Modeling is

gaining a
greater role
in improving
throughput
and energy
efficiency

Improve Your Refrigeration System

Properly Measure Liquid/Liquid

Interfaces
m ay 2 0 1 1

Be Levelheaded About
Surge-Tank Control

Set the Right Goals

CP1105_01_Cover.indd 1 4/26/11 2:13 PM

 The information you need at your fingertips.

Information at your fingertips in seconds! Whether you’re planning, procuring, installing and commissioning or operating
a plant, W@M – Life Cycle Management from Endress+Hauser keeps you up to date on the complete installed base of pro-
cess automation equipment, even for non-Endress+Hauser products. W@M is designed as an open and flexible information
platform with software applications and services that reduce equipment failure and plant downtime, and minimize repair
and maintenance costs, cutting total life cycle costs. Talk to us today. We’ll be glad to tell you more about how W@M can
help improve your business. www.us.endress.com/W@M

Endress+Hauser, Inc
2350 Endress Place
Greenwood, IN 46143 Sales: 888-ENDRESS
inquiry@us.endress.com Service: 800-642-8737
www.us.endress.com Fax: 317-535-8498

CP1105_full page ads.indd 2 4/26/11 10:55 AM

 PERFORMANCE THROUGH ENGINEERING

BETE HydroWhirl™ Orbitor
A New “Revolution” In Tank Cleaning
BETE’s new HydroWhirl™ Orbitor
is a versatile Clean-In-Place (CIP)
rotating tank cleaning machine
that combines high-impact
cleaning efficiency with
extended operating life,
reduced life cycle costs
and simple on-site service.
The Orbitor can be completely
stripped and rebuilt for maintenance
ON-SITE in less than 15 minutes.
MaxiPass™ (MP) Nozzles from BETE
The ultimate in clog-resistance with
the largest free passage available in
a full cone nozzle
Two unique s-shaped internal
vanes allow free passage of
particles equal to the orifice
size, making the MP perfect
for handling dirty, lumpy liquids.
Pattern uniformity is exceptional, providing
an even distribution throughout. Reliable
spray under difficult conditions. Low flow
model available.
The XA Nozzle System from BETE
Produces a no-drip or high-speed
spray shut-off
BETE’s low flow, air atomizing
XA series nozzles provide
very low flow rates. They
are available in eight
different spray patterns
and numerous flow rates.
The XA nozzles can be supplied with
a number of hardware options to allow
cleanout, shutoff of both. Hardware
options are available in manual and
pneumatic versions.

BETE is your strategic partner for TF Nozzles from BETE

We cover all angles...and flows
engineered spraying solutions. One of the original spiral nozzles
invented by BETE, the TF has
high discharge velocity, is clog
resistant and has no internal
parts. The TF is available in
Tank Cleaning brass, 316 stainless steel,
PVC, Polypropylene and PTFE.
Mixing Special materials are available
upon request.
Scrubbing
BETE HydroWhirl™ S
Quenching A slotted rotating spray nozzle for
quick, efficient tank cleaning
Injection The HydroWhirlTM S tank washing nozzle,
with a 360° coverage, directs the cleaning
water through a rotating
Washing head at the tip of the spray
assembly. This spray pattern
uses impact and repetition
to quickly wash the tank
which breaks up and
removes contaminants.
The low-maintenance, dual-bearing
design, uses less water and lower
pressure than static tank washers.

BETE’s HydroWhirl
tank cleaning nozzle

IN-HOUSE CAPABILITIES
• 3D design, modeling, and measurement tools to create customized
nozzle solutions
• State-of-the-art spray laboratory to verify performance and supply BETE Fog Nozzle,Inc.
detailed test results
BETE Fog Nozzle, Inc.
• Investment casting foundry for complete quality control and fast delivery 50 Greenfield St.
• Specialized fabrication and welding expertise for multi-component assemblies Greenfield, MA 01301
T (413) 772-0846
F (413) 772-6729
PERFORMANCE THROUGH ENGINEERING
www.bete.com

Let our experience provide

you with a successful
spraying solution.
www.bete.com BETE Fog Nozzle,Inc.

CP1105_full page ads.indd 3 4/27/11 10:14 AM

 What are the benefits of modernizing
my APACS+ system to SIMATIC PCS 7?

Join us at the June 27 – 30

Automation Walt Disney
Summit World® Resort

Siemens has the expertise to maintain your APACS+ and PCS 7

systems, minimizing risk during your modernization.
Integrating PCS 7 with APACS+ provides you with enhanced alarm management, the latest cyber security, and
integrated asset management. See other PCS 7 benefits and possibilities for your process by visiting us online at
www.usa.siemens.com/apacs2020.

Answers for industry.

APACS_Ad_3_ChemProc_MayJune_2011_SummitStamp.indd 1 4/14/2011 10:46:26 AM

CP1105_full page ads.indd 4 4/26/11 10:56 AM
 CONTENTS
MAY 2011 | VOLUME 74, ISSUE 5

14 21 30

COVER STORY COLUMNS

14 Debottlenecking Takes a Broader View 7 From the Editor: Could You Be the
Simulation techniques are allowing greater integration of Ultimate Plant Manager?
debottlenecking projects into wider plant operations. In ad-
dition, processes previously considered too difficult to model 8 Chemical Processing Online: Key
now are benefiting from the same techniques. Resource Resurfaces Online.

FEATURES 9 Field Notes: Don’t Zone Out On Area

DESIGN AND OPTIMIZATION Classifications.
21 Improve Your Refrigeration System
Using carbon dioxide as a refrigerant presents some technical 12 Energy Saver: Optimize Heat Exchangers.
challenges, but new pumps designed and optimized for CO2
can offer a number of benefits for refrigeration systems. 13 Compliance Advisor: EPA Issues Final
Rules for Boilers.
MAINTENANCE AND OPERATIONS
27 Set the Right Goals
42 Plant InSites: Find the Real Maximum
Many organizations have poorly scoped and compartmental-
Pressure.
ized performance measures and goals. These can encourage
behaviors that seem sensible for the particular group but cause
50 End Point: Bio-chem Industry Gets Social.
chaos for another.

SOLIDS AND FLUIDS HANDLING DEPARTMENTS

30 Properly Measure Liquid/Liquid Interfaces 10 In Process: Proteins Step Up as Biochemi-
Much confusion exists about the correct nozzle configurations cal Source | Resins Process Promises Plenty
for level measurements of liquid/liquid interfaces. Follow a of Pluses
simple ‘Golden Rule’ to determine the right nozzle placement.
40 Process Puzzler: Make the Best of a
INSTRUMENTATION AND CONTROL Blunder.
34 Be Levelheaded About Surge-Tank Control
Vessels used to smooth out flow pose special tuning issues. Be- 44 Equipment & Services
cause their aim is to ensure that changes in discharge flow are
less rapid and extreme than changes in feed flow, tight control 47 Product Spotlight/Classifieds
of level is counter-productive.
49 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
operating management in the chemical processing industries at no charge. To apply for a qualified subscription, fill in the subscription card. To nonqualified subscribers in the United States, subscriptions are $68
per year. Single copies are $14. Canadian and foreign annual subscriptions are accepted at $115 surface per year. Single copies are $16. Canada Post International Publications Mail Product Sales Agreement No.
40028661. Canadian Mail Distributor information: Frontier/BWI, PO Box 1051, Fort Erie, Ontario, Canada, L2A 5N8. Copyright 2011 Putman Media Inc. All rights reserved. The contents of this publication may not
be reproduced in whole or in part without the consent of the copyright owner. REPRINTS: Reprints are available on a custom basis. For price quotation, contact Foster Reprints, (866) 879-9144, www.fostereprints.
com also publishes Control, Control Design, Food Processing, Pharmaceutical Manufacturing and Plant Services. Chemical Processing assumes no responsibility for validity of claims in items reported.

5 CHEMICALPROCESSING.COM ● MAY 2011

CP1105_05_TOC.indd 5 4/26/11 2:15 PM

 Explosion
Protection
Codes and
Regulations
Overwhelming
You?

Fike can help you make the right decisions.

Proper explosion protection is essential for a safe facility. But may be hard to get your
hands around all the changing regulations, codes, and legislation in the U.S. Fike has been
providing explosion protection solutions for nearly 40 years. We have the expertise to help
you make good decisions to improve the safety of your facility and comply with regulations.
Without spending a fortune.

EP Solutions to Fit your

Facility and your Budget.
VENTING SUPPRESSION CONTROL TESTING

To request a free consultation with a Fike Explosion Protection

professional, email us at: EPanswers@Fike.com

1-866-758-6004 See Fike at NFPA, Booth #361 WWW.FIKE.COM

BASF
CP1105_full page ads.indd 6 4/26/11 10:56 AM

Could you Be the Ultimate Plant Manager?
A new online game lets you compete against others to achieve the best performing site
Last year, I editorialized that it would be great
to see a new generation of educational and entertain-
ing hands-on toys to get children interested in science
and technology — “We Need Another A.C. Gilbert,”
www.chemicalprocessing.com/articles/2010/017.
html. I added that using the virtual world to that
end certainly would help, too. While I haven’t seen
any new toys of that ilk on the shelves, a promising
online game debuted in late March. It comes from a
company that some might consider an unlikely source
— Siemens Industry, Inc., Alpharetta, Ga.
Siemens launched “Plantville,” www.plantville.
com, an online gaming platform that it says simulates
the experience of being a plant manager. “Players are
faced with the challenge of maintaining the operation
of their plant while trying to improve the productiv-
ity, efficiency, sustainability, and overall health of their
facility,” explains the company.
“Plantville is an innovative, educational and fun way
for Siemens to engage customers, employees, prospects,
students and the general public while driving awareness
of Siemens technologies and brand. The game enables
players to improve the health of their plants by learn-
ing about and applying industrial and infrastructure
products and solutions from Siemens. Gamers will be
measured on a number of Key Performance Indica-
tors (KPIs), including safety, on-time delivery, quality,
energy management and employee satisfaction.”
“Siemens is capitalizing on the tremendous growth
of online engagement to demonstrate how our expertise
can make industry and infrastructure more competitive
by increasing sustainability, energy efficiency and pro-
ductivity in a fun and educational environment,” says
Daryl Dulaney, Siemens Industry’s president and CEO.
“We also hope Plantville will generate excitement in the
areas of math, science and technology while inspiring a
new generation of plant managers and engineers.”
Players can select from three types of virtual
plants — vitamin production, bottling or train
manufacturing.
“The players must identify the challenges facing
their plant and implement solutions to improve their
plants KPIs. Gamers will compete with one another
on a number of levels, including plant-to-plant and on
specific KPIs,” notes the company.
As in the real world, every decision affects plant
performance. So, succeeding depends upon striking
the most appropriate balance among many factors.
Players can gain help and insight from the key char-
CP1105_07_Edit.indd 7
From The eDiTor
acter in this virtual world — Pete, the plant manager
of AC/DC Motors, whose facility has just been named
“Plant of the Year.” Pete shares his best practices and
hosts a leader board that shows the top gamers. He
interacts with players through live weekly chat sessions
in the so-called Plantville Cafe, which later will be avail-
able on demand, as well as via Facebook, LinkedIn and
Twitter. Engineers for
The Plantville Cafe also includes frequently asked
once should
questions, not just on the game, but also on five areas
of technology: drive technologies, industry services, outperform
industry automation, building technologies, and
teenagers in an
transportation and logistics. For instance, the Indus-
try Services section gives some advice on the most online game.
appropriate UV filtration system to provide acceptable
quality for up to 3,000 gal/min.
Pete also poses “puzzlers” that test problem-
solving skills (much like those in our long-running
Process Puzzler department, see, e.g., p. 40 and www.
ChemicalProcessing.com/voices/process_puzzler.
html). Solving a puzzler provides gamers with insights
for enhancing their plants’ performance. The first
person with the correct answer gets bonus points and
recognition on Plantville’s Facebook page.
The game also features a multi-media room with
a number of YouTube videos, including one in which
Pete answers questions at the press conference for the
Plant of the Year award.
“Plantville, like the plants within it, will undergo
updates and changes. Siemens will continue to de-
velop and enhance this innovative platform to reflect
the continuing advancement of its technologies, as
well as other elements that change or have an impact
on industry and infrastructure,” notes the firm.
I hope Plantville attracts lots of young people and
gets them interested in science and technology while
sensitizing them to the challenges of real-world manu-
facturing. However, engineers had better outperform
teenagers in this online game.
I also hope that other technology firms will follow
Siemens’ lead in developing such educational and
entertaining online offerings.
Mark rosenzweig, Editor in Chief
mrosenzweig@putman.net
7 chemicalprocessing.com may 2011
4/26/11 2:16 PM
 CHEMICAL PROCESSING ONLINE

