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AD_Jigsaw Puzzle_Chem Processing_20110627:Layout 1 6/27/11 3:05 PM Page 1 CHEM

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 contents
July 2011 | Volume 74, Issue 7

22 34 37

cover story columns

22 The Best Get Hand Picked 7 From the Editor: How Do You Picture
Respondents chose their favorite technology leaders in 47 Safety?
different categories in Chemical Processing’s eighth annual
Readers’ Choice Awards survey. Read on to see if your 9 Chemical Processing Online: Benefit
favorite vendor is a top pick. From Our Brain Trust.

Features 11 Field Notes: Survey the Sources of Elec-

DesIgN AND oPTImIzATIoN trical Risk.
29 Properly Assess Compressed Air Demand
Most compressed air systems offer significant opportuni- 19 Energy Saver: Recover Low Level Heat,
ties for improvement. A thorough evaluation of an existing Part I.
or new system can help increase reliability and perfor-
mance, and minimize lifecycle costs. 21 Compliance Advisor: U.S. Wants More
Transparency in Trade.
solIDs AND FluIDs HANDlINg
34 Pneumatic Conveying Keeps Moving Ahead
45 Plant InSites: Pick the Proper Centrifugal
Demand for conveying solutions that increase throughput,
Pump.
shorten lead times, handle various solids, reduce costs, improve
safety and simplify maintenance are spurring suppliers to develop
58 End Point: Energy Policies Threaten U.K.
innovative solutions.
Chemical Firms.
INsTRumeNTATIoN AND CoNTRol
37 Make the Most of Radar departments
The emergence of radar has significantly advanced level 13 In Process: Method Makes Z Alkenes |
monitoring. However, there are some important consider- Energy Harvesting Gets Hot Option
ations to keep in mind when applying radar technology.
43 Process Puzzler: Prevent Pump Problems.
mAkINg IT WoRk
41 Mixer Seal Gets Major Makeover 47 Equipment & Services
Effectively sealing a shaft entry point in a vessel used
for high temperature mixing of titanium tetrachloride 55 Product Spotlight/Classifieds
required a unique retrofit. A dry-running split seal and
sleeve prevent leaks and offer additional benefits. 57 Ad Index

Chemical Processing (IssN 0009-2630) is published monthly by Putman media Inc., 555 West Pierce Road, suite 301, Itasca, Il 60143. Phone (630) 467-1300. Fax (630) 467-1109. Periodicals postage paid at Itasca,
Il, and additional mailing offices. PosTmAsTeR: send address changes to Chemical Processing, P.o. Box 3434, Northbrook, Il 60065-3434. suBsCRIPTIoNs: Qualified reader subscriptions are accepted from
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5 chemicalprocessing.com ● July 2011

CP1107_05_TOC.indd 5 6/27/11 3:06 PM

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how do You Picture safety?
An unusual photo contest seeks your creative take on the topic
“Cameras Prohibited” or “No Picture Tak-
ing” proclaim signs at guardhouses and reception
areas at many chemical facilities. This policy may
stem from a legitimate concern about photographs
revealing details about proprietary technology, such
as the type of reactor or separator used in a process,
or commercial information, such as the supplier of a
key raw material or the amount of product inven-
tory on hand. Often, undoubtedly, it simply reflects
the innate conservatism of the legal department at
company headquarters. Some critics of our industry
certainly will contend that the ban frequently relates
more to corporate anxiety about outsiders snapping
shots of less-than-stellar safety and environmental
practices.
In May, the U.S. Occupational Safety and
Health Administration (OSHA) launched a program
to get photos. But it’s not for the reason you might
think. OSHA isn’t trying to obtain evidence of
wrongdoing or workplace lapses — instead, the
agency is looking for shots that celebrate safety.
OSHA unveiled its “Picture It! Safe Workplaces
for Everyone” contest as part of its yearlong 40th
anniversary celebration. “OSHA challenges anyone
with a passion for photography to capture an image
of workplace safety and health and share it with the
agency. The goal of the contest is to collaborate with
the public — relying on the talent, imagination and
creativity of participants — to kick off a national
effort to raise awareness about workplace safety and
health,” noted the press release announcing the photo
competition, which is the first in OSHA’s history.
“Photographers may interpret ‘image of work-
place safety and health’ in any way they choose.
They are not restricted to particular subject mat-
ters or themes,” adds the agency. Moreover, digital
manipulation of images is allowed.
However, entries must comply with two key
restrictions:
1. Photos can’t appear to endorse a commer-
cial product or service. They shouldn’t show brand
names, recognizable places of business, or other sub-
jects identifiable with a specific manufacturer; and
2. Images must not depict a violation of an
OSHA standard, uncontrolled hazard or unsafe
procedure or practice. “Be aware of any unmarked
hazard, improperly installed piece of equipment or
other violation that might be visible in your frame,”
cautions the agency.
CP1107_07_Edit.indd 7
From The eDiTor
In addition, the shots must have been taken in
the United States or its territories, and you must have
a release form for each person who is recognizable in
a photo.
Anyone 18 years old and up (except OSHA and
on-site consultation employees) can enter up to
three photos by midnight Eastern time on Friday,
August 12th. The images must be submitted online OSHA is looking
via www.osha.gov/osha40/photo-contest.html.
for shots that
There, you also can find more details on the contest,
acceptable photo file types and size, and a sample celebrate safety.
release form.
The panel of judges consists of Earl Dotter, a
photojournalist; Kathleen Klech, photo director
of Condé Nast Traveler magazine; George Tolbert,
official U.S. Senate photographer (retired); Shawn
Moore, chief photographer of the U.S. Department
of Labor; and Carl Fillichio, senior advisor for
communications and public affairs at the Depart-
ment of Labor. They will evaluate the entries for
“artistic value, and ability to raise awareness about
safety and health to the general public.” Judging
criteria are the photo quality, originality, creativity,
the clarity of the safety and health message con-
veyed, inclusion of worker, employer or workplace
imagery, and suitability for possible use in OSHA
publications.
Framed copies of the first-, second- and third-
place photos will be displayed at OSHA’s headquar-
ters in Washington, D.C. — “where they will serve
as a daily reminder for leading policymakers and
prominent professionals on the real-life impact of
OSHA’s mission,” says the agency. The winner also
will get a framed letter of congratulations from U.S.
Secretary of Labor Hilda L. Solis, while the two
runners-up will get framed certificates signed by
OSHA Director David Michaels. The winning and
finalist photos also will appear prominently on the
contest web page in September.
Chemical plants and other industrial sites have a
reason to soften their stance on photographs at least
for a while.
mark rosenzweig, Editor in Chief
mrosenzweig@putman.net
7 chemicalprocessing.com July 2011
6/27/11 12:26 PM
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 chemical processing online

555 West Pierce Road, Suite 301

Itasca, IL 60143
Phone: (630) 467-1300
Fax: (630) 467-1109
www.chemicalprocessing.com
benefit from our brain trust
E-mail: cpnews@putman.net Insight from industry experts is just a mouse click away.
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Editorial Staff
i lEarnEd long ago to surround myself with smart people. Not only am I
lumped into the group by association, but I get to tap the brain trust whenever I
Mark rosenzweig,
Editor in Chief, x478 need answers to life’s many questions.
mrosenzweig@putman.net
I certainly can’t take credit for the idea of a brain trust — I was inspired in
amanda Joshi, my grade school history class after reading about Franklin D. Roosevelt’s team of
Managing Editor, x442
ajoshi@putman.net educated advisors. That was the first time I realized I didn’t need to have all the
traci Purdum,
answers, I just needed to know where to look for enlightenment.
Senior Digital Editor, x428 You don’t have to have all the answers either. You can just look to one of our Look to one
tpurdum@putman.net
myriad resources for expert advice.
Seán ottewell,
Recently I added a section that houses all of our Special Reports (www.chemi- of our myriad
Editor at Large
Ireland calprocessing.com/special_reports). Here you will find several in-depth pieces on resources for
sottewell@putman.net
single topics. Do note that you must register to download each one, but it is a quick
Contributing EditorS
process that grants you instant access. expert advice.
andrew Sloley, There is a report on pilot plants from Continental Technologies that highlights
Troubleshooting Columnist
lynn l. bergeson, ten factors that will impact the design, construction and operation of next-genera-
Regulatory Columnist
Ven Venkatesan,
tion pilot plant units.
Energy Columnist Want to learn more about conveyors? Hapman’s special report looks at the dif-
dirk Willard, Columnist
ferent types of conveyors, discusses the use of tubular bag conveyors, and provides
dESign & ProduCtion
ten tips to prevent a variety of common problems that could occur with pneumatic
Stephen C. Herner, conveyors.
Vice President of Creative Services, x312
sherner@putman.net Some of these special reports feature podcasts that delve even deeper into the topic
brian Hertel,
at hand. For example, Edgewater Fullscope’s report on condition monitoring has a pod-
Associate Art Director, x413 cast I recorded with the company’s senior vice president Russell Smith. We chat about
bhertel@putman.net
how enterprise resource planning (ERP) can help manage the supply chain.
rita fitzgerald,
Production Manager, x468
Another section of the website that will help you find the answers you need
rfitzgerald@putman.net showcases future and on-demand events hosted by Chemical Processing. Located at
Editorial board www.chemicalprocessing.com/webinars, this page lists upcoming webinars (we do
Vic Edwards, Aker Solutions
at least one webinar a month) and enables you to gain instant access to programs
tim frank, Dow Chemical we’ve already done. So far, we have 17 on-demand events covering everything from
ben Paterson, Eli Lilly
roy Sanders, Consultant the U.S.’s Chemical Facilities Anti-Terrorism Standards (CFATS), and other govern-
Ellen turner, Eastman Chemical
ben Weinstein, Procter & Gamble
ment initiatives such as Registration, Evaluation, Authorization and Restriction of
Jon Worstell, Consultant Chemicals (REACH) and Globally Harmonized System (GHS) for classification
Sheila Yang, Bayer
and labeling of chemicals to bulk solids cooling and heating, emissions, and energy
ExECutiVE Staff
efficiency. Again, registration is required.
John M. Cappelletti, President/CEO Webinars on the horizon include in-depth coverage of dust control, which will
Julie Cappelletti-lange, Vice President
rose Southard, Vice President of Technology take place on July 21 at 2 p.m. ET. This discussion will examine the various regula-
Jerry Clark, Vice President of Circulation
Jack Jones, Circulation Director
tions and standards that target dust and dust-collection systems and explore how to
handle dusts that potentially pose risk of explosion and fire.
rEPrintS
Our Sept. 22 webinar (2 p.m. ET) will cover the topic of process safety. Panel-
Jill Kaletha , reprint Marketing Manager
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866-879-9144 ext. 168 associated with plant operations.
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4295 S. ohio Street, These are just two areas of ChemicalProcessing.com that will make you feel like
Michigan City, in 46360
you have your own brain trust working for you. Be sure to poke around the rest of
the site to find other answers. And if you need assistance, don’t hesitate to drop me
an e-mail at tpurdum@putman.net. If I don’t know the answer, I bet I will know
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traCi PurduM, Senior Digital Editor

tpurdum@putman.net.
Folio Editorial Excellence Award Winner

9 chemicalprocessing.com July 2011

CP1107_09_Web.indd 9 6/27/11 12:27 PM

 If you’ve paid for automatic control valves,
none of your loops should have to be in manual mode.

There must be a better way.

Loops in manual mode due to poor-performing rotary valves require constant operator
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CP1107_full page ads.indd 10 6/27/11 9:13 AM


Survey the Sources of electrical risks
A walk-down helps determine the need for purged electrical boxes
My teaM was ready. We only had a week to define
potential sources of hazards and complete a battery-
limit Electrical Area Classification (EAC) drawing.
We spent an hour walking down the unit. I complet-
ed the source spreadsheet in two hours. We reviewed
the spreadsheet in another hour and then sent it to
the designers. They finished the EAC drawing in two
days. It took several months for us to become this
proficient.
An EAC drawing is crucial for reducing the risk
of electricity igniting flammable, even explosive,
chemicals. As my last two columns have pointed out,
the effort starts with defining chemical risk (“Don’t
Zone Out On Area Classifications,” www.Chemi-
calProcessing.com/articles/2011/electrical-area-clas-
sification.html), followed by selecting zones around
sources (“Don’t Push the Envelope,” www.Chemical-
Processing.com/articles/2011/avoid-ignition-dangers.
html). Here, I’ll describe how sources demarcate the
areas requiring purged electrical boxes.
The walk-down team, at a minimum, should
include a drawing designer, a unit operator and an
engineer. Before venturing into the unit, collect
current versions of plot plans, an elevation drawing
if available, Process and Instrumentation Draw-
ings (P&IDs), Process Flow Diagrams (PFDs), the
equipment index, material safety data sheets and
material balances.
The purpose of this battery-limit survey is to
identify “clouds” based on the worst-case sources.
The walk-down may identify layout errors such as a
source near a road or a walkway frequently used by
operators.
Developing an uncluttered EAC drawing
requires care in source selection. You want a point
source posing the greatest risk defined by NFPA
497 and API 500. But it’s not as simple as pick-
ing a Group B chemical over a Group D one.
There are other factors — e.g., the auto-ignition
temperature (AIT), which define electrical risk.
The most common Group B chemical is hydrogen,
which is lighter than air. Lighter-than-air (LTA)
materials have a smaller envelope. And hydrogen
has a higher AIT than all Group D compounds;
pure hydrogen’s AIT is 1,040°F while, for example,
naphtha’s is 450°F. When both B and D chemicals
are present, as in a knockout drum, define points
by choosing a nozzle at the bottom for B (LTA)
and an upper one for D. Use normal conditions —
CP1107_11_FieldNotes.indd 11
field notes
if B wouldn’t be at the drum bottom then, find a
nozzle where it would appear.
Consider high risk factors such as temperature,
quantity and pressure. Pick points based on the
greatest risk: temperatures, e.g., within 30°F of
flash point, sufficient to make a Class II or Class
III compound a hazard (OSHA 1910.106(a)(18)
(iii):Class II); flows greater than 500 gpm; and pres- Consider high
sures exceeding 500 psig. It’s best to select a number
of points within 50 ft of the battery limit or 100 ft risk factors such
for high-risk sources. as temperature,
Other factors — for example, tall (i.e., over 25 ft)
or long vessels (including heat exchangers), distilla- quantity and
tion columns and reactors where composition varies, pressure.
and banks of equipment — can complicate selecting
source points. With long or tall equipment choose a
point every 50 ft for heavier-than-air (HTA) com-
pounds and every 15 ft for LTA ones. For shorter
vessels, use one nozzle near the battery limit. Pick an
upper flange for an HTA compound and a low nozzle
for an LTA one. For vessels with diameters larger than
50 ft, refer to API 500. You can consider a flange or
nozzle as part of a vessel only if it’s within 10 ft. To
measure the height of stacks and nozzles, I suggest a
clinometer (see “Strive for a Surveyor’s Eye,” www.
ChemicalProcessing.com/articles/2009/184.html).
Source designations include: pumps — measured
from centerline or seal connection; compressors —
same as for pumps; control valves — pipe centerline;
condensers — bottom of tubesheet or shell flange;
vaporizers — top of tubesheet or shell flange; miscel-
laneous heat exchangers — top for liquids, bottom
for vapors; vessels containing liquids — top-most
flange; vessels containing liquids and vapors — top-
most flange and bottom flange; and vessels contain-
ing vapor — bottom-most flange. Also, of course,
account for furnaces, diked areas, etc.
Some surveys include flanges and manual valves
but many restrict sources to automatic valves and
control valves. The thought behind this is that staff
will detect leaking manual valves.
After completing the walk-down, prepare the
source table based on the points collected and elimi-
nate any redundant ones. Then, run material balances
to evaluate compositions. Review the source table at
least twice before handing it over to the designers.
dirk willard, Contributing Editor
dwillard@putman.net
11 chemicalprocessing.com July 2011
6/27/11 12:28 PM
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 in process

