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Page 1
reliability
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12/13/07 3:21:25 PM
Color: 4c
Bleed: 8.125 x 11
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1 CHE 1-08.indd 1
12/17/07 3:27:05 PM
Circle 05 on p. 58 or go to adlinks.che.com/7368-05
2 CHE 1-08.indd 2
12/13/07 3:26:06 PM
JANUARY 2008
IN THIS ISSUE
COVER STORY
30 Cover Story
www.che.com
Controlling SO2
Without Corroding
the Bottom Line
Mist Eliminators in wet
scrubbers comprise a
large portion of system
operating costs. Consider these material
selection and replacement criteria to curb
chronic maintenance
requirements
5 Editors Page
2008: Climate still
on the plate A
number of policy
developments are in
the works, and CPI
companies appear to
be taking their own
initiatives
DEPARTMENTS
Letters . . . . . . . . . . . 6
Bookshelf . . . . . . . . 8,9
NEWS
Whos Who. . . . . . . 28
11 Chementator Save space, money and water with this new clarifier process; A new off-shore
Reader
Service page . . . . . . 58
GTL production system takes advantage of microchannel reactors; This CO2-recovery process
set to enhance EOR; Using living plants to synthesize metallic nanoparticles; This solar reactor
will recycle carbon dioxide; Purification of single-walled using froth flotation; Commercialization is set for a Fischer-Tropsch process; Turning dishwashing waste into fuel; and more
38 Feature Report Integrated Computerized Maintenance Management Systems For Effective Plant Performance
Controlling gigabytes of predictive maintenance data isnt easy, but its essential for
streamlining your process
44 Engineering Practice Seal-Fluid-Circulation Devices: Understanding the Differences Knowing the options in fluid-circulation designs helps in the selection process
48 Operations and Maintenance Technology and Scheduling: The Perfect Chemistry By utilizing efficient scheduling software, companies in the CPI can improve
enterprise agility and compliance
Economic
Indicators . . . . . 59, 60
ADVERTISERS
ADV
Product Showcase . . . 50
Classified
Advertising . . . . .5156
Advertiser Index . . . 57
COMING
IN FEBRUARY
Look for: Feature
Reports on CPI WaterSteam Chemistry; and
Recommended Safety
Practices for Pumps
Handling Hazardous Liquids; A Solids
Processing article on
Coatings for Bins &
Silos; An Environmental Manager article on
Hydrocarbon Leaks in
Cooling Water Systems
Effects and Remedies; A You and Your
Job article on When
It Becomes Necessary
to Fire an Employee; A
Focus on Flowmeters;
News articles on Electronic Chemicals; and
Asset Management;
Facts at Your Fingertips on Pressure Relief;
and more
Cover: David Whitcher
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4 CHE 1-08.indd 4
12/13/07 3:18:09 PM
NELLA VELDRAN
DAVID WHITCHER
EDITORS
REBEKKAH J. MARSHALL
Editor in Chief
rmarshall@che.com
Art Director
dwhitcher@che.com
DOROTHY LOZOWSKI
MICHAEL D. KRAUS
GERALD ONDREY
STEVE OLSON
Managing Editor
dlozowski@che.com
(Frankfurt)
Senior Editor
gondrey@che.com
MATTHEW PHELAN
Assistant Editor
mphelan@che.com
KATE TORZEWSKI
Editorial Assistant
ktorzewski@che.com
CORRESPONDENTS
GERALD PARKINSON
(California) gparkinson@che.com
EDITORIAL
ADVISORY BOARD
JOHN CARSON
DAVID DICKEY
MixTech, Inc.
MUKESH DOBLE
IIT Madras, India
WILLIAM C. GRAHAM
Ad Production Manager
bgraham@che.com
MARKETING
HOLLY ROUNTREE
Marketing Manager
hrountree@accessintel.com
AUDIENCE
DEVELOPMENT
SYLVIA SIERRA
JOHN ROCKWELL
Vice President,
Audience Development Chemical
jrockwell@accessintel.com
LAURIE HOFMANN
TERRY BEST
GEORGE SEVERINE
Fulfillment Manager
gseverine@accessintel.com
CHRISTIE LAMONT
HENRY KISTER
TREVOR KLETZ
DANA D. CAREY
Fluor Corp.
GERHARD KREYSA
DECHEMA e.V.
RAM RAMACHANDRAN
BOC
INFORMATION SERVICES
ROBERT PACIOREK
JOHN STRAZZA
Director of eMedia
jstrazza@accessintel.com
CHARLES SANDS
Senior Developer
Web/business Applications Architect
csands@accessintel.com
PECK SIM
Senior Manager,
Conference Programming
psim@chemweek.com
BEATRIZ SUAREZ
STEVE BARBER
JOHN PEARSON
Divisional President
jpearson@accessintel.com
HEADQUARTERS
110 William Street, 11th Floor, New York, NY 10038, U.S.
Tel: 212-621-4674
Fax: 212-621-4694
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For photocopy or reuse requests: 800-772-3350 or info@copyright.com
Editors Page
Letters
Opinion on ChE graduate shortages
Your editorial (Calling all chemical engineers, Sept., p.
5) on the subject of the lack of entrants to chemical engineering studies and careers invited readers to reply.
I think that this problem will not go away until the
industries desiring chemical engineers examine the
source of the problem.
In my opinion any high school leaver with more
brains than a sausage will have noticed the fact
that chemical engineers are downsized in wholesale
amounts. For instance, recently the pharmaceutical industry has tossed out piles of chemists and chemical engineers; the Wall Street Journal last [month] described
how Pfizer has thrown out the guys who developed
drugs and brought Pfizer billions.
Under the circumstances I cannot blame them for
choosing other, hopefully more secure, professions, and
ignoring we desperately need chemical engineers
type hype.
Regards,
Solly Zitron
Samuel Engineering, Inc., Greenwood Village, Colo.
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Do you have
Ideas to air?
Feedback about our articles?
Comments about todays
engineering practice or education?
Job-related problems or gripes to share?
If so Send them, for our Letters column, to
Rebekkah Marshall
Chemical Engineering, Access Intelligence,
110 William St., 11th floor
New York, NY 10038; letters@che.com
6 CHE 1-08.indd 6
12/26/07 1:48:46 PM
Warning
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One more reason ITT should be your choice for all critical pumping needs. Call
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Goulds Pumps
Circle 08 on p. 58 or go to adlinks.che.com/7368-08
7 CHE 1-08.indd 7
12/13/07 3:24:18 PM
Bookshelf
Introduction to Process Engineering
& Design. By S. B. Thakore and B. I.
Bhatt. Tata McGraw Hill, B-4, Sector
63, Distt. Gautam Budh Nagar, Noida,
UP-201301. Web: tatamcgrawhill.com.
2007. 768 pages, Rs 500.
his book is intended as a textbook for an undergraduate process design course in a chemical or
petroleum engineering program. It can also serve as
a useful reference guide for practicing process engineers.
The authors have extensive experience in industry as well
as in teaching. The book is organized into ten chapters.
The first four chapters deal with basic material, including units and dimensions, stoichiometry, general process
engineering considerations, and process flowsheets. The
remaining chapters focus on the design of piping and
fluid-flow systems, heat exchangers, liquid-liquid extractors, distillation columns, absorbers and chemical reactors.
The chapter on the design of piping and fluid-flow sysBeltran_Wet Precipitators_Rev:Layout 1 12/6/07 4:55 PM
tems includes pressure-drop calculations through pipes,
Circle 09 on p. 58 or go to adlinks.che.com/7368-09
valves, and fittings; design of pumps and compressors;
and the design of flow meters, including orifice plates and
rotameters. A very brief discussion on two-phase flow is
included as well.
The chapter on the design of heat exchangers is quite
extensive and includes shell-and-tube heat exchangers,
plate-and-frame heat exchangers, reboilers, vaporizers,
air-cooled heat exchangers and air heaters, heat-exchanger networks and energy integration.
The chapter on liquid-liquid extraction includes a
discussion of desirable solvent properties and selection,
design of counter-current multistage extraction units and
supercritical extraction.
Acid Mists
The design of distillation columns is the focus of the
next chapter, which includes a discussion of the McCabe SO3 Plumes
Thiele and Ponchon-Savarit methods for binary distil Submicron
lation and the Fenske-Underwood-Gilliland method for
Particulates
multicomponent distillation. More rigorous methods are
Opacity
also presented, including Lewis-Matheson, Thiele-Geddes
and equation-tearing procedures. There is considerable
Heavy Metals
discussion with regard to the design of trays and column
Enables the use
internals. Batch distillation, short-path distillation, reactive and catalytic distillation, and azeotropic distillation
of heavy oil/coal
are also presented.
instead of more
The chapter on absorbers includes the design of packed
expensive low-sulfur
towers, spray towers, and falling-film absorbers.
refined fuels.
The design of chemical reactors is presented in a chapter that focuses on batch reactors, continuous flow reactors, bubble columns and fixed catalyst beds. There is also
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the book. Practical advice and examples of important in-
WET ELECTROSTATIC
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Circle 10 on p. 58 or go to adlinks.che.com/7368-10
12/26/07 1:53:42 PM
Circle 11 on p. 58 or go to
adlinks.che.com/7368-11
12/26/07 1:54:10 PM
In the auto
industry, no one
drives faster
than Uniseal.
Uniseal is known throughout
the OEM auto industry as a
premier supplier of structural
adhesive and sealant systems.
With fast-moving R&D,
custom formulations and
superb quality, its easy to
see why this company has
been so successful.
To keep production in the
passing lane, Uniseal relies on
the finest equipment available
anywhere for high-viscosity vacuum
mixing: 10- to 1,500-gallon double
planetary and triple-shaft mixers
engineered right here at Ross.
Wed like to help you succeed, too.
Call 1-800-243-ROSS.
Or visit www.mixers.com.
Tom DiGiannurio,
Senior Engineer,
Ross Employee Owner
Circle 12 on p. 58 or go to adlinks.che.com/7368-12
January 2008
enhance heat-transfer efficiency and increase the reaction speed, thereby improving productivity at lower capital costs, says
TEC. In addition, the new reactor system
can utilize a highly active catalysts with
tailored properties, says TEC.
TEC will design the GTL plant, based on
the microchannel reactor system developed
by Velocys, and Modec will construct a sea
vessel (platform or ship). A 50-bbl/d test
plant of the microreactor system is planned
for the U.S. in the near future. After the
confirmation test, the group plans to build
a 1,000-bbl/d commercial facility on a platform or ship in 2013.
Investment costs for a 1,000-bbl/d plant
are estimated to be about $73 million. The
total cost for the entire FPSO (floating,
processing, storage, and offloading) platform, including a 5,00015,000-bbl/d GTL
production plant, is estimated at $455910
million. The group expects the new system
will be profitable if future oil prices continue to be over $3040/bbl.
Self-powered sensor
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controlled by varying the plants growth conditions. The group soaked plant seeds in 5%
H2O2 for 15 min. (to avoid fungal contamination) and then washed them thrice with deionized water. The plants were grown under artificial light, for three to four weeks. The plants
were then transferred to Petri plates containing solutions of CoCO3, ZnCl2, CuSO4.5H2O,
Ni(NO3)2.6H2O, AgNO3, and KAuCl4.