555 West Pierce Road, Suite 301

Itasca, IL 60143

Key Resource Resurfaces Online Phone: (630) 467-1300

Fax: (630) 467-1109
www.chemicalprocessing.com

Site offers access to landmark work on preventative maintenance E-mail: cpnews@putman.net

RECENT NEWS about Southwest
Airlines grounding 79 of its older
Boeing 737 aircraft for inspections
after a hole that opened in the roof of
a similar plane forced an emergency
landing made me think about the
resource section I recently added to
All reliability- our website.
The section, Reliability-Centered
centered mainte-
Maintenance, (www.chemicalprocess-
nance came out ing.com/reliability_centered_mainte-
nance), features PDFs that provide a
of that study.
wealth of useful information for devel-
oping efficient scheduled (preventative)
maintenance programs for complex
equipment, and managing such pro-
grams on an on-going basis. These so-
called reliability-centered maintenance
(RCM) programs aim to achieve the
inherent safety and reliability capabili-
ties of equipment at a minimum cost.
Written by F. Stanley Nowlan and
Howard F. Heap for United Airlines
in 1978, this 520-page document
delves into many areas, including
four basic maintenance tasks, how to
Subscriptions/Customer Service:
(888) 644-1803 or (847) 559-7360
If you’ve ever had the pleasure to EDITORIAL STAFF
work with Eisenbise, you’ll know that
Mark Rosenzweig,
one of his favorite phrases is, “If you Editor in Chief, x478
mrosenzweig@putman.net
want peaches, you have to shake the
trees.” He started shaking the trees Amanda Joshi,
Managing Editor, x442
hoping that Chemical Processing would ajoshi@putman.net
post this document on its website. Ac- Traci Purdum,
cording to him, this document is hard Senior Digital Editor, x428
tpurdum@putman.net
to fi nd since it didn’t originate in an
Seán Ottewell,
electronic format — it was written on Editor at Large
a typewriter (gasp!). It was converted Ireland
sottewell@putman.net
to a PDF and Eisenbise divided it into
CONTRIBUTING EDITORS
three sections to make it more man-
ageable for our audience to download. Andrew Sloley,
Troubleshooting Columnist
Since its posting on our site at the Lynn L. Bergeson,
Regulatory Columnist
end of March, nearly 1,000 people Ven Venkatesan,
have accessed this resource. The three Energy Columnist
Dirk Willard, Columnist
PDFs are large (each is at least 150
DESIGN & PRODUCTION
pages), so they do take some time
to download. I have a high-speed Stephen C. Herner,
Group Art Director, x312
connection via my cable-TV pro- sherner@putman.net
vider that enables me to download Brian Hertel,
each PDF in a few minutes. You can Associate Art Director, x413
bhertel@putman.net
access the page directly by follow-
Rita Fitzgerald,
ing the URL at the beginning of this Production Manager, x468
column, or you can fi nd it under the rfitzgerald@putman.net

develop an initial RCM program, and
the role of scheduled maintenance. It
also goes into great detail on the na-
ture of failure, and RCM analysis of
systems, power plants and structures.
I fi rst learned about this docu-
ment from Michael Eisenbise, global
reliability implementation special-
ist for BP Downstream and past
chairman of the Society for Main-
tenance and Reliability Profession-
als. Eisenbise spoke at a condition
monitoring webcast that Chemical
Processing hosted in February. (You
can access the on-demand event
here: www.chemicalprocessing.com/
articles/2011/webcast-condition-
monitoring.html). He insists that this
32-year-old document is the bible for
maintenance and reliability profes-
sionals and often still refers to it. He
even states, “All reliability-centered
maintenance came out of that study.”
Resources tab of the menu bar on
ChemicalProcessing.com.
I certainly hope this document
proves worthwhile for you. I know
Mr. Peachtree himself thinks very
highly of it — and that’s saying a lot
from a reliability engineer with 35
years of experience.
TRACI PURDUM, Senior Digital Editor
tpurdum@putman.net.
SPECIAL REPORTS
Chemical Processing Special Reports
delve deep into current topics that
impact and influence your chemical
facility. Partnering with industry lead-
ers, these reports offer a wealth of
information on a single topic.
www.chemicalprocessing.com/spe-
cial_reports
EDITORIAL BOARD
Vic Edwards, Aker Solutions
Tim Frank, Dow Chemical
Ben Paterson, Eli Lilly
Roy Sanders, Consultant
Ellen Turner, Eastman Chemical
Ben Weinstein, Procter & Gamble
Jon Worstell, Consultant
Sheila Yang, Bayer
ADMINISTRATIVE STAFF
John M. Cappelletti, President/CEO
Julie Cappelletti-Lange, Vice President
Rose Southard, IT Director
Jerry Clark, Vice President of Circulation
Jack Jones, Circulation Director
REPRINTS
Jill Kaletha , Reprint Marketing Manager
jillk@fosterprinting.com
866-879-9144 ext. 168
Fax 219-561-2033
4295 S. Ohio Street,
Michigan City, IN 46360
Folio Editorial Excellence Award Winner

MAY 2011 CHEMICALPROCESSING.COM 8

CP1105_08_Web.indd 8 4/26/11 2:18 PM


Don’t Zone Out On Area Classifications
Electrical ratings must start with analysis of chemicals present
A fire erupted on May 4, 2009, at the Veolia ES
Technical Solutions Hazardous Waste Facility in West
Carrollton, Ohio, injuring two workers. The U. S.
Chemical Safety Board suggested that poor zone clas-
sification might have contributed to the incident.
The mission of Electrical Area Classification
(EAC) is to prevent a leak from leading to something
far worse. However, a hazard classification has conse-
quences beyond safety — it can complicate efforts to
fully utilize expensive plant real estate.
EAC is an arcane science. As an “expert” in EAC,
let me attempt to make it less mysterious.
The first step in classifying a zone is to identify the
chemistry there. Are you dealing with dust, flam-
mable or combustible liquid, flammable gas or some-
thing harmless? If material balance information isn’t
available, use Material Safety Data Sheets (MSDSs) to
define chemicals in the area.
The National Fire Protection Association (NFPA)
provides several references to explain EAC: NFPA-30,
“Flammable and Combustible Liquid Code;” NFPA-
499, “Recommended Practice for the Classification of
Combustible Dusts and of Hazardous Locations for
Electrical Installations;” and NFPA-497, “Recommend-
ed Practice for the Classification of Flammable Liquids,
Gases, or Vapors and of Hazardous Locations for
Electrical Installations in Chemical Process Areas.” In
addition, the American Petroleum Institute (API) offers
“Recommended Practice for Classification of Locations
for Electrical Installations at Petroleum Facilities Classi-
fied as Class I, Division 1 and Division 2.”
Another resource, the National Electric Code
(NEC) Standard 500, divides hazards into three classes:
Class I — gases and liquids, Class II — dusts, and Class
III — fibers. It further categorizes liquids from A to D
in order of decreasing risk. In contrast, NFPA-30 Sec-
tion 1.7 defines liquids in the following categories: Class
I — flammable liquids with flash point <100°F, Class
II — combustible liquids with flash point ≥100°F and
<140°F, and Class III — combustible liquids with flash
point ≥140°F. The NEC-500, upon which NFPA-497
and API-500 are based, subdivides ignitable vapors
and gases into groups: A, acetylene; B, 1,3 butadiene,
ethylene oxide, propylene oxide and H2; C, acetalde-
hyde, CO, ethylene and H2S; and D, the most common,
acetone, ethanol and other hydrocarbons.
Classifying dusts and fibers is more difficult. If a
dust layer forms, is less than 1/32-in. thick after 24
hours and its surface color is discernable, an area can be
CP1105_09_FieldNotes.indd 9
field notes
unclassified. Accumulated dust is more dangerous than
clouds; risk is greatest in dry conditions — as in winter.
NFPA and API also use relative density compared
to air to characterize gases and vapors. Heavier-than-
air vapors pose a greater risk because they hug the
ground. Light or hot gases rise and disperse.
Vapors and gases aren’t the same. In EAC work, a
vapor is a gas that condenses at 100°F or less at ambient Vapors are espe-
pressure. At these conditions, a gas has a compressibility
factor, Z, of 1; a wet gas has a Z less than 1. Vapors are cially dangerous
especially dangerous because they can evaporate and re- because they can
condense somewhere they may start a fire — that’s why
butane, with a boiling point of 31°F, is so dangerous! evaporate and
Determining whether a chemical is a hazard is the recondense.
most difficult challenge in EAC work. Here’re some
general guidelines for classification: 1) only consider
NFPA-30 Class I liquids — Class II and Class III liq-
uids don’t produce enough vapor, unless heated; 2) treat
a fire danger of at least 3 in an NFPA diamond (refer
to NFPA-704) as Class I; 3) categorize mixtures with
>30% H2 by volume as Group B (API-500, 5.5.5) and
mixtures with >25% H2S as Group C (API-500, 5.5.4)
— NFPA-497 Annex B provides a rule for estimating
the NEC group for mixtures of vapors or gases but it
doesn’t work for H2 and H2S; 4) when in doubt about
the chemistry use the worst case in evaluating a hazard;
and 5) if you can’t measure the molecular weight (MW)
of a complex organic, you can get a good estimate for
n-alkanes with MWs from 80 to 1,400 via the equation
in “Select the Right Hydrocarbon Molecular Weight
Correlation” by Donald Schneider of Stratus Engineer-
ing: MW = 3.3955×10-15Tbf 6 - 1.2416×10-11Tbf 5 +
1.8256×10-8Tbf4 - 1.3234×10-5Tbf 3 + 5.2285×10-3Tbf 2 –
0.741692Tbf + 116.19, where Tbf is the boiling point.
EAC is based on the auto-ignition temperature
(AIT) — the minimum temperature at which a
combustible material will burst into flame without an
external ignition source. AITs reported in MSDSs of-
ten aren’t tested for the particular mixture but reflect
testing of a pure compound. There are no mixing rules
for the AIT, which severely handicaps studies. Use the
following simplification if no other data are available:
for compositions containing compounds with MW
exceeding 50 use AIT = 280°C; for others, use 200°C.
In later columns, I’ll discuss enclosures, preparation
of drawings, defining envelopes and remediation.
Dirk willArD, Contributing Editor
dwillard@putman.net
9 chemicalprocessing.com may 2011
4/26/11 2:18 PM
 in process

Proteins Step Up As Biochemical Source

Such feedstocks promise advantages over carbohydrates and lipids
Protein Researcher
ReSeARcheRS At the Henry Samueli School engineer microbial cells
of Engineering and Applied Science at UCLA, Los to control their cellular
Angeles, have discovered for the first time a way to nitrogen metabolism.”
use proteins as a potential raw material for biomass The process Liao’s
production. Currently, only two types of raw materi- team developed uses
als, carbohydrates and lipids, are used to produce an artificial metabolic
biofuel and other bio-based chemicals. system to dump reduced
“Proteins had been completely ignored as a nitrogen out of cells.
potential biomaterial because they’ve been thought of This tricks the cells
mainly as food. But in fact, there are a lot of differ- to degrade proteins
ent proteins that cannot be used as food,” says James without utilizing them
C. Liao, the Chancellor’s Professor of Chemical and for growth. Liao’s team
Biomolecular Engineering (Figure 1). “These proteins then removed the am-
were overlooked as a resource for fuel or for chemicals monia in the proteins
because people did not know how to utilize them or and recycled it back Figure 1. Professor James C. Liao
how to grow them. We’ve solved these problems.” for the growth of the and his team have discovered a
“This research is the first attempt to utilize protein algae they worked with. way to use proteins as a potential
raw material for bio-mass produc-
as a carbon source for energy production and biorefin- Algae, which can grow tion. Source: Don Liebig, UCLA.
ing,” adds Kwang Myung Cho, a UCLA Engineering quickly, were used only
research scientist. “To utilize protein as a carbon source, as a carrier to assimilate carbon dioxide and produce
complex cellular regulation in nitrogen metabolism protein, resulting in more CO2 fixation and growth.
had to be rewired. This study clearly showed how to This strategy eliminates the use of expensive photo-
bioreactors. More details appear in a recent paper in
economic Snapshot Nature Biotechnology.
85.0
The advantages of using proteins are numerous.
63,000
Proteins are a major component in fast-growing micro-
84.0
62,000 organisms and their accumulation rate surpasses that of
83.0
any raw material. The recalcitrance problems of ligno-
61,000 82.0 cellulose or the dewatering problem of algal lipids don’t
81.0 surface in proteins. Compared to cellulosic biomass,
60,000
80.0 which is difficult to break down, protein biomass can
59,000 79.0 be much more easily digested for microorganism use.
78.0
However, challenges remain in protein-based biorefin-
58,000 ing. The researchers note it has been difficult to effectively
$ Million

