6:34:00 PM

L. B. Bohle
Lenze-AC Tech
SKF USA
Shaft-sealing solutions pump Series is offered in nitrile- or fluoro- tablets. It inspects for irregularities
lubricant back to the bearing rubber to fit shaft diameters from 12 on all faces using a six-camera sys-
The low-friction Waveseal shaft-seal- to 280 mm. A non-hardening polyac- tem to provide a 360-deg. view of each
ing solutions (photo) feature a spe- rylate coating on the outside diameter tablet, sorting at over 200,000 tablets
cially molded lip to form a sinusoidal of the seal compensates for small im- per hour. Also available is the Proditec
pattern around the shaft surface. This perfections in housing bores. — SKF Inspectab 100, a smaller, more cost-
enables lubricant to be pumped back USA, Inc., Kulpsville, Pa. effective model that is ideal for small
to the bearing for optimized lubricant edlinks.che.com/7369-353 to medium batches, processing 100
retention while pushing dirt away tablets per hour. Both units feature a
from the lip/shaft surface. According Inspect and sort tablets quickly versatile feeding and line-up system
to the manufacturer, the lip generates and accurately that adapts to all shapes and sizes of
25–35% less heat at the contact point, The Proditec Visitab 2 automatic vi- tablets without special tooling. — L. B.
minimizing premature seal failure due sion inspection/sorting system (photo) Bohle LLC, Warminster, Pa.
to heat checking, blistering, hardening provides fast and accurate checking edlinks.che.com/7369-354 O
or lubricant breakdown. The Waveseal for visual defects on pharmaceutical Kate Torzewski

$)&.*$"-&/(*/&&3*/(888$)&$0.'&#36"3:24D-7
www.che.com
China Supplements
Journey on the path to greater sales in China’s CPI in 2008

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Chemical Engineering, in collaboration with Process China, will publish two supplements this year (April and
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About Process China magazine

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FULLSuppl_CHE.indd
PAGE 2-08.indd 11 1/23/08
1/30/08 3:01:02
3:28:50 PM
PM
Pump Engineering
Zwick
FEBRUARY
Measure material strain

with this laser-based system
This firm’s latest strain-measurement
system, laserXtens (photo), has been
successfully used for applications in
chambers where materials are typi-
cally exposed to temperatures from –70
to 250°C whilst being subjected to ten-
sile or compression loads. The system Syrris
measures biaxial strain without any
specimen contact and without the need
to attach any marks to the specimen.
The sample surface is illuminated via
laser-speckle interferometry, then as
the load is applied, the speckle pattern
is tracked by two digital cameras. Re-
altime software algorithms convert the
Michael Smith Engineers
data directly into strain. This measure-
ment technology has been shown to be
immune to the effects of frost forma- with a precision of Cv less than 1%
tion on the sample. — Zwick GmbH & across a flowrate range from 0.25
Co. KG, Ulm, Germany µL/min up to 1,152 mL/min, making
edlinks.che.com/7369-390 them suitable for OEM, analytical,
biotechnological and related applica-
Efficient heating for just about tions. The pumps handle differential
any size flask pressures up to 150 bar, and offer
Atlas Dry Bath is the latest addition long service life, thanks to the use of
to the Atlas family of modular syn- wear-resistant tungsten carbide and
thesis products. Designed as a new ceramics. — Michael Smith Engi-
Parker/TexLoc, Parker Hannifin
method for heating round-bottomed neers, Woking, Surry, U.K.
flasks and vials, the Dry Baths avoid edlinks.che.com/7369-392 Heat exchangers can benefit
issues commonly associated with oil from this fluoropolymer tubing
baths and stay safe-to-the-touch dur- Consider this valve This Fluoropolymer FEP and PFA
ing operation. They are also compat- when control is critical tubing (photo) can be formed and
ible with leading brands of hotplates. As the U.K. distributor for Badger welded into heat-exchanger transport
Stacking Dry Bath (photo) has a series Valves, this firm can supply control lines that offer a nonstick, bacteria-
of concentric cups that accommodates valves to meet the demands of chal- free transport of deionized water and
flasks of varying volumes (from 50 mL lenging applications. For a reverse other corrosive media. Unlike steel,
to 1 L), and provide “excellent” ther- osmosis application, for example, con- which is susceptible to corrosion and
mal transfer for fast heating times. sider the RC250 barstock valve (photo) bacteria buildup, fluoropolymer tub-
— Syrris Ltd., Royston, U.K. in Duplex stainless steel and an MC60 ing, with its more than 0.01% mois-
edlinks.che.com/7369-391 electrical actuator with three speed ture absorption, withstands almost
settings, which closes the valve over a any harsh chemicals except those
Extreme operating conditions are 20-s time span to allow the pressure with fluorine and alkali metals, says
no problem for these tiny pumps to drop at a steady rate. The RC250 the manufacturer. The tubing oper-
This new range of miniature, ultra-low barstock control valve is available in ates in temperatures up to 260°C and
flow, positive-displacement, micro-annu- sizes of 1/4-, 1/2-, 3/4- and 1-in. sizes is said to have the lowest coefficient
lar gear pumps are capable of dispens- with a globe barstock body and handle of friction of any tubing available.
ing a wide range of liquids with precise, pressures up to 340 bar. — Pump En- — Parker/TexLoc, Parker Hannifin
smooth, pulse-free flows. The ultra-com- gineering Ltd., Littlehampton, U.K. Corp., Ft. Worth, Tex.
pact HNP Series (photo) deliver liquids edlinks.che.com/7369-393 edlinks.che.com/7369-394
Note: For more information, circle the 3-digit number $)&.*$"-&/(*/&&3*/(888$)&$0.'&#36"3:24I-1
on p. 62, or use the website designation.
New Products
ARCA-Regler Thermo Scientific
A big valve for

big applications
The demand for valves with
large dimensions is increas-
ing, and this firm has extended
its unit-construction system to
manufacture valves with DN
600 (photo), which are now
also available in cast design.
The valves can be used as anti-
surge control valves for large
turbo compressors and for
starting and stopping the com-
pressor in a controlled man-
ner to protect it in the case of
breakdown. This valve size is
available in pressure classes DIN/EN design of fiber optic cable is used to tool for plant design — Cadison R8
DN600 PN16, 25 and 40, as well as DN transmit a beam of light up to a 90 (photo, p. 24I-6) — is now available for
24 in. ANSI 150 and 300, in standard deg. angle, which illuminates the in- making the work of users more efficient
casings GP240GH/A216-WCB-216 or side of the vessel. A hermetically fused and faster. For example, a new material
1.4581/A351-CF8M, or in special ma- metal-to-glass window provides a 3-in. designer Isomat (for piping class) can
terials. DN 600 valves are suitable dia. viewing width, while being able to be generated in about 4 h, compared to
for water recycling plants, steelworks, withstand temperatures up to 1,000°C 3–4 d needed by conventional methods,
petroleum refineries and huge chemi- and pressures over 600 bar. An Ether- says the firm. About 40 new functions
cal plants. — ARCA-Regler GmbH, net or analog camera mounted to the have been added and 190 functions
Tönisvorst, Germany viewing window provides a realtime have been revised. With the help of In-
edlinks.che.com/7369-395 look inside the vessel. — Allison Engi- ternet browsers and the new module,
neering, Basildon, Essex, U.K. Engineer2Web, each entitled user can
Don’t waste costly ingredients edlinks.che.com/7369-397 access the current planning conditions,
with this granulator regardless of the location or time. Spe-
The Pharma Twin-screw Granulator Take a close, accurate look at cial access procedures were developed
(TSG; photo) is this firm’s first TSG particle size and shape to ensure that only authorized person-
specifically designed for pharmaceu- Making its Pittcon debut next month nel can change object information, or for
tical applications. The Pharma TSG (New Orleans, La.; March 2–7) is the entering new objects. — ITandFactory
eliminates batch variations and de- Morphologi G3 automated particle- GmbH, Bad Soden, Germany
creases ingredient and equipment characterization system (photo, p. 24I- edlinks.che.com/7369-399
costs through a continuous mixing 4). The system provides microscopic
process, enabling operators to use quality images and delivers statis- A collaboration to improve the
smaller, more-precise amounts of ex- tically significant particle size and flow of laboratory information
pensive ingredients. Key features in- shape information through the rapid Together with Mettler Toledo (MT;
clude: removable components (barrel analysis of hundreds of thousands of Greifensee, Switzerland), this firm
liners and screws); high free volume; particles, with little or no user inter- has introduced an integrated solution
reduced scale up risks, and reduced vention. A major development in the that is expected to improve the work-
in-process inventory. — Thermo Scien- Morphologi G3 is its novel, fully-inte- flow and the transfer of information
tific Inc., Karlsruhe, Germany grated dry-powder dispersion system. in laboratories for many disciplines,
edlinks.che.com/7369-396 Precise software control of all disper- including life science, chemistry, food
sion parameters ensures highly repro- and petrochemical industries. The two
Level control takes ducible dispersions with consistent firms have collaborated to provide re-
a completely new look and controlled particle orientation. searchers the means to exchange data
This new range of level-control devices The sample is completely enclosed, between precision instruments, includ-
offers a new approach to level mea- and the system allows easy dispensing ing balances and titration instruments,
surement. The Canty range of light, from bulk materials and the prepara- and laboratory information-manage-
sight and camera devices (photo, p. tion of multiple aliquots. — Malvern ment systems (LIMS). The unique so-
24I-4) has been developed to provide Instruments, Malvern, U.K. lution seamlessly integrates the firm’s
users with a realtime view of condi- edlinks.che.com/7369-398 SQL*LIMS with MT’s LabX Data
tions inside process vessels, and there- Management Software. The combina-
fore has advantages and benefits over Software to improve tion creates the ability to manage data
traditional liquid-level-measurement the efficiency of plant design more efficiently, while saving research-
technologies, says the firm. A patented- The latest release of the engineering ers time and costs in day-to-day labo-
24I- Chemical Engineering www.che.com February 2008
24i1-7 CHE 2-08.indd 2 1/29/08 6:37:47 PM

NEW
ROBOX evolution ES 5:
Compact Blower package for
the WWT industry
• Complete range: from 240 up to 10.500 m3h.
• Robuschi RBS 3 lobe P. D. Blower with a
patented device to reduce the pulsations:
LOW PULSE.
• Low noise: < 5 d(B)A under all types of
operating conditions.
• ROBOX evolution ES 5 can be transported
easily fully assembled without removing
enclosure.
• LOW MAINTENANCE • LOW PULSE • LOW NOISE
Sentinel: Electronic
monitoring system
Simple oil change
Easy oil check
PUMPS AND BLOWERS

ROBUSCHI S.p.A. Via S. Leonardo, 71/a 43100 PARMA - ITALY
Italia Tel. +39 0521 274911 Export Tel. +39 0521 274991 Fax +39 0521 771242
e-mail: robuschi@robuschi.it
www.robuschi.com
24i-3 CHE 2-08.indd 1 1/15/08 4:10:39 PM

New Products
Allison Engineering
Malvern Instruments
ratory processes, when compared to tions. The “starter” package includes Effect Matrix, which allows users to
using instruments that are controlled a basic configured drive, input fusing, add a cause and effect matrix for each
by their own software and that operate RFI filter and enclosure. The options safety integrated function (SIF) when
independently of any information sys- are then designed to add functionality creating a Safety Requirements Speci-
tem. — Applied Biosystems, an Applera or features in line with the demands of fication. — exida, LLC, Sellersville, Pa.
Corp. business, Warrington, U.K. the end application. These options can edlinks.che.com/7369-403
edlinks.che.com/7369-400 include power features, such as circuit
breakers, isolators, I/O and bypass Condensation does not bother
Experts keep your GC/MS contactors and line reactors. Control this dewpoint transmitter
running with this remote service and communications options include: The DryCap Dewpoint and Tempera-
This firm’s Intillegent Services remote control interfaces (analog and digital) ture Transmitter Series DMT340 is
instrument monitoring and diagnos- and serial communications, such as designed for industrial low-humidity
tics capability is now available for the DeviceNet, ControlNet and so on. Op- applications, such as compressed-air
6890/7890 Series gas chromatograph erator interfaces include HMIs, door- drying and metal treatment. The Dry-
(GC) systems and 5973/5975 Series mounted devices and meters. Motor- Cap sensor is immune to particulate-
GC-Mass Spectrometer systems. interface options include encoders, matter contamination, water conden-
The Intelligent Services feature uses resolvers, thermistors, RTDs, cooling sation, oil vapor and most chemicals.
proven, secure IT technology to link blowers and space heaters. All config- Since the sensor withstands conden-
instruments to the firm’s customer- ured drives are assembled and tested sation, its performance is “unmatched”
support centers, where experts provide in accordance with ISO9001 and com- for low-dewpoint applications that ex-
proactive technical support designed ply with EEC directives 73/23, 89/336 perience water spikes in the process,
to address problems before they affect and EN 61800-3. — Rockwell Automa- says the manufacturer. The device’s
laboratory productivity. The Push-for- tion Ltd., Milton Keynes, U.K. stability is due to the patented auto-
Help feature enables single-button edlinks.che.com/7369-402 calibration function, which calibrates
requests for assistance, and the firm’s and adjusts the transmitter while the
service engineers can remotely deter- The latest software release can measured process is running. Dew-
mine the status of the system before improve SIS development points from –60 to 80°C are measured
responding. Realtime Collaboration Release 2.0 of exSILentia offers users with an accuracy of ±2°C. — Vaisala
allows engineers to open an ultra-se- several expanded and new functional- Oyj, Helsinki, Finland
cure remote desktop sharing session ity providing more efficient develop- edlinks.che.com/7369-404
to provide advanced diagnostics to ment of their safety-instrumented-sys-
facilitate immediate, remote problem tem (SIS) life-cycle activities. Among An idle exhaust-abatement
resolution. — Agilent Technololgies the new functions are new plug-in system does not waste fuel
Europe, Waldbronn, Germany capabilities; plug-in modules add The Atlas and TPU families of com-
edlinks.che.com/7369-401 functionality to exSILentia and can bustion exhaust-management systems
be licensed in combination with the are now available with an "idle-mode"
Now there’s help for specifying a exSILentia license. R2.0 now offers feature. Idle mode allows the abate-
drive system the following plug-in modules: PAH ment system to go into a standby mode
To help smooth the process of speci- Import, which allows users to import with reduced fuel and water consump-
fying and ordering a.c. drives and re- data from third-party software; Cus- tion when exhaust is not flowing from
lated ancillaries, this firm has intro- tom Proprietary Equipment Database, attached process equipment. When
duced a configured-drives service that which allows the use of a proprietary idle, the system only consumes fuel to
has been designed to meet the needs equipment reliability database; and maintain the pilot flame, and water to
of a wide variety of industrial applica- System SRS Creation with Cause & refresh the recirculation system once
24I-4$)&.*$"-&/(*/&&3*/(888$)&$0.'&#36"3:
an hour. On Atlas, these levels repre- can still be maintained and expensive research organizations to maximize
sent a reduction of 89% for fuel and failures avoided. Mini8 also offers the their potential through increased pro-
nearly 100% for water. Idle mode can Modbus protocol both on RS 485 or ductivity. The database was developed
also be provides as an upgrade to ex- Ethernet. — Eurotherm, London, U.K to eliminate classic obstacles, such as
isting TPU systems where even higher edlinks.che.com/7369-407 different operating systems, limited
percentages of fuel reduction can be support for database formats, or lim-
made, says the firm. The system moni- This database is not picky about ited access to a central storage facil-
tors signals from process equipment to the operating system used ity, says the firm. The security and
determine active and idle status. It en- CLC Bioinformatics Database enables maintenance of the new database can
ters idle mode automatically and can
return to full operation status within

10 s. — Edwards, Wilmington, Mass.

An RFID system alerts against

pallet tampering
Together with Pliant Corp. (Schaum-
burg, Ill.), this firm has successfully
demonstrated a solution for tamper-
proofing pallets with RFID-enabled
stretch film (shrink wrap). Pliant’s
electrically conductive stretch film,
combined with this firm’s PowerG
labels for tracking freight and high-
value pallets, provides a viable solu-
tion by overcoming the limitations of
barcode technologies, the limited per-
formance of standard passive RFID,
and the high cost of active RFID read-
ers, claims the manufacturer. Electri-
cally connected to the film wrapped
around the pallet, the PowerG label
is readable by RFID readers when the

film is intact and the electrical circuit
is closed. However, when the stretch
film is tampered with, the circuit is
broken, rendering the label unread-

able and thereby alerting a supply-
chain manager to possible tampering.
— PowerID Ltd., Petah Tikva, Israel

Perform PID loops
from outside the PLC
The Mini8 controller makes it possible

to perform PID loops outside the PLC
without compromising the benefits of
an integrated solution, says the man-
ufacturer. The Mini8 has four plugin
I/O slots, and can cater for a variety

of signals, such as thermocouple and
RTD inputs and relay, logic and ana-

log output. Up to eight discrete control

loops can be connected to major field-

buses, such as Profibus, DeviceNet and

!
CANopen, thus taking the responsibil-

" # $ % "

ity of the loops outside the PLC. Thus, &'()*( +
,-. / '010 / (2*
in the event of of the PLC going down, 3 ,-. / '010 / (2 0* .)
equipment pressure and temperature
$)&.*$"-&/(*/&&3*/(888$)&$0.'&#36"3:24I-5
New Products
ITandFactory
potentially help organizations stop device that communicates over

misuse or loss of data, as well as help the firm’s OneWireless indus-
protect their intellectual property. The trial mesh network. It collects
database is cross-platform, running on acceleration, velocity, tempera-
OS X, Windows and Linux. — CLC bio, ture and bearing-condition data
Aarhus, Denmark and delivers it to process opera-
edlinks.che.com/7369-408 tors and maintenance personnel
to alert them of any equipment
Track equipment health problems. — Honeywell Process
without wires Solutions, Phoenix, Ariz.
In collaboration with SKF, this firm edlinks.che.com/7369-409
has introduced OneWireless Equip- achieves separations of N = 10,000–
ment Health Monitoring (EHM), the A tiny GC with 25,000. — C2V, Enschede, Netherlands
latest addition to its portfolio of indus- huge performance edlinks.che.com/7369-410
trial wireless solutions. OneWireless The C2V-200 micro gas chromatograph
EHM will wirelessly transmit com- (GC) is claimed to be the world’s fastest Check air for microbes
plete spectral information — including and smallest GC, providing the highest with this sampler
vibration amplitude and operating-pa- quality separation. The device performs SAS ISO is a new generation of SAS
rameter information — from the field an analysis in 10 to 30 s, has an eas- samplers for the microbiological test-
to the plant control room, helping re- ily exchangeable GC channel cartridge, ing of air. The system is based on
duce equipment failures and improve operates at temperatures up to 180°C the impact of micro-organisms onto
business performance through lower and provides a sensitivity of parts per an agar surface of a contact plate or
maintenance costs, says the firm. One- million (with TCD detector). The tiny standard Petri dish. SAS ISO uses
Wireless is a compact, eight-channel (4 unit requires a minimal carrier/refer- a single, certified aspirating head
X vibration, 4 X 4–20 mA) monitoring ence gas (1 mL/min operational) and made of stainless steel or aluminum,
The new SPECTRO ARCOS ICP spectrometer records the
The Sharpest ICP Ever