Method Makes Z Alkenes

Catalyst reportedly provides unprecedented levels of reactivity and selectivity
A joint team of scientists from Boston College,
Chestnut Hill, Mass., and Massachusetts Institute of
Technology (MIT), Cambridge, Mass., have developed
a new catalytic method for the synthesis of a large class
of carbon-carbon double bonds. It enables production of
the higher energy or Z isomer of alkenes.
Amir Hoveyda, a professor of chemistry at Boston
College, says these higher energy carbon-carbon double
bonds are very important to organic synthesis and ma-
terials research. For instance, Z alkenes serve as starting
materials for some common chemical transformations.
Hoveyda and his team rely on a molybdenum-based
catalyst to spur a Z-selective “cross metathesis” reaction
— in which two different alkene-containing molecules
combine, with only ethylene as a byproduct. Remov-
ing the generated olefin by running the reactions in a
vacuum significantly improves the desired process and
yields unprecedented levels of reactivity and selectivity.
Z isomers require a sufficiently active catalyst to
prompt the chemical reaction while still maintaining
the cis olefin’s U-shape geometry.
“The trick here was to come up with a catalyst that
is active enough to promote Z-alkene formation but not
too active to also want to react with the product. So,
Catalytic Reaction
Figure 1: Researchers
Such work could last several years, depending on designed an efficient
process that favors
what the researchers determine as the desired outcome. formation of higher-
“If the eventual goal is to develop an efficient energy carbon-car-
version for all possible catalytic stereoselective cross- bon double bonds
through a catalytic
metathesis reactions, then we are looking at least at a “cross metathesis”
decade. But we already have very promising leads on reaction. Source:
Amir Hoveyda.
four new classes,” Hoveyda adds.
While all catalysts are designed and developed by
the team at Boston College and MIT, Switzerland-based
XiMo, AG, has licensed the technology and is work-
ing with the researchers to further develop the process.
XiMo aims to use the available catalysts and technolo-
gies, as well as develop new ones for large-scale use.
Economic Snapshot

in a way, we had to walk on a very tight rope. Olefin

metathesis is a reversible reaction and you always run the 64,000
86.0
risk of going back and forth between product and start- 85.0
63,000
ing material, which forces you to end up with a lower
84.0
energy and less desirable isomer. What we have found 62,000
83.0
are catalysts that are sufficiently active to promote this
difficult reaction but are also discriminating enough not 61,000 82.0

to go after the product and cause it to isomerize.” 81.0

60,000
The team demonstrated the catalytic method 80.0
through synthesis of antioxidant plasmalogen phospho- 59,000 79.0
$ Million

lipids. Further details appear in an article in Nature.

%

78.0
For future research, there are a number of possible 58,000
77.0
steps to take, says Hoveyda, as well as other cross- 57,000 76.0
metathesis processes that must be developed.
75.0
“We develop new methods based on their degree of 56,000
relevance to facile and efficient preparation of various 74.0
55,000
classes of important biologically active molecules.” 73.0
Like any highly active catalyst, the molybdenum- 54,000 72.0
based catalyst is sensitive to air and moisture; the team 71.0
is working towards designing air-stable variants. 53,000
70.0
“Once this phase of our research is completed, and May 10 June 10 July 10 Aug 10 Sep 10 Oct 10 Nov 10 Dec 10 Jan 11 Feb 11 Mar 11 Apr 11

considering the effectiveness of the catalysts that we Shipments (NAICS S325) Capacity utilization
have and the significance of cross-metathesis reactions,
the technology will be a formidable force in chemical Shipments and capacity utilization both continued to rise.
Source: American Chemistry Council.
synthesis,” he believes.

82
13 chemicalprocessing.com July 2011
81
80
79
CP1107_13_16_InPro.indd 13 6/27/11 3:07 PM
 IN PROCESS

How have your site’s efforts for leak detection and

Energy Harvesting repair changed over the past twelve months?

21.4%
Gets Hot Option Modestly
increased
28.6%
Stayed the
same
THE SURFACE temperature of heat exchangers, other
process equipment and piping may serve to generate
electricity a plant could use to recharge batteries of wire-
less devices, say researchers at the U.S. Department of
Energy’s Oak Ridge National Laboratory (ORNL), Oak
Ridge, Tenn. They have developed tiny cantilevered
structures that produce electricity when exposed to
temperature gradients. These micro-electro-mechanical
7.1%
systems (MEMS) boast far higher efficiencies than other Modestly
pyroelectric (heat-to-electricity) techniques — likely to decreased
28.6%
reach 10–30%, depending upon heat source, versus the Significantly 0%
increased Significantly
1–5% of the others, contend the researchers. 14.3% decreased
“The key difference between our harvester and Not applicable
previous attempts is the fact that we use a MEMS Responses (%)
device (bimaterial cantilever) that self-actuates when Half of respondents say efforts have increased. To participate
exposed to a constant temperature difference,” notes in this month’s poll, go to ChemicalProcessing.com.
Panos Datskos, a senior research scientist at ORNL.
The cantilever is attached to an anchor affixed to “The tip of the hot cantilever comes into contact
a substrate like a computer chip or equipment surface with a cold surface, the heat sink, where it rapidly
(Figure 2). Heat from the substrate causes the cantilever loses its heat, causing the cantilever to move back and
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 IN PROCESS

Hunter, who leads the development
team. “The cantilever continues to
oscillate between the heat source
and heat sink as long as the tem-
perature difference is maintained
between the hot and cold surfaces.”
“The fast rate of exchange in the
temperature across the pyroelectric
material is the key to the energy con-
Energy Harvester
version efficiency and high electrical
power generation,” Hunter notes.
The technology will work with
gradients from just a few degrees up
to several hundred. “The higher the
temperature the more efficient the
device,” adds Datskos.
Each cantilever structure is
about 1 mm square — about

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1,000 can fit onto a 1-in. square
surface. Although each device
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electricity, 1–10 mW, large arrays
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enough, for instance, to power
remote sensor systems, the re-
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The converters can be fabricat-
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Hunter foresees initial use
on high-performance computer
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electricity generation the main
driver. However, Datskos notes,
“Hot surfaces of equipment [such
as] heat exchangers and pipes are
also very good applications.” The
electricity generated could serve
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devices, he adds.
“The harvester will need to
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application and set of conditions.
For example, the temperature
differential and the duty cycle are
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determined, then my best guess is

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 energy saVer

recover Low Level Heat, Part i

This two-part series highlights innovative concepts for recovering such heat

Most raw materials and final products usu- already been successfully implemented in some
ally are stored at ambient temperature. Because industries for low level heat recovery.
the driving force for heat transfer is the difference For example, a pharmaceutical plant in North
in temperature between hot and cold streams, Carolina maintained a portion of its process area
it theoretically isn’t possible to perfectly match at a controlled humidity and temperature. The
heating and cooling loads. Hence, heating and air circulated in that area was first dehumidi-
cooling have become the two important steps fied with chilled water and then reheated to the
carried out independently — and heaters, boilers, required temperature with steam. Because it was a Heat pipes used
cooling towers and air-fin coolers represent the critical process area, 100% fresh air was supplied.
most commonly used equipment. We recommended installing wrap-around heat to preheat the
All modern process plants are designed with pipes across the chilled water coil in the supply combustion air
maximum possible heat integration between air duct. This heat pipe installation reduced the
the heating and cooling streams. (What’s really air temperature by 7°F before entering the chilled are gaining
operationally feasible depends upon more than water coil, and increased the air temperature by interest.
heat transfer issues — see, for example, “Control 6°F before it entered the reheat coil. The plant
Challenges Can Pinch Energy Savings,” www. engineers credited this as one of the best applica-
ChemicalProcessing.com/articles/2010/206.html.) tions of low level heat recovery.
But most plants designed prior to 1980 didn’t
consider heat recovery from process streams that More Low LeveL Heat recovery aPPLications
were below 350°F–400°F. Such process streams At a Midwest refinery, product gasoline from a
should include the f lue gas from heaters and boil- debutanizer column was cooled from 300°F to
ers that are part of the process heating system. 50°F by an array of heat exchangers with cooling
Flash steam near atmospheric pressure that is tower water. Very close to that location, a propane
vented also is a common case of low level heat vaporizer was heated with steam to supply the
rejection. fuel gas system. We proposed a new heat exchang-
In recent years, low level heat recovery has er upstream of the existing propane vaporizer,
gained more attention for three reasons: in which the hot gasoline from the debutanizer
1. Higher energy prices could justify the ad- passed through to vaporize the propane stream.
ditional heat recovery equipment; This heat integration arrangement yielded both
2. Improved heat recovery technologies have steam savings as well as a reduction in cooling
become commercially available; and tower load.
3. Innovative energy integration concepts Low level heat recovery applications such as
could be developed into the processes. this can save energy and improve efficiency.
At current high energy prices, process engi- Another potential for low level heat recovery
neers should consider opportunities to recover is the f lash steam vented from the blowdown
low level heat. I’ll describe several. water of the process-waste-heat steam genera-
tors. Although blowdown heat recovery systems
Heat PiPes Gain MoMentuM are commonly installed at utility boiler houses,
If the f lue gas from heaters and boilers is leav- they usually are omitted at the process-waste-heat
ing the stack at temperatures above 300°F, then steam generators. At a Midwest refinery, it was
adding an air preheater to supply hot combustion observed that 3,000 lb/hr of additional low pres-
air may make sense. In the past, conventional re- sure steam could be generated from the blowdown
cuperators and regenerators were the only options water drained at its process-waste-heat boilers.
for air preheaters. Now, heat pipes used to preheat More innovative concepts of low level heat
the combustion air are gaining more interest. recovery applications will be highlighted in part
Heat pipes use a low-boiling medium that II.
results in better heat transfer efficiency and can
operate at very low differential temperatures be- ven v. venkatesan, Energy Columnist
tween the hot and cold streams. Heat pipes have VVenkatesan@putman.net