77.0
%

57,000
convert protein hydrolysates to fuels and chemicals.
76.0
“Microorganisms tend to use proteins to build
75.0
56,000 their own proteins instead of converting them to
74.0 other compounds,” says Yi-xin Huo, a postdoctoral
55,000
73.0 researcher and lead author of the study. “So to achieve
54,000 72.0 the protein-based biorefining, we have to completely
71.0 redirect the protein utilization system, which is one of
53,000
70.0
the most highly regulated systems in the cell.”
Further, Liao notes large-scale algae production
52,000 69.0
and nitrogen recycling “will certainly introduce new
68.0
Mar 10 Apr 10 May 10 June 10 July 10 Aug 10 Sep 10 Oct 10 Nov 10 Dec 10 Jan 11 Feb 11
and unknown challenges.”
Shipments (NAICS S325) Capacity utilization “We are currently testing conditions for open algae
culture in preparation for large-scale cultures. The labo-
Shipments rose slightly but capacity utilization slipped a bit. ratory experiment will take at least two years,” he adds.
Source: American Chemistry Council.
While current research focuses on using proteins

May 2011 cheMicalprocessing.coM 10

CP1105_10_11_InPro.indd 10 4/26/11 2:19 PM

 in process

how do you expect staffing to change at your site over

the next twelve months?
for alcohols as a proof of principle, Liao says that
making other compounds, such as bulk chemicals, 5.6%
Modestly decrease
monomers and pharmaceutical intermediates should
27.8%
follow without much of a scientific barrier. 27.8% Significantly
Modestly decrease
The current process achieves 56% of the theoreti- increase
cal yield for the protein-to-alcohol conversion. Liao
believes a mature process could reach 85–95% of the
theoretical yield. Prospective changes
Compared to other biomass-based alcohol routes, in staffing level defy
consensus. To participate
Liao predicts the cost of the new protein process will in this month’s poll, go to
be lower “because the process avoids the difficult ChemicalProcessing.com.
lignocelluloses deconstruction problem.” 5.6%
Liao expects to reach pilot-plant stage in three Significantly
increase
to five years, but says large-scale commercialization 33.3%
could take more than 10 years. Stay the same

Responses (%)

Resins Process Promises require a catalyst, although one can be used. “We have

Plenty of Pluses achieved very high yields. Quantitative yields are pos-
sible,” notes Rothenberg. “The operating conditions
Dutch ReseaRcheRs have used feedstocks de- are similar to those used in the resins industry.”
rived from biomass to make thermoset materials ranging The researchers now are evaluating how the resins’
from rigid foams to flexible sheets. These materials, in physical and mechanical properties and processabil-
contrast to today’s petrochemical-based thermosets, are ity compare to conventional products. They expect
fully biodegradable and non-toxic and don’t release any to have results shortly. “We must provide the same
harmful substances upon combustion, say Prof. Gadi performance or better at the same cost or, preferably,
Rothenberg and Dr. Albert Alberts (Figure 2) of the lower,” says Rothenberg. “Right now, it looks like our
Heterogeneous Catalysis and Sustainable Chemistry re- materials will be considerably cheaper.”
search group at the University of Amsterdam. Moreover, The new resins potentially could replace polyure-
the straightforward process and renewable-resource- thane and polystyrene in construction and packaging
based feedstocks promise plastics that are significantly applications and epoxies in the production of plywood
less expensive than those produced conventionally from and medium-density fiberboard.
petrochemicals, they add. Process development work is underway — scaling
The process not only is straightforward but doesn’t up the five main product types to the kilogram level.
Biomass-based Plastics
The key challenge, he says, is “proving to ourselves
and others that we can make kilos of this material at
a cost that is substantially lower than the competing
petroleum-based plastics.”
If all goes well, piloting might start in as soon as 12
to 18 months. Already over 25 companies have shown
interest in cooperating on the development, he notes.
The researchers don’t yet know whether industrial
scale production will pose any particular obstacles. “But
we do not see any crucial process engineering problems,”
says Rothenberg. The technology most likely will be
ready for commercialization in four years, he adds.
Experienced plastics people told Rothenberg: No
self-respecting polymer scientist would ever try this
out because it is known that doing something like this
is stupid and only leads to trouble — but you did not
know this and so you tried and apparently it works. So,
Figure 2. Materials may offer both environmental and economic
advantages, say researchers Rothenberg (right) and Alberts. he counsels: “Go and try those crazy ideas, and long
Source: Patrick Post, Trouw. live the Friday afternoon experiments!”

11 chemicalprocessing.com may 2011

CP1105_10_11_InPro.indd 11 4/27/11 2:20 PM

 energy saVer
Optimize Heat Exchangers
Three parameters govern a heat exchanger’s effectiveness
It Is very rare to see a process plant without a heat
exchanger. Usually, the effectiveness of the heat
exchanger is critical and, in some cases, even deter-
mines the overall energy efficiency of the plant.
Heat exchanger design addresses the suitabil-
ity for the f luids involved and maintainability,
among other factors (see “Keep Others from
Fouling silently Making ‘Classic’ Mistakes,” www.chemicalpro-
cessing.com/articles/2007/070.html). Here, how-
robs the ever, we’ll focus on existing heat exchangers.
efficiency of an The effectiveness of a heat exchanger installed
in a process plant is governed by the following
exchanger. three parameters: 1. the area available for heat
transfer; 2. the overall heat transfer coefficient;
and 3. the difference in temperature between the
hot and cold f luids.
Because plant engineers don’t have much control
over the area of an existing heat exchanger, let’s
focus on the overall heat transfer coefficient and the
temperature difference. In simplified terms, heat
exchanger effectiveness drops due to both fouling
of the heat exchange surface and falling approach
temperature in the exchanger.
Exchanger fouling is the most common prob-
lem encountered that silently robs the efficiency
of a heat exchanger. Fouling not only reduces
heat exchanger effectiveness but, in certain cases,
could lead to more valuable process streams be-
ing put into less valuable byproduct streams. For
example, petroleum refineries suffer when mar-
ketable propane and butane (LPG) are dumped
into the non-saleable fuel gas stream due to less
efficient heat exchanger systems.
The plant engineers must evaluate the fre-
quency needed for exchanger tubes’ cleaning to
maintain the fouling at low levels. Both on-line
and off-line cleaning techniques are available to
minimize exchanger tube fouling. Also, in certain
types of heat exchangers, such as water-cooled
condensers, it is essential to analyze the quality
of cooling water periodically and to control its
scaling properties. For more on fouling, check out
“Avoid Fouled Exchangers,” www.chemicalpro-
cessing.com/articles/2008/074.html.
Monitoring the approach temperature is also
crucial to process equipment — especially those
linked to water-cooled condensers. When the
cooling water to a power-plant turbine condenser
is supplied 5°F above normal, the vacuum in
May 2011 cheMicalprocessing.coM 12
CP1105_12_EnergySaver.indd 12
the condenser — and consequently the tur-
bine power output — could drop by 1–2%. For
turbo-alternators with capacities over 10MW, this
would result in a huge power output loss for every
operating hour.
In plants with multiple streams of process heat-
ing and cooling, it is necessary to conduct a Pinch
analysis. Now, well-tailored heat-exchanger-network
software programs are available for optimizing a
plant’s overall heat-transfer operations. For smaller
plants, simple spreadsheet-based software programs
can handle Pinch analysis. Such analysis can help
modern plants achieve higher heat recovery, lower
cooling tower loads and decreased heat input at the
process heaters.
Consider the following techniques, as applicable,
to optimize heat exchanger efficiency:
1. Changing from series to parallel exchanger
operation. Piping modifications may allow
switching heat exchangers from series to parallel
operation. This might help lower pressure drop
without compromising much of the heat exchang-
ers’ effectiveness.
2. Checking and correcting exchanger tube veloci-
ties. Periodically assess the tube velocities of water-
cooled exchangers with heat- and mass-balance
calculations and adjust the flow to stay above a
minimum of 3 ft/sec.
3. Increasing air flow to air-cooled exchangers.
During summer months, boosting the fan speed in
an air-cooled exchanger could compensate for the
increase in air temperature.
4. Adding more heat exchanger surface. Install-
ing more plates in plate-type heat exchangers
and replacing an existing ordinary tube bundle
with a high-f lux one in shell-and-tube exchangers
may help in some cases. (For more on shell-and-
tube exchangers, see “Succeed with Condensate
Control,” www.chemicalprocessing.com/ar-
ticles/2008/107.html and “Eliminate Exchanger
Tubing Troubles,” www.chemicalprocessing.com/
articles/2007/214.html).
5. Replacing shell-and-tube exchangers with plate
heat exchangers. When the approach temperature
is low, consider switching out a shell-and-tube ex-
changer for a plate unit.
VEn V. VEnkatEsan, Energy Columnist
VVenkatesan@putman.net
4/26/11 2:20 PM

EPA Issues Final Rules for Boilers
New subcategories place emission limits on different types of boilers
ThE U.S. Environmental Protection Agency (EPA)
reports that more than 200,000 boilers, process heaters
and incinerators will be impacted by a set of Clean Air
Act regulations issued on February 21, 2011. Since EPA
first proposed the Maximum Achievable Control Tech-
nology (MACT) rules in April 2010, several industry
sectors have argued the costs of implementing the rules
would pose an unreasonable burden on businesses. In
response to this criticism, EPA revised the rules in a
manner that it believes cuts the cost of implementation
by about 50%.
ThE NEw RUlES
EPA issued in February four sets of final regulations.
The first applies to boilers at major sources of toxic
emissions. This will impact about 13,800 boilers. The
second rule applies to boilers located at smaller sources
of emissions, referred to as area sources. About 187,000
boilers are subject to this rule. A third rule applies to
commercial and industrial solid waste incinerators,
while the fourth sets emission standards for sewage
sludge incinerators. Collectively, there are about 300
solid waste and sewage sludge incinerators.
EPA issued the proposed rules in April 2010 and
was immediately flooded with some 4,800 com-
ments objecting to provisions in the rules. In the
wake of these comments, EPA revised the proposed
standards. EPA now estimates that for every dollar
spent to cut these pollutants, the public will see $10
to $24 in health benefits. Because the final standards
significantly differ from the proposals, EPA believes
further public review is required. Therefore, EPA will
reconsider the final standards and seek additional
public review and comment.
The most controversial of the four rules is the
MACT for boilers and process heaters located at major
sources of air pollution. EPA made several changes
requested by industry, such as creating subcategories of
emission limits for certain types of boilers. However,
EPA declined an industry request that it adopt a health-
based standard that would exempt units from the rule.
For boilers and process heaters located at major
sources, the final rule establishes a work practice stan-
dard instead of numeric emission limits. The operator
will be required to perform an annual “tune-up” for
each unit. Units combusting gases other than natural
gas can qualify for work practice standards by demon-
strating that they burn “clean fuel,” with contaminant
levels similar to natural gas.
CP1105_13_Comp.indd 13
compliance advisor
All new and existing units with a heat input
capacity less than 10 million Btu/hr and “limited use”
boilers (those that operate less than 10% of the year, as
emergency or backup units) also require a work prac-
tice standard — and a tune-up once every two years.
For all other existing and new boilers and process
heaters located at major sources (including those that
burn coal and biomass), the final rule sets numeric EPA made several
emission limits. The rule also establishes emission limits
for mercury, dioxin, particulate matter (PM), hydrogen changes industry
chloride, and carbon monoxide (CO) and requires had requested
monitoring to assure compliance with emission limits.
The standards for units located at area sources but declined a
address emissions of mercury, PM and CO and are bi- major one.
furcated into standards for new boilers and those for ex-
isting boilers. For new boilers, the final rule requires that
coal-fired boilers with heat input equal or greater than
10 million Btu/hr meet emission limits for mercury, PM
and CO. Biomass and oil-fired boilers with heat input of
at least 10 million Btu/hr must meet emission limits for
PM. Boilers with heat input less than 10 million Btu/hr
must perform a boiler tune-up every two years.
Existing coal-fired boilers with heat input of at
least 10 million Btu/hr must meet emission limits for
mercury and CO. Biomass boilers, oil-fired boilers
and small coal-fired boilers are not required to meet
emission limits. They must perform a boiler tune-up
every two years to improve combustion efficiency.
This will optimize fuel use and thus reduce emissions
of mercury and all other air toxics. All area source
facilities with large boilers also are required to conduct
an energy assessment to identify cost-effective energy
conservation measures.
EPA’s changes to the rule and its plans to recon-
sider portions of it do not appear to have assuaged
industry’s concerns. Several industry sectors and trade
associations have pledged to continue to push EPA for
additional revisions. Stay tuned, as this area is being
closely watched.
lyNN BERgESoN and ChRISToPhER R. BRyANT
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. Christopher R. Bryant is a senior regulatory and policy
analyst with B&C. The views expressed herein are solely those of
the author. This column is not intended to provide, nor should be
construed as, legal advice.
13 chemicalprocessing.com may 2011
4/26/11 2:21 PM
 Debottlenecking
takes A broader View Modeling is
gaining a
greater role
in improving
throughput
and energy
efficiency