required spectrum with a performance that has never been
seen before: The resolution is 8.5 picometers in the most
significant range between 130 and 340 nm – 15 picometers at
higher wavelengths up to 770 nm – enabling unusually sharp
The New SPECTRO ARCOS High Performance ICP Spectrometer spectrum, an unbeatable sensitivity and extreme precision.
SPECTRO ARCOS
High Performance ICP Spectrometer
– Paschen-Runge optic with extended wavelength range from
130 to 770 nm completely in first order
– 8.5 picometer resolution from 130 to 340 nm;
15 picometer from 340 to 770 nm
– Robust free-running, air-cooled generator with 5 kW ceramic tube
– Low maintenance UV system with minimal operating costs
– Compact, space-saving design
Find out more about the new ICP performance class

for complex analytical requirements.
www.spectro.com/arcos, spectro.info@ametek.com, Tel. +49.2821.892-2102
Visit us: Pittcon 2008, New Orleans, March 2-7, Booth 5143
Analytica 2008, Munich, April 1-4, Hall A2, Booth 205/304
24I- Chemical Engineering www.che.com February 2008
24i1-7 CHE 2-08.indd 6 1/29/08 6:39:43 PM

or Dispo-Head, a certified, sterile bance and on mitigating its effects. Now produce more
disposable plastic head. The system — Hyperion Systems Engineering, pharmaceutical grade water
offers traceability functions, such as Athens, Greece The new generation of the Orion
date, operator name, sampling loca- edlinks.che.com/7369-412 pharmaceutical water package has
tion and volume of aspirated air, an enhanced reverse osmosis module,
which can be transferred to a printer A transmitter for when the water which gives improved recovery of up
or PC. — International Pbi S.p.A., pressure is on to 90% for single-pass systems and
Milan, Italy VegaWell 51 is a new generation of 75% for twin-pass. This means lower
edlinks.che.com/7369-411 suspension pressure transmitters operating costs and a reduced carbon
suitable for water and wastewater footprint, says the firm. Like its pre-
A new tool applications, including hydrostatic- decessors, the new Orion is fully hot-
for process simulators level measurement in vessels, and water sanitizable. The Orion range
This firm has introduced a PI sys- gauge measurement in deep wells. has been extended to up to 10,000
tem, historian-database comparison Mounting is accomplished by means L/h, and can meet water-quality stan-
tool for use with process simulators. of a stress clamp or a threaded fitting dards of USP 30 and Ph Eur Purified
PI-Compare is an easy-to-use tool (G1 A). The sensor itself is a small, Water and Ph Eur Highly Purified
that identifies the simulator initial Certec measuring cell, with a ceramic Water, and is fully compliant with
condition that closely matches a PI diaphragm and shielded measur- FDA, cGMP and GAMP requirements.
system recorded plant state just being-cell seal. The selectable measur- The control PLC interfaces with most
fore a disturbance. Instructors and ing range is between 0.1 and 10 bar, SCADA systems, and a 21 CFR part
engineers can then quickly identify and the standard output is 4–20 mA. II compliant option is also available.
and use the simulation that matches A HART signal can also be supplied — Veolia Water Solutions & Technol-
that plant state and use the simula- on request. — VEGA Grieshaber KG, ogy, Marlow, U.K.
tor to investigate or train operators Schiltach, Germany edlinks.che.com/7369-413 n
on the characteristics of the distur- edlinks.che.com/7369-413 Gerald Ondrey
PI – REAL-TIME INFRASTRUCTURE
from PLANT to ENTERPRISE
Software that enable the creativity of the USERS

Robust software – CUSTOMERS rely on
OSIsoft mission to maximize the VALUE customers
get from our PRODUCT & SERVICES
WWW.OSISOFT.DE
OSI SOFTWARE GmbH

Hauptstraße 30 • D-63674 Altenstadt • Germany
Phone: +49 6047 9890 • email: gmbh@osisoft.com

Chemical Engineering www.che.com February 2008 24I-
24i1-7 CHE 2-08.indd 7 1/29/08 6:40:04 PM

www.che.com
China Supplements
Journey on the path to greater sales in China’s CPI in 2008

As China rapidly takes leadership in the World Trade Organization and opens its markets to foreign competition,
securing your presence is more critical than ever. Chemical Engineering is proud to present this exclusive
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The supplements will contain practical, how-to articles that have been
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PAGE 2-08.indd 11 1/23/08
1/30/08 3:01:02
2:51:41 PM
PM
Causes of
Overpressurization
Department Editor: Kate Torzewski
T
he failure of a device or of a group of range to maximum pressure. As a general A pressure relief valve (PRV)
components can lead to overpressuriza- rule, when sizing a PRV, maximum heat-duty is an automatic pressure-
tion and subsequent adverse events, such assumed for the abnormal case should be no relieving device that is actu-
ated by pressure at the inlet
as fire, explosion, spill or release. The most more than 125% of normal heat duty.
of the valve. Though safety
common causes of overpressurization are valve, or safety relief
listed below. Understanding the circumstanc- Abnormal vapor input valve, is the terminology
es surrounding overpressurization will help Abnormal vapor input can be caused by the for valves relieving gas
an engineer to avoid these failures. failure of the upstream control valve to fully or vapor, we will use “PRV”
open, or upstream-relieving or inadvertent to describe all types of
External fire valve opening. The required relieving pressure relief valves. A
According to API RP 520 and 521 standards, capacity must be equal to or greater than the relief valve, used for
liquid service, generally
a fire-exposed area is within an area of amount of the vapor accumulation expected
opens in proportion to
2,500 and 5,000 ft2, and below a height of under the relieving conditions. any increase in pressure
25-ft above the grade. In this scenario, the over opening pressure. 4QSJOH
exposed vessel is blocked in. Potential vapors Loss of absorbent flow A safety valve has char-
resulting from the fire must be relieved using When gas removal by absorbent is more acteristics similar to a
a PRV on the vessel, or via a vent path that than 25% of the total inlet-vapor flow, an relief valve except that
remains in a locked-open position between interruption of absorbent flow could cause it usually opens rapidly
the vessel and an adjoining vessel. pressure to rise in the absorber. The PRV (pops), and is primarily
used for gas or
should be sized base on the net accumulation
vapor service
Blocked outlets of the vapor at the relieving conditions.
The closure of a block valve on the outlet of a
pressure vessel can cause the vessel's internal Entrance of volatile materials
pressure to exceed its maximum allowable The entrance of a volatile liquid, such as
working pressure if the source pressure water or light hydrocarbons into hot oil dur-
exceeds the vessel design pressure. Blocked ing a process upset, can cause instantaneous
outlets can be caused by control valve failure, phase expansion. Instead of relying on PRVs,
inadvertent valve operation, instrument-air processes should be properly designed with
or power failure, and other factors. A PRV the use of double block valves, the avoid- Source:
must have sufficient capacity to pass a fluid ance of water-collecting pockets and use of Farris
flowrate that is equivalent to the difference steam condensate traps and bleeds on water Engineering,
Brecksville,
between those of the incoming fluids and the connections. Ohio
outgoing fluids.
%JTD
Accumulation of non-condensibles
Utility failures Accumulation can result from blocking of the /P[[MF
These failures can include the following: gen- normal non-condensible vent or accumulation the downstream vessel should should be
eral power failure, partial power failure, loss in the pocket of a piping configuration or designed to handle the pressure and volume
of instrument air, loss of cooling water, loss of equipment. Because this can result in a loss of of the incoming stream without overpressur-
steam, and loss of fuel gas or fuel oil. For these cooling duty, PRV analysis should be handled izing. If the upstream vessel does not have
cases, a flare header should be designed and the same way. adequate relief capacity, the downstream
sized based on the maximum relief load that vessel should have a PRV of its own.
could result from a potential utility failure. Valve malfunction When two vessels are connected by an
Check-valve malfunction results in backflow, open path and the first has its own PRV and
Loss of cooling duty which can be from 5 to 25% of the normal discharges to a flare header, the second
Cooling-duty losses can include the following: flowrate. Required relief capacity should be will experience the impact from the relieving
loss of quench stream, air-cooled exchanger based on this. pressure of the first vessel and should be
failure, loss of cold feed and loss of reflux. Inadvertent valve operation results in a analyzed accordingly.
Relieving capacity should be calculated by valve position that is opposite from normal
performing a heat balance on the system, operating conditions, which is largely caused Upstream relieving
based on the loss of the condensing duty. by human error and can be avoided by care- Required relief capacity should be greater
ful operation. than the vapor generated because of heat
Thermal expansion Control valve failure to open or close is buildup in the system.
When liquid is blocked in a vessel or caused by electronic- or mechanical-signal
pipeline, external heat input can cause liquid failure. This typically will affect just one valve Runaway chemical reaction
temperature, and hence volume, to rise. This at a time and should be analyzed on a case- Runaway reactions tend to accelerate with
can be caused by the following: liquid that by-case basis. rising temperature; extremely high volumes
is blocked in a pipeline and is being heated, of non-condensibles with high energy can
the cold side of a heat exchanger being filled Process control failure cause the internal pressure of a vessel or
while the hot side is flowing, or a filled vessel This situation refers to the failure of process pipeline to rise rapidly. PRVs may not provide
at ambient temperature that is being heated controllers, such as programmable logic sufficient relief, so vapor-depressurizing
by direct solar radiation. PRVs used in these controllers and distributed control systems. systems, rupture disks and emergency vents
cases can be easily analyzed and sized. The potential impact of failure of every con- are preferable.
trol loop should be analyzed, as well as the
Abnormal heat input impact if one loop fails but all others remain References
This failure can be caused by: the supply of active. As a general rule, the required relief 1.Wong, W., Protect Plants Against Overpres-
heating medium, such as fuel oil or fuel gas to capacity must be greater than the vapor gen- sure, Chem. Eng. June 2001, pp. 66–73.
a fired heater, being increased; heat transfer erated because of heat buildup in the system. 2.Goodner, H., A New Way of Quantifying
occuring in a new and clean heat exchanger Risks: Part 2, Chem. Eng. November 1993, pp.
after revamp; control valve for the fuel supply Exchange tube rupture 140–146.
failing to fully open; or supply pressure of the When an upstream vessel is relieving by 3.Emerson, G., Selecting Pressure Relief Valves,
heating steam being changed from normal discharge fluid to a downstream vessel, Chem. Eng. March 18, 1985, pp. 195–200.
25 CHE 2-08.indd 25 1/29/08 6:11:24 PM

26 CHE 2-08.indd 26 1/15/08 4:09:04 PM

CE Community
Crossword: Managing Projects

By Myles Mellor
Across 36. Degree of the highest 11. Outdated
1. M and A challenge level 12. Master and wonder
7. Location technology 38. Columbus is its capital ending
9. Exhibitors’ offering 41. Integrated circuit, abbr. 13. Sets of data processed
12. Centers of attention 43. Nanosecond, abbr. in a single program run
13. Virus 44. Train 15. Profit
14. Home of the girl from 47. Coordination and 17. To process uranium
Ipanema execution are its key 19. Useful software for 29
15. To view laser-scanning challenges across
output 50. Roth and Sep 20. Spectroscopy technique
16. Survey company 51. United, but lean (acronym)
18. Critical business 53. It’s composed of light 21. Vanished Look for the solution at www.che.com
survival point particles 23. Tommy __ Jones 34. Reminder notice 45. Go down
22. Power source that is 54. Standard or source? 24. Promotions (abbr) 37. Head’s of operations 46. Serial bus standard
being revitalized 55. Supervision 30. Economic measure by title (abbr) 47. Handheld
25. Comprised of 20 country 39. Integrate (abbr) 48. Bottleneck
protons Down 31. Protected 40. Test 49. Watch
26. daratechPLANT 1. Usable between 32. Innovative plans 42. Nuclear reactor _____ 52. Inside prefix
audience different systems
27. Two are better than one 2. Earth-crust related February’s Web-exclusive
28. Popular membrane 3. Information
treatment technique 4. With no exceptions “New Radiation Curable Acrylic Pressure-sensitive Adhesives”
29. This category of 5. Dutch bank by Dr. Graeme A. Roan and others, National Adhesives
personnel are getting 6. Sodium symbol This paper addresses the development of UV-curable pressure-
very scarce for projects 7. World viewing software sensitive adhesives (PSAs) as an alternative for solution acrylic
33. EPC alternate 8. Importers and exporters
PSAs in industrial tape applications www.che.com/ceextra
35. Mixes 10. Unrefined rock
27 CHE 2-08.indd 27 1/29/08 6:46:23 PM

People
WHO’S WHO
Dunbar Carter Oyler Hebel Ferrara
Atlas Material Testing Tech- Jim Nyquist is promoted to president Michael C. Ferrara becomes CEO of
nology (Chicago, Ill.) elects Rick of global sales by Emerson Process Microfluidics (Newton, Mass.).
Weiler president and CEO. Management (Austin, Tex.). He is
replaced as European president by PolyOne (Cleveland, Ohio) names
Stephen Pegler joins BEM Systems David Dunbar. Lawrence Johnson director of market-
(Phoenix, Ariz.) as senior engineer. ing for the healthcare market.
Tex Carter joins IAP (Cape Canaveral,
Albert N. Crawford is named vice Fla.) as commercial vice president. Bill Alhofen is promoted to senior
president of sales by Charkit Chem- product manager by Charles Ross &
ical Corp. (Norwalk, Conn.). JWC Environmental (Costa Mesa, Son Co. (Hauppauge, N.Y.).
Calif) appoints Kenny Oyler director
Kelly Semrau is appointed chair- of Monster Separation Systems. The Chemical Heritage Founda-
man of the board of the Consumer tion (Philadelphia, Pa.) appoints Anke
Specialty Products Association Key Technology (Walla Walla, Timmermann historian. n
(Washington, D.C.). Wash.) names Richard Hebel CTO. Kate Torzewski
Cut cost 4 ways

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only one air inlet and outlet slash Cut engineering cost
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87_Flexim-Anzeige-ChemEngin 1 11.01.2008 11:18:49 Uh
28 CHE 2-08.indd 28 1/29/08 6:47:49 PM

Feature
Cover Story
Report
CPI Water and Steam

Chemistry Bradley Buecker
Chemist
Careful control of water

and steam chemistry
at CPI facilities can pay
off handsomely
in reliable operation
S
ometimes lost in the hustle and tion revealed that total-organic-carbon hydrogen damage of the boiler tubes.
bustle of production issues at (TOC) levels in the condensate-return Within a month, tubes began to fail at
chemical-process-industries lines to the boilers had been known such a frequent rate that the unit had
(CPI) facilities is that high-purity to reach 200 parts-per-million (ppm). to be shutdown and entirely re-tubed
water, and steam produced thereby, is Given that ASME guidelines [1] call at a cost of $2 million [2].
the lifeblood of the plant. Yet, equip- for a maximum TOC concentration Example 4. For decades, the conven-
ment failures and curtailed production of 0.5 ppm in boilers of this pressure, tional treatment program for conden-
due to water and steam issues can cost it was easy to see why so much foam sate and feedwater systems called for
a company hundreds of thousands of existed in the boiler water, and why chemical dosages at sufficient concen-
dollars, or more, on an annual basis. impurities carried over to the super- tration to remove all dissolved oxygen.
This article outlines methods to im- heaters on a continual basis. This regime is now known to be very
prove water and steam operation at Example 2. A petrochemical plant in troublesome and has caused piping
chemical and industrial plants. southern U.S. experienced short runs and tube failures that have killed at
and poor performance of a makeup least 10 people in the utility industry
Chemistry deficiencies demineralizer. In particular, the anion in the last decade or so. Industrial
The following examples come from resin of the unit underperformed. boilers, including heat-recovery steam
direct experience on projects for the Analysis revealed that the raw water, generators (HRSG), are not immune
CPI or related facilities. They outline which came from an area where rice from this attack.
straightforward issues that may arise was grown, contained high concentra-
at many plants. Following these ex- tions of natural organics. Pretreat- Impurities and their control
amples is a discussion of problems and ment ahead of the demineralizer As the introductory examples illus-
solutions to water and steam chemis- consisted of clarification and media trate, multiple contaminants can
try issues. filtration. Clarification satisfactorily enter steam-generation networks from
Example 1. A colleague and I visited removed suspended solids, but many many locations. Impurities include in-
an organic chemicals plant in the Mid- organics passed through and fouled organic ions from raw water, such as
west, in which the steam superheater the anion resin. calcium, magnesium, sodium, chloride,
bundles in four, 550-psig package boil- Example 3. I have personally wit- sulfate and bicarbonate, to name the
ers had to be replaced every two years nessed and have heard many reports most important, while process opera-
or so due to internal scaling. Upon ar- of plant personnel keeping steam gen- tions may introduce these materials
riving, we were first shown a bundle erators online during longterm steam and organic compounds to condensate
that had been recently removed, and surface condenser leaks. Such leaks, return. Upfront treatment systems to
indeed the internal tube surfaces which introduce raw cooling water di- remove these impurities offer the first,
were covered with a 1/8–1/4 in. scale rectly to condensate, cause severe prob- and usually most important, line of de-
coating. We then walked around the lems in boilers. In one case, in the early fense. Makeup-water treatment may
boilers and immediately noticed foam 1980s, operation of an 80-MW, 1,250- range from relatively simple systems
issuing from the saturated-steam psig utility boiler for three weeks with for low-pressure steam generation to
sample lines. Subsequent investiga- a condenser leak resulted in severe perhaps reverse-osmosis (RO) and ion-
30-34 CHE 2-08.indd 30 1/29/08 6:15:32 PM