B. juncea showed the greater ability to accumulate all of the metals investigated. With
all species, the greater the plant concentration
and substrate-metal concentration, the greater
the metal uptake. Also, the metals accumulated far more in the roots than in the shoots.
Ag was most readily accumulated, to a maximum of 9.2% on a dry weight basis, followed
by Au (5%), both with Indian mustard. Co was
the least extracted (1.5 wt.% maximum).
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Circle 13 on p. 58 or go to adlinks.che.com/7368-13
12/26/07 2:00:21 PM
Turning dishwashing
waste into fuel
Algae-to-fuel
Circle 14 on p. 58 or go to adlinks.che.com/7368-14
12/26/07 2:00:57 PM
Newsfront
CPI CA
CAPITAL S
SPENDING
NG
OUTLOOK
FOR 2008 & 2009
ACCs chief economist says growth
will moderate in the near future
Thomas Kevin Swift
American Chemistry Council
Economic environment
The U.S. economy has clearly lost momentum, but despite the downturn in
housing, growth outside of housing
has been strong, driven by a surge in
exports and by resiliency in consumer
spending. The latter has been robust
as a result of sustained job creation
and strong income gains but growth
should slow in wake of negativewealth effects from falling home prices
and tighter credit. Any additional significant weakening of housing along
with a slowdown in job creation has
the potential to create the conditions
consistent with a recession scenario.
According to the International Mon-
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Bioengineering
Inversina
the gentle way
of mixing.
The Inversina mixes solids or liquids
thoroughly and efficiently. The process
is clean, because mixing takes place in
closed containers that can be quickly
interchanged. The Inversina mixes a
diverse range of components rapidly
and in an extremely gentle way.
Segregation does not occur, even
after extended mixing times, by virtue
of the eversion phenomenon ( Paul
Schatz principle ) .
Applications for the Inversina: analytical labs, metal finishing shops, powder
metallurgy and nuclear industry,
manufacture of batteries, cement,
ceramics, cosmetics, dental products,
diamond tools, dyes and pigments,
electrical and electronic devices,
explosives and pyrotechnics, foods,
homeopathic products, household
products, medicines and pharmaceuticals, plastics, printing inks and many
other products. The Bioengineering
Inversina is available with capacities
of 2, 20, 50, 100 and 300 L .
Bioengineering, Inc.
Waltham, MA 02451, USA
Bioengineering AG
8636 Wald, Switzerland
info@bioengineering.ch
www.bioengineering.ch
Circle 15 on p. 58 or go to
adlinks.che.com/7368-15
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Newsfront
Emissions Compliance
Through Catalyst Innovation,
Experience & Nanotechnology
Circle 16 on p. 58 or go to adlinks.che.com/7368-16
18
12/26/07 1:45:47 PM
T-0630 4 Product
and other factors. This pushed spending down to a trough of $112 billion in
2001, an overall decline of 10%. Since
then, spending has surged, increasing
71%, with the global business of chemistry investing $191 billion in new
plant and equipment (P&E) during
2006. The data presented in the chart
are presented for the first time to the
public. ACC does not adjust its historical figures for inflation to attempt constant dollar comparisons, but backof-the-envelope calculations show
substantially more is invested today
than a decade ago.
Capacity utilization rates are relatively good as are profit margins in
much of the world. Additional growth
in demand is expected and the cost
of credit is still modest. In addition,
availability of credit does not appear
to be a problem. As a result, the global
outlook for spending is positive. As
the current investment cycle further
matures, capital spending will increase 15.5% to $223 billion in 2007.
Given announced projects and industry dynamics, the global investment
cycle will continue, with additional
strong but maturing growth prospects. Global capital spending by the
business of chemistry is expected to
increase 14.8% to $256 billion in 2008
and decelerate, increasing only 12.3%
to $284 billion in 2009. Prospects beyond 2009 are less certain.
The bulk of the additional investment will arise in the Asia-Pacific
region, which will account for 58% of
the incremental gain during the 2006
to 2009 period. Africa and the Middle
East will account for nearly 15% of the
incremental gain. The developed nations of North America and Western
Europe will account for less.
Turning to the U.S., the accompanying chart (Figure 1) illustrates that the
past peak in capital spending occurred
in 1996. The worst business conditions in a generation led to a difficult
environment for capital spending by
the business of chemistry, especially
during the 2000 through 2003 period.
Lingering uncertainty concerning future demand combined with volatile
feedstock and other energy costs hindered capital investment. As a result,
sustaining capital played a large role
earlier this decade, and for a number
5/13/05
8:03 AM
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12/26/07 1:46:12 PM
Newsfront
of years capital spending was actually
below depreciation levels.
Capital spending cycles generally
lag cycles of industry activity. Improved profit margins set the stage for
moderate increases in new plant and
equipment (P&E) investment. Improving capacity utilization rates could
trigger renewed capital spending by
Summary
Author
Circle 18 on p. 58 or go to adlinks.che.com/7368-18
20
12/26/07 1:47:09 PM
Newsfront
CLEANING UP WITH
CATALYSTS
As worldwide regulations grow more
stringent, catalyst development focuses
on providing cleaner energy sources and
cleaning up air pollution
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Topse specializes in
(Columbia, Md.). By
Catalysts technology providers
building new facilities
reducing the end point
Albemarle
edlinks.che.com/7368-591
with the latest technoloof the gasoline, they are
BASF Catalysts
edlinks.che.com/7368-592
gies and catalysts necesgiving up volume. But if
Bayer
edlinks.che.com/7368-593
sary to allow refineries
we can reduce the gasoDuPont
edlinks.che.com/7368-594
to process these crudes.
line sulfur with catalysts
Haldor-Topse
edlinks.che.com/7368-595
And because the cataor additives and allow
Institute for Green Oxidation Chemistry
edlinks.che.com/7368-596
lysts feature improved
refiners to avoid underJohnson Matthey
edlinks.che.com/7368-597
catalyst activities, refincutting, it will increase
Sd-Chemie Group
edlinks.che.com/7368-598
eries can run long cycles
their yield of gasoline.
W.R. Grace
edlinks.che.com/7368-599
even with lower-quality
Similarly, Topse is
crude, explains Rasdeveloping new generamussen.
for producing cleaner transportation tions of catalysts that enable refiners
New formulations for this applica- fuels, but they also allow refiners to to make more money by processing
tion include high activities for certain get more product a plus during the more barrels of crude. Rasmussen
reactions that are beneficial when current refinery crunch.
says that Topse has optimized the
running low-quality crude. When
As a result of sulfur reductions, active sites on its catalysts, which
you run these difficult crudes, you many refiners are undercutting, or helps generate clean fuels more efalso have problems with octanes in reducing the end point of the gasoline ficiently. Using Topses BRIM techgasoline and cetanes in diesel, he because the sulfur is found in this nology, refiners are able to put about
says. These new catalysts offer good heavier boiling range of gasoline frac- 94% of the barrel into jet, diesel or
conversions of the components that tions, says Joanne Deady, vice presi- gasoline engines. This means that
provide more desirable octane and dent, marketing/research and devel- not only is more being produced, but
cetane levels.
opment with Grace Davison Refining less is going to waste as sulfur and
Chem_Eng1-1_177x123_Januar08
07.12.2007
11:33 division
Uhr Seite
1
Not only are catalysts responsible
Technologies
of W.R.
Grace carbon.
rum and
Mller D Systems
er
Contain
1.1
ums
cans
Lidded Dr
/ hopper
th bungs
Drums wi
Hoppers
Silos
rs
Containe
Valves
Butterfly
ucks
Drum Tr
www.mueller-gmbh.com
Circle 19 on p. 58 or go to adlinks.che.com/7368-19
Chemical Engineering www.che.com January 2008
23
12/26/07 1:30:35 PM
Newsfront
Todays refiners have coking technology, which helps squeeze the last
drop of transportation fuel from the
bottom of the barrel, explains Rasmussen. In the old days the stuff at
the bottom was turned into asphalt,
but now refiners can go through it
one more time and get more fuels out
of it. Fuel production is cleaner and
more efficient today than it was years
ago due to new catalyst technologies.
Air-pollution control
"IZESPQSPDFTTJOHDBUBMZTUGSPN(SBDF
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Pulse dampeners and accumulators with capacities from 0,025 to 5,500 litres.
Pressure up to 700 bar/10,000 psi. Housing in carbon steel,
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Circle 20 on p. 58 or go to adlinks.che.com/7368-20
24$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:
Newsfront
Whats next
Nominees can be from any country. They need not hold a degree
in chemical engineering. But their
achievements must have involved
use of chemical-engineering principles in solving problems, and part
of the activity must have been in
20052007.
The Personal Achievement Award
has been hailed and respected since
its inception. We welcome your nomination, to help us maintain this worthwhile activity.
Rebekkah Marshall
When thinking about whom to nominate, keep in mind that a distinguished career
can take many forms. Here, for instance, are the most recent winners:
Lawrence B. Evans has been Henry Kister, of Fluor, has Michael Lockett, of Praxair, John Pelton, also of Praxair,
cited for his leadership in devel- been hailed as the world's whose career has involved who spent over six decades
oping and applying integrated foremost authority on distilla- academe as well as industry, in industry, was the driving
systems for modeling, simula- tion and absorption trouble- may be best known for his de- force behind innovations in
tion and optimization of chemi- shooting. He has written two velopment of new distillation such fields as crystal formacal processes. After early years widely consulted engineering and heat-transfer technolo- tion and growth, high-temas a chemical engineering pro- books on distillation, as well as gies. Correlations and papers perature flame-coating, confessor at M.I.T., he devoted the over 70 articles, and has taught of his on distillation-tray ef- version of waste to fuel gas,
bulk of his career to founding courses and spearheaded sym- ficiency long have been stan- and aluminum refining
25 CHE 1-08.indd 25
25
12/27/07 1:38:09 PM
100% American-Made
Co nway, S C
26 CHE 1-08.indd 26
M a tt h ews, N C
12/20/07 6:45:00 PM
Sedimentation
Centrifuging
Department Editor: Kate Torzewski
basics of Sedimentation
Centrifuging
The mechanics of sedimentation centrifuging make it ideal for two-phase systems
with a high-density differential. As an
incoming slurry spins in a sedimentation
centrifuge, it forms an annulus adjacent to
the bowl wall. The centrifugal force causes
the denser material to move outwardly toward the wall of the centrifuge bowl, while
the liquid overflows from the bowl or is
applications
Vs
References
stoKes' law
1
7 2r ( R s
R L ) d 2
18 M
where
Vs = Settling velocity, m/s
= viscosity, kg/ms
= angular speed of rotation, rev/min
s = density of solid, kg/m3
L = density of liquid, kg/m3
d = particle diameter, m
r = centrifuge radius of curvature, m
Type
Mechanics
Tubular
Bowl
Purification of lubricating
A
vertical cylinder with the feed
The heavier phase becomes concenslurry introduced in the bottom of
trated against the wall, while the lighter
and industrial oils
the bowl
phase floats on top
Food, biochemical and
The use of a distributor and baffle The two phases are separated by a baffle
pharmaceutical applications
assembly accelerates the slurry to Liquid discharges over the top of the bowl, Solids should be less than 1%
the speed of rotation
while solid buildup is removed manually
in volume of the slurry
Multichamber
C
onstructed of a series of tubular
sections arranged concentrically
The slurry feed enters in the
smallest tube and continues
through the outer tubes as they
increase in size
Skimmer
Feed enters the hub end and
When a thick solid layer begins to form
pipe /
is accelerated to speed before
on the bowl wall, supernatent liquid is
knife
entering the separation pool
removed with a skimmer, and solids are
discharge Solids settle on the bowl wall while
knifed out with centrifugal filters
liquid overflows the ring weir
C
larifying fruit juices, wort
and beer
H
eavy-duty applications,
such as coal dewatering
Disc
Decanter
S
olids are removed from the conical
Applications that require
discharge end (the beach)
continuous removal of solids,
where feed solids are high
Bowl and conveyor rotate in the same
and volume reduction is
direction, but at different speeds, creating
important
a speed differential that controls the
speed of solid removal
A solid bowl decanter with a cylindrical screen added to the conical end
Improved cake dryness and
highest product purity
Screenbowl
27 CHE 1-08.indd 27
C
onstructed of a solid external
bowl and an internal screw
conveyor mounted horizontally
1/2/08 11:22:33 AM
People
WHOS WHO
Berendsen
Geisel
Oetinger
Maroske
Golden
Particulate Monitors
Emissions Filter Leaks Flow
ADVANCED TECHNOLOGY
PROVEN SOLUTIONS
FilterSense
1-978-927-4304
www.filtersense.com
Circle 21 on p. 58 or go to adlinks.che.com/7368-21
28
385-3c
Circle 22 on p. 58 or go to adlinks.che.com/7368-22
28 CHE 1-08.indd 28
12/26/07 1:26:18 PM
Master Bond
Spectroline
JANUARY
VICI Metronics
SKF USA
APEM
Components
$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:28D-1
New Products
Bessamaire
Fluke Corp.