By seán ottewell,
editor at large

May 2011 cheMicalprocessing.coM 14

CP1105_14_20_CoverStory.indd 14 4/27/11 10:27 AM

 Simulation techniqueS are enabling greater integration of
debottlenecking projects into wider plant operations. At the same time,
processes previously considered too difficult to model now are benefiting
from the same techniques.
“The key issue now is getting the model to fit the plant,” says Rian
Reyneke, senior advisor, process consulting services, AspenTech, Burlington,
Mass. “For example, you might have to choose between repacking a tower
or installing a completely new one. But is the model good enough to give
the correct answer? So we spend a lot of time validating simulation models
because we have to have complete confidence in them. Otherwise the client
will default to the more conservative solution — a replacement tower, for
example — which is generally a more expensive approach and, in the extreme,
may render the project unviable. What we are trying to help clients achieve is
to squeeze as much out of their plants without big capital charges.”
AspenTech’s strategy is to seek more innovative and lower-cost debottle-
necking solutions by looking at the system in a broader way, considering
whole plant operation from a process and energy point of view as opposed
to addressing each bottleneck in isolation.
“Our teams look at both the process and energy sides and consider both
design and the operation. It’s a very multi-faceted approach to debottleneck-
ing. So we can offer better design while also limiting operational costs. And
by better designs we mean greater process flexibility, lower energy costs and
often optimal capital investments. It is ultimately an optimization solution
in response to the customer’s business objectives,” says Sanjeev Mullick,
director, industry marketing, AspenTech.

incReaSinG inteReSt
A telltale sign is the record number of papers on debottlenecking to be
presented at the company’s Optimize 2011 global conference in Washing-
ton, D.C., in late May.
One such case study involves a 39,000-tonne/yr Reliance Industries’ ac-
rylonitrile plant in India. Here, AspenTech’s modeling tool, Aspen Plus, was
used to develop a steady-state model of the total plant in an effort to address
a number of processing challenges. The simulation so far has spurred a 50%
reduction in hydrogen cyanide emissions, a 75% decrease in effluent color
and a 15% increase in acetonitrile concentration. An ongoing study at the
same site also might lead to a cut in flare losses that currently are running
the equivalent of about $22,500/yr.
“The capability of Aspen Plus for simulation of large flowsheets with
complex unit operations and highly non-ideal systems helped us in develop-
ing a plant model that is being utilized for process optimization, environ-
mental protection, plant safe operation, and energy optimization,” notes
Reliance’s abstract.
Another project spotlighted at the conference involves cryogenic unit
number one at Pemex’s Ciudad Pemex gas processing plant in Mexico. It
had been operating at an efficiency of 76.72% for C2+, well below its origi-
nally designed capability of 81.94%. Once updated to reflect the plant’s cur-
rent operating conditions, the Aspen Plus model pinpointed low efficiency
in a heat transfer unit. Adjusting that unit gave a production improvement
worth $7.6 million/yr.
“When considering energy, it is important to remember that many of
these projects get their payback via energy reduction. It’s not necessarily

15 chemicalprocessing.com may 2011

CP1105_14_20_CoverStory.indd 15 4/26/11 2:22 PM

 Porvoo Complex
Figure 1. Finnish site achieved a record-fast startup, increased capacity and lower emissions thanks to modeling.
Source: Borealis.
extra production capacity that a customer is look-
ing for. Debottlenecking projects often involve both
increasing throughput and reducing energy consump-
tion. So we always deal with them together. There is a
big drive to reduce specific energy consumption and
to reduce the carbon footprint. Companies want these
projects to have an attractive payout in both situations
of increased or lower product demand,” notes Mullick.
At the end of the day, he adds, the better the
model, the better the insight into potential debottle-
necking opportunities.
As an example of this in action, Mullick cites a
recent project carried out on a Dow plant in the U.S.
The plant uses four large thermosiphon reboilers to
supply heat to bottoms that are recycled back into a
main distillation column where an organic product
is separated from an organic peroxide. However, the
emergence of significant flow oscillations in the col-
umn raised fears that the peroxide could be nearing its
decomoposition point — a potential explosion hazard.
So, production was cut back.
To understand what had changed in the process,
Aspen Plus was used to simulate the operation of the
thermosiphons — replicating what was happening in
the field by increasing the pressure on the hot side of
the heat exchanger model.
The modeling led to two potential solutions, with
the one finally chosen being somewhat controversial.
May 2011 cheMicalprocessing.coM
CP1105_14_20_CoverStory.indd 16
It involved placing a valve at the outlet to the high
vapor compartment on the process side of the thermo-
siphon to suppress vaporization on the thermosiphon
side and allow some vaporization on the column side
of the valve. This only works because the compart-
ments are completely sealed from one another for
safety reasons.
The result was elimination of column flow
oscillations, a 13% increase in column capacity and
lowering of peroxide composition to a safe operating
level — overall, a debottleneck worth $65 million/yr
in extra capacity.
MORE SUCCESSES
Meanwhile, Honeywell Process Solutions, London,
Ont., notes its UniSim simulation solution is in de-
mand in the oil and gas, air separation and plant con-
struction sectors. “Within these there are a number of
large segments, for example, oil-and-gas production
and treatment, petrochemicals and end products. So
debottlenecking projects can include, for example,
greenfield design, process optimization and flare
analysis,” says Peter F. de Jonge, a Calgary, Alta.-based
simulation business consultant at the firm.
The company has just completed a typical
debottlenecking project at Borealis’ main integrated
petrochemical complex in Porvoo, Finland. The site
includes a cracker for the production of olefins (ethyl-
16
4/26/11 2:23 PM
 When the right
reaction matters ...

Trust BASF Process Catalysts

and Technologies
At crucial moments, the right reaction matters. When you are
looking for the right reaction from your process catalyst, turn to
BASF. Our technical experts will recommend the right catalyst
from our innovative product line that will achieve the desired
reaction. The end results may also include greater yield and
better end product properties. When the catalyst is right, the
reaction will be right. Trust BASF.
 Adsorbents  Chemical catalysts  Custom catalysts

 Polyolefin catalysts  Refining catalysts

For more information, please visit

www.catalysts.basf.com/process

BASF 4167page
Chemical Processing CCP Ad_R1.indd 1 6/2/0910:56
3:34AM
PM
CP1105_full ads.indd 17 4/26/11
 Multi-tubular Reactor
Figure 2. Key design objective is to ensure uniform horizontal temperature distribution to minimize catalyst deactivation.
Small adjustments in internal geometry provided better results (right). Source: PSE.
ene, propylene and butadiene), a phenol and aromatics
plant that produces phenol, acetone, benzene and
cumene, two polyethylene plants and one polypropyl-
ene plant (Figure 1).
UniSim helped Borealis debottleneck a plant
expansion. Specific benefits include: a record-fast
startup, documented as the best in the history of the
Porvoo cracker: ethylene product was on-spec in an
unprecendented three days, ten hours from feed in
— two days earlier than planned; ramp-up was the
best ever recorded, with the new production capacity
target exceeded in just 21 days; average normalized
production rate versus boilerplate capacity 45 days af-
ter feed in was at 92%, compared with 67% and 57%
for previous turnarounds; flaring losses were 2,000
tonnes less than ever before. Return on investment
was significant, with the total value of the startup
improvements estimated to be over five times the cost
of the simulator.
UniSim also has helped with new controls and pro-
cedures at Porvoo. In one case, after a steam loss caused
a plant shutdown, the simulator was used to develop a
mitigation practice to allow operations to be main-
tained if the same thing happened again. Similarly,
UniSim has served to test and optimize a new fuel-gas
lineup and controls — allowing a flawless hot cutover.
May 2011 cheMicalprocessing.coM
CP1105_14_20_CoverStory.indd 18
Honeywell also is seeing a rise in demand for
debottlenecking procedures associated with less tradi-
tional technologies such as shale oil extraction.
“In Alberta, for example, there is a lot of growth
in steam-assisted gravity drainage. A lot of new plants
are being constructed there with a potential need for
debottlenecking in water treatment, oil handling and
steam generation. Such processes are very heat inte-
grated, presenting good opportunities for process and
capital cost optimization. But this is a very industry-
specific, localized example,” explains Pete Henderson,
product manager for the simulation business.
A less-localized example of increasing demand is
in power generation, particularly for new clean coal
technologies. “A lot of these essentially involve the gas-
ification of coal and are becoming more like chemical
facilities themselves. There are some different unit
operations involved in gasification, some peculiarities,
for example, coal crushing and gasification equip-
ment. You also have to consider the hardness of the
coal, its particle characteristics; these are fundamental
things. So UniSim has to move, too,” notes de Jonge.
A urea-granulation debottlenecking project il-
lustrates another new area. Here, the company used
a third-party simulation package but transferred the
operating conditions from a UniSim design. “It’s a
18
4/26/11 2:23 PM
 very extensible product, which
makes it very customizable,” adds
Henderson.

EXPANDING EFFORTS
Process Systems Enterprise
(PSE), London, U.K., also is
benefiting from broader work in
debottlenecking.
One key business area is
purified terephthalic acid (PTA)
production, where its flagship
gProms high-fidelity predictive
modeling platform is at the heart
of debottlenecking activities.
“We are doing work with a lot
of PTA manufacturers on a range

Save hours of
of different options — on one
level adjusting concentrations of
feedstock, on a second level rede-
signing internal configurations of,

cleaning time
for example, feed locations, during
shutdown. Depending on the
price of paraxylene and acetic acid
feedstocks, these can yield $2–4
million/yr in reduced feedstock
costs,” says Mark Matzopoulos,
chief operating officer and market-
With a Saflex™ 3000 water jet system from NLB, an operator can
ing director. The payback period clean three tubes at once and stay well clear of the action. Key
typically is 6–12 months, depend- features include:
ing on whether the project requires
■ Operating pressures to 40,000 psi
capital expenditure.
A recent success has come ■ Convenient wireless controls
from its work with Spain’s Rep-
sol, which is working on a new ■ Adjustable for tube length and I.D.
hydrogen peroxide to propylene
■ No hose reel needed
oxide (HPPO) process to compete
against those being developed by The Saflex™ 3000 is one of several NLB
other manufacturers. tube bundle cleaning systems, automated
“We have been carrying out and semi-automated, to suit different user
model-based optimization of the
needs. For details — and a free white
reactor and separation sections.
The key here is the complex multi-
paper — visit our website
tubular reactor, which is difficult www.nlbcorp.com or give us a call.
to design to give uniform per-
formance across the tube bundle
(Figure 2) — it is also very difficult
to model. Poor design leads to
NLB. The Leader in Water Jet Productivity
unwanted side reactions and the
potential for hot spots. So we con-
structed a flowsheet that included
(248) 624-5555
a high-fidelity multi-tubular
nlbmktg@nlbusa.com

CP1105_14_20_CoverStory.indd 19 4/26/11 2:24 PM

 RELATED CONTENT ON CHEMICALPROCESSING.COM
“Discrete Event Simulation Offers Real Value,” www.ChemicalProcessing.com/articles/2011/discrete-
event-simulation-offers-real-value.html
“Consider Discrete Event Simulation,” www.ChemicalProcessing.com/articles/2010/178.html
“Profit More from Process Simulation,” www.ChemicalProcessing.com/articles/2009/157.html
“Achieve Model Operations,” www.ChemicalProcessing.com/articles/2008/087.html
“Dig Deeper to Find More Capacity,” www.ChemicalProcessing.com/articles/2005/580.html
“Succeed at Plant Debottlenecking,” www.ChemicalProcessing.com/articles/2004/35.html

reactor model and a separation
section with many columns, and
performed a rigorous economic
optimization that maximized
annual profit as the objective func-
tion,” explains Matzopoulos, who
adds that PSE specializes in reactor
optimization of all kinds.
This model involved 49 deci-
sion variables, which is way beyond
what anyone has done before, he
claims. It included, for example:
reactor design decisions such as
tube diameter, pitch and quantity;
distillation column operating deci-
sions such as reflux ratios and pres-
sures; intermediate stream purities;
and configuration decisions such as
number of trays.
“The outcome was an improve-
ment in process economics of tens
of millions of euros per year — the
result of losing two distillation
columns, just one of which had
capital and operational costs of €5
million/yr,” he notes.
PSE also is finding increasing
customer interest in using dynamic
modeling to reduce the size of flare
systems needed and minimize
use of expensive alloys for low-
temperature operation — enabling
significant cuts in capital cost.
“The current steady-state
techniques widely used can lead
to gross over-design. It is now
possible to perform dynamic
capacity analyses for revamps that
can demonstrate that the required
capacity already exists — where
steady-state analyses showed that a
new flare line was required — sav-
ing millions of dollars,” Matzopou-
los stresses.
The company carries out a lot
of work with customers on new
process development, all the way
from laboratory experimenta-
tion to detailed equipment design
and full plant optimization. “The
earlier model-based engineering
techniques are applied, the greater
the economic benefit in terms of
accelerating innovation and devel-
opment, reducing technology risk,
and in designing plants with better
economic performance — Repsol
being a case in point,” he adds.
Debottlenecking also is
becoming a watchword in more
general processing sectors such
as foods, pharmaceuticals and
consumer goods, to which many
modeling tools traditionally
don’t cater. “One of the biggest
innovators out there is Procter &
Gamble. We developed gSolids in
collaboration with the company
and this is a step change when
it comes to modeling solid flows
around the flowsheet. Drying is
also a big issue in these operations,
so optimization of recycle flows
to minimize equipment size and
energy costs is another important
area where millions of dollars per
year can be saved.”
It’s a similar story with gCrys-
tal, which optimizes crystallization
processes. “Here we are usually
dealing with batch processes in
which we can halve the batch time
— so double the throughput — by
optimizing cooling curves, for
example,” notes Matzopoulos.