Figure 1.
Condensate
return and/or
poorly operated
steam condens-
ers can introduce metal passivator into the feedwater (H2S) and sulfur dioxide (SO2), both
large quantities Mechanical methods for O2 control. of which are quite corrosive.
of dissolved oxy- For industrial steam generators that For industrial boilers that operate
gen into feedwa-
ter systems; this
include a steam turbine, the condenser at pressures above 900 psig, alterna-
can lead to big is normally equipped with one or more tive chemicals are more suitable for
problems. Shown air-removal compartments for gas re- oxygen scavenging. The workhorse for
here is the effect moval. Each compartment consists of many years was hydrazine (N2H4),
of oxygen pitting a shroud, open at the bottom, to which which reacts with oxygen as follows:
on an econo-
mizer tube a mechanical vacuum is applied. The
N2H4 + O2 → 2H2O + N2↑ (3)
Dr. James Dillon, Nalco Co. vacuum removes air from the conden-
sate, and discharges it to the outside Hydrazine is advantageous because
exchange (IX) polishing for high-pres- atmosphere. Condenser performance it does not add any dissolved solids to
sure applications. If process-induced should be monitored on a regular basis, the feedwater, it reacts with oxygen
organic compounds are of concern, as a crack in the condenser shell or in a one-to-one weight ratio, and it is
treatment might include activated car- other failure will allow excess air to supplied in liquid form at 35% concen-
bon filtration. Pre-treatment to protect enter. Air will coat condenser tubes and tration.
RO and IX units is often vital, with reduce heat transfer, plus oxygen may A primary benefit of hydrazine is
suspended solids removal by clarifica- enter the condensate. that it will passivate oxidized areas of
tion or via the emerging technologies Downstream from the condenser, piping and tube materials as follows:
of micro- and ultrafiltration [3]. the deaerator (DA) provides addi-
N2H4 + 6Fe2O3 → 4Fe3O4 + N2↑ +
Let’s now look at the condensate tional mechanical removal of dis-
2H2O (4)
feed to the boiler. As a preface to the solved gases. As condensate is sprayed
following discussion it must be noted or flows through trays downward into Similarly, if the heat exchangers
that when steam generators are first the DA-scrubbing vessel, the rising have copper-alloy heat-exchanger
placed in service, steel develops a pro- steam heats the condensate and liber- tubes, the chemical will return oxi-
tective coating of iron oxide known as ates gases. A properly operating DA dized layers of cupric oxide (CuO) to
magnetite (Fe3O4). This mechanism should reduce dissolved oxygen con- the more stable cuprous oxide (Cu2O).
also occurs on boiler waterwall tubes. centrations down to 7 ppb or less.
N2H4 + 4CuO → 2Cu2O + N2↑ +
Chemical control of O2. Into the
3Fe + 4H2O → Fe3O4 + 4H2↑ (1) 2H2O (5)
1980s, in the U.S. at least, conven-
Similarly, copper alloys develop tional wisdom called for complete Hydrazine residuals were typically
a protective layer of cuprous oxide removal of oxygen from feedwater. It maintained at relatively low levels of
(Cu2O). Formation of protective oxide was thought, incorrectly as we shall perhaps 20–100 ppb.
layers is a very important concept. see, that the total absence of O2 was Given the simplified chemistry of
Of general importance in condensate best for corrosion control in the feed- hydrazine, it would appear to be the
and feedwater systems is pH. In pip- water network. Thus, mechanical ideal oxygen scavenger. Unfortunately,
ing and heat-exchanger systems of all- O2 removal was supplemented with hydrazine is considered to be a poten-
ferrous metallurgy, the optimum pH chemical treatment. One of the first tial carcinogen and is now registered
range is 9.2 to 9.6. For networks con- practical chemicals to be employed in as a hazardous compound. Handling
taining heat exchangers with copper- steam generators was sodium sulfite procedures have become very strin-
alloy tubes, the recommended range is (Na2SO3). Sodium sulfite reacts with gent. This difficulty has, in part, led
a bit lower at 9.1 to 9.3. Control is usu- oxygen to produce sodium sulfate: to the development of other treatment
ally achieved by feed of ammonia or an chemicals. Many of the major water-
2Na2SO3 + O2 → 2Na2SO4 (2)
organic amine to the condensate. treatment companies provide alterna-
Condensate return and poorly oper- The primary advantages of sodium tive oxygen scavengers, some principal
ated steam condensers can introduce sulfite are that it is a common and ones being hydroquinone, carbohydra-
large quantities of dissolved oxygen inexpensive chemical, is non-toxic, zide (N4H6CO), and methyl ethyl ke-
into feedwater systems. The oxygen in and can be used to treat boiler water toxime (C4H9NOH). All of these prod-
turn can cause big problems, as shown in which the steam is extracted for ucts also passivate metals.
in Figure 1. food processing or other applications Safe hydrazine systems. It is possible
Methods to control oxygen corrosion regulated by U.S. Food and Drug Ad- to set up a hydrazine feed system that
primarily comprise the following: ministration (FDA). Sodium sulfite does not expose workers to the com-
• Mechanical removal of gases in the is primarily used in low-pressure in- pound. In one such system at a western-
condenser if the plant has a power- dustrial boilers (<600 psig), because U.S. utility, the hydrazine solution is
generating steam turbine it adds too many dissolved solids to supplied in portable, reusable contain-
• Mechanical removal of gases by a high-pressure boiler water. Also, in ers. Personnel connect each new con-
deaerator located in the feedwater boilers that operate above 900 psig, tainer to a permanent metering pump
system sodium sulfite will thermally decom- and distribution line, which transport
• Injection of an oxygen scavenger or pose to produce hydrogen sulfide precise dosages of the chemical in neat
30-34 CHE 2-08.indd 31 1/29/08 6:15:55 PM

Cover Story Dr. James Dillon, Nalco Co.
.BHOFUJUF%JTTPMVUJPOBTB'VODUJPOPG
"NNPOJB$PODFOUSBUJPO "DUVBMMZQ)
Figure 2.
The dissolu- QQN
tion behavior of QQN

QQN
magnetite at a QQN
temperature range QQN
*SPO QQC

and chemical con- QQN
ditions common
to the feedwater
network is shown
here (Data is from
the 1986 EPRI In-

terim Consensus
Guidelines, now

out of print) 5FNQFSBUVSF '
form to the feedwater system. A varia- environment causes contin- Figure 3. Flow-accelerated corrosion develops at
flow disturbances and direction changes, for exam-
tion of this concept is a system in which ual leaching of ferrous ions ple at feedwater and economizer elbows, reducers
the primary feed tank supplies a closed +2
(Fe ) from the tube surface and tees, in strongly reducing environments
day tank, which is vented to the outside that weakens the wall struc-
atmosphere. The operator introduces a ture and eventually reduces
measured volume of hydrazine to the pipe strength to the point of .BJOTUFBN (FOFSBUPS
)1 *1 -1
day tank, followed by dilution water. A sudden failure. An example 4UFBN UVSC UVSC UVSC
$POEFOTFS
metering pump feeds the solution into of FAC is shown in Figure 3. ESVN
$PMESFIFBUTUFBN
the system. FAC has been a problem in &DPOP
$8
heat-recovery steam genera- NJ[FS $8
PVU
JO
Flow-accelerated corrosion tor (HRSG) waterwall tubes, 4) 3) )PUSFIFBUTUFBN .BLFVQ
The use of a pH conditioner and oxy- which have many tight-ra- $POEFOTBUF
'MVF 'VSOBDF QPMJTIFS $POEFO
HBT TBUF
gen scavenger (metal passivator), par- dius elbows. The low-pres- FYJU QVNQ
ticularly the latter, constitutes what sure circuits of HRSGs often #VSOFST #VSOFST 0YZHFO
JOKFDUJPO
is known as an all-volatile reducing operate near the temperature
AVT(R) program in condensate and of highest corrosion potential
feedwater systems. In the 1980s and (shown in Figure 2), which )JHIQSFTTVSF %FBFSBUPS -PXQSFTTVSF
1990s, researchers began to discover further exacerbates the issue. IFBUFST IFBUFST
that AVT(R) was the cause of previously A particular difficulty with 0YZHFO
unspecified problems. Most notable is HRSGs is that the two or #PJMFS JOKFDUJPO
the dissolution of magnetite at a tem- three semi-independent wa- GFFEQVNQ
perature range and chemical conditions terwall circuits make chem- Figure 4. Oxygenated treatment requires the con-
common to the feedwater network. This istry control rather difficult. trolled injection of O2 into the condensate/feedwater
behavior is shown in Figure 2. One solution, albeit at some system. The O2-injection points for a typical utility
boiler are shown here
As the title of Figure 2 suggests, pH cost, for controlling FAC in
in high-purity condensate and feedwa- HRSGs in the design phase
ter is typically a function of the am- is to specify tube material, at least in as combined water treatment (CWT).
monia concentration. It is the lower elbows, of 1.25% chrome steel. This Both NWT and CWT require the
pH, at low ammonia concentrations material is resistant to attack. controlled injection of O2 into the con-
in a reducing environment, which is The next sections outline chemical densate and feedwater system. Prop-
responsible for magnetite dissolution. techniques for combating FAC, while erly applied, OT establishes a surface
This explains why corrosion can be preventing other corrosion in feedwa- layer in part composed of ferric oxide
much higher at an NH3 concentration ter systems. hydrate (FeOOH), which is more sta-
of 0.1 ppm than in any other case. The Oxygenated treatment (OT). OT ble than magnetite. Typical injection
ammonia does not attack the magne- is a feedwater treatment developed points are just after the condensate
tite directly. So, in a reducing environ- over 30 years ago for the utility in- polisher and again at the deaerator
ment established by feed of an oxygen dustry. In an OT program, oxygen is outlet (Figure 4). In CWT programs,
scavenger (metal passivator), gradual deliberately introduced to the con- which are most common in the U.S.,
magnetite dissolution has led to sud- densate and feedwater system. Two oxygen is dosed to maintain a 30 to
den, and in some cases fatal, failures variations of oxygenated treatment 150 ppb residual. Ammonia is added
of mild steel by flow-accelerated-cor- are most popular. In the first, O2 is to raise the pH within a range of 8.0 to
rosion (FAC). FAC develops at flow injected alone without any pH-con- 8.5. Typically, 20 to 70 ppb of ammonia
disturbances and direction changes, ditioning chemicals. This program is will control water chemistry within
for example at feedwater and econo- known as neutral water treatment this pH range.
mizer elbows, reducers and tees, in (NWT). More often, ammonia is also The keys to an OT program are con-
strongly reducing environments. The injected for pH control. This is known trolled oxygen feed and high-purity
30-34 CHE 2-08.indd 32 1/29/08 6:16:19 PM

Dr. James Dillon, Nalco Co. Dr. James Dillon, Nalco Co.
Figure 5. The presence of hydrogen can cause cracking in Figure 6. Caustic gouging can occur in boilers operating at
steel, greatly weakening its strength. Shown here is tube fail- higher pressures when phosphate treatment is used
ure caused by hydrogen damage
condensate, where cation conductivity and corrected as quickly as possible. and sulfate, as well as other materials
can be maintained at ≤0.15 microSie- AVT(R) for mixed-metallurgy sys- including suspended solids. As these
mens/cm (µS/cm). OT is probably too tems. For mixed-metallurgy systems, contaminants enter the boiler, a num-
elaborate for low-pressure industrial OT and AVT(O) are not acceptable, as ber of temperature-induced reactions
boilers, but it has been applied to some they would initiate and sustain exces- will occur. Two common reactions are
utility drum units and to HRSGs. OT sive copper corrosion. However, opera- shown below.
cannot be used in systems that con- tion with complete removal of oxygen
tain copper-alloy feedwater heater leads to FAC. So, the correct program Ca+2 + 2HCO3–1 → CaCO3↓ + CO2↑ +
tubes, as copper corrosion would be is to feed an O2 scavenger, but at re- H2O (6)
much too severe. duced concentrations to minimize Ca+2 (or Mg+2) + SiO3–2 → CaSiO3↓
AVT(O). An offshoot of OT is a pro- FAC. Chemistry control can be quite (or MgSiO3↓) (7)
gram developed by the Electric Power difficult when relying upon standard
Research Institute (EPRI) known as dissolved-oxygen and oxygen-scav- Equations (6) and (7) are typical scale-
all-volatile treatment (oxidizing), or its enger analyses. The technique of forming reactions. Even a relatively
acronym AVT(O). The idea continues oxidation-reduction-potential (ORP) thin deposit layer will significantly re-
to be the establishment of a FeOOH monitoring is becoming popular for duce heat transfer, and a boiler must be
layer on the feedwater piping, but by mixed-metallurgy condensate/feed- fired harder to achieve the same level
a less intensive mechanism. What the water chemistry. In short, online ORP of steam production. This in turn can
researchers found is that, in conden- monitors measure the electrochemi- lead to overheating of the boiler tubes,
sate and feedwater networks where cal potential of the solution versus a which will shorten tube life.
air seepage into the condenser (air in- standard electrode, most commonly Much more problematic, particularly
leakage) is minor and condensate dis- Ag/AgCl, saturated KCl. A general in high-pressure boilers of at least
solved oxygen levels stay at or below rule-of-thumb is that the O2 scaven- 1,000 psig or higher, is the effect that
10 ppb, discontinued feed of an oxygen ger should be fed to maintain an ORP cooling-water leakages into the system
scavenger allows the FeOOH protec- within a range of –350 to –300 mV. have with regard to rapid and poten-
tive layer to form naturally. As with This corresponds to a range of –150 tially catastrophic corrosion. The reac-
OT, this program is only applicable in to –100 mV for a standard hydrogen tion shown below is a prime example.
systems with all-ferrous metallurgy. electrode (SHE). However, chemists
MgCl2 + 2H2O → Mg(OH)2↓ + 2HCl
One major difference from OT is that have found that this guideline should
(8)
the pH should be maintained within not be considered an absolute [4]. A
a range of 9.2 to 9.6. An operating better plan is to set up comprehensive As can clearly be seen, a product of
guideline is cation conductivity ≤0.2 tests that include dissolved iron and this reaction is hydrochloric acid.
µS/cm. Excursions in dissolved-oxygen copper analyses, and coordinate the While HCl may cause general cor-
concentration and cation conductivity, optimum ORP range with minimized rosion in and of itself, when concen-
particularly the former, indicate excess copper and iron concentrations. trated under deposits, the acid reacts
air in-leakage within the condenser. with iron to generate hydrogen, which
Increased air in-leakage also intro- Boiler-water issues in turn can lead to hydrogen damage
duces excess carbon dioxide, which in- Raw makeup water or heat-exchanger- of the tubes. In this mechanism, hy-
fluences corrosion. Thus, for a unit on cooling water from a lake or river typi- drogen gas molecules, which are very
AVT(O), any air leaks into the system cally contains several hundred ppm small, penetrate into the metal wall
that raise condensate dissolved-oxy- of cations and anions, most notably and react with carbon atoms in the
gen levels much above a mid-teen ppb calcium, sodium, magnesium, potas- steel to generate methane:
concentration should be investigated sium, bicarbonate, chloride, silica,
2H2 + Fe3C → 3Fe + CH4↑ (9)
30-34 CHE 2-08.indd 33 1/29/08 6:16:40 PM

Cover Story
Figure 7. The phenomenon
known as wick boiling occurs when
Formation of the gaseous methane water penetrates a porous tube
deposit. As the water approaches
and hydrogen molecules causes crack- the tube surface, the temperatures
ing in the steel, greatly weakening its 5VCFXBMM increase and the water boils off,
strength. Hydrogen damage (Figure leaving other species behind
5) is very troublesome because it can-
not be easily detected. After hydrogen chemistry programs actually allowed calcium hydroxyapatite:
damage has occurred, the plant staff the formation of calcium carbonate on
10Ca+2 + 6PO4–3 + 2OH–1 →
may replace tubes only to find that tube walls to protect the tube surface
3Ca3(PO4)2.Ca(OH)2↓ (13)
other tubes continue to rupture. from the boiler water.
Condensate return may carry any In the 1930s, researchers developed Magnesium and silica react with
number of contaminants, including the technique of adding tri-sodium the alkalinity produced by phosphate
organic chemicals as mentioned in the phosphate (Na3PO4) to boilers to gen- to form the non-adherent material,
first example. Organics can bake onto erate alkaline conditions. serpentine:
tube surfaces, and they will also cause
Na3PO4 + H2O → Na2HPO4 + NaOH 3Mg+2 + 2SiO3–2 + 2OH–1 + H2O →
foaming in boiler drums, which in turn
(10) 2MgSiO3.Mg(OH)2.H2O↓ (14)
leads to carryover of impurities to
steam. The superheater failures men- In early, low-pressure boilers, phos- Calcium hydroxyapatite and ser-
tioned in Example 1 are one possibil- phate concentrations in a range of pentine exist as soft sludges and
ity, but if the system produces power 20–40 ppm were common. However, as are much easier to remove than the
with a steam turbine, the impurities higher-pressure boilers came on line, hard scale or corrosive products that
can settle out on turbine blades and tubes began to fail due to the phenom- would otherwise form. They typically
cause additional corrosion. enon of caustic gouging (Figure 6). settle in the mud drum or lower head-
Modern technologies offer tech- Research showed that this failure ers from which they are removed by
niques to combat organic fouling in occurred underneath boiler tube de- blowdown. ■
condensate return. Space limitations posits. Figure 7 illustrates a porous Edited by Gerald Ondrey
prevent an in-depth discussion of tube deposit where water penetrates
these technologies in this article, but the deposit through various channels. References
Reference [5] outlines a modern sys- As the water approaches the tube 1. “Consensus on Operating Practices for the
Control of Feedwater and Boiler Water
tem to control organics. The system surface, temperatures increase. The Chemistry in Modern Boilers,” The American
utilizes adsorption cartridges and water boils off, leaving other species Society of Mechanical Engineers, New York,
NY, 1994.
bioreactors to remove organics, even behind. This phenomenon is known as 2. Buecker, B., “Condenser Chemistry and Per-
from refinery condensate-return wick boiling. In the case of early phos- formance Monitoring”; in the proceedings of
the 60th Annual International Water Confer-
streams, such that the purified water phate programs, and to a lesser but ence, October 18–20, 1999, Pittsburgh, Pa.
reportedly contains low-ppb concen- not unknown frequency today, sodium 3. Buecker, B., Microfiltration for CPI Wastewa-
trations of carbon-based compounds. hydroxide remains after wick boiling. ter, Chem. Eng., May 2007, pp. 63–65.
Successful operation of this type of Concentrations may rise to levels many 4. Shulder, S., “Practical Application of Oxidation
Reduction Potential to Control Oxygen Scav-
equipment would certainly have re- times that in the bulk boiler water. The enger Injection to Fossil Power [Systems],”
in the proceedings of the 21st Annual Elec-
duced the headaches encountered by concentrated NaOH attacks the boiler tric Utility Chemistry Workshop, May 8–10,
the personnel in Example 1. metal and protective magnetite film 2001, Champaign, Ill.
via the following reactions: 5. Abbot, K. and Dittburner, D., RO/DI Pretreat-
ment to Remove Oils and Organics and Allow
Treatment by phosphate for Process Water Reuse, Ultrapure Water,
For over seven decades, steam-gen- Fe + 2NaOH → Na2FeO2 + H2↑ (11) March 2007, pp. 38–41.
eration chemists have utilized sodium

Fe3O4 + 4NaOH → 2Na2FeO2 + Author
phosphate compounds for corrosion
N2FeO2 + 2H2O (12) Brad Buecker is the air
control and prevention of solids de- quality control specialist at
a large U.S. power plant, and
position in the waterwall circuits of Because phosphate serves another can be reached at beaker-
drum-type, steam-generating systems. valuable function besides pH control, too@aol.com. He has previ-
ous experience as a chemical
Alternatives are also available, but programs were not discontinued but cleaning services engineer, a
can be tricky to control. rather modified to current regimes water and wastewater system
supervisor, and a consulting
In the early days of steam gen- where free NaOH alkalinity is limited chemist for an engineering
eration for power production, vari- to 1 ppm, with phosphate concentra- firm. He also served as a re-
sults engineer, flue gas desul-
ous odd-sounding treatment methods tions of 0.2 to 3 ppm in the low range furization (FGD) engineer, and analytical chem-
ist for City Water, Light & Power, Springfield,
were used. Some of these treatments and 3 to 10 ppm for those who feel Ill. Buecker has written more than 70 articles
had operators putting sawdust or po- comfortable with more protection. on steam generation, water treatment, and FGD
chemistry, and he is the author of three books on
tato peels into boilers. These natural Control of contaminant in-leakage, steam generation chemistry and steam genera-
products contributed large organic at least until repairs can be made, tor fundamentals published by PennWell Pub-
lishing, Tulsa, Okla. Buecker has an A.A. degree
molecules such as lignins, tannins, constitutes a phosphate program’s in pre-engineering from Springfield College in
and starch to the water. The chemi- second major function. Phosphate re- Illinois and a B.S. in chemistry from Iowa State
University. He is a member of ACS, AIChE,
cals sequestered hardness ions. Other acts directly with calcium to produce ASME, and NACE.
30-34 CHE 2-08.indd 34 1/29/08 6:17:07 PM

Superheated
steam
650 psig
Cold
condensate
Free
925 psig Float Trap
Conquer
1500 psig
Superheat!
This thermograph of a 1,000 simple operation ensures
psig steam line to vacuum superior reliability. Unlike
discharge clearly shows the other designs, there are no
outstanding performance levers or linkages—the float
delivered by Free Float itself provides sealing, and is
steam traps. As you can see, the only moving part. The
they not only survive result is exceptional service life
1150 psig superheat, they conquer it! under the most demanding
Only Free Float traps have conditions.
3-point seating—a patented For maximum reliability and
technology that provides energy efficiency, choose from
effective sealing even in severe ’s extensive line of high
service like no-load superheat. pressure Free Float traps to
In addition, the Free Float’s keep superheat under control.
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Circle 24 on p. 62 or go to adlinks.che.com/7369-24 www.tlv.com
35 CHE 2-08.indd 35 1/15/08 4:19:18 PM