19 chemicalprocessing.com July 2011

CP1107_19_EnergySaver.indd 19 6/27/11 12:28 PM

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U.s. Wants More Transparency in Trade
New memorandum focuses on encouraging trade, coordination and public participation
On May 19, 2011, the Office of the U.S. Trade Rep-
resentative (USTR) and the Office of Information and
Regulatory Affairs (OIRA) jointly issued a memoran-
dum to U.S. departments and agencies highlighting the
importance of regulatory transparency and openness
to promoting international trade. The memorandum
telegraphs the Administration’s renewed emphasis on
the significant role international collaboration has in
domestic policy development.
The communication builds upon President Obama’s
January 2009 Memorandum on Transparency and
Open Government and the December 2009 Open
Government Directive from the Office of Manage-
ment and Budget (OMB). It describes several existing
agency obligations that can reduce barriers to trade and
contribute to economic objectives, such as economic
growth, entrepreneurship, job creation and innovation.
These obligations include: conducting robust regulatory
analysis, avoiding the creation of unnecessary barriers
to trade, providing domestic and foreign stakeholders a
meaningful opportunity to participate in the rulemak-
ing process, and encouraging international collabora-
tion. The memorandum is available at www.Chemical-
Processing.com/trade_memo.
The memorandum notes that Executive Order (EO)
13563, EO 12866, and OMB Circular A-4 all establish
principles governing regulatory analysis. For economi-
cally significant rules, agencies are directed by these
EOs to analyze and, to the extent feasible, quantify the
costs and benefits of proposed regulatory actions. The
memorandum states that, in some cases, such costs and
benefits can impact productivity, employment, and the
ability of small- and medium-sized enterprises (SME) to
participate and compete in the global economy. Where
any such effects are reasonably anticipated, agencies
should provide a publicly accessible assessment.
The memorandum also reminds agencies that, under
the Trade Agreements Act of 1979, they are prohibited
“from engaging in ‘any standards-related activity that
creates unnecessary obstacles to the foreign commerce of
the United States.’” One way to avoid creating such un-
necessary obstacles is to consider relevant international
standards.
Consistent with EO 13563, federal agencies should
provide the public with timely access to regulatory
analyses and supporting documents, as well as opportu-
nities to comment. To that end, the memorandum states
agencies should provide a description of the methods
used in their analysis; publish information online; and,
CP1107_21_Comp.indd 21
compliance advisor
to the extent feasible, provide the underlying data in
downloadable format.
Public access via the Internet ensures that rules,
analyses, and supporting documents are available to,
and allow comment by, both domestic and foreign
stakeholders, thus promoting exports and trade.
In addition, the memorandum notes the World
Trade Organization (WTO) Agreement on Technical Better agency
Barriers to Trade (TBT Agreement) requires the U.S.
and other member states to notify the WTO of certain collaboration
draft product standards and related procedures for could help
comment by other members. To fulfill this requirement,
the U.S. TBT Inquiry Point, which is housed in the promote job
National Institute of Standards and Technology, under- creation and
takes the day-to-day notification functions of the U.S.
To implement these existing requirements, and help support export
ensure regulatory actions don’t create unnecessary bar- goals.
riers to exports and trade, agencies have adopted, in cer-
tain cases, collaborative practices to discuss and evaluate
potential trade implications. These include information
exchanges, dialogues, meetings with other governments
and stakeholders, and coordination of regulatory activi-
ties with other governments. The goal is to share best
practices and harmonize relevant regulatory approaches,
standards, and related procedures, and that these efforts
contribute to the development of regulatory measures.
These practices can help reduce regulatory costs
while also promoting U.S. exports and trade by decreas-
ing unnecessary regulatory divergences, which impose
costs on U.S. exporters — especially SMEs. This can
help promote job creation and support export goals.
These collaborative efforts could have many domestic
benefits, including increasing the safety and quality of
other countries’ exports to the U.S. and thus helping to
protect U.S. consumers.
Long-pending trade agreements are being addressed
and approved in the current Congress, in contrast to
languishing during the first two years of the Obama Ad-
ministration. The memorandum is, in part, a response
to the desire by all in Congress to focus on jobs, while
allowing the Administration to improve environmental
and labor protection provisions.
Lynn BergesOn, Regulatory Editor
lbergeson@putman.net
Lynn is managing director of Bergeson & Campbell, P.C., a Wash-
ington, D.C.-based law firm that concentrates on chemical industry
issues. The views expressed herein are solely those of the author.
21 chemicalprocessing.com July 2011
6/27/11 12:29 PM
 respondents select technology leaders
in more than 40 categories.

By amanda Joshi, managing editor

ChemiCal ProCessing’s 2011 Readers’ Choice

Awards survey, which is now in its eighth year, continues
to generate strong response from readers. But for many
of the 1,000 respondents this year, picking a favor-
ite technology provider in 47 different categories
wasn’t always easy.
“In all categories I found more than one excel-
lent supplier,” explains one participant.
As in past surveys, some vendors remain
strong favorites in certain categories, while
in others several suppliers garner substantial
votes. The winners in some categories differ
from last year. This may ref lect increased
awareness of a particular vendor’s offerings or
improved products.
For instance, one reader noted a category that
has enhanced its offerings. “Process simulation soft-
ware has greatly improved lately and is much more of
a help now,” he says.
People also used the survey to express their
desires. “I wish there were more automation vendors;
every year we need more control of the system,” notes
one respondent.
Readers recognized that, in the past several years, many
companies have merged or consolidated to help expand or
improve their product offerings.
“With all the mergers and consolidations during the last 20
years, those companies that remain should be embraced, as they
have been through a very rough economic time period,” says
one reader.

July 2011 chemicalprocessing.com 22

CP1107_22_27_CoverStory.indd 22 6/27/11 3:02 PM

 23 chemicalprocessing.com July 2011

CP1107_22_27_CoverStory.indd 23 6/27/11 3:02 PM

 Past Contenders remain strong CrunChing the numbers
Many technology leaders held their ground, main- Readers received e-mail notices, electronic
taining their high rankings from previous years. Em- newsletters, used a link posted on www.Chemi-
erson Process Management, a strong favorite from calProcessing.com or responded to Twitter and
year-to-year, took top honors in seven categories, and Facebook postings to complete the questionnaire.
placed in six other categories. A total of exactly 1,000 readers cast their votes
“Of all the dealings I have had with Emerson, about which vendors they consider technology
they always are willing to come by my office and work leaders in 47 different categories. Categories were
with me and my colleagues to find a solution. They listed, but respondents had to enter the name of
also have such a wide variety of products that are time the technology provider in a blank text box. By
tested that we can always find what we’re looking for,” not providing a pre-selected list of companies in
says one participant. each category, the survey avoided bias.
“Emerson is the best in my opinion because they The rankings show the percentage of total
have been more than willing to work with customers responses in each category that a particular company
to resolve any issues even if it takes a couple of months received. We only list firms that got at least 5% of
to actually figure out the root cause of the problem,” the votes in a category. Scores within 3% of each
adds another reader. other should be considered a statistical tie.
Honeywell, another strong performer, received top
honors in two categories and placed in four others. AlArm mAnAgement SoftwAre Percent
Readers also gave accolades to AspenTech, Alfa Honeywell (Matrikon) 26%
Laval and GE (Bently Neveda) — each gained two Emerson 16%
first place finishes. PAS 10%
In addition, ABB, Rockwell Automation, Siemens, Yokogawa 7%
Flowserve and SPX all garnered multiple mentions in
several categories. BeAringS
A few contenders moved up the ranks in their SKF 51%
categories to earn top honors this year from readers. Timken 11%
These include Cleaver Brooks, Flexicon, MAC Equip-
ment and Chicago Bridge & Iron (CBI). BoilerS/SteAm SyStemS
Further details about the winning companies in Cleaver Brooks 14%
each category are included on the following pages. Babcock & Wilcox 11%
For additional information about any of the vendors Thermax 8%
or products listed, we encourage you to visit www. Spirax Sarco 5%
ChemicalProcessing.com and search for bearings,
pumps or any other category that interests you. Re- cAtAlyStS
sults from previous Readers’ Choice Awards also are BASF (Engelhard) 13%
available online: Johnson Matthey 12%
Honeywell (UOP) 11%
• 2010 — www.ChemicalProcessing.com/ Haldor Topsoe 6%
articles/2010/127.html Criterion 5%
• 2009 — www.ChemicalProcessing.com/
articles/2009/133.html centrifugAl PumPS
• 2008 — www.ChemicalProcessing.com/ ITT (Goulds) 31%
articles/2008/112.html Flowserve 12%
• 2007 — www.ChemicalProcessing.com/ Sulzer 7%
articles/2007/108.html KSB 5%
• 2006 — www.ChemicalProcessing.com/
articles/2006/111.html centrifugeS
• 2005 — www.ChemicalProcessing.com/ Alfa Laval 21%
articles/2005/523.html GEA Westfalia 12%
• 2004 — www.ChemicalProcessing.com/ Andritz Bird 7%
articles/2005/363.html Beckman 5%

July 2011 chemicalprocessing.com 24

CP1107_22_27_CoverStory.indd 24 6/27/11 3:03 PM

 Providing higher yields and greater safety.
Achieving increased regulatory compliance.
Eliminating all those trips up the ladder.
Amazing what the right level instrumentation could do.

It’s Emerson products and the people that make all the difference. Our portfolio of Rosemount level instrumentation
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CP1107_full
CT0903_FPA.indd
page ads.indd
15 25 6/27/11
2/24/09 9:14
3:52 AM
PM
 Compressors filtration systems
Ingersol Rand 32% Pall 14%
Atlas Copco 18% Millipore 7%
Siemens 6%
Computerized maintenanCe
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SAP 25% Emerson Process Management 51%
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Condition monitoring heat exChangers

GE (Bently Nevada) 27% Alfa Laval 24%
Emerson Process Management 16%
Rockwell Automation 8% heat transfer fluids
Dow 44%
Conveying (meChaniCal) Solutia 18%
Flexicon 9%
Hapman 8% infrared thermography equipment
FLIR (Extech) 41%
Conveying (pneumatiC) Fluke 36%
MAC Equipment 11%
Dynamic Air 8% instrument CaliBration systems
Vac-U-Max 8% Fluke 25%
Emerson Process Management 15%
Cooling towers
SPX (Marley) 36% level instrumentation
Paharpur 11% Emerson Process Management 41%
Baltimore Aircoil 10% Endress+Hauser 13%
Magnetrol 5%
distillation equipment
Koch-Glitsch 28% luBriCants
Sulzer 24% ExxonMobil 28%
Shell 18%
dryers Royal Purple 7%
GEA Niro 12% Lubrizol 5%

dust-Control systems mixing systems

Donaldson Torit 22% SPX 30%
Chemineer 12%
explosion proteCtion systems
Fike 26% motors
Fenwall 15% ABB (Baldor Reliance) 50%
Siemens 11%
fans & Blowers GE 7%
New York Blower 15% Emerson 7%
Howden Buffalo 10%
Dresser Roots 8% paCkings and gaskets
Chicago Blower 6% Garlock 15%
John Crane 11%
feeders Flexitallic 10%
K-Tron 28%
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 Properly Assess
Compressed Air Demand
A careful analysis can lead to substantial savings and more
By William Scales, Scales Industrial Technologies Inc.
MOST COMPRESSED air systems at process
plants offer significant opportunities for improve-
ment. A rigorous evaluation of an existing or new
system can establish sustainable best practices for
maximizing reliability and performance and mini-
mizing lifecycle costs. In addition, it can forestall
product contamination and scrap as well as the
possibility of environmental damage.
The same optimization strategies and tech-
niques apply to new systems and improvement
of existing ones. They ref lect a key common
denominator: energy costs alone generally exceed
the purchase price of a compressor in its first year
of operation. Often, addressing the inappropri-
ate application of compressed air and the proper
control of the compressed air system provide the
greatest savings.
CP1107_29_33_Design.indd 29
Efforts must begin with analysis of demand. Ev-
ery new plant will have specific initial requirements
while an existing plant has established consumers.
However, both of these likely will change over
time, so always consider anticipated growth.
HOW MUCH AIR IS NEEDED?
Start by creating a “demand profi le” form and list-
ing each steady demand, based on manufacturers’
specifications, including the required pressure and
operating flow rates at minimum, average and peak
conditions. Identify and separately list all intermit-
tent demands with compressed air “on/off ” cycle
times in seconds or minutes. Include the number of
shifts and resulting variations and potential future
additions. Indicate whether the air is for process or
general plant use or serves as breathing air.
29 CHEMICALPROCESSING.COM JULY 2011
6/27/11 2:03 PM
 Industrial Compressed Air Quality

Class 1 2 3 4 5 6
maximum particulate size, micron 0.1 1 5 15 40 —
maximum particulate concentration, mg/m3 0.01 1 5 8 10 —
oil aerosol and vapor, mg/m 3
0.01 0.1 1 5 25 —
Water vapor pressure dew point, °F -94 -40 -4 37.4 44.6 50

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

Typical Components of Demand The type and size of compressors needed and
Leaks - 10-20% the air quality necessary for the applications are
Inappropriate Uses -
15-25% very important factors. Consider the air quality
Artificial Demand -
10-15% requirement for the applications in selecting the
compressors and the air treatment. While a specific
process or plant standard may call for an oil-free air
compressor, some sites have successfully installed
lubricated compressors with proper filtration and
excellent maintenance to provide oil-free air. In
other cases, where a plant requires some oil-free air
but has an almost equal demand in other applica-
tions that can tolerate a given lubricant level, two
separate systems may make sense. International
Organization for Standardization (ISO) standards
classify the level of particulates, degree of dryness
and amount of lubricant in the air.
Operating at the lowest possible system pressure
Production - 50% allows for the most efficient operation. For example,
in many compressors, reducing the compressor
Figure 1. Leaks and inappropriate uses usually amount to
at least a quarter of demand. discharge pressure 10 psi can cut specific power
by 5%. Many plants supply compressed air to the
main distribution system at a pressure that is at
Costs Over Ten Years least 5 psi above the required minimum, which is
Maintenance - 12% determined either by the most significant uses or
one most sensitive to lower pressure.
Equipment - 12%
Figure 1 shows components of demand and
their typical levels. “Artificial Demand” relates to
increased air consumption required by any unregu-
lated uses due to system pressure in excess of what
actually is necessary. “Inappropriate Uses” refers to
applications where replacing compressed air with
other options potentially can improve effectiveness
or efficiency. “Leaks” covers unintended losses.
Leaks typically represent 10–20% of total
demand. In the past, recommendations were to
maintain the leakage rate below 10%. However,
compressed air now is recognized as a very expen-
sive utility and standards at many plants call for
holding leaks to less than 5% of peak flow.
A corollary is to provide automated equipment
Electricity - 76%
to shut off air to applications when not in use.
Figure 2. Electricity generally accounts for more than A few end uses requiring higher pressure can
three quarters of overall expenses. lead to maintaining the entire system pressure at an

July 2011 chemicalprocessing.com 30

CP1107_29_33_Design.indd 30 6/27/11 2:03 PM

 GET MORE DETAILS
The subjects covered in this article are discussed in much greater detail in “Best Practices for Com-
pressed Air Systems,” which is available via www.compressedairchallenge.org. The 325-page manual ad-
dresses topics such as distribution piping systems, specific end uses, measuring and estimating the cost
of leaks, monitoring systems for optimum performance, and self-auditing opportunities.