28D-2$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:
Space at a premium?
Compact Fisher-Klosterman MS Series Particulate Scrubbers save
valuable plant space, allowing for additional processing equipment. Our innovative
design provides efficient particle and water droplet removal at gas velocities much higher
than larger, more expensive, traditional cyclonic separators, without the use of internal
baffles or packings. Its a system thats so efficient, we offer guaranteed performance
when provided with complete operating information.
Fisher-Klosterman will have your plant swimming in profits.
(502) 572-4000
Fax: (502) 572-4025
fki@fkinc.com
fkinc.com
Circle 25 on p. 58 or go to adlinks.che.com/7368-25
12/13/07 3:19:36 PM
New Products
DSM Somos
Palmer Wahl
Instrumentation
Group
PROTECT PUMPS
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28D-4$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:
Circle 42 on p. 58 or go to adlinks.che.com/7368-42
Alfa Laval
digital
communication protocol
that is ready for
interface to a DCS,
c o m p u t e r- b a s e d
SCADA
system
or asset-management
software.
The TFZ saves
wire and installation costs, says
the firm, by allowing up to 32 field
Moore IndustriesInternational
devices (126 with
repeaters) to be networked onto one,
low-cost FF H1 segment. It requires
only 10.5 mA for normal operation.
The bus-powered, two-wire device
sets up from the control room over
segment wiring using a standard
FF configuration tool, to handle 14
RTD types, nine thermocouple types
as well as direct millivolt and resistance/potentiometric inputs.
Moore Industries-International, Inc.,
North Hills, Calif.
edlinks.che.com/7368-396
This material has the benefits of
liquid silicone and fluorosilicone
Composed of 100% Fluoro Liquid
Silicone Rubber (F-LSR), the Silastic
elastomer is designed to meet stringent automotive engine requirements
regarding temperature, fuel and oil
specifications. F-LSR combines the
ease of processing of liquid silicone
rubber with the temperature and fuel
resistance of fluorosilicone rubber. Silastic withstands harsh fuel, lubricant
and oil environments with tempera-
Circle 28 on p. 58 or go to
adlinks.che.com/7368-28
New Products
ture resistance within the range of 60
to 220C. This material, well suited for
co-molding on thin, high precision and
intricate parts, improves manufacturing efficiency and part performance.
Dow Corning, Midland, Mich.
edlinks.che.com/7368-344
Sunlight does not impede the accuracy of this transmitter
The new version of the Mobrey
MSP900 ultrasonic level transmitter
has been optimized for use in openchannel flow measurements. The
MSP900FH (photo), which features a
pre-wired remote temperature sensor,
is ideal for helping water and industrial processing sites to comply with
MCERTS legislation. Used in the
open air, conventional U.S. level transmitters are prone to suffer from inaccuracies caused by solar gain whenthe sun shines directly on them. The
MSP900FH has been designed to overcome this problem by using a remote
Premo
Circle 20 on p. 58 or go to adlinks.che.com/7368-29
28D-
Emerson
Circle 30 on p. 58 or go to adlinks.che.com/7368-30
12/26/07 4:01:46 PM
system and new motor and drive system ensure long life and low operating cost with maintenance intervals
as long as five years, says the firm.
All pumps include RS 232/485 (Profibus) serial-communication interfaces.
Edwards, Wilmington, Mass.
edlinks.che.com/7368-394
Kate Torzewski
6/12/2007 11:05:37 AM
28D-
12/26/07 4:02:08 PM
Achieving Max
Performance with
Limited Resources.
Who Should Attend:
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Circle 27 on p. 58 or go to adlinks.che.com/7368-27
12/20/07 6:49:37 PM
ProMinent
JANUARY
Alfa Laval
$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:28I-1
Moore Industries-International
New Products
performance or service
disruption in metering
lines. The venting function is executed periodically
or after airlock detection.
ProMinentDosiertechnik GmbH,
Heidelberg, Germany
edlinks.che.com/7368-393
The latest in
RFIS antennas
This company claims to be the first
in the world to integrate three single
RFID antennas in one, monolithic
component several years ago. Since
the device was patented in 2001, the
firm has introduced a new RFID antenna (photo) that is said to offer the
maximum sensitivity in the smallest
space. It is recommended for RKES
and RFID access systems that integrate 3D identification. The antenna
is suitable for SMD mounting, offering
a flat surface for pick and place. Antennas are available for 20- and 125kHz applications. Premo Corp. S.L.,
Campanillas, Malaga, Spain
edlinks.che.com/7368-397
Valves for
LNG transportation
Liquefied natural gas (LNG) has only
one to six hundredth of the volume
of gaseous natural gas, thus is more
suited for economical transportation of large quantities; for distances
over 3,000 km, vessel transportation
of LNG is said to be more profitable
than via pipeline. Cryogenic valves
designed for use down to 196C, and
this firms bypass valves for two parallel nitrogen compressors have recently
been delivered for use on LNG vessels.
The N2 compressor is an expander
that is switched afterwards for cooling
the plant. To regulate the temperature
of this expander, the firm delivered the
temperature-control valves designed
for 196C. ARCA-Regler GmbH,
Tnisvorst, Germany
edlinks.che.com/7368-398
Up to 32 field devices
are handled by this transmitter
The TFZ Foundation-Fieldbus (FF)
Temperature Transmitter (photo) can
be installed on the same segment with
all standard FF devices. The TFZ converts a temperature sensor input to a
Premo
28I-2$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:
Edwards
bearing
turbomolecular
vacuum
pumps (photo) exhaust process gases
from physical and vapor deposition,
etching, or ion-implant equipment
in semiconductor, flat-panel display,
solar energy and industrial-glasscoating applications. The pumps feature power-supply and control modules that can be mounted in various
configurations directly on the pump,
or remotely, thereby eliminating
cables and accessory racks. The first
pump in the iXA family is rated at
2,200 L/s larger sizes are planned
for future development. The pumps
five-axis magnetic-bearing system
and new motor and drive system ensure long life and low operating cost
with maintenance intervals as long
as five years, says the firm. All pumps
include RS 232/485 (Profibus) serialcommunication interfaces. Edwards, Wilmington, Mass.
edlinks.che.com/7368-394
A new member added to this family of materials-testing machines
This firm has enhanced its range of
zwicki-Line universal testing machines. They are now available in four
load capacities (0.5-, 1.0-, 2.5- and a
new 5-kN model), and three different height combinations to suit most
applications and laboratory requirements for testing materials and components. These new products are fitted with the manufacturers latest
testControl system, and are designed
to meet the needs of both R&D laboratories and quality-assurance environments. Test and crosshead-positioning
speeds of up to 3,000 mm/min enable
high-speed tests or short cycle times,
which is useful for the testing of elastomers and springs. Zwick GmbH &
Co. KG, Ulm, Germany
edlinks.che.com/7368-399
In perfect harmony.
Excellent performance!
Berndorf Band has always worked closely
together with its customers and strives
to meet or exceed the customers steel
belt requirements. Berndorf Band can find
the right solution for any application.
Circle 32 on p. 58 or go to adlinks.che.com/7368-32
12/21/07 9:27:13 AM
New Products
This machine can wash,
dry and rinse
The T 406 machine (photo) can be used
at several places in the processing line
of plants that recycle mixed plastics
waste. It can serve as a friction washer
after the size-reduction step to unravel
paper ands separate dirty water from
the product stream. It can also be used
as a mechanical drying centrifuge at
the end of the washing process; with
hot washing systems for separating
glues, the T 406 can do the job of an
alkali separator. The unit can be supplied with drives up to 30 kW, and
will achieve a throughput of up to 2
m.t./h. Herbold Meckesheim GmbH,
Meckesheim, Germany
edlinks.che.com/7368-411
Herbold Meckesheim
WIKA
Samson
IPI Global
Pressure transmitters
made in Germany
This firm has developed an intelligent production line
for making its A-10 pressure transmitters (photo). Hardly
any solder joints are needed, and faults are avoided from
the beginning by automatic monitoring of each production
step. Only five components and nine production steps are
required to manufacture this new transmitter. Extensive
field tests have proven the A-10s capabilities under real
operating conditions, says the firm. WIKA Alexander
Wiegand GmbH & Co. KG, Klingenberg, Germany
edlinks.che.com/7368-406
Late Model
www.dovebid.com
Circle 42 on p. 58 or go to adlinks.che.com/7368-42
28I- Chemical Engineering www.che.com January 2008
hydrocarbon-processing applications. The valves are available in globe, angle and three-way body styles, in all common
pressure ratings and in all common materials of construction. The 240 and 250 Series are designed to conform with
ANSI, DIN and JIS standards and can be combined with
various flange styles and butt-weld ends. Pneumatic actuators with a rolling diaphragm and springs evenly arranged
in the actuator case are made to precisely fit on valves over
robust yokes to ensure a compact and integral control-valve
package. Samson AG, Frankfurt, Germany
edlinks.che.com/7368-405
Gerald Ondrey
12/26/07 3:50:25 PM
17-12-2007
15:36
Pagina 1
italian jewels
12/26/07 3:38:35 PM
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Circle 33 on p. 58 or go to adlinks.che.com/7368-33
28I-6]]]]]]$)&.*$"-&/(*/&&3*/(]]]]888$)&$0.]]]]+"/6"3:
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*
NEW
ROBOX evolution ES 5:
LOW PULSE
LOW NOISE
Sentinel: Electronic
monitoring system
12/13/07 3:27:27 PM
Elisabetta | Dreamstime.com
Pump innovation
Consistent investment gives
Finder Pompe the edge
12/26/07 3:40:08 PM
Circle 35 on p. 58 or go to adlinks.che.com/7368-35
Simply
a better
blower
Robuschi has a new, higher-capacity
version of its ROBOX packaged blower
Circle 38 on p. 58 or go to adlinks.che.com/7368-38
28I-10||||||CHEMICAL ENGINEERING||||WWW.CHE.COM||||JANUARY 2008
12/26/07 3:40:38 PM
Circle 41 on p. 58 or go to adlinks.che.com/7368-41
12/20/07 6:31:48 PM
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adlinks.che.com/7368-40
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Feature
Cover
Story
Report
ponents; and improve the longterm reliability of these capital- and maintenance-intensive, pollution-abatement
systems. This article presents comparisons between polysulfone and the
other prevailing materials of construction (polypropylene, FRP and stainless
steel) that are routinely used for mist
eliminators, and related brackets and
supports. The article includes data
and anecdotal evidence from three
plants that were surveyed during its
development (Table 1) the Cholla
Station for Arizona Public Service
(APS), Colstrip Montana Station for
PPL Corp., and the Gavin Station for
American Electric Power (AEP). Each
has operating experience with several
of the competing materials.