Feature Report
Pump Hazardous
Liquids Safely
Stanley Grossel
Process Safety & Design
Reduce the problems associated with handling result of the normally high dikes used
in tank farms. For some chemicals,
hazardous liquids by following these guidelines depending on the properties of the liq-
uid, such as flammability and corro-
siveness, fire or mechanical damage to
P
umps are one of the most ubiq- mechanical seal or packing and other associated electrical equipment could
uitous items of equipment found trim) should be compatible with the occur when the pump is submerged. In
in chemical processing plants. liquid being pumped. Cast iron should special circumstances, such as when
Often, they are used to transfer not be used for hazardous liquids, at handling high flash point, combustible
hazardous liquids, such as flammable, pressures above 200 psig or tempera- liquids or viscous liquids that neces-
combustible, toxic and corrosive chem- tures above 175°C. Cast iron is brittle sitate a short suction line, the pump
icals. In order to ensure safety during and can be cracked by mechanical or may be located inside the dike wall. In
pumping, certain design and operat- thermal shock, which could result in this case, a local motor start-and-stop
ing practices should be followed. This leaks and subsequent fires. Ductile control station should be provided out-
article discusses safe practices for iron is also appropriate for some ap- side the diked area and properly iden-
centrifugal, positive displacement and plications, but it should be noted that tified. Also, consideration should be
sealless pumps. ductile iron, when exposed to high given to locating the pumps in a sub-
temperatures produced by fires, can divided area for containment of seal or
POTENTIAL PROBLEMS revert to cast iron, and should be lube-oil leaks.
AND HAZARDS avoided if there is any risk of fire.
A number of problems and hazards The pump casing, impeller and other Backflow protection
can occur during the pumping of haz- moving parts should be constructed of Backflow can occur in a pumping sys-
ardous liquids. These can include the non-sparking materials if the pump tem when the motor (or other driver)
following: will run dry at frequent intervals. is stopped, either intentionally or ac-
• Mechanical seal failures resulting in cidentally. Depending on what type of
leaks or fugitive emissions Pump location pump is used, this may result in the
• Deadheading Pumps should be installed and lo- flow of the pumped liquid through the
• Reduced or low flow in centrifugal cated in a way that facilitates safe pump to the suction vessel and possi-
pumps maintenance. When they are intended ble vessel overflow. It may also result
• Overpressurization to handle hazardous liquids such as in reverse rotation of a non-running
• High temperature toxic, pyrophoric or water-reactive installed spare pump, which could
These problems and hazards can re- liquids, pumps should not be located cause damage.
sult in severe incidents, such as fires, beneath main-plant pipe racks. If a To avoid or limit backflow, a check
explosions and toxic releases, if they fire occurs at the pump, flames could valve should be installed in the pump
are not addressed by preventive or reach the piping above and overpres- discharge line. For highly hazardous
protective measures. The following surize the fluid contained in the pip- liquids, it may be desirable to install
sections discuss these issues, as well ing or stress and weaken the piping two check valves in series. Alterna-
as recommended practices to elimi- due to heat absorption. tively, a fast-acting open-shut valve,
nate or minimize problems for various Pumps, especially those handling activated by a low-pressure sensor in
types of pumps. hazardous liquids, should be located the discharge line that will shut the
in open, well-ventilated areas to pre- valve tightly, can be used.
GENERAL vent accumulation of leaking hazard- When check valves or fast-acting
RECOMMENDATIONS ous vapors. open-shut valves are used in the dis-
Materials of construction In the design of tank farms, many charge line of a pump, it may be nec-
Materials of construction should be companies prefer to situate the trans- essary to establish a way to prevent
chosen based on the corrosive prop- fer pumps outside of the dike with a hydraulic hammer.
erties of the liquid being pumped. At separate curbed and drained area to
a minimum, pumps should be con- prevent the spread of seal or packing Pump piping and valves
structed of cast steel. All the compo- leaks. In the event of a large spill, the Pump suction and discharge piping
nents of the pump (casing, impeller, pumps may become submerged as a should be supported independently of
36-42 CHE 2-08.indd 36 1/29/08 6:19:39 PM

Table 1. A comparison of sealless pumps
Selection Criteria Magnetic Coupling Canned Motor Pump
How safe is the Restricted: unit has only one sealed liner; if Extended: two boundaries exist, the can and the
unit during failure? liner ruptures, the fluid escapes into the atmo- motor housing; if the can ruptures, the motor hous-
sphere ing takes over as a gas-tight barrier
Applications Restricted: limited by the rotating mass and Extended
construction size
Viscosity range Restricted: an increase in viscosity establishes Extended: the fluid is warmed going through the
relative limitations motor section, allowing the pumping of higher
viscosity material
Total viscosity Equal Equal
Temperature Restricted: limited to applications between 100 Extended: can be used at temperatures between
limitation and 754°F –200 and 1,000°F
Temperature Restricted: only the pump can be insulated Extended: both the pump and the motor can be
control and traced insulated and traced
Maximum operating Restricted: the can thickness limits the maxi- Extended: the achievable working pressures are
pressures mum pressure independent of the can thickness because sup-
port can be furnished outside of the gap, the
current limit for system pressure is approximately
17,000 psi
NPSH required Better: the lower heat input to the recirculation Worse
stream assures better net positive suction head
(NPSH) characteristics
Explosion protection Restricted: see comments under row 1 Extended
due to leakage
Repair of motor Better: uses a standard motor Worse
Sensitivity to solids Worse: units are more sensitive to solids, espe- Better: Units are available with slurry designs,
cially when ferrous particles are in the fluid which isolate the motor section from the pumped
fluids
Starting problems Can exist: extreme care must be taken in ap- Not normally
plying the torque requirements to these units
Noise levels Greater: much higher levels due to the fan on Lower: these pumps are especially quiet; cooling,
the motor and the additional bearings in the coupling, and bearing noises do not exist
coupling
Overall length Greater Less
Flexibility of installa- Restricted Extended: units can be installed either vertically
tion or horizontally in generally a much smaller space
Interchangability with Depends on individual manufacturer Depends on individual manufacturer
standard chemical
pumps
Electrical installation Depends on individual manufacturer Depends on individual manufacturer
Cost of manufacture Greater Less
Foundation Required Not required
Coupling Yes No
Coupling guard Yes No
Coupling alignment Yes No
Cost of repair Less: the repair of the pump and the coupling More: repair requires mechanical as well as elec-
can usually be accomplished by normal main- trical knowledge
tenance mechanics
Bearing wear Not normally available Widely used
monitors
the pump. Supports should be designed for piping loops. If not, then this flex- the suction line, given that the valve
to ensure that the pump flange load- ibility can be achieved through the use is closed at the time. Lines in which
ings are minimized and do not exceed of flexible hoses or expansion joints, there is no flow may fail quickly when
the loadings specified by the pump which should be constructed of a fire- exposed to fire. If the pump has a long
manufacturer. Additionally, the pipe resistant material. If expansion joints suction line, shutoff valves should be
supports should be adjustable. are used, they should be of the packless provided near both the pump inlet and
The piping should be designed to type, without circumferential welds in at the suction vessel. Fire-safe valves
withstand the maximum pressure the bellows. should be used when a loss of valve in-
generated by the pump at “deadhead” Shutoff valves on the suction and tegrity due to a fire would result in a
conditions. Pump piping that accom- discharge of the pump should be pro- large leak of hazardous liquid.
modates hot liquids is often required to vided. If the suction vessel is nearby, Shutoff valves that can be operated
provide flexibility for thermal expan- the pump shutoff valve should be from a remote location should be used
sion and contraction. If possible, this mounted on the vessel nozzle. This for critical applications, for example,
should be provided through design of can prevent dumping of the vessel when large releases of hazardous liq-
the piping itself with adequate area contents in the event of a fire near uids could occur upon pump failure.
36-42 CHE 2-08.indd 37 1/29/08 6:20:05 PM

Feature Report 'JMMJOHWBMWF 1SFTTVSF
HBHF
$IFDLWBMWF
-"-
&YUFSOBMHBT
The actuation devices for these QSFTTVSF
valves should be located in safe, pe- UPQTJH
ripheral areas, such as control rooms BCPWFTUVGGJOH
5PQVNQ CPYQSFTTVSF
or in service racks outside of unit bat- NPUPS * -4
tery limits. Interlock remotely oper- -FWFMTXJUDI
ated shutoff valves to automatically -JRVJEMFWFMNVTU
CFBCPWFSFUVSOMJOF
shut down the pump when the valves DPOOFDUJPO
are closed.
7FOUBJSGSPN *OUFSOBM
Other safety considerations TZTUFNQSJPS DPPMJOHDPJM
UPTUBSUVQ
• Provide warning lights on location -JRVJETVQQMZ
for pumps that are remotely or au- UBOL"4.&
0VUMFUBU QTJHNBY
tomatically started IJHIFTUQPJOU
• Clearly identify pump shutdown PGTFBMIPVTJOH
and start-stop switches regardless
of whether the switch is local or re- $PPMJOH
XBUFSJO
mote, and provide lockout capability $PPMJOH
at the pump driver or power source XBUFSPVU
• Provide a shaft-coupling guard for
all pumps with exposed shafts
• Allow for the safe drainage of the
4UFFMPS44UVCJOH
pump casing and the suction and dis-
charge piping for all pumps. Provide
schedule 160 (or heavier, when neces-
Figure 1. Mechanical-seal buffer-liquid system with pressurized external reservoir
sary) casing drains and casing vents
for pumps handling hazardous liq-
uids. These should be socket or seal mechanical seals be used with a com- interlocked to the pump motor, or other
welded, and terminated at a raised- patible buffer liquid between the seals. driver, to shut it down. It may also be
face flange or socket-weld fitting The following hazards can occur desirable to close the valve at the supply-
• Monitor pump-bearing temperature with standard centrifugal pumps: vessel nozzle or at the pump-suction
with alarms and/or motor shutdown • Mechanical seal failure inlet. With tandem mechanical seals, the
at high temperature. Lack of lubrica- • Reduced or low flow buffer liquid is usually at atmospheric
tion can result in high bearing tem- • Overpressurization pressure or slightly higher, and a failure
perature and possible failure, which • High temperatures of the inner seal will result in rapid filling
in turn can lead to shaft misalign- • Cavitation of the reservoir with process liquid. A
ment and mechanical seal failure These hazards and their preventive high-pressure or liquid-level switch
• A temperature sensor should be in- and protective measures are discussed in the reservoir should be installed to
stalled in a pump casing if the pump below. alarm and shut down the pump motor.
is handling a temperature-sensitive Mechanical-seal failure can also
liquid. The sensor should be inter- Mechanical seal failure be caused by corrosion products and
locked to shut the motor off when A mechanical seal failure can result other particle debris in the liquid being
the high-temperature limit of the in fugitive emissions or large spills of pumped, so measures should be taken
liquid is reached hazardous liquids, problems that could to remove these from the liquid, such
• Pumps handling flammable liq- lead to fires or explosions. One cause of as providing an adequate strainer in
uids should be properly bonded failure is the loss of flow of the buffer the pump-suction line. API STD 682 [1]
and grounded to prevent electro- liquid through the seal. This can be gives additional information on pump
static ignitions avoided by creating a buffer-liquid seal mechanical seal systems.
• The seal areas of pumps handling system that consists of a circulating, In recent years, gas-barrier seals have
corrosive liquids may require spray pressurized reservoir with an internal been used in place of buffer-liquid seals
shields for personnel protection cooling coil and a low-level alarm. in many applications and should war-
Figure 1 is a schematic of such a system rant serious consideration. Gas seals op-
STANDARD for a double mechanical seal. If there is erate on a gas fluid film and do not gen-
CENTRIFUGAL PUMPS a seal failure, pressure on the reservoir erate significant frictional heat. Unlike
Standard centrifugal pumps are usu- will force the liquid either into the process in single mechanical seals, the process
ally provided with either packing or fluid or out of the seal on the low pressure fluid is not the lubricant, and unlike in
mechanical seals. For pumps handling side, and the liquid level in the reservoir double and tandem mechanical seals, a
hazardous liquids, packing should not will show an abnormal level drop. The compatible barrier liquid is not required.
be used. It is recommended that dou- level switch in the seal-liquid reservoir Gas seals use either compressed air or
ble, inside mechanical seals or tandem should be connected to an alarm and nitrogen as the barrier gas. With gas-
36-42 CHE 2-08.indd 38 1/29/08 6:20:38 PM

(BTJO
(BT suction line, an ammeter to measure the

GMPXNFUFS draw of the motor and a power monitor
1SFTTVSF to measure the motor horsepower. These
#ZQBTT 1SFTTVSF
TXJUDI HBHF sensors can be interlocked with the
DPOUSPM
WBMWF motor to shut it down upon the detec-
tion of reduced or low flow, more details
of which are discussed by Volk [11].
1SFTTVSF
TXJUDI
'JMUFST Overpressurization
'MPX Overpressurization protection from
1VNQEJTDIBSHF TXJUDI thermal expansion is needed for cen-
trifugal pumps that can be valved-in
*TPMBUJPO $IFDL
WBMWF WBMWF when there is remote startup capability
or when the suction and discharge lines
4FBM both have automatic closing valves. The
WFOU
pump generates heat, which will cause
liquid expansion and possible vapor-
1VNQ ization, leading to excessive pressure
WFOU if the heat is not removed. Overpres-
surization protection is also needed if
1VNQ Figure 2.
Externally supplied gas-barrier the pump shut-off head exceeds the
TVDUJPO
mechanical seal system pressure rating of the system piping.
Overpressurization relief is usually
provided by a pressure relief valve in
barrier seals, liquid seal reservoir main- bility points are reached as pump flow which discharge is directed back to the
tenance costs, specialized refilling proce- is throttled. An unstable flow condi- pump supply vessel. With liquids that
dures and their impact on reliability are tion many be encountered at flows of can polymerize, however, pressure re-
eliminated. Figure 2 is a schematic of a 50—60% (or lower) of flow at the best lief valves may not operate properly,
gas-barrier seal system. More on these efficiency point of the pump. This in- so the use of a rupture disk should be
systems is found in Ref. [6]. stability condition can cause exces- considered.
Another possible cause of mechani- sive vibration and damage to pumps,
cal-seal failure is shaft misalignment. drivers, couplings, gears, piping and High temperature
The appropriate alignment techniques adjacent equipment. Therefore, cen- As discussed above, high tempera-
should be used to check pumps prior trifugal pumps should be provided tures can occur when a pump oper-
to startup, and the alignment should with a minimum-flow recirculating ates against a closed valve, which is
be rechecked if continuous bearing or (bypass) line from the pump discharge known as deadheading. This is a very
mechanical-seal problems occur. side of the pump, located upstream of dangerous situation, as excessive
Dial-indicator alignment and laser- the block and check valves. This by- temperatures can lead to decomposi-
optic alignment are the two available pass line should preferably be routed tion reactions and subsequently to an
methods of laser alignment. Laser- back to the pump supply vessel if it is explosion. When pumping such high-
optic alignment systems have sev- an adequate “heat sink.” Otherwise, hazard liquids, it is very important
eral advantages over dial-indicator the minimum flow bypass line should to provide a temperature sensor in
systems. When time savings, reduced be routed through an external cooler the pump casing that will alarm and
downtime, increased reliability, fewer before returning to the supply vessel cause the motor to shut down before a
repair costs and lowered electricity or pump suction. This cooling of the thermal runaway occurs.
costs are all considered, a high-qual- pumped fluid is required because a
ity, laser-optic alignment system is centrifugal pump will raise the tem- Cavitation
clearly the better choice. The main dis- perature of the fluid being transferred Cavitation can cause pressure varia-
advantage of a laser-optic alignment due to the pump’s mechanical work on tion, shaft deflection, vibration or me-
system is the high up-front cost of the the liquid, such as efficiency losses. chanical shock that will damage seal
system in comparison to a dial indica- The effect ranges from a small temper- components. These problems can be
tor system. Bloch [4,5], Piotrowski [9] ature rise during normal operations to avoided by proper design of supply
and API RP 686 [3] are good sources of a high temperature rise when the flow vessels and suction-piping systems. It
information on this technology. is completely stopped. The minimum is especially critical to ensure that the
flow requirements should be obtained pump has adequate net-positive suc-
Reduced or low flow from the pump manufacturer. tion head (NPSH) and that entrained
Operation of centrifugal pumps at There are a number of methods avail- gases are avoided. NPSH requirements
severely reduced flow or at shutoff able to detect low-flow conditions, includ- should always be obtained from the
should be avoided. Frequently, insta- ing the use of a flow sensor in the pump pump manufacturer.
36-42 CHE 2-08.indd 39 1/29/08 6:21:36 PM

Feature Report .PUPSTUBUPS
.PUPSSPUPS
POSITIVE-DISPLACEMENT
PUMPS
Positive-displacement pumps comprise "JSWFOU
two main categories: rotary and re-
ciprocating pumps. Some rotary types
commonly used in the chemical pro-
cess industries are gear, lobe, screw,
vane, progressing cavity and peristaltic
pumps. The reciprocating types are pis- 4UBUPSDBWJUZ
ton (or plunger) and diaphragm pumps.
Rotary pumps that handle hazard-
ous liquids usually have mechanical 1VNQNPUPSTIBGU *NQFMMFS
*OEVDFS
seals, and the hazards and protective %SBJO
PQUJPO
measures that are discussed above 1VNQDBTJOH

for centrifugal pumps apply to rotary Figure 3. Typical canned-motor pump
pumps as well.
Most positive-displacement pumps liquids. The space between the two the rotor is reduced so that the high
require a pressure relief device to pro- diaphragms can be fitted with any of temperature is reduced. The develop-
tect against overpressure, which can be several leak-detection sensors (using ment of this new stator design, result-
caused by a closed discharge valve or a pH, liquid conductivity or pressure ing in improved safety, is discussed by
restricted discharge line. External re- sensor), which will detect a problem Osborne [8]. This new design may also
lief valves are typically used, because and set off an alarm when the primary be applicable to the pumping of other
they are easy to see when open, can diaphragm develops a leak or fails. highly hazardous liquids.
easily be adjusted to any set pressure, Air-operated diaphragm pumps usu-
and remain open only long enough to ally vibrate because of their mode of op- SEALLESS PUMPS
relieve pressure, thereby reducing pro- eration. Therefore, the suction and dis- Two kinds of sealless pumps are avail-
cess liquid loss. The relief device discharge piping should not be hard-piped able: canned-motor and magnetic-
charge should be sent back to the sup- to the pump nozzles, but should have drive types, which are compared in
ply vessel, or if being recycled back to flexible hose sections. The hoses should Table 1. As the name implies, sealless
the pump suction piping, an external be able to move enough that the move- pumps do not have any packing or me-
cooler should be installed to remove ment of the pump caused by vibrations chanical seals, and are therefore much
any heat input to the liquid from the is offset. If the hoses are not long enough less likely to have leaks of hazardous
pump. Positive-displacement pumps to provide movement, they become com- liquids. Centrifugal and rotary posi-
are sometimes provided with an inter- parative to hard-piping and can cause tive-displacement pumps are avail-
nal relief valve. A major drawback is damage to the pump. It is recommended able as sealless pumps.
that an internal relief valve does not that the hoses be a metal-braided type The difference between canned-
dissipate heat. Even if the pump comes rather than rubber hoses. motor pumps and magnetic-drive
equipped with an internal relief valve, Progressive-cavity pumps are widely pumps lies in how the rotor is driven.
it is strongly recommended that an ex- used for transferring slurries, viscous A canned-motor pump, as seen in
ternal relief valve also be used when liquids and highly hazardous liquids, Figure 3, has a standard a.c.-induc-
handling hazardous liquids. An exter- such as water-based explosives. Tests tion motor stator separated from the
nal relief device should be located as by explosives companies and investiga- pumped liquid by a non-magnetic
close as possible to the pump discharge tions into incidents have shown that membrane. The electrical rotating
nozzle and before any block valve. If the this type of pump can develop danger- magnetic field of the stator drives the
pump is handling a slurry or a chemi- ously high temperatures when oper- rotor, as in any standard a.c.-induc-
cal that might possibly polymerize, a ated deadheaded or dry. In some inci- tion motor. The membrane is in what
rupture disk should be installed, as a dents and tests, explosion or detonation would normally be the “air gap” (the
backup in case the relief valve plugs. of the explosive (or residual explosive) space between the rotor and stator) of
Diaphragm pumps are used for in the pump resulted. To address this the motor, and causes the air gap to be
many hazardous-liquid handling ap- operational problem, One manufac- larger than normal.
plications, because they have no me- turer has developed and patented a A magnetic-drive pump, as seen in
chanical seals or packing and are es- progressive cavity pump stator (made Figure 4, has a rotor containing mag-
sentially sealless pumps. They can be of a urethane compound) that gives ex- nets mounted outside and concentric
either motor-driven or air-operated, cellent service life at normal pumping to the containment shell, also known
and can have either single or double temperatures but melts before typical as the “can.” This rotor, which con-
diaphragms. Since single-diaphragm ammonium nitrate decomposition tem- tains a series of powerful magnets, is
pumps can leak if the diaphragm peratures are reached. mounted on a shaft that is driven by a
fails, double-diaphragm pumps are When the stator material melts, separate motor. The external rotating
recommended for highly hazardous the heat-producing interference with magnetic field, rather than electrical
36-42 CHE 2-08.indd 40 1/29/08 6:22:11 PM