“artificially” elevated level, resulting in increased
energy consumption. In some plants, it’s possible
to modify end uses to operate at a lower pressure.
In other cases, a motor-driven booster can handle
continuous demands for higher pressures and an air
amplifier can take care of intermittent ones.
Sometimes a low-pressure blower can replace
compressed air. There are many examples of such
switches for sparging processes for aerating or
agitating liquid. Depending on the height of the
column and specific gravity of the liquid, the design
blower discharge pressure usually runs 4–15 psig.
For a 15-psig design pressure, the energy saving is
approximately 60%. Before making such a move,
check for any adverse effects on the process and
necessary changes to the distribution piping.
Electric motors often can replace air motors,
reducing energy consumption by 80%. Similarly,
where applicable, swap out double-diaphragm
pumps with electric-motor-driven pumps.
Another often very worthwhile move is to create
vacuum for continuous applications with a vacuum
pump rather than compressed air venturi methods.
Compressed air must meet the requirements of the
process equipment it serves. A minimum pressure
dew point of 35–39°F, supplied by a refrigerated
air dryer, may not always suffice. A regenerative
desiccant dryer to provide a substantially lower dew
point may be necessary — but will consume more
energy. The requirements of the air consumer also
may demand greater fi ltration. You can locate these
additional fi lters centrally at the compressors or at
points of use.
Packaging and instrument air. Most plants
defi ne packaging air as air used in packaging lines
that does not come in contact with the product in
any way.
Instrument air is defi ned as air used for instru-
mentation and controls. Most instrumentation

COMPRESSED AIR QUALITY

For most industrial applications, ISO 8573.1:2009,
the international standard for compressed air quality,
defines the level of contamination permissible (Table
1). The standard identifies three primary forms of
THINK
contamination: solid particles, water (vapor) and oil.
BIGGER!...

BOILERS
It classifies contaminants and assigns an air quality
level ranging from Class 1, the highest purity level,
to Class 9. A user or supplier can specify an even-
more-stringent requirement, Class 0. ▪▪▪ Heavy Industrial-Duty Fired and Waste Heat Boilers
- Pressures - up to 2,000 PSIG
There also are other possible gaseous con- - Capacities - up to 400,000 PPH
taminants. Their acceptable level depends on the
▪▪▪ Massive Manufacturing Facilities
application; the purification methods will depend - State-of-the-art equipment is utilized to maintain superior levels of quality
control for each and every step of the manufacturing process
on the specific requirements. Compressed air users
must understand what are considered potential con- ▪▪▪ Large Inventory of Parts
- Wall-to-wall boiler-room parts -- ready to ship 24/7
taminants in their applications, the effects of these
gases, and the methods to achieve successful and
sustainable contamination control.
Process and laboratory air. Process air some-
times is defi ned as air that comes in contact with
the product or has incidental product contact.
Visit: www.victoryenergy.com For immediate inquiries call: 918.274.0023
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Advertiser: Victory Energy Operations, LLC

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CP1107_29_33_Design.indd 31 Publication: Chemical Processing 6/27/11 2:03 PM
 Sophisticated Controller
sociation (CGA) Commodity Specification for air
ANSI/CGA-G7.1. The OSHA standard references
this specification and is essentially consistent
with ANSI. Breathing air also must be tested for
contaminants such as methane, nitrogen oxide,
nitrous oxide, halogenated hydrocarbons and other
hydrocarbons. Grossly contaminated or oxygen
deficient air may not be able to be purified to levels
acceptable for breathing.
The CGA Standard Commodity Specification
G7.1, Grade D, commonly is specified for plant
breathing air systems. At a minimum, this air must
conform to OSHA standard 1910.134 (revision effec-
tive April 1998) or, in Canada, Canadian Standards
Association standard CAN3-Z180.1-M85. Check to
ensure compliance with all local standards.

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

July 2011 chemicalprocessing.com 32

CP1107_29_33_Design.indd 32 6/27/11 2:04 PM

 exhaust fan discharge, as this could contaminate RELATED CONTENT ON
the inlet air to the compressor. If not supplied with CHEMICALPROCESSING.COM
the compressor, install an inlet vacuum gauge to “Cut the Cost of Compressed Air,” www.
monitor the condition of the intake fi lter. ChemicalProcessing.com/articles/2009/204.html
Adequate compressor room ventilation is es- “Don’t Err with Air Compressors,” www.
sential for heat rejection. Usually, however, it is not ChemicalProcessing.com/articles/2008/050.html
cost effective to air condition the area. If the com- “Energy Savings Are Often Disguised as
pressor ventilation air is ducted out of the room, Problems,” www.ChemicalProcessing.com/ar-
the total static pressure of the combined inlet and ticles/2006/107.html
outlet ductwork generally should not exceed 0.12 “Compressed Air Systems: The Secret is in
in. of H 2O. You many need to install a ventilation the Pipe,” www.ChemicalProcessing.com/ar-
fan in the ducting for heat recovery or to address ticles/2005/12.html
large ducting losses.
It may be possible to recover almost all the heat
generated by the air compressors to significantly Effective control strategies require documented
reduce your plant’s total energy consumption. For data to monitor:
more on heat recovery, see: “Air Compressor Heat • flows (use mass flow meters that compensate
Recovery Is a Hot Topic,” www.PlantServices.com/ for pressure and temperature);
articles/2003/103.html. • power and energy consumption;
• pressure and pressure drop (∆P) before and
OPTIMIZATION AND CONTROL after major components such as dryers and fi lters;
A control strategy should strive to match system • temperatures (sensors often come with the
demand with compressors operated at or near equipment); and
their maximum efficiency levels. Th is should result • pressure dew point of the system.
in compressors running at their lowest possible Another optimization strategy relies on a pres-
input power and total energy consumption for all sure/flow controller. Th is is a device that serves to
demand conditions. Excessive part-load or no-load separate the supply side of a compressor system
operation is wasteful — avoid it where practical. from the demand side of a compressed air distribu-
Some examples of multiple compressor sequencing tion system. The controller maintains a constant
are cascading systems and rate-of-change systems. demand-side pressure with varying demand loads.
A cascading system overlaps the pressure setting For this controller to work properly, the
in the compressors installed so that an increase or supply-side pressure generally must exceed the
decrease in pressure starts or stops the appropri- demand-side requirement by a minimum of 10 psi.
ate compressor, loaded or unloaded. Th is type of The compressors operate at an elevated pressure
system generally requires a large pressure band and and increased horsepower, but pressure on the
considerable storage volume. demand side can be maintained at a lower stable
Today, modern multiple-compressor systems level to minimize actual compressed air consump-
can benefit from sophisticated controls, like Smart tion. Storage, sized to meet anticipated fluctua-
Sequencers (Figure 3), to efficiently match compres- tions in demand, is an essential part of the control
sor operation and air delivery to the system require- strategy.
ments at the lowest energy consumption. Th is type Using a pressure/flow controller may not be
of sequencer can be used with any combination of necessary in all cases. Each compressed air system
compressor types and manufacturers. For addition- differs in supply, distribution and demand aspects.
al information, see: “Taming Multiple Compres- So, it’s essential to properly evaluate the benefits of
sors,” www.PlantServices.com/articles/2010/01Tam such a controller for the particular system. Ad-
ingMultipleCompressors.html. ditional primary and secondary air receivers often
Reducing compressor discharge pressure 2 may serve as an alternative to, or in conjunction
psi will cut input power 1% for many types of with, a pressure/flow controller.
compressors. Proper sequencing controls should
consider fluctuations in demand, available storage WILLIAM SCALES, P.E., is CEO of Scales Industrial
and the characteristics of the equipment supplying Technologies Inc., Carle Place, N.Y. Email him at bscales@
and treating the compressed air. scalesair.com.

33 CHEMICALPROCESSING.COM JULY 2011

CP1107_29_33_Design.indd 33 6/27/11 2:04 PM

 PVDF Conveyor
Pneumatic
Conveying
Keeps Moving Ahead
Technical developments enhance performance and economics
By Seán Ottewell, Editor at Large
CHEMICAL COMPANIES’ demands for convey-
ing solutions that increase throughput, shorten lead
times, handle vastly differing solids, reduce costs and
simplify maintenance — all while ensuring worker
and plant safety — are spurring suppliers to develop
innovative solutions.
At dense-phase pneumatic conveying specialist
Air-Tec, Calderara di Reno, Italy, for example, cus-
tomers’ desire to handle products with vastly different
levels of abrasiveness is driving developments.
The company has installed conveyors at many
chemical plants. “The most common challenge that we
have to face is the abrasiveness of the product,” says mar-
keting and communication manager Fulvia Lombardo.
“Abrasive materials can wear the conveying line
and be damaged by high-velocity transportation; thus
we find the lower conveying velocity of a dense-phase
system best. This lower speed, combined with a reduced
amount of compressed air or other gases, avoids pipe
wear, preserves the integrity of the product and contrib-
utes greatly to reduced maintenance costs,” she adds.
JULY 2011 CHEMICALPROCESSING.COM 34
CP1107_34_36_Solids.indd 34
Figure1. Pneumatic line
connects to hopper
through a valve receiver.
Source: Air-Tec.
The company uses air boosters to introduce gas
into the conveying systems to reduce friction inside
the pipes, and relies on anti-wear cast iron elbows to
extend downtime intervals.
Air-Tec has just completed a project at the
research center of a major European-based supplier
of specialty cross-linkage compounds. The challenge
here was to convey one metric ton of polyvinylidene
fluoride (PVDF) powder per hour over a distance of
30 meters. The conveyor also had to be usable with
materials both more abrasive and fragile than PVDF,
and ensure the quality of all products during handling
procedures.
To achieve this, the company installed a TPA (Air-
Tec Pneumatic Transport) system, its most advanced
offering, which provides greater flexibility and control
of transport cycles. Material is discharged into the
TPA from bags and conveyed the 30 meters to two
hoppers with load cells connected to gravimetric feed-
ers. Valves allow PVDF into the hopper; they close
when the target weight has been reached (Figure 1).
6/27/11 2:05 PM
 Impact of Properties

property has impact on

Particle shape Discharge from hoppers
Particle size and particle size distribution Flowability and compressibility
“This solution has also met the requirement for flex- Particle hardness Abrasiveness on equipment and particle
ibility and can be used to convey other materials with fragility
different levels of abrasiveness and fragility that might Bulk density (loose and compact) Size of storage vessels and compressibility
be present in the client laboratory,” says Lombardo. of material

In a sign of what’s to come, Air-Tec’s research and Moisture content Cohesive strength and arching ability of
bulk materials
development department is working on combining
different ratios of air and inert gases to boost conveying Compressibility Tendency to pack in a feeder hopper

efficiencies and save energy. In collaboration with engi- Cohesiveness Minimum outlet diameter for bins, hop-
pers, and outlets
neers at the University of Bologna, Italy, the company
Can velocity Sizing of filter receivers and bin vent filters
has developed a mathematical model that enables plants
to “drastically” reduce energy consumption during Conveying velocity Saltation velocity