The diverse operating experience
of these utilities helps to showcase
polysulfones distinct performance
advantages over the other materials, in terms of improved short-term
thermal properties, greater longterm
load-bearing capacity and stiffness at
elevated operating temperatures, and
better resistance to fouling and oxidative attack by the alkaline-scrubbing
reagents and acid gases found inside
the wet scrubber. Common failure
modes associated with the prevailing
materials, such as melting and distortion from loading (polypropylene),
pitting and corrosion (stainless steel),
and delamination and overall degradation (FRP), are also discussed. An
* The findings discussed in this article were first
presented by these authors in a paper entitled,
Mist Eliminators Proper Material Selection
Can Reduce Maintenance Costs and Improve
Reliability in Wet Scrubbers, at the 2006 Mega
Symposium Conference.
Wet scrubbing is one of the most popular technologies for removing acid
gases, such as SO2 and HCl, from the
fluegas that is produced during coalfired power generation and industrial
combustion-related processes. Wet
scrubbers equipped with mist eliminators are not reserved solely for power
plants; rather, such systems are also
routinely used during industrial operations throughout the chemical process
industries (CPI), to capture acid and
particulate-laden fluegas streams produced by thermal oxidizers, incinerators, boilers, kilns, foundries and other
combustion units, and to treat other
sulfur- or acid-laden process-exhaust
streams produced during various petroleum refining, gas processing, petrochemical, chemical, pharmaceutical
and metals-smelting operations.
The reliable operation of wet scrubbers has a direct impact on a facilitys
ability to ensure regulatory compliance with mandated SO2 limits, and
problems with mist eliminators can
lead to unplanned or excessive downtime of the wet scrubber. Making
matters worse, when backup scrubbing capacity is not available as
was the case with the PPL Colstrip
Station surveyed during the development of this article the resulting
downtime required for mist eliminator cleaning can lead to megawatt
12/26/07 5:20:47 PM
Location
Unit number
Generating capacity
Coal used
Cholla Station
APS
Joseph City, Ariz.
2
280 MW
Lee Ranch
McKinley
Gavin Station
AEP
Winfield, W.Va.
1 and 2
2,600 MW
North
Appalachian
Colstrip Station
PPL Corp.
Colstrip, Mont.
1 and 2
716 MW
PRB
sub-bituminous
31
12/26/07 5:21:10 PM
Cover Story
3,000
2,500
PSU
Storage modulus, MPa
2,000
1,500
1,000
PP
500
0
20
70
120
170
Temperature, F
220
270
lus, toughness, rigidity and other thermal and mechanical properties at elevated temperatures, compared to the
other polymeric options. (Polysulfones
particular performance advantages in
mist eliminator applications are discussed in greater detail below.)
Stainless steel: Stainless steel is the
most costly of the four prevailing mist
eliminator materials. It is valued for
its superior mechanical strength and
rigidity under prolonged exposure to
elevated temperatures. It is also perceived to be easier to clean, because
its superior mechanical strength allows the operator to use water blasting at significantly higher pressure
to remove solids buildup. However, as
discussed below, stainless steels particular vulnerability to surface pitting
by oxidative attack makes this perception more of a misconception under
real-life, wet-scrubber conditions.
The types of problems that are routinely experienced with mist eliminators typically fall into two basic categories: Fouling and corrosion; and
heat-related damage to the mist eliminator components.
Fouling and corrosion have the biggest impact on the system operating
efficiency, and on operation and maintenance requirements. Fouling occurs
12/26/07 5:21:40 PM
when solids and salts produced during the wet scrubbing process accumulate on the chevron mist eliminators. Corrosion occurs as a result of
oxidative or chemical attack to the surfaces and crevices of mist eliminator
components, when they are exposed to
hot, moist acid gases in the wet scrubber environment.
In particular, when solids are allowed to accumulate on the surfaces
of the wet-scrubber mist eliminators,
the buildup can close off the available
open area within the chevron baffles.
This leads to increased pressure drop,
raises local velocities in the constricted
passageways, and reduces the collection efficiency of the mist eliminator,
which can result in mist carryover
out of the tower. Such solids buildup
increases the frequency and duration
of cleaning, which brings with it attendant costs associated with extensive
system downtime and maintenance.
Material buildup on the chevrons
can also result in excessive mechanical loading, which can be especially
challenging for mist eliminators and
related connectors and support bracing that are made from several of
the polymeric materials that tend to
lose their mechanical strength when
subjected to the hot, corrosive environment inside a wet scrubber. For
instance, under prolonged exposure
to elevated operating temperatures,
components made from polypropylene
can experience softening and melting.
Coupled with excessive loading from
solids buildup, this loss of thermal
and mechanical integrity can lead to
warping, buckling and the premature
failure of the components. In some
cases, polypropylene mist eliminators
require extra bracing to accommodate
the excessive load on the chevron baffles that resulted from solids buildup
(this was the case for the APS Cholla
Cleaning challenges
33
12/26/07 5:22:04 PM
Cover Story
(Figures 3, 4 and 5), while the
chevrons made from polysulfone show minimal buildup
(Figure 6; note that in this
photo, solids buildup did occur
on the polypropylene brackets
that are used to support the
Figure 3. Shown here is a polypropylene
Figure 5. During the APS Cholla experipolysulfone chevron blades).
mist eliminator with considerable solids
ment, the buildup on the stainless-steel
Based on its experiments buildup, from the trial installation at the APS
mist-eliminator chevrons occurred mainly
at the edges
comparing the four leading Cholla power plant
mist eliminator materials,
and its favorable operating
experience with polysulfone,
the APS Cholla facility is in
the process of retrofitting its
remaining wet scrubber towers in Unit 2 with mist eliminators constructed from polysulfone, as each of the existing
polypropylene mist eliminators reaches the end of its useful life. Plans are also in the
works to retrofit the existing
Figure 6. The polysulfone mist-eliminawet scrubbers in Unit 1 and
tor chevrons remained largely free of solids
Unit 4 at the same plant with Figure 4. During the APS Cholla trial instalbuildup during the APS Cholla trial, while the
polysulfone mist eliminators, lation, the mist-eliminator chevrons made from supports made from polypropylene did experiFRP
also
experienced
solids
buildup
as well.
ence the telltale solids buildup
The following section contains a more detailed discussion of
When particles are able to become a wet scrubber can also damage mist
how each of the various materials embedded in the polypropylene chev- eliminators composed of FRP, leadfares in terms of solids buildup and rons that have softened under the ing to the formation of cracks on the
surface damage under typical wet elevated temperatures found inside surface, weight loss, and reduction in
scrubber conditions.
the wet scrubber, they create a signifi- bending strength [1]. In particular,
Polypropylene: As noted earlier, cantly roughened surface on a micro- at temperatures on the order of 140
polypropylene is subject to oxida- scopic level. The resulting roughened 160F, and relative humidity in the
tion when exposed to the high tem- surface helps to explain the experience neighborhood of 85% (both of which
peratures inside a scrubber, and of many operators including those are common within a wet scrubber),
often experiences softening at el- at the APS Cholla facility who rou- FRP tends to experience hydrolytic
evated operating temperatures. A tinely report that once polypropylene attack, which weakens the bonds besurface morphology examination of mist eliminators have been put into tween the resin matrix and the glass
used polypropylene and polysulfone service, no amount of cleaning can fibers. Different rates of thermal exmist eliminator components from the ever restore the mist-eliminator chev- pansion and contraction between the
APS Cholla facility, carried out using rons to a good-as-new quality again. glass and resin matrix cause the forscanning electron microscopy (SEM), Instead, polypropylene users con- mation of tiny cracks and voids, which
revealed an interesting finding.
sistently report that after operation increases the potential for delaminaAs shown in the SEM images pro- through an initial fouling and clean- tion. The cracks and exposed glass
vided in Figures 7 and 8, the sample ing cycle, subsequent fouling seems to fibers create a rough surface, which
taken from the cleaned but aged poly- occur more frequently, and that more similar to what is experienced by
propylene mist eliminator chevron is rigorous, more-frequent offline clean- used polypropylene mist eliminators
roughened, and shows the presence of ing must be undertaken to remove the makes it difficult to restore the
embedded particles. To the operators buildup. The operators at APS Cholla, components to a truly pristine condisurprise, chemical analysis indicated when surveyed during the develop- tion during periodic cleaning.
that these particles do not contain ment of this article, summed it up this Polysulfone: When it comes to recalcium thus, they do not represent way: No matter how much we clean sistance to fouling, solids buildup,
a buildup of post-scrubbing sludge. the polypropylene, its never the same and corrosion from acid attack, the
Rather, their composition closely mim- as new packing. It just doesnt func- high-temperature engineering plastic
ics that of the ash found in the McKin- tion as well, even if it looks clean.
polysulfone shows the greatest chemiley and Lee Ranch coal that is burned FRP: As many power plant operators cal/oxidative stability in mist eliminaat the facility.
have found, the environment inside tor applications, compared to both of
34
12/26/07 5:22:55 PM
Mechanical and
thermal properties
35
12/26/07 5:23:25 PM
120
Cover Story
PSU
Percent retention
100
80
60
FRP 1
40
FRP 2
20
0
1
Months of exposure
Figure 9. Exposure to acids causes a degradation in the mechanical properties of
many polymeric materials. The laboratory data shown here illustrate the loss of flexural strength over time for both fiberglass-reinforced polymer (FRP) and polysulfone
(PSU) under simulated scrubber conditions
Economic considerations
12/26/07 5:24:56 PM
Conclusions
Acknowledgements
References
1. Nishizaki, I., and Meiarashi, S., Long-Term
Deterioration of GFRP in Water and Moist
Environments, Journal of Composites for
Construction, Vol. 6., No. 1., February 2002.
2. Shoemaker, L.E., and Crum, J.R., Experience
in Effective Application of Metallic Materials
for the Construction of FGD Systems, Special Metals Corp.