*OTJEFPGDPOUBJONFOU
TIFMMBOEQSPDFTTJT
JTPMBUFEGSPNBUNPTQIFSF
$POUBJONFOU
TIFMM 4FDPOEBSZ
ESJWFTZTUFN
.BHOFUJD
DPVQMJOH
4IBGUEPFT
OPUQFOFUSBUF
QSFTTVSFCPVOESZ
Figure 4. Typical magnetic-drive pump
Table 2. Causes and effects of sealless pump failures

with appropriate failure-detection monitors
Cause Effects Results Type of Monitor Available
Dry-running (worst pos- Rapid temperature rise of contain- Ultimate, if not immediate Flow switch
sible condition — no ment shell failure Pressure switch
flow in any part of the Decrease in horsepower Power/current sensor
pump) Accelerated bearing wear Temperature monitor
Closed Discharge Valve Temperature of containment shell Failure will depend on Flow switch
(no discharge flow, but fluid will rise length of time pump is op- Power/current sensor
fluid circulates through Decrease in horsepower erating in given condition Temperature monitor
shell area) Highest discharge pressure
Decoupled (inner mag- Temperature of containment shell Failure will depend on Flow switch
net is not rotating, no will rise length of time pump is op- Power/current sensor
flow but pump is wet) Decrease in horsepower erating in given condition
Worn sleeve bearings/ Wear has reached maximum, caus- Failure (possible leakage) Bearing wear monitor
shaft inside pump ing inner magnet to offset and rup- Vibration monitor
ture containment shell, and impeller
to contact volute
Worn roller/ball bear- Outer magnet is offset and contacts Leakage through contain- Temperature monitor
ings (in power frame) containment shell (possible rupture) ment shell (based on friction heat)
or other part of the pump housing Vibration monitor
induction, drives the inner rotor. Thus, if the rotor bearings, which are bearing wear and failure, as well as
Magnetic-drive pumps can be di- internal and lubricated by the pumped monitor high can temperatures.
vided into two sub-groups, based on liquid, wear enough to cause the rotor Several operating precautions should
inner-rotor construction. These two to rub against the can, the can may be observed to minimize potential
types are synchronous (also called become punctured and rupture. This problems when using sealless pumps.
“permanent magnet”) pumps and eddy- will cause considerable and uncontrol- Low-boiling liquids may flash when cir-
current pumps. Specially designed lable loss of the liquid being pumped. culated through the internal bearings
magnetic-drive pumps are available A number of pump manufacturers ad- and rotor assembly, resulting in vapor
with dual-containment shells. dress these potential problems with in- binding of the pump when the liquid is
Sealless pumps are available in a novative design features. Some pumps returned to the lowest pressure zone at
wide range of magnetic materials, are constructed with an outer shell the back of the impeller. This can usu-
along with various metallic and non- that serves as a secondary containment ally be prevented with canned-motor
metallic containment-shell materials. should the can rupture. Some pump pumps by using a reverse circulation
Although these pumps do not have manufacturers provide a sensor well in system and returning some liquid back
a mechanical seal or packing and are the secondary containment shell for a to the suction tank that feeds to the
normally much less likely to leak, there moisture-sensing probe, which can be pump. With magnetic-drive pumps, a
are two weak points in sealless pumps interlocked to an alarm and possibly reverse circulation system cannot be
that can result in serious leakages. to the motor to shut it down. Another as easily installed because the can is
These weak points are the contain- safety option is the incorporation of a blinded on the back side by the external
ment shell and the bearings. The con- mechanical seal between the radial magnetic drive. However, a small by-
tainment shell is usually fairly thin to ball bearings and the secondary con- pass stream can sometimes be taken off
allow enough of the magnetic field to tainment housing. On most sealless the discharge end, cooled externally and
pass through the can to drive the pump. pumps, sensors are available to detect then injected back into the can area.
36-42 CHE 2-08.indd 41 1/29/08 6:22:31 PM

Feature Report
Another possible cause of failure is the ical-seal piping that includes strainers, Table 2 lists causes of sealless pump
existence of solids in the pumped liquid. separators, and external flushing. It is failures and their effects and lists types
This can create problems with the inter- very important to avoid running seal- of failure detection monitors for seal-
nal lubrication system, as the solids can less pumps dry, as this can result in less pumps. See Nasr [7] for a discus-
constrict or block passageways entirely. worn bearings and internal rotor gall- sion of temperature monitoring, motor
Various pump manufacturers use dif- ing, or ripping the open can. A number monitors and bearing wear monitors,
ferent methods to handle this problem, of different types of monitors and sen- and Refs. [2, 10] for additional informa-
such as self-cleaning strainers, and a sors are available to detect a dry-run- tion on sealless pumps.
piping arrangement similar to mechan- ning sealless pump.
Acknowledgments
I should like to thank the following
individuals who provided me with
technical material that was helpful
in writing this article: Heinz P. Bloch
(Process Machinery Consulting),
Henry Febo (FM Global), Alfred M.
Osborne (Dyno Nobel Inc.) and Robert
Walz (ABB Lummus). ■
Edited by Kate Torzewski
References
1. API STD 682. Pumps — Shaft sealing Sys-
tems for Centrifugal and Rotary Pumps. 4th
ed. American Petroleum Institute, Washing-
ton, D.C., 2006.
2. API STD 685. Sealless Centrifugal Pumps
for Petroleum, Heavy Duty Chemical, and
Gas Industry Services Downstream Segment.
American Petroleum Institute, Washington,
D.C., 2000.
3. API RP 686. Recommended Practices for Ma-
chinery Installation and Installation Design.
American Petroleum Institute, Washington,
D.C., 1996.
4. Bloch, H. P., Laser Optics Accurately Measure
Running Shaft Alignment. Oil & Gas Journal,
pp. 42-45, Nov. 5, 1990.
5. Bloch, H. P., Chem. Eng. Update Your Shaft
Alignment Knowledge. pp. 68–72, September
2005.
6. Boyson, S., Gas Up Your Sealing Knowledge.
Chem. Process., pp. 20–25, December 2006.
7. Nasr, A., Prevent Failures of Mag Drive Pumps.
Chem. Eng. Prog., pp. 21–24, November 1992.
8. Osborne, A. M., Progressive Cavity Pump
Safety Improvement. Proc. 28th Annual Conf.
on Explosives and Blasting Technique, Vol. II,
pp. 119–127, 2002.
9. Piotrowski, J., Shaft Alignment Handbook.
3rd ed., CRC Press, Boca Raton, FL., 2006.
10. Vetter, G., Leak-Free Pumps and Compres-
sors Handbook. Elsevier, Burlington, MA and
Oxford, U.K., 1995.
11. Volk, M. W., 10 Ways to Prevent Low-Flow
Damage in Pumps. Flow Control, pp. S-4 to
S-8, December 2002.
Author
Stanley S. Grossel (4 Mar-
ble Court, Unit 9, Clifton,
NJ 07013-2212; Phone: 973-
779-3668; email: Psadi28@aol.
com) is a consulting chemical
engineer in the fields of pro-
cess safety/loss prevention;
powders and bulk solids stor-
age, handling, and processing;
air pollution control; and pro-
cess design of batch plants.
He has over 57 years of ex-
perience in the process design and application
of process safety and loss prevention principles
to process plants for pharmaceuticals, organic
chemicals, petrochemicals, and inorganic chemi-
cals. He has a B.Ch.E. from the City College of
New York (1950) and a M.S.Ch.E from Drexel
Institute of Technology (1957).
36-42 CHE 2-08.indd 42 1/29/08 6:23:06 PM

FOCUS ON
Flowmeters
A durable flowmeter for re-
mote applications outdoors
A thermal-dispersion, mass-flow
sensing technology, the ST50 Flow
Meter Series (photo) boasts ±1%
accuracy (repeatability ±0.5%)
Flow
for 2–24-in. line sizes and a built- Technology
in temperature compensation
for reliable measurement over
a 40–100°F temperature range.
There is almost no pressure-drop,
according to the firm. The ST50
Series is suitable for measuring
air within 1–125-std ft/s, com-
pressed air between 4–400-std
ft/s, and process gases, including
nitrogen at 1–150-std ft/s. Built-in
wireless IR communication tech-
nology comes standard with free
Palm-OS based software provided
for download. (Other outputs are Universal
also available.), Built for longevity Flow Monitors
in outdoor and field-installation

applications, the ST50 series is
available in three field-adjustable, connection. The P420 is designed to
U-length probes, 6-, 12- and 18- transmit fluids that are compatible
in., accommodating 2–124-in. pipe with PVC, including liquids that may
sizes. The all-aluminum, epoxy- Fluid Components International contain particles. The flowmeter is
coated, electronic components en- available in five pipe sizes between 0.5
closure is NEMA 4X (IP66) rated and The magnetic field is generated by two and 2.0-in., with max. flow rates from
FM/CSA approved for use in hazardous Hastelloy-C 22 electrodes in a sealed 12 to 200 gal/min. The device’s electri-
locations. — Fluid Components Inter- electrode and coil assembly for immu- cal output is rated “Intrinsically Safe”
national LLC, San Marcos, Calif. nity to humidity variation. The base when used with barriers; and its elec-
edlinks.che.com/7369-431 transmitter, optional panel mounted tronics package is enclosed for protec-
display and multiple output converter tion from shorting, corrosion, leaks,
This electromagnetic with integral display can be either humidity or condensate from conduits
flowmeter is submersible directly or remotely mounted on the or thermal cycling. — Universal Flow
Available in line sizes from 1 to 16- flowmeter. When remotely mounted, Monitors, Inc., Hazel Park, Mich.
in., the Extended Linearity (EL) 2200 the EL 2200 meets the IP 68 standard edlinks.che.com/7369-433
Series of electromagnetic flowmeters for permanent immersion in water up
(photo) promises accuracy in turbu- to a depth of 1.5 m. — Flow Technol- An insertion vortex meter that is
lent, transitional and laminar flow re- ogy, Inc., Tempe, Ariz. reliable in large pipes
gimes. Based on the Faraday principle, edlinks.che.com/7369-432 The Innova-Mass Model 241 Inser-
electromagnetic flowmeters are appli- tion Multiparameter Meter (photo, p.
cable in process applications where the A way to measure corrosive flu- 44) measures three process variables
fluid measured is electrically conduc- ids cost-effectively — velocity, temperature and pres-
tive. Fluids cross a magnetic field in Suitable for chemical, desalination and sure — at a single point. This allows
the flowmeter, generating a potential water-treatment operations, the P420 the device to calculate the Reynold’s
directly proportional to their velocity. Series of vortex-shedding flowmeters number in real time, yielding accurate
The EL 2200 Series’ “extended linear- (photo) is an inexpensive analyzer de- determinations of the true mass flow
ity” means a measurement range of up void of moving parts that might be af- and point velocity for up to 72-in. dia.
to 1000:1 turndown without the aid of fected by corrosive fluids. It has no O- pipes. The flowmeter has an accuracy
linearization software. The device also ring seals. Its connections are made by of ±1.0% and a repeatability of ±0.2%
measures flow in both directions with either solvent-welding PVC pipe into making it suitable for monitoring flows
no moving parts and no pressure drop. the provided socket port or threaded in large pipes where inline meters are
Note: For more information, circle the 3-digit number $)&.*$"-&/(*/&&3*/(888$)&$0.'&#36"3:43
on p. 62, or use the website designation.
Focus
cost prohibitive. The Model 241 comes

equipped with a patented “low-mass”
sensor making it more sensitive to
Omega Engineering
the vortices formed and less sensitive
to equipment vibration. It can be in-
serted into existing pipe through a 2-
in. NPT or a 2-in. 150, 300 or 600 lb
flange with or without a permanent
retractor. — Sierra Instruments, Inc.
Monterey, Calif.
A flow-conditioning meter for

easy retrofitting
A centrally located cone inside the
Wafer-Cone Flowmeter (photo) re-
shapes the velocity profile of a fluid
Sierra Instruments McCrometer
to create a lower pressure region im-
mediately downstream. The pressure
difference created is then measured an adapter is needed. And while the tional temperature range is 0 to 60°C
via two pressure sensing taps and Type 8711 is constructed of aluminum and the safe storage range is –40 to
incorporated into a derivation of the with FPM and EPDM sealing materi- 70°C. The FTB690 Series is rated for
Bernoulli equation, determining the als and NPT 1/4-in. port connections, fluids with viscosity near 1 centistoke,
flow rate. This built-in flow condition- other sealants and ports are available but can be field calibrated for viscosi-
ing gives the Wafer-Cone an accuracy on request. — Burkert Fluid Control ties as high as 100 centistokes. It has a
of ±0.5% and a repeatability of ±0.1% Systems, Ingelfingen, Germany. pressure rating of 150 psig. — Omega
over a 10:1 flow range. The firm rec- edlinks.che.com/7369-436 Engineering, Inc., Stamford, Conn.
ommends the Wafer-Cone for small edlinks.che.com/7369-438
line size processes, as the flowmeter This meter has
was designed for liquid or gas service low maintenance costs A large Coriolis mass flowmeter
in line sizes from 0.5–6.0-in. It has Also operating on electromagnetic for petrochemicals applications
been approved by the U.S. Bureau of induction, the FCMI flowmeter mea- The largest Coriolis mass flowmeter
Land Management for use in coal-bed sures flow rates between 0–37.5 L/min commercially available according to
methane applications. — McCrometer, with a measuring accuracy of ±0.1% the manufacturer, the Rotamass XR
Inc., Hemet, Calif. during low-flow regimes (1–5 L/min). has been tailored to the needs of the
edlinks.che.com/7369-435 The device is serviceable for a range oil, gas and petrochemical industries,
of electrically conductive fluids with offering ±0.1% accuracy of measured
This device improves settling a minimum conductivity of 10 µS/cm value for liquids and ±0.5% for gases.
time and accuracy or greater, 15 µS/cm or greater in the The device also offers a temperature
Intended for neutral, non-contami- case of water. Designed with short-cir- measurement accuracy of ±0.5°C. For
nated gases, and others if specified, cuit and reverse-polarity protections, anywhere up to its maximum flow rate
the Type 8711 Mass Flow Controller it has a medium temperature range of of 600 ton/h, the flowmeter is capable
boasts a settling time of under 300 5–60°C and is resistant to pressure up of bi-directional measurements of mass
ms and an accuracy of ±0.8%. Linear- to 10 bar. — Hans Turck GmbH & Co. flow, density and temperature as well
ity and repeatability are both ±0.1%. KG, Mülheim an der Ruhr, Germany as calculations for concentration, volu-
The device’s CMOSens technology edlinks.che.com/7369-437 metric flow and net flow. The flange
sensor is housed in a bypass channel concept allows for connections up to
designed to permit laminar flow condi- A compact, no-frills flow-mea- 8-in. ASME class 300. A high-power
tions and is comprised of two tempera- surement device option allows the Rotamass to handle
ture sensors divided by a heating re- The FTB690 Series turbine meter two-phase flows. Built-in self-diag-
sistor. The flowmeter can be calibrated (photo) performs all operations (such nostic features, corrosion detection,
by the analyte gas or air by way of a as the display of cumulative total, slug flow detection and compensation,
conversion factor. It’s flow rate range batch total, and rate of flow) with only come standard. Digital communication
is 0.02–50 L/min. The operating ambi- two buttons. Memory is available for is provided via HART or Foundation
ent temperature range is 14 to 122°F; a single-point field calibration curve. Fieldbus. Its operational temperature
medium temperature is 14 to 158°F; The device boasts a repeatability of range is –200 to +230°C. — Yokogawa
and the maximum operating pressure ±0.1% and an accuracy of ±3% with Electric Corporation, Tokyo, Japan
is 145 psi. Digital communication is a lessened accuracy of ±5.0% during edlinks.che.com/7369-439 O
standard RS232 or RS485, though extended low-flow regimes. The opera- Matthew Phelan
44$)&.*$"-&/(*/&&3*/(888$)&$0.'&#36"3:
SolidsProcessing
Solids Processing
Tank Coatings:
Covering the Basics of
Selection and Specification
Good quality coatings can make all
the difference where corrosion and
chemical compatibility are concerned
Peter Vodak
CST Industries/Columbian TecTank
T
he interior surfaces of your cases because if
storage tanks are constantly properly coated, it
at risk. If you walk past a combines strength
tank often without giving and strong perfor- 5IFIJHIFTURVBMJUZDPBUJOH
thought to what is happening on the mance at a reason- BQQMJDBUJPOJTQFSGPSNFEBU
inside, it is because you trust the in- able cost. UIFGBDUPSZVOEFSFOWJSPO
NFOUBMMZDPOUSPMMFEDPOEJ
terior coating to protect not only the Nearly all tanks UJPOT5BLFOPOFTUFQGVSUIFS
storage vessel, but also to protect the are coated on the UIFDPBUJOHTTIPVMEBMTPCF
product being stored from any corro- interior to protect UIFSNBMMZDVSFEBUUIFGBDUPSZ
sion that might occur on the tank. the tank as well as
Without a doubt, corrosion is the the product being stored. Corrosion materials that it will hold means less
principal enemy of a storage vessel. occurs when the tank coating fails maintenance over time and less con-
It shortens a tank’s lifespan incre- and the product is exposed to the tank cern for you each time you pass by.
mentally and increases the possibility wall. Unprotected steel can begin to
of contamination. Dry bulk products corrode in a matter of hours. With ag- Variety in coatings
are often abrasive to the tank walls, gressive liquids, holes through a tank Tank manufacturers are often defined
requiring a strong coating to resist sidewall or floor could develop in a by their coatings. The quality of a
scratches and gouges, which expose matter of months. coating and its resistance to corrosion
the steel to corrosion. In addition, liq- All materials, whether dry bulk determines the lifespan and quality of
uids are particularly aggressive, so chemicals, potable water, wastewater the tank. Many different coatings are
the coating found on the interior of or liquid chemicals, will react differ- found on the market today, including
the tank is essential when it comes to ently to the storage vessel and have epoxy, glass fused-to-steel, high-heat
protecting a tank against the harmful individual and specific storage re- coatings, cold-weather coatings and
effects of corrosion. quirements. Chemicals will require coatings designed to withstand high
While the old adage that “a tank a tank coating that strongly resists levels of acidity or bases.
is a tank” is no longer true, tanks do aggressive products, such as acids The choice of one coating over an-
often share the same materials of con- or bases. Dry bulk materials require other should be made depending on
struction. Tanks and silos are made hard, abrasion resistant coatings that the product to be stored. Each product
from a variety of materials, including are slick, to ensure that all material has its own requirements and speci-
aluminum, stainless steel, plastic, fi- passes out of the tank leaving mini- fications. For example, wastewater
berglass and most commonly, carbon mal residue. Liquids require a coating and wastewater sludges will require a
steel. The tank material choice is typi- that withstands immersion for long coating that is designed to withstand
cally driven by cost and compatibil- periods of time. Choosing a tank with the aggressive effects of ever-present
ity with the stored product. Carbon a high-quality coating that has been fatty acids and hydrogen sulfide.
steel is the material of choice in many tested and proven to withstand the Epoxy coatings are very common in
$)&.*$"-&/(*/&&3*/(888$)&$0.'&#36"3:45
Solids Processing
the tank industry. They are generally