transport of any product, says Lombardo. Permeability Ability to flood

Table 1. A wide va-

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

35 chemicalprocessing.com July 2011

CP1107_34_36_Solids.indd 35 6/27/11 2:05 PM

 Slide Angle
Figure 2. One mea-
sure of flowability is The accuracy of the now-automated system’s load-
the minimum slope
at which a powder
ing, weighing and mixing operations has improved over-
will move down all product quality and repeatability. In addition, using
an incline. Source:
bulk bags in place of 25-kg sacks of PVC has reduced
K-tron.
the amount of floor space needed for materials storage.
Flexibility is another advantage. A single con-
veyor can handle powders with a wide range of bulk
densities, as well as flakes, pellets, capsules, tablets
and other friable materials. Because the Pneumati-con
system fully evacuates the vessel being discharged
and the conveyor line itself, cross-contamination of
multi-ingredient systems is minimized. The system
also boasts easy-to-maintain filter receivers and rotary
airlock valves.
PRESSURE BALANCE
One of the secrets of a successful and highly ef-
ficient pneumatic conveying system, whether a
RELATED CONTENT ON CHEMICALPROCESSING.COM
“Chemical Processing Special Report: Conveyors,” www.Chemical-
Processing.com/whitepapers/2009/008.html
“Install Pneumatic Conveyors Correctly,” www.ChemicalProcessing.
com/articles/2006/040.html
“Pneumatic Conveying Moves Ahead,” www.ChemicalProcessing.
com/articles/2005/426.html
JULY 2011 CHEMICALPROCESSING.COM 36
CP1107_34_36_Solids.indd 36
high-pressure dense-phase system or a low-pres-
sure dilute-phase, is achieving an optimum pres-
sure balance, notes Dynamic Air, St. Paul, Minn.
Many systems operate in an unstable or unbal-
anced pressure condition, says the company. This
means the conveying system can be using either
too much or not enough compressed air, both of
which are undesirable.
To effectively counterbalance all the friction
factors normally inherent in a pneumatic convey-
ing system, Dynamic Air has developed DC-5
Air Saver technology, which accurately controls
and pressure balances the pneumatic conveying
system. It achieves the proper pressure balance
by automatically sensing system conditions and
reacting instantaneously and accurately with-
out overcompensation. So material is conveyed
through the line in a smooth, controlled man-
ner and at the desired velocity, to optimize the
conveying process for higher performance and
reliability.
DC-5 Air Saver cuts energy consumption,
improves system reliability, allows highly abrasive
materials to be transported, reduces dust han-
dling requirements, and decreases the dynamic
loading experienced at pipe bends by controlling
the conveying velocity, says the company.
6/27/11 2:06 PM
 make the most of
radar
Following some best practices can ensure accurate level measurement
By Sarah Parker, Emerson Process Management
The emergence of radar has significantly
advanced level monitoring. Radar provides cost-ef-
fective and accurate measurements that are immune
to density and other process fluid changes, as well as
most vapor-space conditions.
Radar level measurement systems come in contact-
ing and non-contacting versions, both of which are
widely applied in the process industries. Contacting
generally is a good fit for small spaces; it easily replaces
older technologies such as displacers and capacitance
probes. Non-contacting usually is better for dirty,
viscous or corrosive applications and when agitators are
present. Currently, contacting devices called guided-
wave radar (GWR) are slightly more prevalent, primar-
ily because they can measure interface level (e.g., oil and
water) as well as standard direct level (Figure 1).
There are some important considerations when
applying both types of radar technology. For example,
getting accurate measurements in steam applications
of more than 400–500 psi (30–35 bar) requires GWR
systems that have dynamic vapor compensation.
Similarly, in applications where signal reflection is
weak, you must select a device with technology that
CP1107_37_40_Instru.indd 37
minimizes losses in the returned signal. In cases —
including some solids applications and those with low
dielectric fluids and turbulence due to boiling or en-
trained air — where the return signal is so weak that
it occasionally disappears, the device should be able to
provide a level measurement via alternative methods
such as probe end projection (which uses a combina-
tion of the known length of the probe and an online
reading of dielectric to calculate level).
While GWR works in many conditions and
doesn’t depend on reflecting a signal off a flat surface,
probe choice requires care. Probes come in several
styles — the application, length and mounting restric-
tions influence the correct choice. Unless coax-style
units are used, probes should not directly contact a
metallic object because that will impact the signal.
Twin and coaxial probes are susceptible to clogging
and build up. If the application involves liquids that
tend to be dirty, sticky or can coat, then only use
single-lead probes. For such applications, devices
offering signal quality diagnostics can help determine
if the probe needs cleaning and allow scheduling of
maintenance only when needed.
37 chemicalprocessing.com July 2011
6/27/11 2:07 PM
 Guide Wave Radar
Figure 1. This con-
tacting device can In general, GWR doesn’t suit extremely viscous
detect interface
level as well as
products where fluid flow is minimal. If GWR is
overall level. used with very viscous fluids and installed in a by-
pass chamber, heat-trace and insulate the chamber to
ensure fluidity. In addition, check that the connec-
tions from the tank to the chamber and the cham-
ber’s diameter are large enough to allow good fluid
flow. For applications such as asphalt where heavy
coating is likely, go with non-contacting radar and
mount directly on the vessel, not in a chamber.
Non-contacting radar (Figure 2) demands care-
ful consideration of process conditions and instal-
lation constraints. It requires a clear unobstructed
view of a liquid surface. An unrestricted mounting
nozzle also is important. The measured surface must
be relatively flat, not slanted. Non-contacting radar
gauges can handle agitation — but success depends
on the fluid properties and the amount of turbulence
not limiting the return signal too much. Low dielec-
tric fluids reflect very little radiated energy back to
July 2011 chemicalprocessing.com 38
CP1107_37_40_Instru.indd 38
the gauge. Additional signal loss occurs if the liquid
surface is turbulent, whether from agitation, product
blending or splashing. To overcome this, you can use
bypass pipes — including self-contained chambers or
stilling wells to isolate the surface from turbulence.
Such bypass pipes (Figure 3) provide a calmer
surface in case of turbulence. They offer external
mounting with valves, allow for easier servicing of
level devices and enable radar measurement in tanks
such as towers that only offer side connections.
Always provide multiple holes or slots on one side of
the pipe to ensure good fluid flow-through.
Both GWR and non-contacting radar work well
for pipe or stilling well applications, but GWR is
far simpler to install and maintains accuracy and
sensitivity independently of the pipe. For these types
of applications, correctly dimensioning the chamber
and selecting the appropriate probe are essential.
Choose 75-mm or 100-mm chambers. Smaller
ones raise risks of build-up and flow-through prob-
lems, and increase the chances of the probe contact-
ing the chamber wall.
Select a single probe, as it is less susceptible to
build-up. Most chamber installations rely on rigid
probes but flexible ones also may also be used. En-
sure the probe is suspended vertically and does not
touch the pipe wall. A “centring” disk can keep the
probe properly positioned away from the wall.
For shorter pipes, use GWR with rigid probes.
GWR with flexible probes can work in long pipes, but
the probes must remain taut and away from the wall. A
combination of weights and centring disks can achieve
this. For longer pipes or when head space for installing
probes is limited, opt for non-contacting radar.
SPECIAL CHALLENGES
Several types of applications raise particular issues.
High temperature and pressure. Applications with
extreme temperature and pressure conditions de-
mand a heavy-duty process seal with multiple layers
of protection and a flexible assembly to handle the
stresses and the forces induced. This is to prevent
leakages and ensure the safety and efficiency of
your plant.
When measuring liquids at very high tempera-
tures in a chamber, you must insulate and heat-trace
the chamber. Fluctuations in temperatures alter the
density and volume of the liquid, which then affect
the level in the chamber. Maintaining the tempera-
ture of dirty liquids such as heavy oil also helps
avoid clogging and sticking within the chamber and
enables adequate flow-through.
6/27/11 2:07 PM
 Although radar technology is not affected by
density changes, dielectric variations can have an
impact. For boiler and feed-water systems where
boiling water and high-pressure saturated steam
vapors are present, the returned signal from the
surface becomes weaker as water temperature
increases. In addition, the saturated steam alters
the propagation velocity of the radar signal and
generates an error in the level reading propor-
tional to the measured distance. Dynamic vapor
compensation can address the changes in the
vapor-space dielectric and reduce the incorrect
distance caused by varying pressure or tempera-
ture to less than 2%.
Interfaces. The fluid with the lower dielectric
must always be on top and you must know its
dielectric value. The two liquids must differ in
dielectric value by at least around ten. Effective
measurement requires certain thicknesses of layers.
Typical successful applications have a hydrocarbon-
based fluid with a dielectric around two as the top
layer and water-based fluid with a dielectric over 40
at the bottom.
Applications where the densities of the two fluids
are very close or where emulsifiers are used can
produce fairly large emulsion between the liquids.
This may make the interface indistinct. Heavy and
thick emulsion layers or liquid layers with similar
dielectrics can pose a problem for GWR because
it requires a distinct dielectric difference to detect
Non-contacting Radar
CP1107_37_40_Instru.indd 39
the interface. GWR devices have proven to work in
interfaces with emulsions but success is difficult to
predict. The interface threshold on the radar device
may require manual adjustment.
In applications with large emulsions, a displacer
device (which relies on a buoyancy effect rather than
any dielectric value) can track the midpoint of an
emulsion layer and, so, may provide a better solution.
However, that technology relies on moving parts
that require frequent cleaning and replacement,
thereby reducing the reliability of the measurement
and incurring greater maintenance costs.
Open air and non-metal tanks. Radar often works
well in such applications. In some cases, though,
outside disturbances may interfere with the radar sig-
nal — and you must select a device, such as a GWR
with a smart galvanic interface, with high resistance
to electromagnetic interference. For most open sump
and well installations, an ultrasonic meter is a more-
cost-effective solution. However, should vapors be
present, choose a low-frequency radar device instead.
Overfill protection. In critical applications, you
must install a minimum of two level technologies
or devices; if several measurements rely on the same
technology, you must employ a voting scheme. Using
technologies less influenced by process conditions,
such as radar in combination with vibrating fork
switches, is a good step to more accurate and reliable
measurements.
For radar, most failure modes relate to a loss
Figure 2. Measure-
ments require a clear
unobstructed view of
liquid surface.
39 chemicalprocessing.com July 2011
6/27/11 2:07 PM
 Bypass Pipes
Figure 3. Using
external chambers
of signal. High sensitivity normally results in
for level measure- high availabilities. High sensitivity is achieved by
ment can cope
increasing the signal-to-noise ratio, e.g., via Dual
with turbulence
and enable easier Port and Direct Switch Technology. Enhanced
servicing of device. echologics — the ability to ignore false echoes —
and smart software functions also improve radar
performance. Some GWR devices incorporate
software that improves measurements in the near Process Management, Chanhassen, Minn. Email her at Sarah.
zone (high level areas), especially for low ref lec-
tive targets.
However, above a certain level the surface
echo may not appear at all in the waveform. Using
echologics to monitor signal changes as the level
gets close to the top adds an extra layer of protec-
tion. This supports the basic level signal and gives
informative warnings that the tank is full, even if the
level signal is lost.
Advanced diagnostics is another step in the right
direction for safe measurement. For example, some
GWR devices provide real-time notification if the
JULY 2011 CHEMICALPROCESSING.COM 40
CP1107_37_40_Instru.indd 40
probe gets coated, providing the opportunity to
schedule proactive maintenance.
Today, vibrating fork switches continuously
monitor corrosion of the forks, external damage to
the sensor, internal wire disconnect or breakage, and
over-temperature. This results in a fault indication
and fail-safe operation of the switch output.
INSTALLATION PITFALLS
A good installation is key to success with radar. A new
radar device usually is installed on an existing nozzle.
This nozzle sometimes may be too tall or narrow for the
instrument. Try to minimize the height of the nozzle
used. Ideally, nozzles should be at least two inches in di-
ameter but no more than six inches high for GWR. For
non-contacting radar, the end of the antenna should
extend slightly beyond the nozzle. High-frequency non-
contact radar can use longer nozzles but they must be
smooth and clear of obstructions.
Positioning the nozzle directly over a pipe,
baffle or other obstruction can cause problems.
The obstruction interferes with the radar beam and
it, rather than the process medium in the vessel,
becomes the level measurement. Similarly, a fluid
stream coming into the tank that falls into the path
of the radar beam or on the probe will impact the
reliability of the measurement.
As with all instrumentation, you must correctly
configure radar devices in accordance with ap-
plication needs. Take special care when inputting
thresholds for the radar signal — these will change
depending on the medium being measured. For
example, oil appears very different to a radar device
than water and, therefore, requires very different
threshold settings. However, today good set-up
guides and functions in most cases enable easy con-
figuration in just a few steps.
SARAH PARKER is level application manager for Emerson
Parker@emerson.com.
RELATED CONTENT ON
CHEMICALPROCESSING.COM
“Don’t Impair Level Measurements,” www.
ChemicalProcessing.com/articles/2010/177.html
“Don’t Underestimate Overfilling’s
Risks,” www.ChemicalProcessing.com/ar-
ticles/2010/143.html
“Keep Measurements on the Level,” www.
ChemicalProcessing.com/articles/2006/165.html
6/27/11 2:08 PM

Split Seal
Mixer Seal Gets Major Makeover
Novel retrofit prevents leaks and offers other benefits
By Vic Lundberg, Quadna
SealinG the agitator shaft entry point in a
tank used for high temperature mixing of titanium
tetrachloride (TiCl4) at its Henderson, Nev., plant
was a crucial worker-safety issue for Titanium Metals
Corp. (Timet). TiCl4 is an aggressive chemical that
has a tendency to flash off to form a potentially nox-
ious vapor and toxic white cloud. In addition, when
the chemical comes into contact with water, it can
become hazardous.
In late 2010, Timet sought out Quadna’s advice
on the best way to seal the mixer shaft entry point.
We faced two major challenges in developing an effec-
tive solution.
The first was to determine how to maintain a strong
positive seal. The seal design was of paramount impor-
tance and there were critical metallurgy issues as well.
Previously, the system employed a double mechani-
cal seal with a mineral-oil barrier fluid that provided
lubrication between the inboard and outboard faces.
Timet wanted to use a split mechanical seal instead —
because its installation and eventual replacement take
far less time. However, to enhance the operation, a dry
seal was needed. The problem? At that point in time, no
manufacturer was producing a dry-running split seal.
The second obstacle was the length of the shaft.
CP1107_41_42_MIW.indd 41
making it work
Figure 1. Dry-running
unit coupled with
perfluoroalkoxy sleeve
bearing prevents leak-
age of TiCl4.
The mixing operation uses a long unsupported shaft,
which commonly leads to excessive shaft run-out at
the mechanical seal. We recommended installing a
sleeve bearing made of DuPont Vespel CR6100, a
perflouroalkoxy. The additional sleeve would help the
long shaft run true and minimize shaft run-out.
The typical total clearance for a steady bearing
for a shaft of the diameter used for this mixer (3 in.
to 5 in.) is 0.020 in. The Vespel sleeve bearing was
machined for a total clearance of 0.007–0.010 in. This
dramatic reduction in clearance between the bearing
and shaft allowed the Vespel sleeve bearing to act as
a primary seal, as well as to keep shaft run-out well
below maximum acceptable levels.
The reduction in clearance was possible because
of the unique coefficient-of-thermal-expansion prop-
erties of Vespel. Thermal growth is largely confined
to the Z direction (along the shaft) — growth in the
X and the Y directions is extremely small. In addi-
tion, the material is chemically inert to TiCl4 and
can operate without lubrication because of its very
low coefficient of friction.
Quadna redesigned the mixer stuffing box for a
John Crane Type 3740D cartridge split seal using the
Vespel sleeve bearing — this represented one of the first
41 chemicalprocessing.com July 2011
6/27/11 2:08 PM
 MAKING IT WORK
John Crane dry-running beta split
seal installations.
IMPRESSIVE RESULTS
During final assembly of the
bearing and split-seal system, a
slight dimensional issue prevented
installation of the John Crane seal.
Because time was running short,
CP1107_41_42_MIW.indd 42
the mixer had to be placed back
into service. During subsequent
operation the Vespel sleeve bearing
alone sealed nearly 100% of the
vapor and also demonstrated its
effectiveness in reducing run-out.
So, Quadna and plant officials
decided to continue operating the
unit without the seal while the
minor dimensional issue was ad-
dressed. Then, at the first oppor-
tunity, we put in the dry-running
seal to ensure complete contain-
ment of vapor. The split seal took
only hours to install during a brief
outage (versus the days required
for a double seal) and has operated
without a hitch.
Several vessels in the plant
that were experiencing similar
problems now have received John
Crane Type 3740D dry-running
split seals as well as Dupont
Vespel 6100 sleeve bearings for
their mixer shafts, resulting in the
containment of all TiCl4 vapor.
These enhancements have
provided other benefits too.
Significant savings come from
eliminating the mineral-oil barrier
fluid and specialized seal-support
equipment to regulate flow and
pressure required by double
mechanical seals. In addition, seal
replacement in the future will take
much less time.
Quadna team members are
incorporating all the modifica-
tions as standard offerings for new
mixers that Timet is purchasing
for the plant. Installation of these
mixers should be completed by the
end of 2011.
VIC LUNDBERG is a Las Vegas, Nev.-
based process engineer for Quadna, a
DXP company. Email him at vlundberg@
dxpe.com.
RELATED CONTENT ON
CHEMICALPROCESSING.COM
“Seal Off Centrifugal Pump Prob-
lems,” www.ChemicalProcessing.com/
articles/2011/centrifugal-pump-problems.
html
“New Seals Get Their Turn,”
www.ChemicalProcessing.com/ar-
ticles/2007/113.html
“Gas Up Your Sealing Knowledge,”
www.ChemicalProcessing.com/ar-
ticles/2006/182.html
6/27/11 4:30 PM