Authors
Bill Looney is senior global market manager
for Solvay Advanced Polymers, L.L.C. (4500
McGinnis Ferry Road, Alpharetta, GA 30005;
Phone: 770-772-8200; Email: bill.looney@solvay.com) with 25 years experience in high-performance polymers. For the last 15 years he has
worked extensively in helping Solvays customers understand where high performance plastics can be used to replace corrosion-resistant
metals. He earned his B.S.Ch.E from Michigan
Technological University.
Brian Baleno is a business development
representative for Solvay Advanced Polymers
(Email: brian.baleno@solvay.com). Brian has
spent nearly a decade managing material solutions for customers in automotive, aerospace,
chemical processing, healthcare and, of course,
the power plant industry.
Greg L. Boles is FGD Marketing Manager
for mist eliminators associated with scrubbers
for wet-fluegas-desulfurization applications
at Koch-Otto York Separations Technologies
(4111 East 37th Street North, Wichita, KS
67208; Phone: 316-828-5668; Email: greg.boles
@kochglitsch.com). Boles has spent 20 years
with the Koch Chemical Technology Group,
in various capacities of process design, sales,
and marketing. Greg earned his B.S. from Fort
Hays State University and M.S. from Friends
University.
Jacob Tetlow is overhaul planning manager
at the Arizona Public Service Co. Cholla Plant
(P.O. Box 188, M.S. 4455, Joseph City, AZ 86302;
Phone: 928-288-1537; Email: jtetlow@apsc.
com). He is responsible for planning, scheduling and executing overhauls on four coal fired
units. With more than 12 years of experience
in engineering, operations and maintenance,
Tetlow has worked on numerous power plant
projects and overhauls.
37
12/26/07 5:25:24 PM
Feature Report
Trinath Sahoo
M/S Indian Oil Corp.
Jayantha P. Liyanage
University of Stavanger, Norway
A maintenance management team member takes vibration measurements on a piece of process equipment
Components of a CMMS
12/26/07 5:13:34 PM
main constituents of a
corrective maintenance
analysis system
Periodic reports
There are two main types of failure reports available, namely Failure analysis reports, and Downtime analysis
reports:
Failure analysis report: the various
faults along with the details like
frequencies of occurrence in each
quarter and the corresponding
downtime involved will be reported
under this heading
Downtime analysis report: this report
is generated quarterly and lists all
the downtime involved in various
categories
Query report
The queries are very useful in elucidating the occurrence of hidden failures,
by generating information pertaining
to the underlying technical issue of
concern. Such a query report can consists of the following:
Maintenance history query: given
the machine number and the reference date, the corrective maintenance history from that date onwards will be indicated in this query
Fault query: given the fault code, the
details about the fault will be displayed for a particular machine or
for the entire plant, irrespective of the
machine
Parts failure query: when the part
number is specified, the details
about the failure pattern will be generated in this query
Downtime query: given the machine
number, all the relevant downtime
details for that machine generated
39
12/26/07 5:14:10 PM
Feature Report
For example, repair shutdowns can be
scheduled for more convenient times,
and extensive damage to the machine
resulting from forced failure can be
avoided. Repair time can be kept to
a minimum, resulting in reduced machinery downtime. Machines in good
operating condition can continue to
run as long as no problems develop,
saving time and money.
In a plant where thousands of machines and measurement points are
needed, a computerized data-collection
system is generally needed, not only
to minimize data collection time, but
also to minimize data evaluation. For
example, to evaluate machinery vibration a software program is installed in
the computer and a compatible vibration instrument is used for collecting
data in the field. Most systems not
only provide for collecting and trending overall level of machinery vibration, but also offer detailed analysis
software needed to identify specific
machinery faults. After the data has
been collected and downloaded to
the predictive maintenance software,
numerous reports can be generated
to reveal those machines that have
experienced a significant increase in
vibration or have exceeded a present alarm level. A graphic trend may
also be generated by this data. The
maintenance engineer can see from
the graph, how the vibration has progressed over a period of time. Alarm
and trend reports are only a few of the
many reports that can be generated by
condition monitoring software.
ultimately yield improved responsiveness and service towards internal customers and major clients.
Of course, providing decision-making capabilities and support is also a
key advantage, improving control over
PM schedules and documentation.
Spare part inventories are optimized
by identifying demands for parts and
more effective replenishment strategies. Access to maintenance data and
statistics are simplified through report-generation modules for a wide set
of discipline experts. Enhanced communication means job and resource
conflicts are reduced for coordinated
work activities. Ultimately, a CMMS
establishes a good basis for internal
best-practice and the internal standardization of maintenance work.
12/26/07 5:14:59 PM
Authors
Trinath
Sahoo
is the
maintenance manager
at
M/S Indian Oil Corporation Ltd., Mathura Refinery
(Mathura Refinery, Mathura281005 U.P.; Phone: 0091565-241-7572; Fax: 0091-565248-0226; Email: Sahoot@
iocl.co.in) where he oversees
the engineering and maintenance related issues of the
refinerys equipment. Sahoo
holds a B.S. in mechanical engineering from University College of Engineering, Orissa. He is the
author of several internationally published papers and has delivered lectures at various global
seminars and conferences.
Jayantha P. Liyanage, is
an associate professor of industrial asset management
at the University of Stavanger (UiS; Faculty of Science
& Technology, University of
Stavanger, N-4036, Stavanger, Norway; Phone: +47 51
83 1440; Fax: +47 51 83 1750;
E-mail:
J.P.Liyanage@uis.
no). He is also the chair and
a project advisor of the Center for Maintenance and Asset Management
(SDV), as well as a member of the R&D group
of the Center for Risk Management and Societal
Safety (SEROS) at UiS. Liyanage holds a B.S.
in production engineering, M.S. in human factors, and Ph.D. in offshore engineering. He has
published more than 75 publications in various
books, international journals and conferences
over the last few years. For his performance he
has received a number of prestigious awards including the 2003 Society of Petroleum Engineers
Best PhD Award and the 2004 Emerald Literati
Club Award for Excellence.
41
12/26/07 5:15:40 PM
Feature Report
Engineering
Practice
Corrosion Resistance
Using Rock and Glue
Low-cost, corrosion-resistant castings are being produced
using epoxy and mineral aggregates
Terry Capuano
Accures Casting, LLC
Materials
FIGURE 1.
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VTFEUPNPVOUDIFNJDBMQVNQTBOE
ESJWFNPUPST5IFZBSFDBTUUPQSFDJTFUPMFS
BODFT
TPUIFZDBOCFDBTUBOEVTFEJOUIFTBNFEBZ
5IFZBSFMPXDPTU
QSPWJEFFYDFMMFOUDIFNJDBMSFTJTUBODF
BOE
EBNQFOWJCSBUJPOXIJDIJODSFBTFTUIFMJGFPGCFBSJOHTBOETFBMTBOE
QSPWJEFTBRVJFUPQFSBUJPO5IFTFCBTFTBSFBMTPVTFEGPSBJSDPNQSFTTPST
XIFSFMPXDPTUBOEOPJTFSFEVDUJPOBSFJNQPSUBOU
42$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:
Processing
FIGURE 3.#FDBVTFUIFDBTUJOHQSP
DFTTUBLFTQMBDFBUSPPNUFNQFSB
UVSFBOEQSFTTVSF
XPPENPMETDBO
CFVTFEUPRVJDLMZBOEFDPOPNJ
DBMMZQSPEVDFMBSHFDBTUJOHT5IJT
JTBQIPUPPGBNPMEVTFEUP
QSPEVDFB
MCQSPDFTTJOH
NBDIJOF5IFESBJOQJQFTBSF
DPNNPO17$QJQFT
XIJDI
HFUDBTUJOQMBDF
FIGURE 2.
5IJTQIPUP
TIPXTBDIFNJ
DBMMZSFTJTUBOU
USFODIESBJO
VTFEJODIFNJ
DBMQSPDFTTJOH
QMBOUT
GPPE
QSPDFTTJOH
QMBOUTBOE
BMPOHESJWF
XBZTBUHBT
TUBUJPOT5IFTF
ESBJOTDBQUVSFUIFPWFSGMPXPGQSPDFTT
DIFNJDBMTPSXBTIEPXOXBUFSJOTJEF
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WJSPONFOU0VUEPPSTUIFZBSFVTFECF
DBVTFPGUIFJSSFTJTUBODFUPGSFF[FUIBX
DZDMFTBOEUPTBMUEBNBHF5IFZBSF
FQPYZQPMZNFSDBTUJOHTBOEUIFSFGPSF
SFTJTUNPTUDPNNPODIFNJDBMTBOEBSF
BMTPBDDFQUFEGPSDPOUBDUXJUIGPPECZ
UIF64'PPEBOE%SVH"ENJOJTUSBUJPO
Tooling
Properties
Machine components can be repeatedly cast flat to 0.0005 in./ft, hole diameters to 0.0001 in./in. and feature
dimensions to 0.0005 in./ft. Whereas
iron castings require the production of
a rough casting, followed by precision
machining, with stress relief before
and after, and painting, PPC parts
are simply cast to tolerance, demolded
and used in the assembly. A precise
iron casting may take four months or
more to produce, while a polymer casting can often be produced and used in
days. Since the parts will not rust or
corrode, painting is not necessary.
It is possible to cast integral surfaces with uniquely different properties. A grinding-machine way surface
is cast using a low-friction polymer
material when the part is cast. The
way surfaces use a low-friction epoxy
formulation that provides high lubricity and long life. Castings can be made
to be magnetic, electrically conductive,
heavy or light.
Casting at room temperature allows the use of plastic or cardboard
tubing to produce wire ways, vacuum lines or drainage holes. Using
standard 4-in. dia. polyvinylchloride
Applications
Author
Terry D. Capuano, P.E.,
is founder and president of
Accures Casting, LLC (140
Greentree Rd., Moreland
Hills, OH 44022; Phone: 440343-0461; Fax: 440-247-2293;
Email: TDCapuano@aol.com),
as well as president of TED
Properties, LLC, Teneric, LLC
and the Capuano Foundation,
which is dedicated to helping
children. He has over 25 years
of executive management experience, more than
30 patents and was the youngest vice president in two different 100-year-old companies.
Among his many notable accomplishments are
the startup of the first polymer concrete casting
company in the U.S., and the development of a
number of polymer composites and the Zanite
composite-casting technology. Capuano holds an
AASME degree from Waterbury State Technical
College, a BSME (with honors) from Tri-State
University, and an MBA from Rensselaer Polytechnic Institute.
$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:43
Feature Report
Engineering
Practice
Seal-Fluid-Circulation Devices:
Understanding the Differences
Knowing the options in
fluid-circulation designs
helps in the
selection process
API-682 states
1.5 mm (0.060 in.)
minimum here
Alan Roddis
Aesseal plc.
ver the past few decades, hundreds of seal geometries and a fair
number of seal categories have
evolved. Recently, the distinction
between single- and dual-mechanical
seals has been brought into focus by
heightened safety and environmental
concerns. Dual seals are often selected
where safety is of paramount concern.
To aid in selection, an understanding of
how the fluids used in these seals are
recirculated is important.
Convection or pumped
circulation?
sufficiently below the point of vaporizing the liquid film between the faces.
Cooler operation is an obvious risk-reduction step, which explains why sealcirculation devices have generally
been well received in industry.