tough and chemical resistant, with
excellent corrosion resistance. Epoxy
coatings can be applied electrostatically
either as a powder or a liquid. On the
exterior, epoxy coatings are typically
combined with polyurethane topcoats
to provide protection against environ-
mental elements.
Glass-fused-to-steel coatings are ap-
plied by spraying panels with a water-
based slurry of ground glass particles
in water. The water is then removed
by drying prior to firing. The coated
sheets are sent through a furnace at
1,500°F, which chemically fuses the
glass coating to the steel. The finished Regardless of how good a coating is, it must have a clean surface with an adequate
glass coating is impermeable to liquids blast profile to perform properly
and unaffected by solvents.
Many other types of coatings also Field welded and concrete tanks the same way that the most advanced
exist, and each has its advantages usually receive their coatings onsite skyscraper must have a solid founda-
and disadvantages. Some, such as in- once the tank has been erected. These tion to rest upon.
organic zincs, are intended to provide tanks may need to undergo a chemi- The most common method of sur-
sacrificial corrosion resistance on exte- cal process to protect the coating while face preparation is abrasive blasting.
rior surfaces. Others, such as silicones, the tank is being erected (for instance, Different abrasives can be used, in-
are intended for high-heat applications heat from welding may damage the cluding steel grit or shot, garnet, coal
where high temperatures are expected. coating). For this type of application, slag, and even items such as walnut
Regardless of the type of coating used, you should ensure that adequate qual- shells. The type and size of grit should
it is critical that the coating be suited ity control measures are listed in the be chosen in accordance with the coat-
for its intended storage application. specification, and consider third party ing manufacturer’s recommendations.
inspections. Be aware that once a tank Abrasive blasting may either be done
Coating application process has been erected in the field, there are automatically (typically by a centrifu-
While the market today offers a vari- often areas of the tank that are ex- gal blast machine) or manually (air
ety of coatings, the true differences lie tremely difficult to sand blast or fully blasting). In the case of air blasting, it
in the application process itself. Coat- prepare for field coating. Even “miss- is critical that the air used for blasting
ings in general may have great selling ing the smallest spots” leaves exposed is dry and free of contaminants. The
points and use advanced technology, areas open to corrosion. Also, the surface should be inspected prior to
but if the coating is not applied cor- thickness of coatings applied in the coating application to ensure that the
rectly, the tank wall will be left exposed field cannot be controlled as closely proper cleanliness and profile have
and vulnerable to corrosion. as is possible under ideal factory con- been achieved.
The highest quality application is ditions, which may result in uneven Coating application: Coatings can
done at the factory under environ- application. Finally, weather and the be applied either automatically or
mentally controlled circumstances to environment — dust, humidity, tem- manually. When coating large areas,
ensure the most consistent applica- perature and wind — will affect the liquid coatings are typically applied
tion. Taken one step further, the coat- quality and timeliness of the curing using either airless or air-assisted
ings should also be thermally cured process in the field. airless spray guns. Airless guns give
at the factory. Some manufacturers The coating-application process a higher production rate while air-as-
apply the coatings in the factory and involves three steps, each of which sisted airless guns use less paint and
then allow them to air-dry and cure helps define the quality of the coating provide a smoother finish. In some
with ambient heat, which exposes the and the effectiveness of its resistance cases, electrostatic versions can be
cure to environmental factors such as to corrosion. used to increase transfer efficiency of
dust and humidity. Other manufactur- Surface preparation: Surface prepa- the paint by applying a charge to the
ers outsource the coating process alto- ration is the first and most critical step atomized paint, which is then drawn
gether. The optimal coating solution is in the application process. It involves to the part to be coated, although in
one that is both applied and thermally both cleaning the surface and achiev- this case, the part must be grounded.
cured in controlled factory conditions, ing a profile on the steel. Regardless Rollers can be used if regulatory re-
before the tank is shipped and erected of how good the coating is, it must quirements or environmental concerns
in the field. Factory welded and bolted have a clean surface with an adequate prohibit the use of spray guns.
tanks often offer this feature. blast profile to perform properly, in Powder coatings are applied using
45-48 CHE 2-08.indd 46 1/29/08 6:43:38 PM

spray guns that apply a charge to the of electrostatic application is that the
powder particles when they are atom- charged particles are drawn preferen-
ized in a similar way to how a liquid tially to the thinnest areas, which re-
electrostatic system works. Again, the sults in a more uniform coating. They
part must be grounded. Powder sys- are also drawn to edges that are typi-
tems have the advantage of wrapping cally difficult to coat by other means.
extremely well on exposed edges.
It is important that the coating Performance testing
thickness be measured throughout the To ensure the quality of the coating
application process to ensure that the meets the manufacturer’s specifica-
manufacturer’s recommended thick- tions, coatings are generally tested
ness is achieved. If the coating is too extensively by tank manufacturers
thin, the steel may not be adequately before they are introduced to the mar-
covered and pinpoint rusting can soon ketplace. Common performance tests Bioengineering
occur. If the coating is excessively include the following: ultraviolet (UV)
thick, it may crack from internal exposure, corrosion resistance and Inversina –
stresses or a loss of flexibility. chemical resistance.
Curing: Curing involves the process UV exposure: Coatings will typically the gentle way
of transforming the coating from a lose gloss and their color will change
liquid or powder to a fully set film.
Many coatings cure by polymeriza-
over time when exposed to UV light.
This property is most critical for ex-
of mixing.
tion, wherein a chemical reaction oc- terior topcoats that are constantly ex-
The Inversina mixes solids or liquids
curs. For these types of coatings, cur- posed to sunlight. UV-exposure testingC
thoroughly and efficiently. The process

ing is not the same as drying, which measures a coating’s color and gloss
involves the evaporation of solvents or retention when exposed to sunlight.
M
is clean, because mixing takes place in
water from a liquid coating. A coating Both natural sunlight exposure and
Y closed containers that can be quickly
can be dry to the touch without being accelerated versions that use either CM interchanged. The Inversina mixes a
fully cured. Generally the rate of reac- concentrated sunlight or simulated diverse range of components rapidly
MY
tion (and thus, cure) for these types of sunlight are commonly tested. This and in an extremely gentle way.
coatings can be sped up by increasing test measures how the coating’s colorCY
Segregation does not occur, even
the temperature. There are three main and gloss change over time. CMY after extended mixing times, by virtue
types of cure for polymerization coat- Corrosion resistance: Coatings are K of the eversion phenomenon ( Paul
ings: oxidative, chemical and thermal. tested for resistance to corrosion by Schatz principle ) .
Oxidative coatings (such as oil- exposure to water or salt solutions in a
Applications for the Inversina: analyti-
based house paints) cure by reacting humid or spray environment. For many
cal labs, metal finishing shops, powder
with the oxygen in air. These coatings years, the standard ASTM B117 salt-
tend to have lesser chemical resis- spray test was used, but recently it has metallurgy and nuclear industry,
tance and in most cases are not used fallen out of favor because results did manufacture of batteries, cement,
on storage tanks. not always correlate well with those ceramics, cosmetics, dental products,
Chemical reaction coatings typically seen in the field. More recently the diamond tools, dyes and pigments,
involve either reaction with moisture ASTM D5894 cyclic-corrosion test with electrical and electronic devices,
in the air or reaction between two or its modified salt solution has gained explosives and pyrotechnics, foods,
more components. Epoxies are typical favor and is considered more realistic. homeopathic products, household
coatings that cure by chemical reaction. Regardless of the test chosen, the goal products, medicines and pharmaceu-
In this case, two components are mixed is to assess the degree of rusting and ticals, plastics, printing inks and many
together, which react and then cure. the amount of undercutting seen from
other products. The Bioengineering
The rate of chemical reaction for these a line scribed through the coating.
Inversina is available with capacities
coatings types can typically be sped up Strong-performing coatings will show
by increasing the temperature. no surface rusting and very little to no of 2, 20, 50, 100 and 300 L .
Thermal coatings require a high- undercutting, even when exposed for
temperature bake cycle to achieve thousands of hours.
cure. These are typically high-per- Chemical resistance: The chemi-
forming systems and must be applied cal resistance of coatings is tested
and cured in a factory environment. by immersing a coated sample in the Bioengineering, Inc.
Advantage of powders: Powder coat- liquid to which it will be exposed. The Waltham, MA 02451, USA
ings have an electrostatic charge put temperature may be elevated to ac- Bioengineering AG
on the powder particles while they are celerate a chemical attack. This test 8636 Wald, Switzerland
being atomized. This charge draws it looks for blistering or dissolution of info@bioengineering.ch
to the grounded part. The advantage the coating. In general, if a coating www.bioengineering.ch
Circle 26 on p. 62 or go to
45-48 CHE 2-08.indd 47 1/29/08 6:43:58 PM

Solids Processing
will fail a chemical-resistance test, Factory welded and

it will tend to happen fairly quickly bolted tanks are often
preferred because
(within a week). their coatings can be
For all of these tests, acceler- applied and thermally
ated versions may be used, which cured at the factory
will give a faster indication of how
the coating is likely to perform in
a given environment. However, it
is important to keep in mind that
accelerated tests generally involve
some level of trade-off. Therefore,
look to the tank supplier to provide a Keep in mind that special applica- Costs of corrosion
history of successful projects in simi- tions require specific product approv- Corrosion significantly shortens the
lar applications. als for tank coatings. For example, life of a tank, so a good quality coating
if you plan to use a tank for potable from the beginning often means less
Other considerations water storage in the U.S., the tank maintenance and less chance of the
If you would ever consider moving coating must be NSF Standard 61 cer- need to recoat the tank. A high quality
or relocating a tank, think about the tified. Meanwhile, in the same country, coating that offers proven corrosion
impact this will have on the coat- dry food applications require the tank resistance may have a higher up-front
ing. Tanks featuring factory-applied coating to have U.S. Food and Drug Ad- cost, but lower lifecycle maintenance
coatings are usually moveable with- ministration (FDA) compliance under and recoating requirements make it
out a follow up recoat, as panels are the Code of Federal Regulations (21 the most economical choice for the life
individually coated and easily taken CFR 175.300). Verification of these ap- of the tank.
apart. Coatings applied in the field provals can be obtained from the tank
often set up as a sheet and will tear manufacturer or coating supplier. Vendor selection
or break if the pieces are moved. Also Review the history of the tank manu-
consider whether you plan to expand Inspection and maintenance facturer and coating to be used. Tank
your tank. A bolted tank with factory Tanks should be inspected both in- vendors should provide testing data and
coating would allow for adding rings side and out once a year to make case histories of how the coating per-
(think upward) without affecting the sure they are in good shape. Any cor- formed against corrosion with a product
coating on the original tank. A tank roded areas should be properly pre- like the one to be stored. Other consid-
with a field-applied coating would pared and touched up with a suitable erations include how long the company
require recoating after the expan- maintenance coating. A tank that is has been fabricating tanks, whether it
sion is completed. neglected can result in product con- uses state-of-the-art coatings, if its coat-
tamination, extensive maintenance ings are factory applied and thermally
Safety factors and recoating, safety hazard and sig- cured, what its quality control mea-
Coatings also play a role in safety. nificant downtime. sures are, what its volume sold is, and
Some coatings are designed for stor- Maintenance coatings are typically into what countries and markets it has
ing a wide variety of products, while used to repair larger areas or even an sold. Also consider tank manufacturers
others may react poorly with cer- entire tank. Some maintenance coat- with third-party accreditation, such as
tain products. Manufacturers should ings require the existing coating to the ISO Quality Certification. ■
provide the results of testing of the be fully removed through a process of Edited by Rebekkah Marshall
coating with a particular product to blasting or waterjetting, while other
ensure the coating is suitable for the maintenance coatings are designed to Author
specific application. be applied over an existing coating or Peter Vodak is corporate
coating engineer with CST
It is unsafe to use an old storage even a rusted surface. Contact the tank Industries, Inc. (P.O. Box 2907,
tank for a product for which it was manufacturer for recommendations, Kansas City, KS 6610; Phone:
913-621-3700; Fax: 913-621-
not designed and tested. If you are and make sure that the chosen main- 2145; Email: pvodak@colum-
considering recycling a used tank for tenance coating is compatible with the biantectank.com). He holds a
B.S.Ch.E. from the University
storing a new product (such as using stored product and environment. of Wisconsin-Madison. He is a
a dry bulk-storage tank for liquid stor- One common rule of thumb is that NACE Certified Coating In-
spector. Columbian TecTank,
age, or a potable-water storage tank a tank should be considered for re- a division of CST Industries,
specializes in the design, fabrication, factory coat-
for wastewater), be sure to first have painting when it shows rust on 1% of ing/thermally curing and erection of tanks for
the tank evaluated for safety, flow and its surface. This doesn’t sound like a liquid and dry bulk storage. The company manu-
factures bolted and shop-welded tanks of carbon
corrosion and chemical resistance. In- lot, but in reality represents a fairly steel, aluminum and stainless steel featuring fac-
correct use of a tank could result in large area. For example, a 30-ft dia. tory applied and thermally cured epoxy coatings.
Columbian TecTank tanks are manufactured at
severe corrosion, premature failure of tank that is 20 ft tall has an area of ISO 9001 Certified facilities and are found in 123
the coating, harm to the product or se- 1,885 ft2. A 1% portion of this area is countries worldwide. For more information about
choosing tanks and coatings, please visit www.co-
rious injury to personnel. just under 19 ft2. lumbiantectank.com.
45-48 CHE 2-08.indd 48 1/29/08 6:44:29 PM

Solids Processing
Environmental Manager
Caring for Cooling Water

Systems Finding and fixing the leak
When hydrocarbon leaks are confirmed, first and foremost it is important to isolate the
source of leakage. The following are typical methods:
• Measure oil content in the supply and return headers of the main units to determine the
Hydrocarbon leaks can unit that is leaking
• Once the main unit that is leaking is identified, oil content and oxidation-reduction
disrupt recirculated potential (ORP) should be measured at the inlet and outlet of coolers and condensers.
An ORP level greater than 450 millivolts (mV) indicates that biofouling is prevented in
cooling-water systems. the system. Values of 500–600 mV indicate an almost clean system, while a sudden
dip in ORP value indicates hydrocarbon leaks. ORP measurements are quite effective
Here’s an outline in identifying the source of leaks, and installation of online ORP meters at unit return
headers, and critical coolers and condensers is recommended. Leaks sources should
of effects and remedies be confirmed through laboratory measurements of oil content in the water sample
• Once the leak source is confirmed, the unit should be isolated immediately. This some-
times causes production losses
• After cleaning, the leaking heat exchanger is pressure tested to identify and repair
Sanjib Ghosal the leak ❏
Indian Oil Corp.
W
ater is often the fluid of to long-chain waxy compounds. Mi- oxidizing biocides like sodium hypo-
choice for cooling systems crobes produce enzymes to break down chlorite, chlorine and bromine, and
in the chemical process hydrocarbon chains into small, easily chlorine dioxide greatly increases.
industries (CPI). Recircu- digestible parts. The simpler the con- The immediate effect of hydrocarbon
lated cooling-water systems are used figuration, the easier and faster the leaks is the gradual lowering of free
to control the temperature of process breakdown. Gasoline, naphtha, kero- chlorine content (FRC) in the recircu-
fluids, which is necessary for process sene and benzene are broken down lated water, particularly in the return
control and to achieve target product very easily. Diesel oil is also primarily header. Observations subsequent to
yields and specifications. Hydrocarbon composed of paraffinic chains and is process leaks typically include the fol-
leaks into recirculated cooling-water therefore absorbed very easily by mi- lowing:
systems are of particular concern in crobes. Heavier oils, high-viscosity oils • Visually, an oily layer can be seen on
oil refineries and the petrochemical in- and high boiling-point fractions com- the sump and a rainbow-colored in-
dustry. Contamination in the water can prise long, polymeric chains. These terference pattern may be observed
cause a multitude of problems includ- are very difficult to break down by the • A hydrocarbon-like odor may be
ing biofouling, scaling and microbiolog- microbial enzymes and the organisms noticed in water samples collected
ically induced corrosion. These fouling take a long time to use these products from the sump
and corrosion mechanisms can result as their food. • In case of gas leakage, bubbling in
in operational inefficiencies, equipment the sump may be seen. This can also
failure and environmental concerns. Leak detection be felt during sample collection from
Hydrocarbons, as oils and gases, return headers
Hydrocarbons as nutrients are typically introduced into cooling • Sometimes, the pH of sump water
Petroleum hydrocarbons are com- water systems due to leaks in cool- decreases slightly. H2S ingress takes
pounds consisting of carbon and hy- ers and condensers in the plant. Tube place with most of the petroleum
drogen in various configurations. and gasket failures in the coolers and compounds, thereby forming a weak
Since living cells use carbohydrates condensers are contributing factors to acid in water
as sources of energy; microbiological these problems. • FRC in the system will come down
organisms — such as bacteria, algae Since hydrocarbons are sources of and possibly reach zero if the leak
and fungi — use hydrocarbons as high-caloric and easily digestible food remains undetected for a few days,
their food for growth. Petroleum hy- for microbes, the growth of the organ- or if biocides remain ineffective
drocarbons, therefore, become natural isms increases exponentially when • The turbidity of the sump water will
sources of nutrition for these micro- hydrocarbons are introduced into a gradually increase, particularly dur-
biological species. cooling water system. Due to such ing heavy oil ingress. Turbidity may
Hydrocarbons range from very sim- unwarranted proliferation of microor- exceed 300 NTU (Nephelometric
ple and volatile paraffinic compounds ganisms, the requirement for routine turbidity units) with contamination
49-50 CHE 2-08.indd 49 1/29/08 6:08:33 PM