CP1105_14_20_CoverStory.indd 20 4/26/11 2:24 PM

 New refrigerant pumps for carbon dioxide offer significant benefits
By Bjarne Dindler Rasmussen, Grundfos Pumps

MANY PEOPLE regard carbon dioxide as the
most promising refrigerant for several applica-
tion areas. It’s a natural substance with excel-
lent heat transfer properties and when used as a
refrigerant generally provides opportunities to
enhance system energy efficiency and consider-
ably lower overall environmental impact.
However, using CO2 as a refrigerant brings
some new technical challenges because both its
critical point and triple point fall within the
envelope of practical use. In addition, some
thermodynamic and transport properties (e.g.,
saturation pressure level and liquid viscosity)
are extreme compared to traditionally used
refrigerants (NH 3, HCFCs and HFCs). Table
1 compares some properties of select refriger-
ants relevant to process plants and refriger-
ant pumps. The most significant differences
between CO2 (R744) and the other refrigerants
are its low critical temperature, high saturation
pressure, very low kinematic viscosity and low
surface tension.
In the last 10 years, many technical chal-
lenges related to CO2 have been successfully

Comparison of Refrigerant Properties

Refrigerant
Property R744 R717 R134a R22 R410A
Critical temperature, °F 87.76 270.1 213.9 205.0 161.8
Critical pressure, psia 1,070 1,644 588.7 723.5 714.5
Table 1. Carbon
Saturated liquid density, lbm/ft3 62.07 40.89 83.31 81.91 76.49
dioxide differs
Saturated vapor density, lbm/ft3 4.412 0.1375 0.5761 0.8809 1.274 considerably from the
other refrigerants in a
Latent heat of vaporization, Btu/lbm 113.6 560.4 89.25 91.66 102.1 number of key proper-
ties. Source: Ref. 1.
Liquid kinematic viscosity, lbm/ft-hr 0.07154 3.436 1.309 0.6358 0.3745
Surface tension, lbf/ft 4.50E-04 1.94E-03 9.15E-04 9.34E-04 7.81E-04

21 CHEMICALPROCESSING.COM MAY 2011

CP1105_21_26_Design.indd 21 4/26/11 11:31 AM

 overcome for components such as compressors,
valves and heat exchangers. Now, commercially
competitive versions of these components de-
signed and optimized for CO2 are available on the
market.
Refrigerant pumps have been offered for 60+
years. Most were typically designed for general
chemical industry service and then modified to
CO2 Refrigerant Pump
Figure 1. Use of CO2 requires significant changes in pump design.
Indirect System
Condenser
Compressor
operate with the substances used as refrigerants
(e.g., NH 3 and R22). Due to increasing demands
for low leakage levels, most refrigerant pumps to-
day rely on canned motors or magnetic couplings.
Commercially competitive refrigerant pumps
designed and optimized for CO2 have been on the
market for less than one year (Figure 1).
PUMP ISSUES
The specific challenges for refrigerant pumps oper-
ating with CO2 are:
High system pressure. The saturation pressure of
CO2 is much higher than that of the traditionally
used refrigerants. At 40°F (4°C) the saturation
pressure is 550 psig (38 bar g). Today 750 psig (52
bar g) seems to satisfy most demands — but in
the near future some types of systems will need
a maximum system pressure of 950 psig (65 bar
g). In addition, standstill requirements for many
systems demand a maximum system pressure up
to 1,750 psig (120 bar g).
Subcooling from liquid column. A column
above the pump inlet changes the liquid refriger-
ant condition from saturated to subcooled. This
ensures that internal losses in the pump’s inlet
section don’t generate vapor that can reduce pump
performance. For most traditional refrigerants
each foot of liquid column provides consider-
able subcooling; at nominal operating conditions
the net positive suction head required (NPSHR)
typically is limited to 3–5 ft (1–1.6 m). For CO2 ,
a 3–5-ft liquid column produces practically no

Natural or
subcooling due to the different relation between
synthetic refrigerant saturation pressure and temperature. Therefore, re-
ducing inlet losses and establishing a high degree
of hydraulic robustness to vapor bubbles become
very important design elements for a CO2 pump.
Low liquid viscosity. CO2’s liquid viscosity is
Cascade HX
lower than that of NH 3, HCFC and HFC. For
media-lubricated bearings, viscosity is a very im-
portant parameter for bearing lifetime.
Low surface tension. CO2’s surface tension also
is lower than that of NH 3, HCFC and HFC. Va-
por generated will appear as numerous very small
CO2
bubbles — typically creating a foamy mixture
Pump

(liquid overfeed or DX) instead of a separated liquid and vapor flow.

Low refrigerant temperature. During evacua-
tion, service and charging processes low tempera-
tures occur — the pressure can drop below the tri-
Evaporator(s)
ple point pressure of 75.4 psia (5.2 bar), leading to
formation of dry ice. At atmospheric pressure, dry
Figure 2. Such designs may markedly cut primary refrigerant charge. ice sublimates at a temperature of -108°F (-78°C)

May 2011 cheMicalprocessing.coM 22

CP1105_21_26_Design.indd 22 4/26/11 11:34 AM

 or below. Temperatures in refrig- 1. Indirect system. CO2 tion, significantly decrease
erant pump environments can serves as a secondary volatile primary refrigerant charge when
reach -150°F (-100°C). refrigerant with circulation that refrigerant has a high global
Operation “close” to critical established by a mechanical warming potential (GWP) or is
point or triple point. The differ- pump. The main drivers for flammable or toxic, and increase
ence between liquid and vapor this option are to considerably system energy efficiency. Stud-
density generally is lower for reduce system energy consump- ies show that indirect systems
CO2 than for all other refriger-
ants. As the critical point is ap-
proached, the density difference
goes toward zero. Therefore,
density-difference-driven liquid/
vapor separation isn’t as effective
for CO2 as for other refrigerants.
As the condition comes closer
to the triple point, dry ice may
form inside the pump, poten-
tially damaging canned-motor
centrifugal pumps. #1 in Bearing Isolators
These challenges call for a www.inpro-seal.com
pump design with few seals and
small dimensions. Hydraulic
robustness to vapor in the inlet
must be high. Vapor bubbles
will form there frequently
because liquid subcooling will
be practically zero and the vapor
and liquid don’t separate well.
Therefore, cavitation likely will
occur often — but because
CO2’s surface tension and latent YOUR SAME-DAY SHIPMENT SPECIALISTS
heat of vaporization both are When your equipment is down, you need a partner
low, it shouldn’t have nearly the that ships a solution to you same-day…not some day.
At Inpro/Seal, we recognize the high cost of downtime
same damaging effect as it does facing our customers; that’s why we’ve designed our
in water and NH 3. The pump operations to support quick–turnaround of our
custom–engineered bearing protection products.
should feature materials with
cavitation-resistant properties With manufacturing locations in North America and
the United Kingdom, we’re able to offer industry–
and surfaces, and should handle leading products with unparalleled response time
temperatures down to -150°F and service to customers around the globe.
The right technology…right when you need it.
(-100°C).
In addition, the pump should
satisfy general design require-
ments such as compactness, light
weight, high energy efficiency,
variable speed capacity con-
trol, easy integration, minimal
maintenance needs and easy
servicing.

SYSTEM DESIGNS
CO2 can be used as a refrigerant
in three fundamental ways:

CP1105_21_26_Design.indd 23 4/26/11 11:35 AM

 Cascade System
with CO2 have the same first cost as traditional
systems.
Condenser
2. Cascade system. CO2 is the refrigerant in
the lower-stage part of a two-stage system. This

Compressor
type of system typically appeals where there’s a
Natural or
synthetic refrigerant demand for refrigeration at a low temperature
level (e.g., in process plants) or at two temperature
levels (e.g., in supermarkets). Such a system can
Cascade HX also reduce the charge of the primary (upper-
stage) refrigerant considerably.
3. Transcritical system. CO2 is the only refrig-
erant used. Due to CO2’s low critical temperature

Compressor
these systems must be designed for a cyclic process in
CO2 which heat rejection can take place above the critical
temperature. As a cyclic refrigeration process, the
transcritical system is less energy efficient than the
subcritical process and typically also requires higher
compressor capacity. Therefore, if high ambient tem-
Separator
peratures occur for long periods during the summer
Pump the transcritical cycle becomes less attractive.
Figures 2 to 4 show examples of design
principles for these types of systems. The indirect
system requires refrigerant pumps for circulation
of the liquid CO2 to all the evaporators in the pipe
Evaporator(s) network. In both the cascade and transcritical
systems, refrigerant pumps can establish refriger-
ant circulation to all the evaporators in the pipe
Figure 3. This design suits applications requiring low-temperature-level network but aren’t absolutely necessary — in some
refrigeration. system designs internal pressure differences can
also be used to circulate the refrigerant. However,
Transcritical System pumps often are preferred because they allow
liquid overfeed operation of the evaporators.
Most refrigerant pumps are used to establish
liquid distribution of the refrigerant in the evapo-
Gas cooler/Condenser
rators’ pipe network (Figure 5). Such pumps also
Compressor

serve for liquid pressure boosting — to provide

extra pressure differential for expansion valves and
to enable energy efficient system operation with
low condensing temperatures during cold ambient
conditions in winter (Figure 6). In larger indus-
trial refrigeration systems, the pumps also handle
Separator general liquid transport between components like
Pump receivers and separators at different temperature
levels (Figure 7).