prevent pump problems
Readers suggest possible root causes and ways to improve performance
tHIS mONtH’S pUZZLer
in our gas plant we pump natural gas liquids (ngl) with a
double-suction high-speed centrifugal pump. it runs with a
discharge pressure of 60 Barg at 6,700 rpm, and is designed
for a flow rate of 670 m3/hr. a booster pump discharges at
20 Barg to the ngl pump suction. The ngl, which has a
specific gravity of 0.52, then travels about 400 km to our re-
finery for fractionation. about 35–40% of the pumped fluid
recycles into the surge bullet via a recycle valve, wasting
energy. There are other problems: vibration trips in low flow
due to shaft deflections, seal leaks, etc. so, we’re planning
to buy a new pump, preferably one that will allow us to save
energy and avoid such problems. What type of pump do
you consider the best choice for this application?
DeSIGN FOr eNerGY eFFICIeNCY
The booster pump and the export pump should have their
own minimum-flow recycle valves. These minimum flows
need to be maintained at all times — either by a flow
control valve or a restrictive orifice (RO). An RO is simpler;
however, it will waste energy. I suggest flow control loops
so that the flow is recycled only when needed. If flow above
the minimum rate is required and the economics allow, use
variable speed drives to reduce energy consumption.
The problems may be due to low seal pressure. Double me-
chanical seals require pressure above the pump discharge pres-
sure. Otherwise, hydrocarbon will migrate to the seal system.
Another symptom, pump vibration at low flow, may be due to
improper alignment and cavitation. The same problems will ap-
pear with the new pump if the cause is not clearly established.
Sameer Chawla, lead process engineer Another response appears online at www.ChemicalProcessing.com/
WorleyParsons, Kuala Lumpur, Malaysia voices/process_puzzler.html
September’S pUZZLer
We used an old welded stainless steel silo at our missouri
site to store dried brewers grain. During a september
shutdown, we installed a new bagger and weigh scale. This
prevented us from loading railcars for several days. so, to
keep the dryer running during the outage, we cut its output
to a rate that would only fill up the silo. The weather was
hot but a rainstorm swept through with a cold front. after
the storm, we noticed a seam on the silo had split apart,
dumping several hundred tons of dried brewers grain. now,
corporate managers, concerned because another plant
is planning a similar shutdown and bagger installation
soon, want to know why the silo failed. What do you think
43
CP1107_43_Puzzler.indd 43
process puzzler
reDUCe tHe SHAFt SpeeD
I think the problems can be divided into two categories —
design and operational.
The high rotational speed of these pumps causes overheating
at the seal faces and seal failure. The high peripheral velocities
are too close to the manufacturer’s design limits. Another design
problem is shaft deflection, which is highest at low flow. Under
these conditions, high radial forces, created by the high pressure
in the pump casing, act on the shaft and impeller. The pump’s
double volutes are ineffective. As a result, the pumps vibrate
severely, enough to cause tripping. Operationally, the pump
wastes energy because of the high recycle flow.
I suggest exploring:
1. A lower capacity impeller. Design for the identi-
cal head with increased shaft stiffness and reduced throat
bushing clearances. The material of construction may need
to be changed. These modifications should reduce low-flow
vibration.
2. A two-pole motor, constant speed direct-drive.
3. A multi-stage pump. It offers many advantages over a
single-stage pump, including: a lower shaft speed, resulting in
increased life of bearings and seals; reduced shaft deflection;
elimination of a speed-increaser gear box, reducing energy
consumption; and less motor horsepower.
Although the NGL pump will still be operating well below
its best efficiency point (BEP), the energy losses will be reduced.
As a last resort, another option could be a variable speed drive.
Sakrapani Amirthalingam, shutdown engineer
Gasco/Asab, Abu Dhabi
caused the accident? What should we tell management?
send us your comments, suggestions or solutions for
this question by august 12, 2011. We’ll include as many of
them as possible in the september 2011 issue and all on
cp.com. send visuals — a sketch is fine. e-mail us at pro-
cesspuzzler@putman.net or mail to process puzzler, Chem-
ical Processing, 555 W. pierce road, suite 301, itasca, il
60143. Fax: (630) 467-1120. please include your name, title,
location and company affiliation in the response.
and, of course, if you have a process problem you’d
like to pose to our readers, send it along and we’ll be
pleased to consider it for publication.
chemicalprocessing.com July 2011
6/27/11 2:10 PM
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 plant insites

Pick the Proper Centrifugal Pump

Consider the impact of startup conditions and prospective operating points

Centrifugal PumPs impart velocity to
a f luid and then recover the velocity as pres-
sure head. Performance curves depict the total
dynamic head generated at a given f low rate for a
specific impeller and rotational speed (Figure 1).
They typically show total dynamic head in feet,
not psi, unless the curves are for a defined liquid.
You can convert pressure rise from feet to psi
via:
ΔP = ρΔH/144 (1)
where ΔP is pressure rise in psi, ρ is density in lb/
ft 3, and ΔH is dynamic head in feet.
Pump work applied to the f luid is:
W = QΔP/1,714η (2)
where W is work in hp, Q is f low in gpm, and η is
pump efficiency, as a fraction of one.
Both ΔP and W vary with liquid density. So,
you must know the density to convert from a
dynamic pump performance curve to the physical
pressure rise or power required.
Pump efficiency varies with f low rate. In ad-
dition, the efficiencies of the drive system (belts,
gears, couplings, etc.) and driver come into play.
For an electrically driven pump, the driver ef-
ficiency is the motor efficiency. This can vary as a
function of total load. Motor efficiencies drop at
tion system was near its trip point, a power draw
equivalent to 300 hp. Table 1 illustrates the
normal and startup conditions; efficiency takes
into account the pump, driver and coupling, as
well as an allowance for efficiency changes due to
high viscosity at the startup condition. Designers
should have factored in the need for some extra
startup power. Select a
Good practice requires thinking about dif-
motor sized for
ferent operating points. Consider, for instance,
startup at cold conditions, higher viscosity opera- the maximum
tion, pumping heavier f luids, and installing larger
impeller that fits
diameter impellers in the future.
Many companies, as standard practice, buy in the casing.
pumps with some room to increase impeller size
later to boost capacity. Greater throughput plus
higher discharge head from a larger impeller
rapidly raises the pump power required. Prudent
engineering practice is to select a motor sized for
the maximum impeller that fits in the casing.
In the end, economics sets the best motor
Pump Curve
0.8
Dynamic head
550

Net Positive Suction Head required, ft

low loads. 0.6
Dynamic head in feet doesn’t change as den- 500
15
sity changes. Imposed pressure in psi and power Efficiency

Efficiency, fraction
Dynamic head, ft

demand will vary as liquid density varies. For 450

many processes and conditions, the density is well Net Positive 0.4

understood and known in advance. Suction Head

400

However, densities can vary dramatically in

10
some common situations. For instance, at startup 350
many units are cold, so densities are higher, in- 0.2

creasing power demands. Let’s look at a situation 300

where startup density differences created motor
problems.
250 5 0.0
Figure 2 shows the bottoms of a high tempera- 0 500 1,000 1,500 2,000 2,500 3,000
ture distillation tower. The startup procedure re- Flow, gpm at conditions
quired circulating cold tower bottoms to the fired Figure 1. Dynamic head in feet doesn’t directly give pump power required.
heater reboiler. Limits on both the pump (suction
specific speed) and the fired heater (minimum
startup Versus normal Operation
safe firing with air control) restricted f low rate Overall
to 1,500 gpm for starting conditions. The design Flow, Density, Efficiency,
Condition gpm Head, ft Head, psi lb/ft3 fraction Power, hp
operation was 2,250 gpm. Obviously, the pump
Startup 1,500 550 191 50.0 0.57 294
can handle the lower f low rate.
However, startup usually was a hit-or-miss Normal 2,250 460 111 34.9 0.67 218

affair because the pump motor’s thermal protec- Table 1. Startup requires power draw close to thermal protection trip point.

45 chemicalprocessing.com July 2011

CP1107_45_46_InSites.indd 45 6/27/11 2:11 PM

 PLANT INSITES

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Figure 2. Circulation of cold viscous bottoms at startup

Material Handling Equipment
CAS-195C.indd 1 1/28/11 10:35 AM posed motor cutoff risk.

sizing choice. Higher investment now for a larger

motor saves money in both the motor, electrical
systems and, perhaps, foundation later. It also en-
hances pump reliability. Power consumption costs
really don’t change a lot with larger motors.
Of course, this logic only goes so far. Multiple
margins for cold startup conditions with larger
Drum Discharger Container Discharger impellers may lead to drastic oversizing. Motors
Lift & Dump that run at small fractions of their design load
Container Discharger
have lower efficiency.
Use engineering judgment to choose the right
motor size. Large motors with significant capital
costs may require a true lifecycle analysis of total
system cost.

ANDREW SLOLEY, Contributing Editor

ASloley@putman.net

GET MORE PUMP INSITES

Previous columns include: “Properly Trigger
Bulk Bag Filler Standby Pumps,” www.chemicalprocessing.com/
Lift & Dump Bulk Bag
Drum Discharger Discharger articles/2010/095.html and “Cut Pump Speed to
Cut Problems,” www.chemicalprocessing.com/
articles/2009/167.html.
Call: 800.836.7068
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CP1107_45_46_InSites.indd 46 6/27/11 2:12 PM


Conductivity Sensor
Resists Corrosion
The TCS3020 Toroidal non-
contacting inductive sensor is
designed for performance from
0–1,000 mS and long-term de-
ployment with no maintenance.
It’s resistant to corrosion, coat-
ing and fouling and constructed
from Noryl. The TCS3020
reportedly has a wide solvent
tolerance and temperature
stability to 105°C. It operates up
to 150 psig. The sensor is either
submersible or can be installed
in-line. It includes a standard
style ATC measuring element
and a 20-ft (6 meter) cable. The
TCS3020, when combined with
the TCSMA or TCSTX toroidal
transmitter, is said to offer a
complete conductivity measure-
ment system.
Sensorex
714-895-4344
www.sensorex.com
Temperature Transmitter
Offers Flexibility
The Foxboro RTT30 Founda-
tion Fieldbus two-wire tempera-
ture transmitter receives input
signals from thermocouples,
RTDs, resistance (ohm) and
voltage (mV) sources. The
RTT30 also can measure two
CP1107_47_52_E&S.indd 47
inputs in two-, three- and
four-wire connections, as well
as display the current primary
temperature measurement and
indicate alarms. It reportedly
enables cost savings by send-
ing alarms to trigger predictive
maintenance scenarios. The
transmitter is capable of auto-
matically switching to a back-up
sensor and then notifying the
control room that the primary
sensor has gone bad, which
could prevent loss and improve
productivity.
Invensys Operations Manage-
ment
www.iom.invensys.com
Pumps Handle Low-
Pressure Applications
The 2000 Model WA and WB
positive-displacement pumps
feature a compact, close-
coupled configuration. They
are designed for low-pressure,
low-f low applications that do
not require the full features of a
2000 G1 pump. The models are
claimed to be ideal for industrial
and municipal applications that
require the transfer of highly
viscous f luids and solids where
a close-coupled configuration is
preferred, but the robustness of
a gear joint is desired.
Moyno, Inc.
937-327-3017
www.moyno.com
Sanitary Lump Breaker
Fits Tight Spaces
Model RDC1515-SS sanitary
lump breaker features side re-
moval bed screens for washdown
applications. The all-stainless,
47
equipment & services
low-profile unit reduces ag-
glomerates and friable materials
being discharged from process
equipment, storage vessels and
shipping containers. Material
entering the 15-in. (381-mm)
square inlet is reduced in size by
dual rotors with three-point sin-
gle-piece stainless-steel breaking
heads rotating with minimum
clearance inside a curved, perfo-
rated bedscreen. On-size mate-
rial exits through apertures in
twin bed screens ranging from
1 32 - to 2½-in. (25 to 64 mm) in
/
diameter. At 11-in. (279 mm)
high, the unit is designed to fit
in restricted spaces.
Munson Machinery Company,
Inc.
800-944-6644
www.munsonmachinery.com
Drum Dumper Rotates
180 Degrees
The 180° rotation drum dumper
accepts 55-gallon drums of
non-free-f lowing powders and
discharges the contents into a
vibratory feeder at 83 in. above
f loor level. The unit boasts
dust-tight operation and 304
chemicalprocessing.com July 2011
6/27/11 2:13 PM
 equipment & services
stainless steel product contact
surfaces. It’s available with
discharge heights up to 40 ft for
any size drum or container, and
units can be custom designed
for any application.
Material Transfer
800-836-7068
www.materialtransfer.com
Module Monitors Gas
Turbine Performance
The Envision Gas Turbine (GT)
performance module can help
assist operators and field service
personnel in their day-to-day
operation of General Electric
aero-derivative gas turbines.
The module gathers and ana-
lyzes real-time data to calculate
thermodynamic performance.
Its outputs are ISO-reference
and humidity corrected, specifi-
cally for the General Electric
LM series gas turbines. Its open
architecture supports OPC and
DDE servers. The module is
f lexible and can monitor mul-
tiple trains simultaneously, even
when controlled by different
processors and control systems.
Users also can select from
multiple graph formats or create
trends from stored data.
Dresser-Rand
713-354-6100
www.dresser-rand.com
Video System Boasts High
Resolution Monitoring
The RD-MZ-3630-01 rapid-de-
ploy wireless video system con-
sists of a high-definition color
camera and an internal wireless
July 2011 chemicalprocessing.com
CP1107_47_52_E&S.indd 48
radio. The camera is said to be
capable of transmitting over 30
frames per second of video in
1,280 × 1,024 resolution. Its IR
illuminator provides high-reso-
lution images from over 200 ft
in complete darkness. The sys-
tem connects wirelessly to an IP
network for remote viewing and
recording. Its clasping hooks
can attach to rails and walls up
to 1½-in. thick. The antenna is
mounted on an ultra-high-pull
encased neodymium-iron-boron
rare-earth magnetic base for
secure mounting to sites that
may move or vibrate.
Industrial Video & Control
617-467-3059
www.ivcco.com
Valve Block Reduces
Operating Torque
The Series BBV-0 two-valve block
manifold is considered suitable
for use over a broad range of pro-
cessing applications. The Series
BBV-0 is forged from 316 stain-
48
less steel bar stock and designed
to withstand repeated open and
close cycles. Suited to control oil,
water, toxic fluids, chemicals, air
and steam, the two-valve block
manifold has one isolate and
one vent valve. Each valve stem
is precision machined with hard
seats to reduce operating torque,
the company says.
Dwyer Instruments, Inc.
800-872-9141
www.dwyer-inst.com
Compressor Boasts
Energy Efficiency
The ZH 350+ three-stage turbo
oil-free air compressor is designed
for use in industries that rely on
100% oil-free air. The compres-
sor’s three-stage design helps it
achieve compression between
100 and 160 psi while minimiz-
ing power use, says the company.
The ZH 350+ has no gearbox
— thus eliminating transmission
losses that can reportedly reduce
energy efficiency by up to 9% in
compressors in the 350-kW range.
Its titanium impellers are said to
permit faster load/unload cycles,
allowing for rapid speed changes
which cut power loss during times
of low-air demand. The compres-
sor features optimally sized coolers
that can help reduce pressure
drop.
Atlas Copco
866-546-3588
www.atlascopco.com
Vent Heads Recover
Condensate
VHT vent heads can help
safely discharge dry steam to
6/27/11 2:13 PM