Environmental Manager
of heavy and viscous materials Microbiologically induced corro- taken to ward off the deleterious effects
• The sulfate-reducing bacteria (SRB) sion (MIC). This is another deteriorat- of leaks in the cooling water system:
counts will steadily rise to 103–104 ing effect of oil leaks in cooling water • Dosing of oxidizing biocide is in-
counts/mL systems. Depending on the function of creased to a higher level. Chlorine
• The total bacteria count (TBC) will bacteria, they are grouped as aerobic dioxide, bromo-compounds and
also show an upward trend (more or anaerobic. SRB is a typical example ozone are also used
than 105 counts/mL) of anaerobic bacteria. Nitrifying bac- • Biodispersants are dosed at a higher-
• The oil content in the sump will teria, which produce nitric acids in the than-normal rate. They cause faster
be significantly higher than the al- presence of ammonia, are aerobic. disengagement of organisms from
lowed values MIC results from various causes, in- the surface so that biocides act ef-
Leaving leaks unchecked will cause cluding: a) Cathodic depolarization of fectively. This enhances both plank-
problems, the effects of which are dis- sulfur-reducing bacteria, such as De- tonic and sessile efficacy
cussed in the next sections. sulfovibrio and Desulfurican. Corro- • Shock dosing of other non-oxidizing
sion typically manifests in the form of biocides, such as quaternary ammo-
The effects of leaks localized pitting and grooving; b) The nium compounds, methyl bis-thio-
Biofouling. Bacteria and algae stick production of corrosive metabolites, cyanate and glutaraldehyde, is also
to almost any surface in cooling water such as acids by Thiobacillus and done to kill the microbes. Selection
systems, particularly where water ve- Thiooxidans and other organic acids of particular biocides and the dosing
locity is low. The microorganisms pro- by various bacteria and fungi species; rates is important because biocides
duce a polysaccharide-layer matrix, c) Sometimes bacteria, such as Gal- possess different levels of efficacy
which is called slime or biofilm. This lionella and Clonothrix, cause direct against various microorganisms, and
film further entraps inorganic matter, oxidation of metal, for example fer- each cooling water system has its
precipitates and corrosion products. rous to ferric, and cause tubercles on unique microbiological population
Numerous problems posed by the bio- metal surface. These are called iron- • An overflow and controlled blowdown
fouling are given below. oxidizing bacteria. Since areas under of the cooling water sump eliminates
• Loss of transfer and operational ef- the tubercles are deficient in oxygen, oil, biomass and froth from the sump,
ficiency as these biofilms are four they act as corrosion cells and result which otherwise would circulate in
times more insulating than even in deep internal grooving; d) Some the system and clog the coolers and
calcium-carbonate scales bacteria are acid-producing bacteria condensers. Any blowdown, however,
• Microbes produce localized con- (APB) and thus corrode metals. directly affects cost
centrations of metabolites, such as MIC may be prevented by routine Before a good cooling-water treatment
corrosive gases and acids, which monitoring of TBC and SRB counts program is formulated, consideration
manifest in the form of pitting and in the cooling water system. However, must be given to the various types of
grooving a common mistake is to measure the process leaks that are possible, and
• Biofilms promote scale formation planktonic count (microbes present in microbiological populations that are
• Restriction of flow inside the cooler the bulk water), which shows poor cor- present in the system. In the past, se-
and condenser tubes relation with the sessile count on the lection of biocides and dispersants was
• Typical chemical treatments can metal surface. Sessile-count monitor- typically based only on their cost and
become ineffective when biofilms ing, and identification of low-velocity effectiveness against the spectrum of
grow in volume, as the biocides zones and fouling-prone coolers and bacteria. Today, the selection is also
cannot penetrate the impermeable condensers are a must for formulating governed by environmental concerns.
structure an effective water-management pro- Research is being pursued in this area
• Biofilm promotes development of gram. It is important to select proper and newer strategies are evolving for
biocide-resistant strains due to ses- biocides to kill unwanted microorgan- the control of biofouling, scaling and
sile growth under and within depos- isms and equally important to use bio- MIC due to hydrocarbon leaks. n
its (sessile refers to microorganisms dispersants to disengage organisms Edited by Dorothy Lozowski
that are attached to the surface) from surfaces so that the biocides can
• Biofilms also harbor some harmful act effectively. Author
species that cause environmental Ammonia and hydrogen sulfide Sanjib Ghoshal joined In-
dian Oil Corp. in 1997 as an
and human-safety related concerns sometimes accompany hydrocarbon inspection engineer and cur-
Scaling. Organic acids and polymers gases to contaminate cooling water. rently works as deputy man-
ager inspection at the Haldia
produced by bacteria in biofilms com- These chemicals also cause the de- Refinery (Indian Oil Corpora-
tion Ltd., Midnapore(E), West-
bine with calcium and magnesium ions mand for chlorine to increase to very Bengal, PIN-721606, India;
to form insoluble oxalates, acetates and high levels and may also lead to both Email: Ghosals@iocl.co.in).
Ghosal obtained his B-Tech
calcium-magnesium polymer complexes. fouling and MIC. degree in metallurgical en-
These insoluble-compound deposits are gineering from the Indian
Institute of Technology, Kharagpur in 1997. His
scales, which make biofilms even more Remedial measures areas of interest include risk-based inspection,
impermeable. As a result, heat-transfer In addition to fixing the actual leak (see reliability improvement through inspection
and advanced NDT, and corrosion of piping and
efficiency drops significantly. box, p. 49), parallel measures are also equipment in cooling water circuits.
49-50 CHE 2-08.indd 50 1/29/08 6:08:57 PM

You & Your Job
When it Becomes
Necessary to Fire
An Employee
These guiding principles will help you
prepare properly and avoid making this task
more unpleasant than it has to be
John P. Creveling
Career Resources Management, LLC
I
f you ever find yourself in a man- is being terminated for performance performance review. Needless to say,
agement position, inevitably at reasons, Sell also emphasizes the im- follow-through is especially impor-
some point you will have to ter- portance of having provided the in- tant if you agree on a plan or strategy
minate an employee. Whether for dividual enough feedback along the for bench marking and development.
performance-related reasons, disci- way and suggests asking the following This way you can be assured that
pline, or business downturns, termi- question: “Does the individual know there will be no surprises should you
nation of an employee for many people what they are doing well, and where decide to terminate an individual.
causes a significant amount of angst there is room for improvement?”
and sleepless nights. Let’s not kid any- Aaron Boucher, HR manager for Making the decision
one, terminating an employee is never Renaissance Marble, Inc., approaches Mike Shaw, director of HR for Rexnord
easy and should not be done without terminations in a similar fashion Corp., believes that when a decision has
forethought or preparation. Termina- by asking “Have we done enough for been made to terminate an individual
tion impacts people’s lives: the person the employee? If an individual is not for performance related issues “It is a
being let go, people remaining, and meeting specific measurements, have must to include documentation in the
the people handling the displacement. we communicated that to them with employee’s file.” He emphasizes, “You
When terminating an employee is un- relevant feedback as to how they can should have your facts and be right
avoidable, the following guiding prin- improve prior to the termination?” on the money.” Shaw has learned the
ciples are important to keep in mind. Sell says, “An individual who is importance of accurate record keeping
being terminated for performance rea- having spent most of his career in HR
Before you decide to terminate sons should be provided with pertinent in union environments where “absent
Dan Sell, director of human resources examples to support the decision, both appropriate documentation you prob-
for Hill International believes that positive and negative.” Boucher and ably never would prevail.”
preceding any employee termination, Sell agree that if a termination is han- Shaw also acknowledges that “al-
several issues need to be considered; dled properly, there should be no sur- though the proper documentation is im-
“Before moving to terminate an indi- prises at the time of termination. “For portant, it’s really about doing the right
vidual for sub-standard performance, an individual to be shocked as to why thing. When you have an employee who
human resources (HR) needs to make he or she is being terminated would be is not meeting performance standards,
sure the appropriate steps have been an egregious mistake,” Sell says. other employees are watching how you
taken to get there.” For instance, “If What Sell and Boucher are say- handle the situation.” Shaw is remind-
contemplating terminating an indi- ing is that communication between ing us that if you choose to ignore poor
vidual because of poor performance, manager and employee is essential performance, it will only get worse. By
HR needs to know that the necessary throughout an employee’s career. choosing not to act, you are still mak-
resources, such as training to do the Make sure you let the individual know ing a decision. Once you have made
job well, have been provided. Objec- what he or she is doing well (positive the decision to terminate an individual
tively, the question should be asked if reinforcement), where improvement for poor performance, discipline, or for
the company has done all that can be can be made, and that you use valid economic reasons, take a course of ac-
done to support the individual’s suc- measurements of performance to give tion that is fair and reasonable for the
cess in our organization.” If a person feedback; not waiting until an annual circumstances.
51-54 CHE 2-08.indd 51 1/29/08 6:49:43 PM

You & Your Job
Preparing for notification about the terminated individual? als being terminated should leave with
Regardless of how many times you • What information or documentation dignity. “When you’re letting someone
have terminated employees in the do you want the displaced individual go, your demeanor and the atmosphere
past, termination of one person or to have as he or she leaves? of the meeting should be respectful and
several, always takes a lot of prepara- • How will you prepare yourself emo- professional at all times,” notes Bren-
tion and coordination. An assortment tionally? nan. If you are displacing someone for
of questions needs to be asked and • What is the message that you will performance or discipline reasons, the
answered prior to the actual termina- communicate to those who remain termination is the culmination of all
tion. Questions to consider include: with the company? the feedback provided along the way.
• Have I conferred with the HR de- Keep in mind that although there is no In other words, if you have been doing
partment to ascertain that I am fol- “boiler-plate” for terminations, prepar- your job from the beginning, the ter-
lowing company protocol? ing in advance is a must. Each time mination notification won’t be a bomb-
• What other key people do I need to you terminate an individual or group shell to the employee. (Possible excep-
involve? of individuals you’ll need to determine tions include discipline issues, such
• What is the best time and place to what groundwork is warranted for that as theft or violence in the workplace,
communicate the termination? particular situation. By being ready, where a suspension or termination
• What is the best location within the you’ll minimize stress and potential could take place immediately.)
company for the termination meet- disruption to yourself, the individual, “Be prepared with what you want
ing to take place? Will we be assured and others within the organization. You to say as well as anticipating an
of privacy? might not be ready for every possible employee’s likely reactions and ob-
• What company assets does the in- scenario, but you’ll feel more confident jections,” advises Brennan. When
dividual possess, such as computer, about what you are doing and know confronted with objections, listen —
building keys, access identification you are doing it for the right reasons. don’t equivocate. If necessary, clarify
card, and so on? and reaffirm why the person is being
• What will I say is the reason for ter- The termination meeting let go. Brennan cautions managers
mination? (Be brief and specific and Whether you are terminating someone to “Stay focused, and if an employee
keep emotions out of it.) If needed, for economic, performance or disciplin- objects, refer to the specific reasons
and especially if you believe you will ary reasons, the termination meeting for termination and restate the cause
be nervous, prepare what you will is not a place for joviality, gratuitous if needed.” If you are nervous about
say in advance and put it to memory remarks, or small talk such as, “Good the planned termination meeting —
(don’t read it). to see you.” “The termination meeting most people are — provide structure,
• Does the individual car pool and will should be conducted in a professional prepare a script and role-play ahead
he or she need a ride home? manner with dignity and respect,” of time with another manager or a
• Do you anticipate that the individ- says Tom Brennan, director of HR for human resources representative.
ual will be disruptive? If so, what is PREIT Services, LLC. “Terminations Prior to the termination meeting
the course of action you’re prepared are serious business. Never berate or decide what documentation or infor-
to take? Will you need to have a se- demean the individual.” mation you need to disseminate to the
curity representative standing by to People will remember what took individual such as severance package,
escort the individual from the build- place at the termination meeting and outplacement services, medical ben-
ing? (If you feel the need to have a how the message was communicated efits, retirement and pension data.
security representative available, long after they leave the company. One You’ll also want to ascertain if the in-
make sure it’s done in a discreet example is the story of a friend of mine dividual is eligible for unemployment
manner so as not to embarrass, in- who was terminated from a manage- compensation. Let the individual know
timidate or disrupt others.) ment position more than 18 years ago. who he or she can contact if questions
• What personal assets does the indi- She reported, “After being with the arise after the termination meeting.
vidual have to remove? What is the company for nine years, they termi- Finally, wherever the termination
best time to remove him or her? nated me in the middle of a hotel lobby takes place, have emergency telephone
• How will the person say goodbye to in less than three minutes. To say I was numbers available and know the next
others? shocked is an understatement.” Shaw steps for the individual. Will he or she
• If you are terminating an individual recommends approaching terminations go back to the workplace or leave the
for discipline or poor performance is- with empathy and advises evoking the company immediately? If the decision
sues, have you properly documented golden rule of doing unto others as you is to leave right away, when will he or
the files to corroborate your decision? would have them do unto you. This she be permitted to pick-up personal
• Is the person eligible for a severance means being fair, honest, and compas- possessions, or will someone else do
package? sionate. It may be helpful to ask your- it? Although you may not feel it is es-
• Do you want to provide outplacement self, “What is the indelible message I sential, evaluate the merits of alerting
or career continuation services? want the individual to take away from company security when terminations
• What will you say when a prospective the termination meeting?” take place, especially if you think the
employer calls seeking a reference All the experts agree that individu- person could be explosive.
51-54 CHE 2-08.indd 52 1/29/08 6:50:09 PM

You & Your Job
You didn’t do it What to say to everyone else At all times, be honest. If you don’t
A number of years ago when I fired After a termination or displacement, know, say so. ■
an employee for not meeting ac- although you may want to hide out Edited by Rebekkah Marshall
ceptable performance standards, I in your office, don’t! As Shaw says
remember thinking “How can I do “Employees are watching how you Author
this?” Initially, I lost sleep over the handle the situation.” Be accessible John P. Creveling is a lead-
ership development and career
decision. Fortunately, when I began and visible, all day long, and let coach and cofounder of Career
to actually answer that question, it people know the next steps. In the Resources Management LLC
(1616 Walnut Street, Suite
didn’t take me long before I realized case of a person being terminated for 1105, Philadelphia, PA 19103;
that I didn’t do it. She did. She had performance-related reasons, don’t Phone: 215-988-023; Email:
john@careerresourcesmgt.
been provided frequent opportuni- denigrate the individual. People are com; Website: www.
careerresourcesmgt.com), an
ties to improve. Standards were set. observing and want to know that you organization development and
Guidelines had been established. are respectful and even empathic. a career management consult-
ing firm. He is a frequent speaker for international
We agreed to how her performance Even though you may want to, and national conferences. He has authored more
would be measured, and feedback don’t feel obligated to defend your than forty business and career related articles
published in professional journals, newspapers
was provided along the way. She position. What people really want to and magazines nationwide and is a frequent guest
chose. know is how they will be impacted on radio and television promoting the benefits of
career development and lifelong learning. Crevel-
This is neither rationalization nor and how quickly the position will be ing has presented at international, national, and
regional conferences for a variety of organizations
justification. Her termination was filled. If there are job responsibility including International Conference of Association
the right thing to do at that time. If changes tell them. Whatever you do, for Psychological Type, International Management
Council, MENSA, National Association of Minori-
you have done your job impartially, be consistent about what you commu- ties in Communications, Society for Human Re-
honestly, and have provided appro- nicate to all employees. If you have source Management, American Society for Train-
ing and Development, and Society of Insurance
priate support and feedback, termi- displaced people because of economic Trainers and Educators. He has an M.A. focusing
nation for poor performance is not reasons, don’t make any promises on Organizational Development and Psychology,
and a B.A. in Business Management.
your fault. you can’t keep to those that remain.
Conference: May 5–8, 2008

Exhibition: May 6–8, 2008
Donald E. Stephens Convention Center
Rosemont (Chicago), IL
For information on attending or exhibiting, visit
Please use Promo Code: AB

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51-54 CHE 2-08.indd 54 1/29/08 6:50:46 PM

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32i-8 CE 10-06.indd 60 1/30/08 2:59:09 PM
Advertisers’ Index
Advertiser Page number Advertiser Page number Advertiser Page number Advertiser Page number
Phone number Reader Service # Phone number Reader Service # Phone number Reader Service # Phone number Reader Service #
* A-T Controls Group 24D-4 Maag Pump Systems Reed Exhibitions 54 The Western States
513-247-5465 Textron AG 16 310-445-4200 Machine Company
24D-7
adlinks.che.com/7369-29 41-44 278 82 00 adlinks.che.com/7369-27 513-863-4758
Badger Meter adlinks.che.com/7369-15 • Robuschi & C.s.p.a. 24I-3 adlinks.che.com/7369-32
Incorporated 13 Membrana 24D-3 39-0521-274911 * Tlv Corporation 35
877-243-1010 704-587- 8888 adlinks.che.com/7369-33 704-597-9070
* Solutia Therminol 2
Bioengineering AG 47 • Osi Software GmbH 24I-7 1-800-426-2463 Tranter Phe, Inc. 42
adlinks.che.com/7369-26 49 6047 9890 adlinks.che.com/7369-05 940-723-7125
• Bronkhorst High-Tech • Spectro Analytical
B.V 24I-7 Paharpur Cooling Towers 9 Instruments GmbH Wood Group Esp 23
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adlinks.che.com/7369-37 & Co.kg 24I-6
• Burgmann 24I-5 * Pneumatic Products 49-2821-892-2102
8 adlinks.che.com/7369-35
49-8171-23-0 Yamatake SECOND
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adlinks.che.com/7369-34 adlinks.che.com/7369-23 Sri Consulting THIRD COVER Corporation COVER
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Conbraco Industries,
Incorporated 19 See bottom of next page for advertising sales representatives' contact information
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adlinks.che.com/7369-17 Classified Index - February 2008 (212) 621-4958 Fax: (212) 621-4976
Continental Disc Send Advertisements and Box replies to: Helene Hicks, Chemical Engineering, 110 William St., 11th Floor, New York, NY 10038
Corporation 15
816-792-1500 Advertisers’ Advertiser Page number Advertiser Page number
adlinks.che.com/7369-14 Phone number Reader Service # Phone number Reader Service #
Product Showcase. . . . . . . . 55
Emerson Process Flowphase Engineering Indeck 58
Management 7 Computer Software . . . . . . 56-57 847-541-8300
Software 57
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Consulting . . . . . . . . . . . . . . 58
* Endress FOURTH adlinks.che.com/7369-242
Intelligen, Inc. 56
+ Hauser COVER Equipment, Used or Fluid Imaging 55 908-654-0088
888-ENDRESS Surplus New for Sale. . . . 57-59 207-882-1100 adlinks.che.com/7369-240
Recruitment. . . . . . . . . . . . . 59 Minox/Elcan 57
Fike Corporation 27 800-283-5226
FPC National 59
1-866-758-6044 adlinks.che.com/7369-246
Advertiser Page number 212-302-1141
adlinks.che.com/7369-22 Paul Mueller Company 55
Phone number Reader Service # adlinks.che.com/7369-245
Flexicon Corporation 1 800-683-5537
ABZ, Inc. 55 Frain Industries, Inc. 58 adlinks.che.com/7369-205
1-888-353-9426
800-747-7401 630-629-9900
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Flexim GmbH 28 973-256-3000
Applied e-Simulators adlinks.che.com/7369-204
510-420-6995 General Spray/CPV
adlinks.che.com/7369-10 Software 57
Drying Services, Inc. 58 Pulsair Systems 55
509-967-5730
George Fischer Signet, 908-353-2477 800-582-7797
Incorporation 10 adlinks.che.com/7369-262 adlinks.che.com/7369-202
714-731-8800 Avery Filter Co. 57
201-666-9664 H&P Equipment Co., Inc. 57 Rev Tech 57
adlinks.che.com/7369-12 973-335-9770
adlinks.che.com/7369-248 515-266-8225
* Heinkel Usa 24D-5 adlinks.che.com/7369-250
Bag Supply Company 57 adlinks.che.com/7369-247
856-467-3399
adlinks.che.com/7369-30 800-722-5790 Heat Transfer Ross, Charles & Son Co. 59
adlinks.che.com/7369-251 Research, Inc. 57 800-243-7677
Interphex 26, 53
CU Services LLC 55 979-690-5050 adlinks.che.com/7369-259
1-888-334-8704
847-439-2303 adlinks.che.com/7369-243
adlinks.che.com/7369-21 Wabash Power
Kason Corporation 28 adlinks.che.com/7369-201 Heyl & Patterson 59 Equipment Co. 57
1-973-467-8140 Custom Metalcraft, Inc. 58 412-788-9810 847-541-5600
adlinks.che.com/7369-09 417-862-0707 adlinks.che.com/7369-257 adlinks.che.com/7369-249
* Larox OY 6 adlinks.che.com/7369-252
HFP Acoustical The Western States
adlinks.che.com/7369-07 EcReCon, Inc. 59 Consultants 58 Machine Co. 58
Load Controls, Inc. 24D-7 856-299-4500 888-789-9400 513-863-4758
888-600-3247 adlinks.che.com/7369-258 adlinks.che.com/7369-244 adlinks.che.com/7369-254
EquipNet Inc. 59 Hilco Industrial, LLC 59 Xchanger, Inc. 58
• International Section 888-371-6555 248-254-9999 952-933-2559
* Additional information in
2006 Buyers’ Guide
22_CHE_021508_AD_IND_RS.indd 61 1/30/08 1:35:47 PM