OPTIMIZATION OPPORTUNITIES
Pumps designed and optimized for CO2 can offer
Evaporator(s) a number of benefits for refrigeration systems:
Reducing direct environmental impact. Us-
ing CO2 and refrigerant pumps can decrease the
charge of refrigerants negatively affecting the
Figure 4. Carbon dioxide serves as the only refrigerant in such designs. environment. A large part of the environmental

May 2011 cheMicalprocessing.coM 24

CP1105_21_26_Design.indd 24 4/26/11 11:35 AM

 Liquid Distribution
impact of industrial refrigeration systems comes Condenser

Compressor
from permanent leaks and accidental release of re-
Natural or
frigerants. Annual leak rates can reach 30% of the synthetic refrigerant
system charge, causing considerable direct impact.
CO2 has a GWP of only 1 while many HFCs have Cascade HX
GWPs up to several thousands (e.g., GWP for
R134a is 1,300).
Decreasing energy consumption by improving Separator

Compressor
operating conditions. Using refrigerant pumps to
establish forced circulation and liquid overfeed CO2 Pump CO2

operation of evaporators can increase evaporator

energy efficiency. Th is allows a rise in evaporation
temperature, which is one of the most important
parameters for boosting overall energy efficiency of
the refrigeration system. Depending on evaporator
type, the refrigerant and the operating conditions,
an increase of 4–8°F (-15– -13°C) is possible. As a
rule of thumb, a refrigeration system’s energy con-
sumption goes down by approximately 2% for each
°F the evaporating temperature goes up.
Cutting refrigerant-pump energy consumption by
better capacity control. Only a few systems operate
with a constant refrigeration load — therefore,
Medium temperature Low temperature
Evaporator(s) Evaporator(s)
Figure 5. Pump circulates refrigerant throughout pipe network with
evaporators.
effective capacity control of the refrigerant pump
is important for performance and energy optimi-
zation. Not all capacity-control options decrease
pump energy consumption. The use of a frequency
converter and closed loop control of the pressure
difference generated by the pump is one of the

How to get your tanks

cleaner in less time
Downtime for tank cleaning can significantly impact
production levels. Our recently expanded tank cleaning
product line includes dozens of solutions to clean your
tanks, totes and reactors in less time – and return
tanks to service more quickly without compromising
cleaning quality.
Whether your tanks are 2 ft. or 100 ft. (0.6 or 30 m) in
TankJet® 360
Tank Cleaner
diameter; require gentle rinsing or high-impact cleaning,
our local sales engineers will help you select the right
TankJet
AA190AG tank cleaner for your operation.
Tank Cleaner

TankJet 75
learn more today:
Tank Cleaner
TankJet D40159 1-800-95-sPraY or www.tankjet.com
Tank Cleaning
Nozzle

Experts in Spray Technology

Spray Spray Spray Spray
Nozzles Control Analysis Fabrication

CP1105_21_26_Design.indd 25 4/26/11 11:35 AM

 Liquid Pressure Boosting Liquid Transport

Suction line Discharge line Return line Suction line (to compressors)

Suction-
Compressor accumulator Low-pressure gas High-pressure
Evaporator(s)

Condenser
equalization line gas equalization
line
Collector
vessel

High-pressure
receiver
Liquid line
Expansion
valve Pump
Pump

Figure 6. Pump provides extra pressure differential for expansion valves. Figure 7. Pump can also handle more general duties in larger systems.

most attractive methods because it significantly

RELATED CONTENT ON
CHEMICALPROCESSING.COM
“Watch Out for Two-Phase Flow,” www.
ChemicalProcessing.com/articles/2010/164.html
“Put Some Heat on Refrigerant Switchover,”
www.ChemicalProcessing.com/articles/2006/004.
html
reduces the pump’s energy consumption.
Lessening refrigerant-pump energy consumption
by better pump protection. The design of refrigerant
pumps and the risk of vapor entering or forming
inside the pump usually restrict the accepted operat-
ing envelope. By tradition, loss-generating protective
devices such as permanent bypasses or Qmax orifices
(to prevent too-high flows that could cause cavita-
tion) have protected refrigerant pumps from opera-
tion outside the accepted envelope — but at the cost

PROTECT PUMPS of significant energy losses. A pump designed for

CO2 coupled with intelligent electronic controls can
obviate these protective devices and the losses they
• Dry Running incur. Such electronic controls also enable improved
• Cavitation monitoring of operations and regulating pump
capacity and bypass in an intelligent way.
• Bearing Failure Field trials that employed all these measures
• Overload achieved cuts in pump energy use on the order of 60–
TRUE POWER LOAD DISPLAY 70%. Pump energy demand fell from a level of 6–7%
• Best Sensitivity of system energy consumption to just 2–3% [2].
COMPACT EASY MOUNTING
• Starter Door • Raceway BJARNE DINDLER RASMUSSEN is global product
• Panel • Wall manager – refrigerant pumps for Grundfos Pumps, Olathe,
TWO ADJUSTABLE SET POINTS Kan. Email him at brasmussen@grundfos.com.
• Relay Outputs
MODEL PMP-25 • Adjustable Delay Timers
4-20 MILLIAMP ANALOG OUTPUT REFERENCES
1. “Engineering Equation Solver,” version
UNIQUE RANGE FINDER SENSOR
8.684, F-Chart Software, Madison, Wis. (Oct.
• Works on Wide Range of Motors
• Simplifies Installation
2010).
2. Rasmussen, B. D. and Pachai, A. C., “En-
ergy Saving Potential of Controlled Refrigerant
CALL NOW FOR YOUR FREE 30-DAY TRIAL Pumps in CO2/R404A-cascade systems,” p. 987,
Proceedings, 8th IIR Gustav Lorentzen Conf. on
888-600-3247 Natural Working Fluids, Copenhagen, Denmark
(2008).

WWW.LOADCONTROLS.COM

CP1105_21_26_Design.indd 26 4/26/11 11:36 AM

 SET THE
RIGHT
GOALS
Too often performance measures wind up counterproductive

By Jason G. Laws, Gulbrandsen Technologies

MOST EMPLOYEES sincerely want to perform
well for the company. There are some exceptions of
course, but the true saboteur is a rare thing. People
usually will perform to the expectations and priori-
ties they perceive as important to management.
However, they always will strive first and foremost to
meet their published goals or performance measures.
This is why developing truly useful and well-inte-
grated performance measures is crucial.
Measuring people and departments is a dangerous
undertaking. Deming went into this with his “Seven
Deadly Diseases” that plague corporations. Even the
best-intentioned measures can work at cross-purposes
to the overall organization’s performance.
Many organizations have poorly scoped and
compartmentalized, or what I like to call “silo-ed,”
measures and goals. Indeed, industry tends to develop
goals for departments and individuals in isolation.
Such performance measures easily can encourage
behaviors that look good for one area of the organiza-
tion but create chaos for another. Typically, organiza-
tions track the outcomes of these actions separately for
each department. So, the performance reviews of the
party that caused the chaos rarely reflect the unin-
tended consequences.
Let me share my experience with three real-world
examples from a chemical plant to highlight this
phenomenon.
In 2005, Company A’s procurement department’s
bonus goals were linked to raw material cost reduc-
tion. The procurement agents were given the author-
ity to substitute raw materials that were chemical
equivalents of those currently approved. (Previously,
the product line manager or the principal chemist
was responsible for approving new material streams.)
The agents found a much cheaper source for a key raw
material in China. The material safety data sheet and
certificate of analysis matched those of the current
material. So, the new material was ordered.
However, the new material came in 55-lb paper
bags. By the time it reached the port by boat, it had
absorbed so much moisture that it no longer was
usable. Unfortunately, the plant generated several
batches of off-spec product before it detected the
problem and rejected the new material. Procurement
was pursuing its goals but this resulted in operations
missing one of its goals, namely, to produce 99% on-
spec product.
Later, the same company created a logistics depart-
ment to contract transportation rates, select shippers

REFERENCES
Fellers, G., “Why Things Go Wrong,” Pelican Publishing, Gretna, La. (1994).
Laws, J., “Management Driven Reliability Philosophy,” p. 9, Solutions, Vol. 5, No. 4 (Aug. 2010).
Laws, J., “Beyond Safety: Using Root Cause Analysis Tools to Improve All Your Business Processes,” Proceedings, TapRoot
Summit, San Antonio, Texas (2010).
Laws, J., “Equifactor and Process Troubleshooting: Managing Your Crucial Tribal Knowledge,” Proceedings, TapRoot Summit,
Nashville, Tenn. (2009).
Parmenter, D., “Key Performance Indicators: Developing, Implementing, and Using Winning KPIs,” Wiley, Hoboken, N.J. (2007).
Price, B., “Error Reduction = Cost Reduction in Plant Processes,” p. 1, Solutions, Vol. 4, No. 2 (2009).

27 CHEMICALPROCESSING.COM MAY 2011

CP1105_27_29_Maint.indd 27 4/26/11 2:25 PM

 and schedule trucking shipments.
In the past, operations would
contact a firm on an approved list of
shippers a few hours before a bulk
batch would be ready for pickup.
There rarely was deadtime.
The logistics department,
which was graded on cents/mile,
The World’s Fastest Ducting
started scheduling truck pickups
two-to-three weeks in advance to
get the lowest rates. This created a
new operational problem — dead-
time due to truck delays.
Typically, this stranded reac-
tors for an average of 18 hours,
costing $400/hour in lost revenue.
That’s around $7,000 per batch.
Saving a nickel per mile driving
all the way around the equator
would amount to only $1,300!
The change resulted in a loss of
more than $6,000. Logistics met
its goals but operations began
missing one of its key measures,
pounds produced/hour.
We’re all familiar with the
“run equipment to failure”
approach that casts the main-
tenance group in an unfavor-

quick-fit
able light while absolving the
operations shift team of one of its
primary responsibilities — tak-
ing good care of the plant and
equipment. Company A gave
Nordfab’s Quick-Fit clamp-together ducting eliminates rivets, that a different dimension. To
screws, welds, and other time-consuming and costly joining reduce production cost, manage-
methods. Thanks to the patented Quick-Fit design, straight ment rolled out a program that
pipes, elbows, branches and other custom pieces snap awarded a gift card every month
together in seconds. And they can be taken apart and to the shift producing the most
reconfigured without tools. pounds the quickest. There’s
nothing wrong with that, right?
After all, product cost directly
relates to raw material cost and
cycle times. Reducing cycle time
would increase the sales margins
the company enjoyed.
However, something less
admirable occurred. Shifts began
to figure ways to take shortcuts
and create hurdles for compet-
It clamps together in seconds!
ing shifts. Th is caused a sharp
increase in quality issues and
process safety concerns. The plant
For a free sample and saw no significant gain in saleable
to find your local dealer product but the more ingenious/
visit our website at devious shifts were able to claim
their gift cards.
www.nordfab.com
On first glance, the goals and
performance measures were well
intentioned — but their results
damaged overall performance.
However, because of the organi-
zation’s silo-like nature and the
manner in which the goals and
measures were developed, commu-
nication never reached manage-
To view our videos, go to our website ment in a way that could prevent
www.nordfab.com. these outcomes.
9001:2008
14001:2004

CP1105_27_29_Maint.indd 28 4/26/11 2:27 PM

 RELATED CONTENT ON
OPTIMIZING PERFORMANCE for effectiveness. Change them CHEMICALPROCESSING.COM
As the examples highlight, later if needed. Keep keeping up “Training Moves With the Times,” www.Chemi-
it’s essential to develop well- the improvement. calProcessing.com/articles/2010/139.html
integrated goals and measures. “Build Operator Expertise Faster,” www.Chemi-
Several steps can help you come JASON G. LAWS, P.E., is plant calProcessing.com/articles/2009/234.html
up with appropriate ones: manager at Gulbrandsen Technologies, La “Improve Your Job Security,” www.ChemicalPro-
• First, defi ne the overall Porte, Texas. E-mail him at jlaws@gulbrand- cessing.com/articles/2008/080.html
objective of the corporation. sen.com.
• Second, find your corpo-
rate gurus who have all the tribal
knowledge. With them, build
cross-functional teams made up of
the key stakeholders in the orga-
nization. Recognize that a small
Did you know
percentage of your teams will try
to use the measures you design to
that 90% of heat
keep from being held accountable transfer fluid
for their poor performance.
• After that, “just do it.” breakdowns
are caused by
In the beginning, the mea-
sures don’t have to be perfect.
You just work together to decide
on what measures and goals will equipment issues?
help the company reach a new
level of excellence that’s aligned
with the overall corporate vi- Listing and temperature range chart for all Paratherm heat transfer fluids.
sion. Kaizen techniques are
useful here to ensure asking the
right questions.
Track the performance
measures’ effectiveness. If they’re
not quite right, feel free to
change them. Strive for continual
improvement — the key perfor-
mance measures should evolve
and improve over time. If you just check your hot-oil on a regular Immersion Engineering™™ Services
Most importantly, keep in basis you could practically eliminate Fluid Analysis
Fluid Maintenance
mind bad performance measures unplanned shutdown or loss of production.
Training
can be worse than no measures at The easy way to do this is by conducting a Troubleshooting
Fluid Analysis. Because Fluid Analysis isn't Consulting
all. Remember the old Navy adage:
just to check your fluid; it's to test your system.
“You don’t get what you expect, When we test your fluid (we suggest Products
you get what you inspect.” In the annually or more frequently for demanding Paratherm CR® HTF Paratherm NF® HTF
end, people will perform to the service) the values we get from boiling range, Paratherm MR® HTF Paratherm OR® HTF
Paratherm MG™ HTF Paratherm GLT™ HTF
goals you establish. viscosity, and acidity tell us what's going on in
Paratherm LR™ HTF Paratherm SC® Cleaner
there. Better yet, together with a one-to-one
To summarize, the best way Paratherm HR™ HTF Paratherm LC™ Cleaner
system review with you, those same test Paratherm HE® HTF Paratherm AC™ Cleaner
to prevent unintended conse- results can help pinpoint emerging issues with
quences of poorly scoped goals oxidation, overheating, or possible mismatch-
and measures is to: get your best es in those interrelated components that could
cross-functional team, ask “what is lead to a downtime-causing problem.
HEAT TRANSFER FLUIDS
This can help you keep the system up
the company trying to accomplish 4 Portland Road
when it's supposed to be up, and know in
and how can we do that?,” then set advance if any corrections are needed for
West Conshohocken PA 19428 USA
800-222-3611
®

goals and periodically check them when you do have scheduled downtime. Your
610-941-4900 • Fax: 610-941-9191
system runs better, your fluid lasts longer, and
®

info@paratherm.com
your process earns its keep. www.paratherm.com

Chemical Engineering
CP1105_27_29_Maint.indd 29 4/27/11 10:12 AM
 Properly Measure
Liquid/Liquid
Interfaces
Follow a simple rule for location of
level gauge nozzles

By Jonathan Webber, Fluor Canada,

and Patrick Richards, Irving Oil

MAY 2011 CHEMICALPROCESSING.COM 30

CP1105_30_33_Fluids.indd 30 4/26/11 2:29 PM

 Heavy Liquid

Heavy Liquid

Nozzle For Each Phase Multiple Nozzle Configuration

Vapor Space

Vapor Space Vapor Space

Light Liquid

Light Liquid Light Liquid

Non-flooded Flooded
Configuration Configuration
Heavy Liquid

Heavy Liquid Heavy Liquid

Figure 2. At least one nozzle must be connected

Figure 1. This arrangement satisfies the Golden Rule and ensures the same to each liquid phase to comply with the Golden
interface level in the vessel and gauge. Rule.