the atmosphere at low veloc-
ity, protecting personnel from
injury, buildings from damage
and minimizing the nuisance
of water spray on the surround-
ings. The internal drain recovers
condensate that would have
otherwise been di-
rected to an external
drain and removes
the possibility of hot
condensate exceed-
ing temperature
limitations of local
drainage. Suitable
for vertical open-ended steam
vent pipes, the vent heads are
manufactured from austen-
itic stainless steel and should
provide life-long, trouble-free
operation. They also are consid-
ered well-suited for blowdown
vessels, feed tanks and conden-
sate receivers.
Spirax Sarco, Inc.
803-714-2000
www.spirax.com
Field Wireless Devices
Follow ISA Standard
Devices based on the
ISA100.11a industrial wire-
less communications standard
include an EJX-B series dif-
ferential pressure and pres-
sure transmitter, a YTA series
temperature transmitter, and an
integrated field wireless gateway
for field sensor networks. With
the ISA100.11a standard, the
production, device diagnostic
and parameter data transferred
between a control system and
field devices are securely en-
crypted. This wireless technol-
ogy is said to be ideal for status
CP1107_47_52_E&S.indd 49
monitoring, device diagnostics
and control applications. The
devices are designed to run on
explosion-proof batteries that
can easily be replaced in hazard-
ous locations.
Yokogawa Corporation of
America
800-888-6400
www.yokogawa.com/us
Flow Meter Suits Tubing
The Traceable ultra-low-flow me-
ter features a simple four-button
operation (flow/total, units, zero
and power) and an LCD display
that shows the current and total
accumulated flow. Accuracy is
±2% full scale with liquid temper-
atures of 20° to 30°C, and ±4%
full scale for all other tempera-
tures ranging from 32° to 122°F
(0 to 50°C). User may adjust a
viscosity compensation correc-
tion. Chemically resistant nylon
⅛ barbed inlet/outlet connectors
are compatible with all types of
tubing. Housing is constructed
of chemical-resistant ABS plastic.
The meter is 6-⅝ × 4-¾ × 4-½
inches and weighs 1 lb.
Control Company
281-482-1714
www.control3.com
Cleaning System Reaches
Small Spaces
The Junior 360º silo and bin
cleaning system has been rede-
49
equipment & services
signed and now offers both a
hydraulic cutting head option
(JR360H) and the previously
available pneumatic cutting
head (JR360P). Enhanced
features include a hydrauli-
cally assisted sectional boom
that adapts to different size
vessels; cutting heads featur-
ing interchangeable blades,
f lails, or chain cutters engi-
neered to safely remove a wide
variety of materials; and a new
chain cutter or whip mounts,
which swivel into the compact
hydraulic cutting head. The
5-in. diameter hydraulic cutting
head is said to fit into extremely
small f low channels or ratholes
without losing any power or
cleaning capacity.
Mole Master
800-322-6653
www.molemaster.com
Heat Transfer System
Cuts Down Degradation
The MOS mid-size hot-oil heat
transfer system is said to assure
responsive and precise electronic
process temperature control in a
space-saving design. It’s con-
sidered ideal for applications in
reactors, evaporators, dryers,
platen pareses, heat exchangers,
roll heating or jacketed kettles,
chemicalprocessing.com July 2011
6/27/11 2:14 PM
 equipment & services
vessels and tanks. The system
provides heat transfer capabilities
to 600°F or, optionally, 650°F at
atmospheric pressure. Available
for operation from 50–150 kW,
the MOS offers SCR electronic
solid state power control. The unit
operates in a closed-loop system
using an optional cold expansion
tank, reducing the degradation of
heat transfer fluids and removing
the need for a nitrogen purge.
Chromalox
800-443-2640
www.chromalox.com
Coriolis Flow Meter
Offers High Accuracy
With its 14-inch diameter and ac-
curacy up to 0.05%, the Promass
83X/84X four-tube Coriolis mass
flowmeter is claimed to be ideal
for pipeline custody transfer and
other high-flow-rate applications
requiring reliability and low main-
tenance. The unit can measure the
mass flow, density and tempera-
ture of oil, gas and other fluids at
rates up to 4,100 tons/hr. For both
models, accuracy of the density
measurement is 0.01 g/cm3 (0.001
g/cm3 optional), while accuracy of
the temperature measurement is
0.5 °C. They also have a balanced
measuring system with high im-
munity to external pipe vibrations
and process influences, and work
in applications with entrained air.
Endress+Hauser, Inc.
317-535-7138
www.us.endress.com
Vacuum Pumps Maintain
Higher Speeds
The Dolphin LX B series liquid-
ring vacuum pumps reportedly
July 2011 chemicalprocessing.com
CP1107_47_52_E&S.indd 50
offer improved pumping speeds
at deeper vacuum levels. These
single-stage pumps provide
end vacuum levels comparable
to most two-stage designs, the
company says. All Dolphin LX
series vacuum pumps are com-
pact, feature a motor-mounted
design and considered ideal for
a wide range of wet or corrosive
applications. Standard construc-
tion includes cast iron housing,
a 316 stainless steel impel-
ler, replaceable port plate and
mechanical seal. The company
notes these rugged pumps can
replace traditional close-coupled,
separate-drive or base-mounted
liquid ring configurations.
Busch USA
800-872-7867
www.buschusa.com
Temperature Sensors
Come In Many Versions
A line of RTD and thermo-
couple sensor assemblies come
in a wide variety of configura-
tions to meet an assortment
of application requirements.
The line includes sensor heads
in aluminum, stainless steel,
cast iron, polypropylene and
explosion-proof models. Termi-
nal blocks and transmitters for
data transfer, including HART
protocol transmitters, are also
50
included. The company offers
thermocouple grounded or un-
grounded elements in types J, K,
or T. Thin film or wire-wound
type RTDs in Class A or B and
two-, three-, and four-wire mod-
els are available.
Palmer Wahl Instrumentation
Group, Inc.
800-421-2853
www.palmerwahl.com
Regulators Feature
Domeloaded Design
RHPS series domeloaded regu-
lators permit high f lows and
reportedly exhibit less droop
than spring-loaded designs in
controlling the pressure of liq-
uids and gases. The domeloaded
design relies on a pressurized
chamber above an elastomeric
diaphragm in place of a spring
to operate the regulator. De-
pending on regulator size and
configuration, inlet pressures
can range to 5,800 psig (400
bar). Regulated pressures span
1.4 to 29 psig (0.10 to 2.0 bar),
0 to 1,000 psig (0 to 70 bar),
0 to 2,900 psig (0 to 200 bar),
and 0 to 5,800 psig (0 to 400
bar). Regulators are available for
pipe sizes ranging from ¼ to 4
in. with corresponding Cv values
ranging from 0.1 to 73.
Swagelok
440-349-5934
www.swagelok.com
Meter Measures
Bi-directional Flow
The RS Series helical-screw flow
meter is based on a low-mass rotor
6/27/11 2:14 PM

design that is said to increase accu-
racy and reduce pressure drop and
response time. The double sensor
electronics allow bi-directional
flow measurement with user-select-
able resolution and signal filtering.
These features provide an accuracy
of ± 0.3% of measured value and
a repeatability of 0.05% with vis-
cosities from 1.2 to 1,000,000 cSt.
Stainless steel or cast iron construc-
tion is available with standard pres-
sure ratings of 450 bar (6,500 psi).
The meter comes in three sizes, for
flow range from 0.5 to 1,000 liters
per minute.
IC Flow Controls, Inc.
309-862-1800
www.icflow.com
Digital Flow Computer
Offers Improved Security
The Summit 8800 Digital Flow
Computer for metering, data han-
dling and system maintenance is
claimed to be ideal for a variety of
custody and process applications.
The unit contains a dedicated
microprocessor with a ¼-second
processing cycle for each input/out-
put (I/O) board rather than using
one shared processor. A removable
memory card stores data with
enough capacity for several years
of flow information. Scroll-and-
click navigation and touch-screen
CP1107_47_52_E&S.indd 51
control helps ease operation. The
device’s large color display, with
multicolor traffic-light guidance,
reportedly simplifies operations
and system maintenance. The unit
also separates fiscal and mainte-
nance data, permitting remote
maintenance without compromis-
ing security and data integrity.
Krohne
978-535-6060
www.Krohne.com/northamerica
Software Upgrade Eases
Navigation
An upgrade to the Enterprise Per-
formance Management (EPM) suite
of business intelligence and analytic
solutions improves visibility into
business operations. The upgrade
enables users to open dashboards
with or without data, includes a
“new documents” tab, and is said to
ease navigation with fewer clicks. It
also includes Sentinels functionality
to the web client, which provides
predictive analysis based on a com-
pany’s key performance indicators
(KPIs). The EPM suite includes four
modules: sales analytics, manufac-
turing, inventory, and accounts pay- tuation mounting pad per ISO5211
able/accounts receivable (AP/AR)
analytics. Customizable manage-
ment dashboards, pre-built reports
and proactive alerts reportedly allow materials include PVC and CPVC.
enterprise users to easily monitor
KPIs in real time.
Ross Systems
www.rossinc.com
Vent Prevents Potential
Dust Explosions
The MV-RD explosion vent pro-
tects personnel and equipment dur- true union ball valves are NSF and
ing deflagrations in high-cycling
or high-vacuum applications. The
vent mounts on enclosures where
dust explosions may occur, and ac- www.haywardflowcontrol.com
tivates to safely relieve pressure in
the event of a deflagration, thereby Kink-Resistant Hose
preventing a large explosion. The
MV-RD can also be used on bulk
storage units and in ductwork re-
51
equipment & services
quiring a square explosion vent. Its
high-vacuum rating (-12 psig/24.4
inHg) helps extend the life of the
vent. The MV-RD’s lower burst
pressures give users the ability to
reach required relief area without
increasing vent size. The vent oper-
ates in temperatures up to 450°F.
Oseco
800-395-3475
www.oseco.com
Ball Valve Includes
Actuation-Ready Features
The large diameter TB Series true
union ball valve incorporates an ac-
and an integral panel mount foot
pad. Sizes range from 2½-in.
(DN63) to 6 in. (DN150). Available
The valve is pressure rated at 235 psi
non-shock. It features low torque
ratings, a full port design, FPM or
EDPM seals, reversible PTFE seats
and double O-ring stem seals. The
valve is interchangeable with earlier
TB Series valves of the same diam-
eter and end connections. TB Series
ANSI 61 listed.
Hayward Flow Control
888-429-4635
Extends Service Life
The Chemfluor Convoflex WCSR
multipurpose chemical trans-
chemicalprocessing.com July 2011
6/27/11 2:14 PM
 equipment & services
fer hose reportedly is designed
to prevent corrosive chemicals
such as acids from damaging the
stainless steel braid commonly
used on hoses for bulk chemical
transfer. The Chemfluor hose is
claimed to provide longer service
life while enhancing plant and
worker safety. Its low profile, heli-
cal convoluted inner core design
provides flexibility, while prevent-
ing kinking — a common cause
of downtime. An acid-resistant
EPDM outer cover protects the
hose when acid or other corrosive
chemicals are accidentally exposed
to the outer surface.
Saint-Gobain Performance Plastics
www.plastics.saint-gobain.com
Seal Design Speeds Up
Replacement
The ChemSeal line of mechanical
seals is designed specifically for
agitator service. The agitator seal
features high runout, reverse rota-
tion and reverse pressure capability.
The line includes both single and
double cartridge configurations for
easy installation and maintenance.
The seals reportedly can be readily
removed from the agitator as a
complete assembly and quickly
repaired on the workbench before
re-installation, saving maintenance
time and effort. The “swing-out”
agitator seal change design also
is said to speed up seal replace-
July 2011 chemicalprocessing.com
CP1107_47_52_E&S.indd 52
ment, helping reduce maintenance
costs. ChemSeals are available in a
variety of materials to meet critical
temperature and pressure ratings.
Chemineer, Inc.
937-454-3200
www.chemineer.com
Tank Cleaner Handles Small
Tanks and Totes
The TankJet 75 fluid-driven tank
cleaner reportedly
provides thorough im-
pingement cleaning of
small tanks without
the expense of high
impact tank cleaners.
The unit uses external
gears to reduce nozzle
speed for improved
impact and cleaning
efficiency. Claimed
ideal for medium-im-
pact cleaning of tanks,
totes and intermediate
bulk containers, the
unit cleans tanks up
to 30 ft (9.1 m) in
diameter. Its rotating
solid stream nozzles
complete a 360° index-
ing pattern every 45
revolutions for full tank coverage.
The unit’s self-cleaning, flow-
through design is said to enable easy
maintenance and requires approxi-
mately five minutes for rebuilding.
Spraying Systems Co.
630-665-5000
www.tankjet.com
Hydrocylcone System Suits
Slurries
Hydrocyclone systems reportedly
provide an economical and effective
method for removing solid particles
in the 4 to 100+ micron range from
slurries. Hydrocyclones typically
make finer separations than are
practical with screening separators
and at significantly higher capaci-
ties. In many applications, cyclones
can be used in place of decanting
52
centrifuges, providing the desired
result at lower cost, the company
says. Hydrocyclones are supplied
in either an open-manifold or a
packed-vessel configuration. Both
configurations can process feed
rates from 10 to 3,000 gallons per
minute, depending on the size and
number of hydrocyclones installed
in the system.
Sweco
859-371-4360
www.sweco.com
Plant Design Software
Adds New Features
The CADWorx 2012 Plant Design
Suite for AutoCAD-based projects
and workgroups includes a new
discontinuity palette for showing
component discontinuities and
overlaps in the model, with full
reporting capabilities. The software
also is compatible with AutoCAD
2012, the latest release from Au-
todesk. An improved pipe support
module provides more flexibility
in pipe support placement and
extends bills of material capabili-
ties to pipe support subassemblies.
The CADWorx Plant Professional
equipment module includes a new
center-of-gravity calculator for mod-
eling equipment and for vessels and
exchangers. Designers can also add
stiffening rings internally and orient
rings around their primary axes.
Intergraph CADWorx & Analysis
Solutions
www.coade.com
6/27/11 2:14 PM
 Register now! 2011 CP PANEL DISCUSSION WEBCAST SERIES!
Join Chemical Processing editors and industry experts as we engage in lively discussions about
strategies, industry challenges and solutions during our CP Panel Discussion Webcasts. Each 60
minute Webcast features experts on the topic being discussed and will also include a Q&A session
with all attendees. Register now for the remaining CP Panel Discussion Webcasts at
www.ChemicalProcessing.com/cpseries