Circulation-device standards
The path towards innovation and reliability differs from one manufacturer
to another, and so several types of circulation devices are currently available. It is important to know fundamental differences between the major
circulation devices in order to select
one for a given application, and it is
also helpful to understand the best
practice information contained in
the API-682 Standard on Mechanical
Seals. This API standard represents
the collective experience of industry
experts in rotating equipment and
mechanical sealing.
Section 8.6.2.3 of the latest API-682
standard, which outlines best-practice
mechanical-seal design, specifies a
radial clearance of 0.062 in. (1.5 mm)
between rotor and stator components
(Figure 1). Just as with impeller wearring clearances, this minimum clearance for seal components is based on
long-term rotating equipment experience. The potential consequences
of metal-to-metal contact are well
known and, more specifically, rubbing
of rotating stainless-steel components
against stationary parts can lead to
serious galling. Such galling and even
seizing is possible if internal seal
clearances are too small and align-
Circulation systems
12/26/07 5:07:09 PM
100 mm (4-in.) seal with API-682 radial clearance-head-flow characteristics for various circulating devices on oil at 3,600 rpm
0
0.5
2
125
Head, mm water
3,000
2,500
FIGURE 3.5BQFSFE
WBOFQVNQTIBWFPQUJ
NVNQFSGPSNBODFBOE
BMPXSJTLPGDPOUBDU
CFUXFFOSPUBUJOH
BOETUBUJPOBSZ
DPNQPOFOUT
75
1,500
50
Screw thread
1,000
500
0
FIGURE 2.1BSBMMFMTMPUPSDBTUFMMBUJPOUZQFQVNQJOHEFWJDFT
BSFMFTTFGGJDJFOUUIBOPUIFSNFUIPETUPNPWFTFBMJOHGMVJE
100
Tapered vane
2,000
25
Parallel slot
0
4
Flow, L/min
3,500
Author
Alan Roddis is the engineering director of Aesseal
plc. (Mill Close, Rotherham, U.K. S60 1BZ; Email:
alanr@aesseal.co.uk) He is a
graduate mechanical engineer
(honors degree) and has been
responsible for the design of
modern sealing devices used in
pumps, mixers, compressors,
steam turbines, gear speed
reducers and dozens of other
machine categories used by hydrocarbon processing, power generation, pharmaceutical, mining,
food processing, paper, and many other industries
in dozens of countries. Roddis holds several U.K.
and international patents on advanced sealing
products and related mechanical devices. In his
position at Aesseal, he continues to spearhead the
design and development efforts at this manufacturer of advanced technology sealing products.
$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:45
FOCUS ON
Mixers
Munson Machinery
Sharpe Mixers
46$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:
Chemineer
jars with 5 or 10 reaction vials. Digital settings for the grinding time and
vibration intensity, as well as storage
features with up to 9 parameter combinations, ensure reproducibility of
sample preparation. Retsch GmbH,
Haan, Germany
edlinks.che.com/7368-435
ber
Matthew Phelan
A d v a n c e d P r o c e s s S o l u t i o ns
LEADING WORLDWIDE IN MIXING TECHNOLOGIES
The EKATO GROUP provides their customers with the technical excellence and
experience of a global market leader. The companies within the EKATO GROUP
operate across the spectrum of mixing technologies.
From simple laboratory mixers to turnkey production plants, the EKATO GROUP provides a range of
engineering services and custom-made solutions for the most challenging customer applications. The
synergies within the EKATO GROUP ensure that reliable and cost-effective solutions can be provided
to the highest quality standards for every application. This is supported by a global service network.
GROUP
www.ekato.com
Circle 24 on p. 58 or go to adlinks.che.com/7368-24
Chemical Engineering www.che.com January 2008
47
12/26/07 5:53:14 PM
Solids Processing
Operations
& Maintenance
Optimized tank scheduling is essential for improving agility and flexibility, as well as maximizing utilization
and throughput of manufacturing facilities. Companies without scheduling technology lose a great deal of opportunity because they cannot quickly
react to changes in the production environment. When evaluating scheduling software, it is essential for manufacturers to identify products that can
dynamically schedule the intricacies
of tanks while simultaneously taking
into account the constraints and processes of their plants.
With visibility into constrained resources and bottlenecks, a company
can adapt schedules that address these
issues more quickly. A comprehensive
scheduling solution should provide 24hour access to view realtime schedules
and reports via the Web, which allows
Timing is everything
12/26/07 5:50:02 PM
.JYJOH7BUT#BTFEPOEJG
GFSFOUJOGMPXBOEPVUGMPX
SBUFT
7BU&5TIPXTGJMM
JOH
GJMMBOEESBXEPXOPG
UIFUBOL7BUT&5
&5
&5BOE&5TIPXGJMMJOH
HSFFOEPUT
NJYJOH EBSL
HSFFO
BOEESBXEPXO
MJHIUFSDPMPSEPUT
GPS
FBDICBUDI
1BDLBHJOH#PUUMFTBOE
$BOTJMMVTUSBUFUIFNPWF
NFOUPGFBDICBUDIJOUP
EJGGFSFOUQBDLBHFT
.JYJOH7"54
1BDLBHJOH
1MBUGPSNT
1MBUGPSNT1MBUTIPXT
TDIFEVMJOHPGMPBEJOH
EPDLTBOE1MBUTIPXT
EJTQPTBMPGCZQSPEVDUT
FIGURE 2.5IJTTDIFEVMFEF
QJDUTUIFQSPEVDUJPOQSPDFTT
GSPNNJYJOHWBUTUPQBDLBHJOH
UPQMBUGPSNTUIBUPQUJNJ[FT
UISPVHIQVUUPNFFUDVSSFOU
EFNBOETXJUIMPXFTUNBOVGBDUVSJOHDPTUT
4DIFEVMJOHQSPHSBNTMJLFUIJTQSPWJEFWJT
JCJMJUZBDSPTTUIFFOUJSFQSPDFTT
FOBCMJOH
NBOVGBDUVSFSTUPRVJDLMZJEFOUJGZCPUUMFOFDLT
BOEFOTVSFCFTUGJMMSBUFTCBTFEPODVSSFOU
DBQBDJUZBOEEFNBOE
$BQBDJUZ
$BQBDJUZ$BQBDJUZVUJMJ[BUJPOPGUIF
QBDLBHJOHMJOFTCZQSPEVDU
-BCPS-BCPSCZEFQBSUNFOUBOE
QSPDFTT
-BCPS
values that actually cause the changeover, such as color, quality, brand or lot
number. As a result, visibility is improved, allowing engineers to react to
current conditions.
To maximize plant utilization, decisions about tank and batch sizes need
to be carefully considered. Future
batch requirements, such as due dates
and quantities, should also be part of
the equation. By considering capacity
and providing dynamic batch sizing
capabilities, a software solution with
advanced tank-scheduling capabilities
will create an optimal schedule, allowing the best utilization of the plant
without adding additional costs.
Tank grouping
& product changes
Business-specific solutions
Author
Rory Granros is the director
for industry and product marketing for process industries at
Infor, a leading global provider
of enterprise software (1356 Morris Road, Suite 4100, Alpharetta,
GA 30004; Phone: 678-319-8000;
Fax: 678-319-8682; Email: rory.
granros@infor.com). With more
than 25 years experience in developing and marketing innovative
PLM, ERP and decision support
solutions, Rory Granros leads the global marketing
initiatives for Infors industry-specific process manufacturing capabilities including PLM, ERP, SCP, SCE,
EAM and CPM. For more information, please contact
inforinfo@infor.com.
$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:49
4DFQUFSNFN
CSBOF NPEVMFT
DPNCJOFSVHHFE
UVCVMBS 44 TVQ
QPSU XJUI B QBU
FOUFE UJUBOJVN
EJPYJEF NFN
CSBOF
QSPWJEJOH
TVQFSJPS TFQB
SBUJPO QFSGPS
NBODFBOEZFBSTPGSFMJBCMFGJMUSB
UJPOJOBQQMJDBUJPOTXIFSFFYUSFNF
QSPDFTTDPOEJUJPOTPSEJGGJDVMUGFFE
TUSFBNTNBLFPUIFSNFUIPETVO
TVJUBCMF 5IF UVCVMBS NFNCSBOF
NPEVMFTIBWFBMMXFMEFE
OPHBT
LFUDPOTUSVDUJPOBOEBSFBWBJMBCMF
JO IPSJ[POUBM BOE WFSUJDBM PSJFOUB
UJPOT.FNCSBOFBSFBTBSFBWBJM
BCMF GSPN UP TR GU XJUI
TFQBSBUJPOSBUJOHTPGBOE
NJDSPOT OPNJOBM
BOE UIF NFN
CSBOFT BSF TVJUBCMF GPS FYUSFNF
DIFNJDBM DPOEJUJPOT
QSFTTVSFT
BOEUFNQFSBUVSFT
(SBWFS5FDIOPMPHJFT
*OD
(800) 249-1990 (US)
TBMFT!HSBWFSUFDIDPNTDFQUFS
XXXHSBWFSUFDIDPN
425.455.1263
800.582.7797
sales@pulsair.com
www.pulsair.com
Circle 202 on p. 58 or go to
adlinks.che.com/7368-202
Bulkflow High
Temperature Cooler
The Innovative
tube exchanger
uses horizontal
tubes instead
of plate design
to process high
temperature
bulk solids with
temperatures
up to 1000C.
Thermal stresses on the tubes
and walls are minimized due to the
geometry of the tubes. This new
design accommodates thermal
expansion. Modular construction
with multiple banks are available
for larger capacities. The technology easily integrates with existing
equipment.
800.336.7300
www.midwescolter.com
We Take The Dust Out of Industry!
50
Circle 204 on p. 58 or go to
adlinks.che.com/7368-204
Circle 201 on p. 58 or go to
adlinks.che.com/7368-201
Bulkflow
Technologies, Ltd.
TEL: 1-866-379-3500
(403) 254-3500
FAX: (403) 254-3501
E-Mail: info@bulkflow.com
Circle 203 on p. 58 or go to
adlinks.che.com/7368-203
High Pressure
Silencers
x
x
x
x
x
Model
D800
Silencer
CU Services LLC
725 Parkview Cir, Elk Grove, IL 60007
www.bulkflow.com
Ph 847-439-2303 rcronfel@cuservices.net
Circle 205 on p. 58 or go to
adlinks.che.com/7368-205
Circle 206 on p. 58 or go to
adlinks.che.com/7368-206
www.cuservices.net
Intelligen Suite
SuperPro
SchedulePro
R e cipe D B
Use SuperPro Designer to model, evaluate, and
debottleneck batch and continuous processes
SuperPro Designer is a comprehensive process simulator that facilitates modeling, cost analysis, debottlenecking, cycle time
reduction, and environmental impact assessment of biochemical, specialty chemical, pharmaceutical (bulk & fine), food, consumer
product, mineral processing, water purification, wastewater treatment, and related processes. Its development was initiated at the
Massachusetts Institute of Technology (MIT). SuperPro is already in use at more than 400 companies and 500 universities around
the world (including 18 of the top 20 pharmaceutical companies and 9 of the top 10 biopharmaceutical companies).