Trapped Liquid
Vapor Space
DETAILED DESIGN of a vessel includes de-
termining the proper locations for level gauge/
transmitter nozzles. There’s little debate on the
Lightinter-
correct nozzle locations for vapor/liquid Liquid

face level measurements — it’s well understood

to locate the upper nozzle in the vapor space and
the bottom nozzle in the liquid phase. Martyn (1)
Heavyinterface
discusses the challenges of liquid/liquid Liquid

level measurements when using bridled (externally

mounted) confi gurations. Our experience indi-
cates that much confusion exists about the correct
nozzle confi gurations for level measurements
of liquid/liquid interfaces. Common questions
include: “How do we know that the interface level
Hoil
in the gauge will be the same as the vessel?” and
“Won’t the light liquid get trapped on top of the Hoil
heavy liquid in the gauge?”
So, here, we’ll provide a simple “Golden Rule” for
nozzle placement that we have used successfully in nu- Hwater

merous refinery interface measurement applications. Hwater

THE GOLDEN RULE

For proper location of externally mounted level-
measurement nozzles, ensure that at least one nozzle
is located in the top liquid phase and at least one
nozzle is located in the bottom liquid phase.
If this simple stipulation is satisfied and the top
and bottom fluids are immiscible and have different
densities, then we can be sure, at equilibrium, that the
pressure balance will equalize the interface levels in
the gauge and the vessel.
Either a non-flooded (i.e., top nozzle connected to
vapor space) or flooded configuration will allow the
pressure balance to equalize the interface levels in the
drum and the gauge (Figure 1). The non-flooded con-
figuration offers the advantage of allowing for a total
liquid level measurement. Sometimes multiple nozzles
are used to cover the expected range of liquid invento-
ries. In these cases the Golden Rule is satisfied as long
Figure 3. In this case liquid becomes trapped in the gauge.
as at least one nozzle is connected to each liquid phase
at all operating conditions (Figure 2).
Oil/water interfaces are common in refining, and
we oftenHhear the question: “Isn’t it possible for the
oil
pressures to balance in such a way that the height of the
interface in the gauge isn’t the same as the height of the
interface in the vessel?” A common argument is that the
extra head of water in the gauge will compensate for the
Hwater
smaller head of oil in the gauge, thereby allowing the
equilibrium interface level in the gauge and vessel to dif-
fer (Figure 3). This argument is flawed — if the Golden
Rule is followed, the two levels will equalize. The sidebar
provides a simple mathematical proof by contradiction.

31 CHEMICALPROCESSING.COM MAY 2011

CP1105_30_33_Fluids.indd 31 4/26/11 2:29 PM

 TEST THE RULE
In Figure 4 assume the Golden Rule is satisfied — Disproving Equation 3
i.e., each liquid phase in the vessel is connected to
the gauge by a nozzle. At equilibrium the pressures
at the middle and bottom nozzles are balanced via
Pv
Eqs.1 and 2, respectively:
Pv + ρoil g H1 + ρwater g H2 = Pv + ρoil g H1* (1)
Pv + ρoil g H1 + ρwater g (H2+ Htap) = Pv + ρoil g (H1*
+ H2*) + ρwater g Hwater (2)
H1 H1*
where Pv is the vessel vapor pressure, ρoil is the oil
H2 Hoil
density, ρwater is the water density, and g is gravi-
tational acceleration. Substitution and algebraic
H2*
rearrangement yields:
ρoil H2* = ρwater H2* (3) Htap
Because the densities of the oil and water phas-
Hwater
es aren’t equal and H2 *≠ 0 (remember we assumed
that the Golden Rule is satisfied), then Equation 3
is a contradiction and can’t be true. Therefore, the
equalization shown in Figure 4 isn’t possible. You
can examine different equalizations, all of which will
result in contradictions unless the gauge interface Figure 4. If the Golden Rule isn’t satisfied, equalization
and vessel interface levels are equal. shown isn’t possible.

MATERIAL MASTER ™
BULK BAG MATERIAL CONDITIONER
NEW patent-pending design delivers superior performance
 Safely and efficiently returns your hardened
materials to a free-flowing state
 Most compact footprint in the industry
 Exclusive pivoting conditioning arms outperform
traditional compression plates
 Factory testing of your specific materials prior to
equipment investment
 Stand alone unit or integrated with our bulk bag
discharging system
 Custom engineered for your application
requirements

Visit www.materialtransfer.com or call: 800.836.7068

CP1105_30_33_Fluids.indd 32 4/26/11 2:30 PM

 APPLYING THE RULE
In practice it can be difficult
to locate nozzles to satisfy the
Golden Rule under all operat-
ing conditions. If a vessel may
contain widely varying levels
of liquid inventories, then it’s
worth considering multiple
nozzle locations. Select nozzle
positioning and spacing to
RELATED CONTENT ONCHEMICALPROCESSING.COM
“Neglect Level Control at Your Peril,” www.ChemicalProcessing.com/ar-
ticles/2011/neglect-level-control-at-your-peril.html
“Treat Tanks with Care,” www.ChemicalProcessing.com/articles/2010/191.
html
“Don’t Underestimate Overfilling’s Risks,” www.ChemicalProcessing.com/
articles/2010/143.html

Safe
minimize the chance that one
no longer is connected to a liq-
uid phase. It’s possible for light
liquid to become trapped in the
gauge, causing an error when
the light liquid inventory no
longer is connected to a nozzle
(Figure 3). Th is could occur,
for example, when the heavy
liquid level drops and too large a
nozzle spacing was used.
Considerations other than
nozzle locations can affect the
accuracy of the level measurement.
It’s well known that temperature
differences between the fluid in the
gauge and the vessel can lead to
erroneous readings.
Single - step decontamination that’s safe
for people, your plant and the environment.
Safe for personnel, plant equipment and the environment,
Zyme-Flow® is non-toxic, non-hazardous and biodegradable.
Its patented formulation delivers fast and highly effective results.
So, less time is needed to prepare equipment for entry while safety
concerns associated with cleaning, degassing and environmental
compliance are simply eliminated. It’s the naturally safe solution
that does it all in a single step.
Get Tough. Get Zyme-Flow®
For information call Dee Bryant at 832.775.1565
dee.bryant@zymeflow.com | www.zymeflow.com

AVOID ERRORS
Adhering to our simple Golden
Rule will ensure the liquid/
liquid interface in the gauge
matches the interface level in
the vessel. If you can’t manage
liquid inventories to satisfy the
rule then errors may arise in the
measurement.

JONATHAN WEBBER is a process

engineer for Fluor Canada, Saint John, NB.
PATRICK RICHARDS is an independent
instrumentation consultant at Irving Oil,
Saint John, NB. E-mail them at Jonathan.
Webber@fluor.com and Patrick.Richards@
irvingoil.com.

REFERENCES
Martyn, K., “Level Measure-
ment in Bridles,” Process West, Zyme-Flow® is a mark of United Laboratories Worldwide Leader in Refinery
International, LLC. 2011 United Laboratories
p. 50, April 2006. International. All Rights Reserved.
Decontamination

Zyme-Flow® tough. From routine decontamination to heavy oil.

CP1105_30_33_Fluids.indd 33 4/26/11 2:30 PM

 Vessels used to smooth out flow pose special tuning issues
The iniTial article in this series, “Neglect Level
Control at Your Peril,” www.ChemicalProcessing.
com/articles/2011/neglect-level-control-at-your-peril.
html, examined the behavior of level processes (such
as in Figure 1). It specifically looked at the behav-
ior of the reset mode when applied to integrating
processes as most industrial level loops are. Espe-
cially for large vessels, traditional tuning techniques
suggest unreasonably large values for the controller
gain, KC . Applying the Ziegler-Nichols equations to
the vessel in Figure 1 gives the following results for
the gain and reset time, TI :
KC = 46 %/%
TI = 1.33 min
The usual action is to reduce KC . However, for
an integrating process, the result is a slowly decaying
cycle with a long period. The previous article clearly
illustrated this for a noise-free environment.
Here, we’ll first examine the behavior in a more
typical industrial level loop with noise on the level
May 2011 cheMicalprocessing.coM 34
CP1105_34_39_Instru.indd 34
By Cecil L. Smith, Cecil L. Smith, Inc.
measurement and frequent changes in flows into or out
of the vessel. Then, we’ll look at surge vessels — where
KC intentionally is set to as low a value as possible.
You can use large controller gains such as 46 %/%
only in loops with virtually no noise, which essentially
restricts them to temperature loops. As illustrated in
the previous article, using such a KC in a noisy level
process translates the noise in the level measurement
to higher amplitude noise in the signal to the final
control element.
Because the amplification of the noise primarily
stems from the controller gain, the logical action is to
reduce KC . The main consequences are:
• decreased amplification of the noise; and
• sacrifice of control performance, especially in
terms of speed of response.
Figure 2 presents the performance for the follow-
ing tuning: KC = 2.0 %/% (a modest amplification of
the measurement noise); and TI = 1.33 min (the same
as suggested by the tuning equations).
4/26/11 2:31 PM
 Impact of Tuning on Vessel Level
Tuning Deviations in Vessel level
KC = 46%/%, TI = 1.33 min ~ ±0.5%
The previous article demonstrated this tuning (Figure 4 in “neglect level at your peril”)
produces a cycle in a noise-free environment. Figure KC = 2.0 %/%, TI = 1.33 min (Figure 2) ~ ±7%
2 depicts a similar cycle. The variability in feed flow KC = 2.0 %/%, TI = 24 min (Figure 3) ~ ±10%
makes the cycle more difficult to quantify. How-
Table 1. Less aggressive tuning leads to greater level
ever, especially in the controller output, cycles of a deviations.
sinusoidal nature are evident in most intervals of the
response. The 12-hr period covered in Figure 2 shows
Simple Feedback Control
at least 26 distinct peaks. This suggests a period (P)
Feed #1
of 720/26 = 27.7 min. Arbitrarily selecting two of the
Feed #2
peaks gives a period of 18 min. In either case, a reset
Feed #3
time of 1.33 min is far too short — TI should be at
Feed #4
least half the period of the cycle.
Visually assessing the nature of cycles in a response
is both imprecise and somewhat subjective. Although
not routinely applied in the process industries, a more LH

rigorous approach is to apply the Fourier integral to

determine the contribution from each frequency to the
LT LC
response. Those loops that exhibit cycles deserve atten-
tion. A cycle usually has consequences, so you must
understand its origin. Perhaps the cycle stems from the LL
controller or perhaps it originates with a disturbance.
Figure 3 repeats Figure 2 with a TI of 24 min,
which hopefully is close to the period of the cycles in Discharge
Figure 2. Consistent cycles of a sinusoidal nature no
longer are evident in the vessel level or controller out-
Figure 1. Level controller can’t influence any feed stream.
put. However, this comes at a cost. As the controller is
made less aggressive, deviations in vessel level from its
set point (SP) increase, as shown in Table 1. vessel level, to the flow through the control valve. This
Reducing KC has a larger adverse effect on perfor- raises two issues:
mance than increasing TI. 1. What are the consequences of variations in ves-
For the process in Figure 1, the level controller sel level? Often the answer is “none.” However, there
moves the variance from the process variable (PV ), the are exceptions — one being thermosiphon reboilers.

35 chemicalprocessing.com may 2011

CP1105_34_39_Instru.indd 35 4/26/11 2:32 PM

 Sinusoidal Cycles
100
P = 18 min KC = 2.0 %/%
TI = 1.33 min
75 The flow through a reboiler is by natural convection,
Vessel level

which is affected by the liquid head, which in turn

50
%

depends on the bottoms level.