New Product Information February 2008
JustFAXit! or go to www.che.com/adlinks
Fill out the form and circle or write in the number(s) Go on the Web and fill out the
✁
below, cut it out, and fax it to 800-571-7730. online reader service card.
Name Title
Company
Address
City State/Province Zip/Postal Code
Country\ Telephone Fax
Email | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | |
FREE PRODUCT INFO 14 Engineering, Design & Construc- 29 10 to 49 Employees 47 Pollution Control Equipment

(please answer all the questions) tion Firms 30 50 to 99 Employees & Systems
15 Engineering/Environmental Ser- 31 100 to 249 Employees 48 Pumps
YOUR INDUSTRY
vices 32 250 to 499 Employees 49 Safety Equipment & Services
01 Food & Beverages
16 Equipment Manufacturer 33 500 to 999 Employees 50 Size Reduction & Agglomeration
02 Wood, Pulp & Paper
17 Energy incl. Co-generation 34 1,000 or more Employees Equipment
03 Inorganic Chemicals
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JOB FUNCTION SPECIFY, PURCHASE 52 Tanks, Vessels, Reactors
05 Drugs & Cosmetics (please circle all that apply)
20 Corporate Management 53 Valves
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08 Organic Chemicals 42 Heat Transfer/Energy Conserva-
22 Engineering 55 Water Treatment Chemicals
09 Agricultural Chemicals tion Equipment
23 Research & Development & Equipment
10 Petroleum Refining, 43 Instrumentation & Control Sys-
24 Safety & Environmental 56 Hazardous Waste Management
Coal Products tems
26 Other———————————— Systems
11 Rubber & Misc. Plastics 44 Mixing, Blending Equipment 57 Chemicals & Raw Materials
12 Stone, Clay, Glass, Ceramics EMPLOYEE SIZE 45 Motors, Motor Controls 58 Materials of Construction
13 Metallurgical & Metal Products 28 Less than 10 Employees 46 Piping, Tubing, Fittings 59 Compressors
1 16 31 46 61 76 91 106 121 136 151 166 181 196 211 226 241 256 271 286 301 316 331 346 361 376 391 406 421 436 451 466 481 496 511 526 541 556 571 586
2 17 32 47 62 77 92 107 122 137 152 167 182 197 212 227 242 257 272 287 302 317 332 347 362 377 392 407 422 437 452 467 482 497 512 527 542 557 572 587
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22_CHE_021508_AD_IND_RS.indd 62 1/30/08 1:36:20 PM

Economic Indicators
Business News
that will produce advanced engineered Taiwan, India, Pakistan and Bangladesh,
Plant Watch
compounds for Asian customers.Ticona, subject to certain customary closing
Oxea Increases Alcohol Capacity with compounding capacity in North conditions. Sale or transfer of assets of
in North America America, Europe and Asia, will build a Monsanto’s India subsidiary is subject to the
January 24, 2008 — Oxea is expanding its 15,000-m.t. compounding unit in the recently approval of its India shareholders.
oxo alcohols capacity at its production site dedicated Celanese complex in Nanjing,
in Bay City,Texas.The production capacity China. Scheduled to be operational in Aker Kvaerner proposed to change
for propionaldehyde and n-propanol will the 1st Q of 2009, the facility will produce name to Aker Solutions
be increased 10% by mid-2008.The new oxo compounds for the many advanced January 22, 2008 — Aker Kværner ASA’s Board
alcohol investment follows the company’s engineering polymers in the Ticona portfolio. of Directors has resolved to propose to the
announcement of increased production annual general meeting that the company
capacity for carboxylic acids and NPG Honeywell to design integrated control change its name to Aker Solutions ASA.
(neopentylgylcol). system for LNG plant During 2007 a longterm and stable ownership
January 10, 2008 — Honeywell has been structure was established for Aker Kvaerner, as
First LyondellBasell license granted for contracted to provide the integrated control more than 40% of the shares in the company
Spherizone technology to PetroChina system for Woodside’s new Pluto liquefied were transferred from Aker to Aker Holding,
January 18, 2008 — PetroChina Daqing natural gas (LNG) project.The project is a holding company controlled by Aker.The
Refining & Chemical Co. has selected Western Australia’s first new LNG plant in owners of Aker Holding have mutually agreed
LyondellBasell Industries’ Spherizone more than 20 years and is expected to that the company will keep its Aker Kvaerner
process technology for a new 300,000 produce 4.3-million ton/yr of LNG.The shares for at least 10 years.The board of Aker
ton/yr polypropylene plant to be built control system project is scheduled for Holding has already verbally agreed to the
at Daqing, Heilongjiang Province in completion in 2009 and production is proposed name change.
China. Startup is planned for 2010.This is expected to commence in late 2010.
PetroChina’s ninth polyolefin license from SABIC enters as partner in OSOS
LyondellBasell in this decade. Fluor wins Marathon Oil's Petrochemicals project
$1.6-billion refinery upgrade January 16, 2008 — Saudi Basic Industries
Metso to supply coke calcining January 4, 2008 — Fluor Corp. has been Corp. (Sabic) and OSOS Petrochemicals
equipment to Seadrift in the U.S. selected to provide integrated engineering, (currently under formation) have signed
January 15, 2008 — Metso Minerals will procurement and construction (EPC) for a Memorandum of Understanding (MoU)
supply coke calcining equipment to expansion and upgrade of Marathon Oil for Sabic to enter as a partner in the OSOS
Seadrift Coke L.P. for upgrading its coke Corp.’s Detroit, Mich. petroleum refinery. Petrochemicals project at Yanbu industrial
plant in Port Lavaca,Texas.The capacity of When the $1.6-billion EPC contract is City. According to this agreement, Sabic will
the Port Lavaca plant is currently close to completed, Marathon will have increased complete in no more than 2 months, the
150,000 m.t./yr of coke. Once the calcining the refinery’s heavy oil processing exploration and review all works, studies
upgrade is complete, Seadrift will have capacity, including Canadian bitumen and agreements prior to updating the
a calcining capacity well in excess of blends, by about 80,000 bbl/d and its respective economic feasibility study. A final
200,000 m.t./yr. total crude oil refining capacity by about agreement will then be signed, if the two
15%, from 100,000 to 115,000 bbl/d, said parties agree on the study.
Evonik JV brings additional production David Seaton, president of Fluor’s Energy
capacity for hydrogen peroxide to Korea & Chemicals Group. Construction is Ineos to buy vinyl acetate monomer and
January 15, 2008 — Evonik Industries expected to begin within the next few ethyl acetate businesses from BP
and Headwaters (South Jordan, Utah) months, subject to receiving the applicable January 11, 2008 — Ineos has reached an
have substantially increased production regulatory permits.The project is expected agreement to acquire the vinyl acetate
capacity for hydrogen peroxide at the to be completed in late 2010, adding more monomer (VAM) and ethyl acetate (EtAc)
facility operated by their joint venture (JV) than 400,000 gal/d of clean transportation businesses from BP.The deal includes a
EvonikHeadwaters in Ulsan, Korea.The fuels to the marketplace. 500,000 ton/yr production capacity at
JV acquired this facility from the Finnish the Saltend manufacturing site in the
company Kemira Oyi, Helsinki, in 2006. Using U.K., along with the Teesside to Saltend
proprietary technology from Evonik, it has Mergers and
Acquisitions Ethylene Pipeline (TSEP).The EtAc plant
more than doubled capacity from the was commissioned in 2001 and has a
original level of 34,000 m.t./yr within a year. Sinochem to acquire Monsanto‘s capacity of 250,000 ton/yr, and the VAM
butachlor and alachlor businesses plant, which also has 250,000-ton/yr
Ticona to add compounding January 21, 2008 – Sinochem International capacity, was commissioned in 2002.The
unit in China Corp. and Monsanto Co. have announced acquisition is being made by Ineos Group
January 14, 2008 — Ticona, the engineering plans for Sinochem to purchase the assets and is conditional on approval from the EU
polymers business of Celanese Corp., associated with Monsanto’s butachlor competition authorities.The transaction is
plans to expand its integrated China and alachlor businesses and certain other expected to close in the 1st Q 2008. n
complex to include a compounding unit assets in the Philippines,Thailand,Vietnam, Dorothy Lozowski
For additional news as it develops, please visit www.che.com

February 2008; VOL. 115; NO. 2
Chemical Engineering copyright @ 2008 (ISSN 0009-2460) is published monthly, with an additional issue in October, by Access Intelligence, LLC, 4 Choke Cherry Road,
2nd Floor, Rockville, MD, 20850. Chemical Engineering Executive, Editorial, Advertising and Publication Offices: 110 William Street, 11th Floor, New York, NY 10038; Phone: 212-
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P.O. Box 1632, Windsor, ON N9A7C9.
For more Economic Indicators, See Next Page Chemical Engineering www.che.com February 2008 63
63-64 CHE 2-08.indd 63 1/29/08 6:06:27 PM

Economic Indicators 2006 2007
DOWNLOAD THE CEPCI TWO WEEKS SOONER AT WWW.CHE.COM/PCI

CHEMICAL ENGINEERING PLANT COST INDEX (CEPCI)
540
(1957-59 = 100) Nov.'07 Oct.'07 Nov.'06
Prelim. Final Final Annual Index:
CE INDEX 526.3 527.1 511.4 1999 = 390.6 525
Equipment 624.5 626.2 605.4
Heat exchangers & tanks 593.6 593.3 565.9 2000 = 394.1
Process machinery 597.9 594.9 558.2 2001 = 394.3 510
Pipe, valves & fittings 731.1 740.2 735.6
2002 = 395.6
Process instruments 417.0 422.1 432.6
Pumps & compressors 842.9 843.2 795.7 2003 = 402.0 495
Electrical equipment 437.4 437.2 418.0 2004 = 444.2

Structural supports & misc 660.4 660.8 639.4
2005 = 468.2 480
Construction labor 318.9 318.3 311.7
Buildings 477.5 476.8 467.8 2006 = 499.6
Engineering & supervision 357.0 355.0 351.3 465
J F M A M J J A S O N D
* Starting with the April 2007 Final numbers, several of the data series for labor and compressors have been
converted to accommodate series IDs that were discontinued by the U.S. Bureau of Labor Statistics
CURRENT BUSINESS INDICATORS LATEST PREVIOUS YEAR AGO
CPI output index (2000 = 100) Dec. '07 = 108.4 Nov. '07 = 109.2 Oct. '07 = 108.4 Dec. '06 = 107.4
CPI value of output, $ billions Nov. '07 = 1,785.3 Oct. '07 = 1,712.1 Sep. '07 = 1,665.3 Nov. '06 = 1,556.6
CPI operating rate, % Dec. '07 = 81.6 Nov. '07 = 82.4 Oct. '07 = 81.8 Dec. '06 = 81.6
Construction cost index (1967 = 100) Jan. '08 = 753.2 Dec. '07 = 753.1 Nov. '07 = 753.3 Jan. '07 = 733.6
Producer prices, industrial chemicals (1982 = 100) Dec. '07 = 244.4 Nov. '07 = 245.8 Oct. '07 = 229.8 Dec. '06 = 210.8
Industrial Production in Manufacturing (2002=100)* Dec. '07 = 115.7 Nov. '07 = 115.7 Nov. '07 = 115.4 Dec. '06 = 114.4
Hourly earnings index, chemical & allied products (1992 = 100) Dec. '07 = 143.6 Nov. '07 = 142.6 Oct. '07 = 141.2 Dec. '06 = 145.0
Productivity index, chemicals & allied products (1992 = 100) Dec. '07 = 130.5 Nov. '07 = 131.3 Oct. '07 = 132.6 Dec. '06 = 133.0
111
CPI OUTPUT INDEX (2000 = 100) CPI OUTPUT VALUE ($ Billions) 85
CPI OPERATING RATE (%)
1850
108 1750 83
105 1650 81
102 1550 79
99 1450 77
96 1350 75
J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D
*Due to discontinuance, the Index of Industrial Activity has been replaced by the Industrial Production in Manufacturing index from the U.S. Federal Reserve Board.
Current business indicators provided by DRI-WEFA, Lexington, Mass.
MARSHALL & SWIFT EQUIPMENT COST INDEX THE ONLINE CEPCI

(1926 = 100) 4th Q 3rd Q 2nd Q 1st Q 4th Q 1405 CE’s Online CEPCI provides ac-
2007 2007 2007 2007 2006 1390 cess to the entire historical CEPCI
M & S INDEX 1,399.2 1,393.0 1,383.6 1,362.7 1,353.8 database (top). And, instead of
Process industries, average 1375
1,452.3 1,445.6 1,433.5 1,410.0 1,399.2 waiting more than two weeks for
Cement 1,435.3 1,427.5 1,417.5 1,398.8 1,385.8 1360
the print or online version of the
Chemicals 1,427.9 1,421.0 1,408.8 1,384.9 1,374.1 1345
Clay products 1,415.0 1,408.8 1,400.4 1,378.1 1,367.6
magazine to arrive, subscribers
1330 to the Online CEPCI can down-
Glass 1,348.8 1,341.8 1,331.3 1,309.5 1,299.5
Paint 1,457.1 1,451.2 1,440.2 1,414.2 1,404.6
1315 load new data as soon as it is
Paper 1,369.2 1,364.0 1,354.0 1,331.6 1,324.2 1300 calculated. Visit www.che.com/
Petroleum products 1,543.7 1,536.2 1,521.0 1,497.9 1,486.3 1285 pci to subscribe to the following:
Rubber 1,500.1 1,494.8 1,486.7 1,463.1 1,449.4 1270
Related industries • Electronic notification of
Electrical power 1,374.9 1,359.0 1,340.7 1,319.5 1,310.1
1255 monthly updates
Mining, milling 1,460.8 1,453.2 1,442.7 1,427.7 1,413.5 1240 • All annual data archives
Refrigeration 1,698.8 1,691.7 1,679.3 1,648.2 1,638.5 1225 (1947 to present) and monthly
1st 2nd 3rd 4th
Steam power 1,416.4 1,407.4 1,394.2 1,369.1 1,359.8 Quarter data archives (1970 to present)
• Option to download data in
Annual Index:
Excel format
2000 = 1,089.0 2002 = 1,104.2 2004 = 1,178.5 2006 = 1,302.3 • A selection of helpful
2001 = 1,093.9 2003 = 1,123.6 2005 = 1,244.5 2007 = 1,373.3 cost-estimation articles O
64$)&.*$"-&/(*/&&3*/(888$)&$0.'&#36"3:
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source of information about chemical manufacturers, their plant locations and
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Smart Research. Smart Business.
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Cover 3 CHE 2-08.indd 3 1/15/08 4:15:05 PM

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Cover 4 CHE 2-08.indd 3 1/15/08 3:58:09 PM

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February Pump

Cover 2 CHE 2-08.indd 2 1/15/08 4:21:47 PM

The pneumatic conveying

It takes more than a great pneumatic

It’s what enables Flexicon to guarantee

1 CHE 2-08.indd 1 1/15/08 4:01:51 PM

2 CHE 2-08.indd 2 1/15/08 4:12:54 PM

COVER STORY COMMENTARY

4 CHE 2-08.indd 4 1/15/08 4:16:51 PM

Published since 1902

Scholarship applications open

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SPAR 2008. Spar Point Research LLC (Danvers, Mass.).

Conexpo-Con/AGG 2008. Association of Equipment

Interphex 2008. Reed Exhibitions (Milwaukee, Wis).

Residuals and Biofuels 2008. Water Environment

Silicone Elastomers 2008. Smithers Rapra Technology

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European Thermoforming Conference 2008. Soci-

Advances in Synthetic Chemistry. Select Biosciences

Hazards XX. IChemE (Cumbria, U.K.). Phone: +44 (0)

ERTC Coking and Gasification Conference. ERTC

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GEO 2008. Kuwait Oil Company (Ahmadi, Kuwait).

PIA Vietnam 2008. Bangkok Exhibition Services Ltd.

P-MEC Japan. CMP Information (London, U.K.). Phone:

Base Oils and Lubricants in Russia and the CIS

PETnology Europe 2008. PETnology GmbH (Regens-

8-9 CHE 2-08.indd 9 1/29/08 5:58:34 PM

10 CHE 2-08.indd 10 1/15/08 4:06:23 PM

New ceramic-membrane system doubles 0WFSIFBEWBQPS

H itachi Zosen Corp. (Hitz; Tokyo, Japan;

porous alumina tube that is closed at one 'FFE

D aihatsu Motor Co., Ltd. (Osaka, Japan;

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Commercial production and debut of a new solid-acid 8BTUFXBUFS

catalyst for making biodiesel .FUIBOPM

L ast month, Benefuel, Inc. (Mt. Prospect, "MDPIPM SFDPWFSZ

One less step to make activated carbon Algae-based biodiesel

N anostructured microporous carbons con-

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If you are looking for lower operating costs and less

So, go ahead, pick a pipe, any pipe and let

4545 W. Brown Deer Road • P.O. Box 245036

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New solid-state heat engine cycles H2

Maintain pH, even at cyrogenic crops, with only 5% of the

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Learn more at www.cambridgeviscosity.com

Circle 15 on p. 62 or go to adlinks.che.com/7369-15 Circle 16 on p. 62 or go to adlinks.che.com/7369-16

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lamps: the Audi R8, the Lexus LS600h

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1/4 the efficiency of the average, com- to Apollo Valves.

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Data + visibility = knowledge

21-24 CHE 2-08.indd 22 1/29/08 6:27:23 PM

of personal protective equipment. But,

WG SPS ad_CE_half_1-08.indd 1 1/7/08 10:38:14 AM

" # $ % "