SchedulePro is a versatile finite capacity scheduling tool that generates feasible production schedules for multi-product facilities that
do not violate constraints related to the limited availability of facilities, equipment, resources and work areas. It can be used in
conjunction with SuperPro (by importing its recipes) or independently (by creating recipes directly in SchedulePro). Any industry
that manufactures multiple products by sharing production lines and resources can benefit from the use of SchedulePro. Engineering
companies use it as a modeling tool to size utilities for batch plants, identify equipment requirements, reduce cycle times, and
debottleneck facilities.
Circle 240 on p. 58 or go to adlinks.che.com/7368-240
12/26/07 5:56:16 PM
SOFTWARE
FlowPhase Inc.
VLEFlash
Cost Effective
Engineering Software
Circle 242 on p. 58 or go to
adlinks.che.com/7368-242
PRODUCT SHOWCASE
Contact Helene Hicks
Tel: 212-621-4958
Fax: 212-621-4976
Email: hhicks@che.com
Phase Envelopes
2 Phase Hydrocarbon VLE
Dew Point Calculations
Bubble Point Calculations
NIST Database
Circle 243 on p. 58 or go to
adlinks.che.com/7368-243
CA
Co PE-O
mp PE
lian N
t!
fired heaters
air coolers
economizers
tube layouts
vibration analysis
HTRI@HTRI.net
www.HTRI.net
FOR
U
Air Cooled
Liquid Cooled
Circle 241 on p. 58 or go to
adlinks.che.com/7368-241
52
Vent Condensing
Circle 251 on p. 58 or go to
adlinks.che.com/7368-251
Circle 252 on p. 58 or go to
adlinks.che.com/7368-252
1-800-243-ROSS
!!!"#$"%
Circle 253 on p. 58 or go to
adlinks.che.com/7368-253
HOCKMEYER
Equipment Corporation
A leader in the grinding and
dispersion industries
www.highshearmixers.com
Filter Presses
Clarifiers
Sand Filters
Tanks Pumps
Filtration
Accessories
WAT E R W O R K S
800.232.9334
219.663.8210
www.airtowater.com
NEW USED SURPLUS
Filtration Equipment
Visit us at www.hockmeyer.com
or call us at 252-338-4705
Wanted to purchase:
Used Dispersers & Mixers
Circle 256 on p. 58 or go to
adlinks.che.com/7368-256
ADVERTISE
IN THE
CLASSIFIED:
Circle 255 on p. 58 or go to
adlinks.che.com/7368-255
Circle 254 on p. 58 or go to
adlinks.che.com/7368-254
www.averyfilter.com
Circle 258 on p. 58 or go to
adlinks.che.com/7368-258
Circle 259 on p. 58 or go to
adlinks.che.com/7368-259
$POUBDU)FMFOF)JDLT
5FM
'BY
&NBJM
IIJDLT!DIFDPN
Circle 260 on p. 58 or go to adlinks.che.com/7368-260
CHEMICAL ENGINEERING WWW.CHE.COM JANUARY 2008
53
TOLL SCREENING
by the screening specialists
reduced screening costs
maximized yield and efficiency
from 10 microns to 10 mesh
from 100 to 1,000,000 pounds
receive the benefits of high-tech screening
before you buy
Discover how much your product can be
improved using our technologies!!
800AT ELCAN
(515) 266-8225
Fax (515) 266-5676
sales@minox-elcan.com
E-mail: sales@revtechlc.com
Web Site: www.revtechlc.com
www. minox-elcan.com
Circle 262 on p. 58 or go to
adlinks.che.com/7368-262
Circle 261 on p. 58 or go to
adlinks.che.com/7368-261
800-704-2002
www.wabashpower.com
wabash
Website: WWW.HPEQUIP.COM
P.O. Box 839; Montville, NJ 07045
Contact Jim Siegel: Jim@hpequip.com
Phone: 973-335-9770; Fax: 973-335-5333
Circle 264 on p. 58 or go to
adlinks.che.com/7368-264
Circle 263 on p. 58 or go to
adlinks.che.com/7368-263
Advertise
in the
Classifieds
Circle 265 on p. 58 or go to
adlinks.che.com/7368-265
Product Showcase
and
Classified pages
Consulting
Classified
KnightHawk
Engineering
Specialists in design, failure analysis
and troubleshooting of static
and rotating equipment
Computational Fluid Dynamics
Finite Element Analysis
Heat Transfer Analysis
Vessel/Exchanger/Machine Design
Rotor Dynamics/Structural Dynamics
Pelletizing Die Design
Process Simulation
Pipe Stress
www.knighthawk.com
Tel: 281-282-9200
Fax: 281-282-9333
Circle 248 on p. 58 or go to
adlinks.che.com/7368-248
54
Circle 249 on p. 58 or go to
adlinks.che.com/7368-249
Design/Scale-up
Size Distribution
Laboratory Investigations
Filtration
Troubleshooting
Purity
Caking
Drying
Particle Habit
Product Micro-Analysis
Polymorphism
Kinetics Studies
Industrial Seminars
Circle 250 on p. 58 or go to adlinks.che.com/7368-250
12/26/07 5:57:49 Pm
Recruitment
MMA
Elastomers
Nylon
Ethoxylates
Caprolactam
Requirements
Education B.Sc. in a relevant engineering or financial field.
Experience Hands-on experience in the fields of marketing, sales, investment planning, and customer support of the specialty
products listed above.
Remuneration Competitive salary, free accommodation, transportation, flight
tickets to self and dependent family members, bonuses, full
medical coverage, and child education assistance.
Details Detailed job descriptions will be communicated upon evaluating the CV.
Candidates are invited
to apply through the
Triple EEE web site
+31 15 215 34 80
Tel:
+31 15 215 34 81
Fax:
info@eee.nl
Email:
Web site: www.eee.nl
55
12/27/07 5:17:54 Pm
Recruitment
Research Engineer
Conduct research and development
in membrane separation area with accountability for quality of experimental
data generated. Duties include: collecting parametric sensitivity data and system performance test runs; interacting
with principal investigators; reporting
to supervising R&D manager on all activities; and maintaining knowledge of
safety procedures and performing assigned duties in safe manner.
Requires Masters degree in Chem. Eng.
or related scientific discipline. Educ. or
exp. background must include: 1) chemical process simulation fundamentals; 2)
analytical techniques such as gas chromatography or high-performance liquid
chromatography. Exp. may be gained
concurrently. Employer will accept any
suitable combination of education,
training, or experience.
Your Executive
Recruiting Partners
specialists in the
chemical industry
Youll Value the Experience
www.fpcnational.com
j.borough@hotmail.com
Classified
Contact Helene Hicks
Tel: 212-621-4958
Fax: 212-621-4976
Email: hhicks@che.com
12/26/07 5:59:01 Pm
Advertisers Index
Advertiser
Phone number
Page number
Reader Service #
28D-6
513-247-5465 adlinks.che.com/7368-30
Axens
adlinks.che.com/7368-04
718-258-6887 adlinks.che.com/7368-10
Berndorf Band
GmbH & Co
28I-3
1-800-393-8450
adlinks.che.com/7368-32
Phone number
Page number
Reader Service #
Heinkel USA
28D-5
856-467-3399 adlinks.che.com/7368-28
18
1-610-692-3490
adlinks.che.com/7368-16
28I-11
adlinks.che.com/7368-15 Commission
adlinks.che.com/7368-41
* Cashco Incorporated
20
785-472-4461 adlinks.che.com/7368-18
* Charles Ross
& Son Company
10
1-800-243-ROSS
adlinks.che.com/7368-12
Chemstations, Inc.
15
713-978-7700
adlinks.che.com/7368-14
FOURTH
COVER
adlinks.che.com/7368-03
Page number
Reader Service #
19
39-0731-231-1 adlinks.che.com/7368-40
Paratherm Corporation
28
800-222-3611 adlinks.che.com/7368-05
1-800-MUELLER
adlinks.che.com/7368-22
28I-13
adlinks.che.com/7368-39
Prosim
33 (0) 5 62 88 24 30
adlinks.che.com/7368-09
56
FPC National
56
39 02 50 831 adlinks.che.com/7368-37
Donadon SDD
28I-10
adlinks.che.com/7368-38
Durr Systems,
Incorporated
28D-7
1-734-254-2314
adlinks.che.com/7368-31
Ekato Ruehr-Und
Mischtechnik
47
Emerson Process
Management
THIRD
COVER
* Endress + Hauser
49 7622 29 0 adlinks.che.com/7368-24
adlinks.che.com/7368-02
888-ENDRESS
adlinks.che.com/7368-06
Filtersense
28
1-978-927-4304
adlinks.che.com/7368-21
39-039-9982.1
adlinks.che.com/7368-36
Fisher-klosterman,
Incoroprated
28D-3
502-572-4000 adlinks.che.com/7368-25
Goulds Pumps,
Itt Industries
1-800-734-7867
adlinks.che.com/7368-08
International Section
* Additional information in
2006 Buyers Guide
24
39-02-5760-3913
adlinks.che.com/7368-20
adlinks.che.com/7368-07
Sri Consulting
29
TEMA
12
adlinks.che.com/7368-23
914-332-0040 adlinks.che.com/7368-13
28D-6
513-863-4758
adlinks.che.com/7368-29
Westfalia Separator Ag
Consulting . . . . . . . . . . . . . . 54
Equipment, Used or
Surplus New for Sale. . . . 52-54
Recruitment. . . . . . . . . . . 55-56
Advertiser
Phone number
Page number
Reader Service #
Applied e-Simulators
Software
52
509-967-5730
adlinks.che.com/7368-242
53
201-666-9664
adlinks.che.com/7368-259
53
800-722-5790
adlinks.che.com/7368-258
Bulkflow Technologies, Inc. 50
866-379-3500
adlinks.che.com/6897-205
CU Services LLC
50
847-439-2303
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Company
Address
City
State/Province
Zip/Postal Code
Country\
Telephone
Fax
FREEPRODUCT INFO
YOURINDUSTRY
01 Food &Beverages
02 Wood, Pulp &Paper
03 Inorganic Chemicals
04 Plastics, Synthetic Resins
05 Drugs &Cosmetics
06 Soaps &Detergents
07 Paints &Allied Products
08 Organic Chemicals
09 Agricultural Chemicals
10 Petroleum Refining,
Coal Products
11 Rubber &Misc. Plastics
12 Stone, Clay, Glass, Ceramics
13 Metallurgical &Metal Products
29
30
31
32
33
34
10 to 49 Employees
50 to 99 Employees
100 to 249 Employees
250 to 499 Employees
500 to 999 Employees
1,000 or more Employees
YOURECOMMEND,
SPECIFY, PURCHASE
40 Drying Equipment
41 Filtration/Separation Equipment
42 Heat Transfer/Energy Conservation Equipment
43 Instrumentation & Control Systems
44 Mixing, Blending Equipment
45 Motors, Motor Controls
46 Piping, Tubing, Fittings
47
16
31
46
61
76
91
106 121 136 151 166 181 196 211 226 241 256 271 286 301 316 331 346 361 376 391 406 421 436 451 466 481 496 511 526 541 556 571 586
17
32
47
62
77
92
107 122 137 152 167 182 197 212 227 242 257 272 287 302 317 332 347 362 377 392 407 422 437 452 467 482 497 512 527 542 557 572 587
18
33
48
63
78
93
108 123 138 153 168 183 198 213 228 243 258 273 288 303 318 333 348 363 378 393 408 423 438 453 468 483 498 513 528 543 558 573 588
19
34
49
64
79
94
109 124 139 154 169 184 199 214 229 244 259 274 289 304 319 334 349 364 379 394 409 424 439 454 469 484 499 514 529 544 559 574 589
20
35
50
65
80
95
110 125 140 155 170 185 200 215 230 245 260 275 290 305 320 335 350 365 380 395 410 425 440 455 470 485 500 515 530 545 560 575 590
21
36
51
66
81
96
111 126 141 156 171 186 201 216 231 246 261 276 291 306 321 336 351 366 381 396 411 426 441 456 471 486 501 516 531 546 561 576 591
22
37
52
67
82
97
112 127 142 157 172 187 202 217 232 247 262 277 292 307 322 337 352 367 382 397 412 427 442 457 472 487 502 517 532 547 562 577 592
23
38
53
68
83
98
113 128 143 158 173 188 203 218 233 248 263 278 293 308 323 338 353 368 383 398 413 428 443 458 473 488 503 518 533 548 563 578 593
24
39
54
69
84
99
114 129 144 159 174 189 204 219 234 249 264 279 294 309 324 339 354 369 384 399 414 429 444 459 474 489 504 519 534 549 564 579 594
10
25
40
55
70
85
100 115 130 145 160 175 190 205 220 235 250 265 280 295 310 325 340 355 370 385 400 415 430 445 460 475 490 505 520 535 550 565 580 595
11
26
41
56
71
86
101 116 131 146 161 176 191 206 221 236 251 266 281 296 311 326 341 356 371 386 401 416 431 446 461 476 491 506 521 536 551 566 581 596
12
27
42
57
72
87
102 117 132 147 162 177 192 207 222 237 252 267 282 297 312 327 342 357 372 387 402 417 432 447 462 477 492 507 522 537 552 567 582 597
13
28
43
58
73
88
103 118 133 148 163 178 193 208 223 238 253 268 283 298 313 328 343 358 373 388 403 418 433 448 463 478 493 508 523 538 553 568 583 598
14
29
44
59
74
89
104 119 134 149 164 179 194 209 224 239 254 269 284 299 314 329 344 359 374 389 404 419 434 449 464 479 494 509 524 539 554 569 584 599
15
30
45
60
75
90
105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360 375 390 405 420 435 450 465 480 495 510 525 540 555 570 585 600
International
Wilhelm Sicking,
Sicking Industrial Marketing
Chemical Engineering
Emmastrasse 44; 45130 Essen, Germany
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Silvera Pubblicita, Viale Monza, 24 Milano
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E-mail: ferruccio@silvera.it/www.silvera.it
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12/27/07 2:42:10 PM
Economic Indicators
Business News
Plant Watch
A new plant for crude-oil processing
to be built in Italy
December 10, 2007 ABB has won a
contract worth more than $86 million from
Eni SpA to design and construct a new oil
processing plant in an onshore oilfield in
Italy.The plant, scheduled for completion
in 2010, will process almost 7,000 bbl/d of
crude oil and 6.7-million ft3/d of gas. It is part
of the larger onshore oilfield development
project, which includes a sulfur treatment
plant, wellhead facilities and a power
generation plant.