Next up! Additional 2011 CP Panel

CFATS & MTSA Security: Tips & Regulatory Updates Discussion topics include:
Date: Thursday, August 18, 2011
Time: 1 - 2 pm, EST Process Safety – Sept.
Many petrochemical companies are faced with the challenge of managing security
compliance programs including CFATS and MTSA. Join us for a NEW 60-minute panel
Energy Efficiency – Oct.
discussion regarding these regulations. Speakers will discuss MTSA II & Harmonization
with CFATS, as well as recent Personnel Surety updates and more.
Learn about the latest legislative updates and their impact on manufacturing, storage
Dry Materials Handling – Nov.
and the use of Chemicals of Interest (COIs) – plus practical tips for compliance. Hear
from industry professionals who have assisted companies with compliance at many Tier Dust Control – Dec.
1-4 CFATS sites, as well as MTSA sites. Register now!
CP Discussions Now Available
Asset Management – On-Demand:
Comprehensive Asset Management Makes Wireless Easy
Date: Thursday, August 25, 2011
Dust Control
Time: 2 - 3 pm, EST
Getting the most out of equipment for efficient and economic plant operations is a
goal for every facility. In an ever-evolving competitive industry, asset management
Alarm Management
often is the one factor that sets companies apart. This discussion will provide practical
pointers for optimizing asset use, improving efficiency and lowering maintenance costs. Emissions
Learn best practices for planning and implementing your wireless network to shift from
reactive and preventive to predictive and proactive maintenance. Also learn the benefits Condition Monitoring
of wirelessly monitoring vibration of any mechanical asset—compressors, motors,
pumps, fans, gearboxes—to detect typical machine problems. Identify developing Energy Efficiency
problems before they become significant and cause plant upsets.

For more information on each of these exciting 60-minute Webcasts,

to watch on demand Webcasts and to register, go to:
www.ChemicalProcessing.com/cpseries

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Product Spotlight

Saflex™ 2000 tube bundle
cleaning system
The Saflex™ 2000 from NLB cleans
twice as fast as manual water jetting,
operating at pressures up to 40,000
psi (2,800 bar). An operator feeds
the lances in and out with push-button
controls, or from a distance with an
optional X-Y positioner and wireless
controls. The system is adjustable for
tube diameters from 4mm to 15mm.
ad-liTs
PumP load control
The PMP-25 pump load control guards against dry running,
cavitation and overload. It monitors true pump power for maxi-
mum sensitivity. The display shows pump load, trip points and
delays. Its NEMA 4X enclosure is small enough to fit on Size 1
starters and can be door-, panel- or wall-mounted. Load Controls
Inc., (888) 600-3247, www.loadcontrols.com.

atomizing SPray nozzlE for HigH ViScoSity fluidS

NLB Corp.
The XAER air atomizing spray nozzle provides a full cone round
(248) 624-5555
www.nlbcorp.com spray pattern that is especially suited for liquids with a high
viscosity. It operates with an external mix, which means the
atomization of the fluid takes place outside the nozzle. As the
XAER is an external mix, (as opposed to an internal mix), the
flow rate is not dependent on the air pressure, which results in
easier control. BETE Fog Nozzle, Inc., 50 Greenfield Street,
Greenfield, MA 01301, T (413)772-2166, F (413)772-6729, www.bete.com,
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CP0902_Autocon_R1.pdf 1 2/26/09 3:27 PM

Equipment

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55
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CP1107_55_57_CLASS.indd 55 6/27/11 3:17 PM
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CP1107_55_57_CLASS.indd 56 6/27/11 3:50 PM

 CLASSIFIED

Boiler ad 2.25_x 6 3/28/08 3/28/08 1:14 P

Equipment MACHINERY INC.
AADVANCED Custom Services

• •
• BOILERSFOR• SALE WANTED TO BUY
• SELL • RENT• LEASE •
• - 24 / 7Tablet/Compacting
- •
Briquetting Presses OLD PLASTIC
• SERVICE 1-SH•
Fitzmills, J, D-6
EMERGENCY Micropulverizer, PREFORM
• PK Blenders, Lab up • to 30 cu.ft. MOLDING PRESSES
• • R-7
Patterson Dbl. Cone Blender, 40 e.f.
Elrich Mixers, RO2VAK, Baldwin Defiance #20, #45
• • FKM-300, FKM-600
Littleford Mixers, FM-130,
Defiance #20, #45
• • 60-S
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Union Process Attritors,
• Sweco Grinding Mills,•DM-1, DM-3, Urethane
Stokes Machines - All Models
IMMEDIATE DELIVERY
• •
Stokes Oscillating Grinders KOMAGE #K-15, #K50
CALL: 800-704-2002
Sales Offices
• • 2hp, L550
Day Pony Mixer, 25 gal. 55
Meyers Dual shaft disperser, Bipel Preformers
PUBLISHING HEADQUARTERS
• 10HP TO 250,000#/hr Replacement parts for • Stokes Presses F/F-4, ANY CONDITION
• 250,000#/hr
150,000#/hr
Nebraska
Nebraska
T/T-4, R/R-4750 psig
Replacement parts for
1025 psig • Stokes Oscillating
750OTTF
900OTTF
• 150,000#/hr
150,000#/hr
Nebraska
Nebraska
Granulators 750 psig
350 psig • 750OTTF Aadvanced
555 W. Pierce Road,
(586) 790-1717
Machinery
Suite 301

• •
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115,000#/hr Nebraska 350 psig Phone: 630-467-1300 • Fax: 630-467-1109
80,000#/hr Nebraska ALL EQUIPMENT IN STOCK!
750 psig Fax. (586) 790-1871
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2000 psig
350 psig • 800OTTF
Web site: www.chemicalprocessing.com
Email: Service@aadvancedmach.com
• 70,000#/hr
60,000#/hr
Nebraska
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AADVANCED MACHINERY,
750 psig
350 psig • 750OTTF INC.
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• 40,000#/hr
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Erie City
350 psig
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Phone: 630-467-1300, x411

• 10-1000HP Firetube 15-600 psig

• Fax. (586) 790-1871
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Phone: 630-467-1300, x314
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350 psig
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• •
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40,000#/hr Nebraska 350 psig Email: mconnaughton@putman.net

• 30,000#/hr
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• wabash POWER
•
EQUIPMENT CO.
ADVERTISER INDEX

• •
ADVERTISER PG #
444 Carpenter Avenue, Wheeling, IL 60090 ADT Security Services 15
Baldor Electric Co. 60
BASF Catalysts LLC 27
Centrifuges Bete Fog Nozzle 8,55
AADVANCED MACHINERY INC.
Horizontal Peeler Centrifuges Inverting Filter Centrifuges Cashco, Inc. / Valve Concepts 46
Newly acquired Comber Nutsche Dynamic Air, Inc. 14
Vertical Basket Centrifuges Filter-Dryers available Emerson Process Mgmt - Fisher 10
856-467-3399
Quality & Service First Emerson Process Mgmt/Plantweb 4
BUY & SELL MACHINERY
www.heinkelusa.com Emerson/Rosemount Inc. 25
586-790-1717 • service@aadvancedmach.com Endress + Hauser 6
WWW.AADVANCEDMACH.COM Greene Tweed 44
Hapman Conveyors 12
International Exposition Company 59
Load Controls Incorporated 55

LOOKING TO
Material Transfer & Storage, Inc. 46
Micro Motion, Inc. 17
MSA Instrument Division 42
Omega Engineering 3,54

ADVERTISE?
Paratherm Corporation 16
Putman Media 53
Siemens Process Automation 18
Sullair Corporation 2
Vega Americas, Inc. 20
Contact Polly Dickson at pdickson@putman.net or 630-467-1300 x396 Victory Energy 31

57 CHEMICALPROCESSING.COM JULY 2011

CP1107_55_57_CLASS.indd 57 6/27/11 3:18 PM

 enD poinT
Energy Policies threaten U.K. Chemical Firms
Government plans call for a 60% reduction in emissions by 2030
U.K. EnErgy Secretary Chris Huhne has been
warned that his “blinkered and dogmatic” energy
policies pose a threat to the country’s £60 billion
($98 billion) chemical industry and its 600,000 jobs.
The charge is made in “Chain Reactions: How
the Chemical Industry Can Shrink Our Carbon
Footprint,” a report compiled by independent civil
New carbon policy think tank Civitas, London. The author,
Civitas research fellow David Merlin-Jones, argues
budget could that by pricing energy-intensive industries out of the
smother U.K. via green levies and taxes, the “greenest gov-
ernment ever” is actually smothering the emerging
emerging green low-carbon economy.
companies. Huhne proposes plans for a 60% reduction in
emissions by 2030, which Merlin-Jones says is too
much, too soon. “A better way to tackle climate
change is not through the hasty decimation of
industry, but the long-term nurturing of existing
low-carbon innovation as found in the chemical
sector,” he writes.
In the report’s foreword, Brendan Barber,
general secretary of the Trades Union Congress,
London, notes that at this crucial moment in energy
policy making, the government must strike the right
balance between its climate change and industrial
polices.
Merlin-Jones reports that, on average, for every
metric ton of carbon dioxide used in the chemicals
industry, two metric tons are saved down the line.
This ratio could double to 4:1, provided that the
government policy fostered — rather than punished
— the sector.
However, short-term green policies have failed
to take into account long-term emission reductions
offered by the chemicals industry, he notes. For in-
stance, insulating materials have an emissions saving
ratio of 233:1.
At the heart of the problem is the U.K.’s 2011
budget, which promises a carbon price floor.
Current plans are set to push the price to £30/mt
($49/mt) of carbon dioxide by 2020. This doesn’t
take into account other levies such as the Renew-
able Obligation (see, http://docs.wind-watch.org/
renewables-obligation-paper.pdf). When all of these
are pooled together, Merlin-Jones says the average
energy-intensive company’s utility bill is set to rise
from £3 million ($4.9 million) to £17.5 million
($28.7 million) by 2020.
Meanwhile, Huhne argues that his plan for a
July 2011 chemicalprocessing.com 58
CP1107_58_EndPoint.indd 58
60% reduction in carbon dioxide emissions by 2020
(versus a1990 reference point) — 14% higher than
the European Union’s goal — is necessary “for our
sheer economic self interest — precisely because it
will send out clearer carbon price signals and allow
us to develop more rapidly across all those low-
carbon sectors.”
Not so, contends Merlin-Jones: “There’s no eco-
nomic benefit to pricing ourselves above competitors.
Moreover, unrealistic goals have created an approach
that relies on forcing out the chemicals sector, de-
spite the fact that its developments are the only way
to reach the long-term target of an 80% reduction by
2050 — let alone the huge leap of an extra 40% cut
in ten years from 2020–30.”
However, the author also points out that all is
not yet lost: “Huhne’s 60% plans are not yet en-
shrined in law, nor is the carbon price floor. There
is no reason Britain can’t maintain parity with
European energy costs. Image is not everything
and green policies should not be driven to the point
where they undermine actual emission reduction.
It’s not an either/or situation: there is no reason
Britain can’t support industry and reduce its carbon
emissions. If energy costs are kept competitive, the
U.K. will create the fertile environment required to
produce a low-carbon industrial renaissance.”
For its part, the Chemical Industries Associa-
tion (CIA), London, recognizes that the sector
faces a new competitiveness challenge. Reacting
to Huhne’s announcement, CIA boss Steve Elliott
acknowledges the government’s acceptance of the
need for transition measures, but cautions that
unless these measures are effective, energy-related
costs (already the highest in Europe) could rise
from 10% to over 100% of profits — turning suc-
cessful green product companies into loss-making
concerns.
Elliott notes the chemical and other industries
want to work with government to make sure the
green future can be delivered. However, if measures
are half-hearted, manufacturing jobs and compa-
nies delivering low carbon solutions will be ripped
out of the industrial heartlands of the U.K. with
very little prospect of new businesses willing to
invest.
SEán ottEwEll, Editor at Large
sottewell@putman.net
6/27/11 2:15 PM
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