A complex is planned in North America
for clean transportation fuels
December 5, 2007 Newfoundland &
Labrador Refining Corp. (NLRC) has selected
UOP LLC, a Honeywell company, to supply
technology, basic engineering services and
equipment for a fuel refinery to be built in the
Placentia Bay area of Newfoundland and
Labrador, Canada. Startup of the complex is
scheduled for 2011.The facility is projected
to process 300,000 bbl/d of Middle Eastern
crudes for the production of transportation
fuels to support demand in North America
and Europe.The NLRC facility will be the first
new refinery constructed in North America
since 1984.
LP Oxo Technology is chosen for a new
facility in Sichuan Provence, China
November 28, 2007 PetroChina Sichuan
Petrochemical Co. has chosen LP Oxo
Technology for its new facility in Chengdu,
Sichuan Province, China.The Sichuan plant
will include the largest custom-designed
single-line low-pressure hydroformylation
unit in the world, with a capacity of 338,000
m.t./yr of normal- and iso-butyraldehydes.
This train will supply two alcohol production
lines, with the first producing 81,800 m.t./yr
of 2-ethylhexanol and the second, 211,900
m.t./yr of normal-butanol and 30,800
m.t./yr of iso-butanol. Startup is planned
for September 2010.This facility is part of a
grassroots petrochemical complex that
PetroChina centered on an 800,000-m.t./yr
ethylene plant.
Portuguese refiner becomes second to
license biofuel technology
November 28, 2007 Portugals largest
refiner, Galp Energia, will use the UOP/Eni
Ecofining technology to produce diesel
Mergers and
Acquisitions
Rockwell acquires Pavilion Technologies
and expands software portfolio
December 6, 2007 Rockwell Automation
has entered into a definitive agreement to
buy Pavilion Technologies, Inc., a privately
held company involved in advanced
process control, production optimization
and environmental compliance solutions
for process and hybrid industries.The
Pavilion Technologies management
team and employees will become part
of Rockwell Automations Architecture &
Software segment.Terms of the transaction
were not disclosed.
Basell to acquire Solvay
Engineered Polymers, Inc.
November 29, 2007 Basell, a leader in
advanced polyolefins, has signed a definitive
agreement with Solvay by which Basell will
acquire Solvay Engineered Polymers, Inc.,
a supplier of polypropylene compounds in
North America.The transaction is subject
to relevant regulatory approvals and is
expected to close in early 2008.
A joint venture is formed for an ongoing
biodiesel-expansion project in France
November 26, 2007 Ineos Enterprises is
moving forward with its project to more than
double biodiesel capacity at its Baleycourt
site in Verdun, France. A new joint venture
(JV), to be known as Ineos Champlor has
been created by INEOS Enterprises, farming
cooperative group Sicla, and oilseed
crushing group C.Thywissen.The JV will
invest more than 70 million in a new oilseed
crushing unit and vegetable-oil refining
plant at the site.The new biodiesel facility
will allow around 400,000 m.t. of locally
produced rapeseed to be transformed into
oil and then biodiesel.
The Linde Group sells BOC Edwards
Pharmaceutical business
November 23, 2007 The Linde Group has
sold the BOC Edwards Pharmaceutical
Systems business to the Italian company
IMA (Industria Macchine Automatiche) at
n
an enterprise value of 36 million.
Dorothy Lozowski
59
12/27/07 1:32:12 PM
Economic Indicators
2006
2007
Oct.07
Prelim.
527.1
626.2
593.2
595.0
740.2
422.1
843.2
437.2
660.8
318.6
476.8
355.0
CE INDEX
Equipment
Heat exchangers & tanks
Process machinery
Pipe, valves & fittings
Process instruments
Pumps & compressors
Electrical equipment
Structural supports & misc
Construction labor
Buildings
Engineering & supervision
Sep.07
Final
528.2
627.2
595.1
599.6
739.6
422.8
836.2
435.3
663.5
320.1
478.4
355.9
540
Oct.06
Final
515.5
610.4
571.5
562.8
740.5
439.0
794.2
419.2
646.0
314.0
474.6
351.9
Annual Index:
1999 = 390.6
525
2000 = 394.1
2001 = 394.3
510
2002 = 395.6
2003 = 402.0
495
2004 = 444.2
2005 = 468.2
480
2006 = 499.6
465
* Starting with the April 2007 Final numbers, several of the data series for labor and compressors have been
converted to accommodate series IDs that were discontinued by the U.S. Bureau of Labor Statistics
F M A M J
A S O N D
LATEST
Nov.07
Oct. 07
Nov. 07
= 108.8
= 1,697.6
= 82.0
Oct. 07
Sep. 07
Oct. 07
=
=
=
108.3
1,665.3
81.7
Sep. 07
Aug. 07
Sep. 07
= 109.1
= 1,614.8
= 82.4
Nov. 06
Oct. 06
Nov. 06
= 106.0
= 1,549.2
=
80.7
Dec. 07
Nov. 07
Nov. 07
Nov. 07
Nov. 07
=
=
=
=
=
Nov. 07
Oct. 07
Oct. 07
Oct. 07
Oct. 07
=
=
=
=
=
753.3
229.8
115.3
141.3
132.8
Oct. 07
Sep. 07
Oct. 07
Sep. 07
Sep. 07
=
=
=
=
=
Dec. 06
Nov. 06
Nov. 06
Nov. 06
Nov. 06
=
=
=
=
=
111
1760
PREVIOUS
753.1
245.8
115.8
143.0
132.1
85
108
1680
83
105
1600
81
102
1520
79
99
1440
77
96
J A S O N D
749.0
227.7
116.1
142.3
131.9
734.3
208.3
113.2
143.1
131.6
75
1360
J F M A M J
YEAR AGO
J F M A M J
J A S O N D
J F M A M J
J A S O N D
*Due to discontinuance, the Index of Industrial Activity has been replaced by the Industrial Production in Manufacturing index from the U.S. Federal Reserve Board.
Current business indicators provided by DRI-WEFA, Lexington, Mass.
M & S INDEX
Process industries, average
Cement
Chemicals
Clay products
Glass
Paint
Paper
Petroleum products
Rubber
Related industries
Electrical power
Mining, milling
Refrigeration
Steam power
4th Q
2007
3rd Q
2007
2nd Q
2007
1st Q
2007
4th Q
2006
1,399.2
1,452.3
1,435.3
1,427.9
1,415.0
1,348.8
1,457.1
1,369.2
1,543.7
1,500.1
1,393.0
1,445.6
1,427.5
1,421.0
1,408.8
1,341.8
1,451.2
1,364.0
1,536.2
1,494.8
1,383.6
1,433.5
1,417.5
1,408.8
1,400.4
1,331.3
1,440.2
1,354.0
1,521.0
1,486.7
1,362.7
1,410.0
1,398.8
1,384.9
1,378.1
1,309.5
1,414.2
1,331.6
1,497.9
1,463.1
1,353.8
1,399.2
1,385.8
1,374.1
1,367.6
1,299.5
1,404.6
1,324.2
1,486.3
1,449.4
1,374.9
1,460.8
1,698.8
1,416.4
1,359.0
1,453.2
1,691.7
1,407.4
1,340.7
1,442.7
1,679.3
1,394.2
1,319.5
1,427.7
1,648.2
1,369.1
1,310.1
1,413.5
1,638.5
1,359.8
Annual Index:
2000 = 1,089.0
2001 = 1,093.9
2002 = 1,104.2
2003 = 1,123.6
2004 = 1,178.5
2005 = 1,244.5
2006 = 1,302.3
2007 = 1,373.3
60$)&.*$"-&/(*/&&3*/(888$)&$0.+"/6"3:
1405
1390
1375
1360
1345
1330
1315
1300
1285
1270
1255
1240
1225
Electronic notification of
monthly updates
All annual data archives
(1947 to present) and monthly
data archives (1970 to present)
Option to download data in
Excel format
A selection of helpful
cost-estimation articles
O
Circle 02 on p. 58 or go to adlinks.che.com/7368-02
12/13/07 3:16:31 PM
Circle 03 on p. 58 or go to adlinks.che.com/7368-03
12/13/07 3:14:35 PM