25
2. What are the consequences of variations in the
flow through the control valve? If discharge flow in
0 Figure 1 is to a large storage tank, the consequences
100 are nil. However, when the discharge flow is to
Discharge valve opening

another process unit, throughput changes usually are

75 major upsets.
50
%

LEVEL CONTROL IN SURGE VESSELS

25 The purpose of a surge vessel is to provide averag-
ing or smoothing so that changes in discharge flow
0 are less rapid and less extreme than changes in feed
400
Feed flow
Discharge flow flow. Tight control of level is counterproductive —
300 very quickly translating any change in feed flow to
Discharge flow

a change in discharge flow. Instead, vessel level is

liters/min

200 allowed to vary “within reason,” that is, as long as

it doesn’t cause process trips on high and low level.
100
The appropriate tuning is the lowest possible KC that
0
doesn’t result in process trips. However, especially in
0 120 240 360 480 600 720 large vessels, reset action in the controller can lead to
Time, minutes
a discharge flow cycle with a very long period.
Figure 2. At least 26 peaks occur over 12-hr period. If the vessel in Figure 1 is a surge vessel, main-
taining as smooth a discharge flow as possible is the
Longer Reset Time primary objective. This suggests low controller gains
and long reset times.
100
KC = 2.0 %/% In addition, variations in vessel level don’t pose
TI = 24 min consequences, provided no process trips are initiated
75
Vessel level

by the high and low level switches. This suggests two

50 requirements on the controller output:
%

1. Before the high level switch is actuated, the

25
control valve should be fully open.
0 2. Before the low level switch is actuated, the
100 control valve should be fully closed (or the flow to the
Discharge valve opening

downstream process should be at its minimum accept-

75 able value).
From these requirements, you can compute values
50
%

for KC .
25
In a proportional-integral (PI) controller, the
equation for the proportional mode is the following
0 proportional-plus-bias equation:
400 M = KC E + MR
Discharge flow
Feed flow
where M is controller output, %; E is control error,
300
Discharge flow

%, which equals PV – SP for a direct acting controller

liters/min

200 and SP – PV for a reverse acting controller; and MR is

controller output bias, %.
100 When the reset mode is present, MR is the output
of the reset mode. If E is zero (PV = SP), M equals
0
0 120 240 360 480 600 720 MR . Some, but not all, commercial controllers will
Time, minutes display the value of MR . If the controller won’t show
Figure 3. This avoids cycles but leads to more level variation. this value, you can obtain it either by computing via

May 2011 cheMicalprocessing.coM 36

CP1105_34_39_Instru.indd 36 4/26/11 2:32 PM

 MR = M – KC E or temporarily set- age valve, valve openings less than On the other hand, if the equal-
ting SP = PV — because E then is 50% give very small flows — not percentage valve is significantly
zero, the value of M is MR . zero, but too small to significantly oversized (say by a factor of four),
From the proportional-mode affect the level. If the requirement the flow at a valve opening of 50%
equation, you can compute an ap- is changed to a valve opening of is nearly the maximum available
proximate minimum value for KC 50% at a vessel level of 10%, KC = flow — once the valve is half open,
as long as you have the following (M – MR)/E = (50% - 70%)/(-30%) opening it more has little effect
information: = 0.67 %/%. on flow. In such cases, MR would
Value for MR. When reset mode
is in use, controller output bias
isn’t constant. However, when TI is
long (as it should be), the value will
change very slowly. In the previous
responses, the value of MR varies
between approximately 60% (for
low throughputs) and 80% (for
high throughputs).
Value for SP. For all previous
responses, the set point for vessel
level was 40%.
Location of level switches. In Fig-
ure 1 the switches are positioned at
vessel levels of approximately 5%
and 95%.
Let’s require the valve to be
fully closed at a level of 10% and
fully open at a level of 90%. The
level controller is direct acting, so E
in the proportional-mode equation
is computed as PV – SP. Based on a
value of 70% for MR, this translates
into the following requirements:
High level trip. At a vessel
level of 90% E is 50%. To have a
controller output of 100%, KC =
(M – MR)/E = (100% - 70%)/50%
= 0.6 %/%.
Low level trip. At a vessel level
of 10% E is -30%. To have a
controller output of 0%, KC = (M
– MR)/E = (0% - 70%)/(-30%) =
2.33 %/%.
There’s one complication to
these calculations — flow through
a control valve rarely varies linearly
with valve opening. The relation-
ship depends on the nature of the
flow system (how much of the
pressure drop available for fluid
flow is taken by the control valve)
and the sizing of the control valve.
In a properly sized equal-percent-

CP1105_34_39_Instru.indd 37 4/26/11 2:33 PM

 Low Controller Sensitivity
100
P = 200 min KC = 0.4 %/%
75 TI = 24 min
be less than 50% and the above calculations could be
Vessel level

performed for M = 10% and M = 50%.

50
%

Often flow characteristics are apparent qualita-

25 tively but rarely are quantitative data available. The
alternative of a nonlinear control equation (as will
0 be described in the next article) usually is the easi-
100 est and most reliable approach to assure the valve
Discharge valve opening

has been driven to a limit before level reaches either

75
trip point.
50
Smaller KC values than those computed above
%

often prove acceptable. Figure 4 illustrates the per-

25 formance of the controller for a KC of 0.4 %/% and
a TI of 24 min. Even with this low sensitivity for the
0 controller, discharge flow varies considerably. On one
400
Discharge flow occasion, the discharge flow changes from approxi-
Feed flow
300 mately 350 liters/min to approximately 100 liters/min
Discharge flow

in about 1 hr. During this same period, vessel level

liters/min

200 varies from just over 75% to under 10% (but above
5%, so there’s no process trip).
100
The vessel level trend in Figure 4 exhibits a cycle
0 with a period of approximately 200 min. The total
0 120 240 360 480 600 720 duration of the trend is only 12 hr., though, which
Time, minutes
isn’t long enough to be certain a cycle definitely ex-
Figure 4. Decreasing controller gain and increasing reset time likely
causes a cycling of level. ists. However, let’s assume it does. A TI of 24 min is
far shorter than half the period of the cycle. Reduc-
Preferable Performance ing KC to 2 %/% from 46 %/% mandates a signifi-
100 cant increase in TI ; so it seems logical that decreasing
KC = 0.4 %/%
TI = 120 min KC to 0.4 %/% from 2 %/% also should require an
75 Set point increase in TI.
Vessel level

50 Figure 5 presents the performance for a KC of

%

0.4 %/% and a T I of 120 min, which is twice the

25 residence time of the vessel. A cycle still might
exist but it’s not as evident or as regular as the
0
one in Figure 4. Even so, its period is roughly 3
100
hr, so a T I of 2 hr exceeds half the period of the
Discharge valve opening

75
cycle.
The performance in Figure 5 generally is prefer-
50 able to that in Figure 4 (with a TI of 24 min). The
%

variations both in vessel level and discharge valve

25 opening (and consequently discharge flow) clearly are
less than in Figure 4. This underscores the need to use
0
400 long values of TI when KC is very low.
Feed flow Discharge flow

300 LONG RESET TIMES

Discharge flow
liters/min

Have you ever seen a controller tuned with a TI of 120

200
min? If not, there’s a very good reason. With conven-
100 tional controllers, the maximum possible TI usually
was around 30 min. With early distributed control
0 systems, the maximum possible TI was comparable
0 120 240 360 480 600 720
Time, minutes (maybe up to 45 min). Even today, some digital con-
trol products impose the format of XX.XX on TI, thus
Figure 5. Setting reset time twice the residence time of the vessel
makes cycle disappear or at least become less evident. limiting the maximum to 99.99 min.

May 2011 cheMicalprocessing.coM 38

CP1105_34_39_Instru.indd 38 4/26/11 2:34 PM


If the required TI exceeds the maximum imposed
by the control system, you can either set TI to the
maximum allowed by the control system or remove
the reset action entirely, which results in proportional-
only control. The latter is preferable.
Although advocated by some for level control ap-
plications, proportional-only control isn’t popular. Most
controller implementations permit the reset mode to be
“turned off ” by entering an appropriate value for the re-
set tuning coefficient. A value for MR is computed when
the loop is switched from manual to automatic. Thereaf-
ter, you must make any changes in MR ’s value manually.
However, manually adjusting MR raises two issues:
Entering a value of MR . Some controller imple-
mentations neither display the value of MR nor permit
entering a value for MR . Given the rare use of propor-
tional-only control, this isn’t surprising. Fortunately,
workarounds usually are possible.
Manual reset. In years past, a practice known as
“manual reset” basically involved adjusting MR . How-
ever, as most loops are PI or proportional-integral-
derivative, very few operators now are trained to make
adjustments in MR .
RELATED CONTENT ON CHEMICALPROCESSING.COM
“Neglect Level Control at Your Peril,” www.ChemicalProcessing.
com/articles/2011/neglect-level-control-at-your-peril.html
“Treat Tanks with Care,” www.ChemicalProcessing.com/ar-
ticles/2010/191.html
“Don’t Underestimate Overfilling’s Risks,” www.ChemicalProcess-
ing.com/articles/2010/143.html
“Look at Liquid Bypass,” www.ChemicalProcessing.com/ar-
ticles/2009/116.html
“Consider Cascade Control,” www.ChemicalProcessing.com/ar-
ticles/2009/025.html
“Succeed with Condensate Control,” www.ChemicalProcessing.
com/articles/2008/107.html
“Achieve Effective Heat Exchanger Control,” www.ChemicalPro-
cessing.com/articles/2008/041.html
Although proportional-only control is
perfectly acceptable for most level applications,
these two obstacles are difficult to overcome in
practice.
CECIL L. SMITH is president of Cecil L. Smith, Inc., Baton
Rouge, La. E-mail him at cecilsmith@cox.net. This article is based
on concepts from his book “Practical Process Control,” published
by John Wiley & Sons.

North America’s Leading Project Acceleration Resource for Process Technology

June 21–23, 2011

Toronto Congress Centre | Toronto, C anada

Meet Industry Leaders with Thousands of the Latest Processing Solutions:

Accessories
Conveyors and Elevators
Dryers
Dust Collection/Control
Energy, Environmental &
Pollution Control
Filtration/Separation Packaging & Bagging Processing/Mixing/
Feeders ParticleEnlarger&Formers Blending Equipment
Instrumentation&Controls Size Reduction Storage
Material Handling & PlantMaintenance/Safety/ Thermal Solids Processors
Transportation Health Products WeighingSystems&Scales
Mixers & Blenders …and much more

18 2 5 3 _ C N _ P T X 11 Register Today at PTXCanada.com Promo code A B

Produced and managed by: UBM Canon • 11444 W. Olympic Blvd. • Los Angeles, CA 90064-1549 • Tel: 310/445-4200 • Fax: 310/996-9499

CP1105_34_39_Instru.indd 39 4/26/11 2:35 PM

 process puzzler
make the Best of a Blunder
Readers suggest ways to get an incorrect exchanger to do the job
This monTh’s puzzler
We heat heavy oil with steam before sending it to a reactor. The oil,
which is pumped through the shell of the heat exchanger, enters at
100°F and exits at 250°F; 125-psig steam goes through the tubes.
The old exchanger had four shell passes and eight tube passes.
someone at corporate engineering mistakenly ordered a heat ex-
changer with three shell passes and six tube passes. The new shell
is rated for 250 psig. The oil/steam overall external heat transfer
coefficient is 100 BTu/lb-hr-°F. is there anything we can do to use
this unit so we don’t have to order a new heat exchanger and delay
production?
sWAp The sTreAms
Switch the f low of oil and steam, i.e., pump the
oil through the six tube passes of the new heat
exchanger and put the steam on the shell side.
Very often the heat transfer coefficient of a liquid
on the shell side is relatively low, usually due to a
small f low velocity. The heat transfer coefficient
of condensing steam is high either on the shell
or tube side; it is not sensitive to f low velocity.
However, the pressure drop on the oil side will
increase, leading to a question regarding the
available pump pressure. Therefore, performing a
detailed calculation of heat transfer and pressure
drop is necessary to make a decision.
Dr. Walter Schicketanz, consultant
Rosenheim,Germany
rAise The oil FloW rATe
Assuming the area is similar to the current
exchanger, I would recommend increasing the oil
f low rate and using higher pressure steam if it is
available. A higher oil f low rate will increase the
overall heat transfer coefficient and the higher
steam pressure will raise the log mean tempera-
ture difference (LMTD).
Donald Phillips, manager
Phillips Engineering, Melbourne, Fla.
BoosT The sTeAm pressure
The obvious solution is to increase the steam
pressure, if high pressure steam is available. The
highest pressure steam that can be used is about
75% of the shell rating pressure: 0.75 × 250 =
188 psig. If the pressure reaches around 80%, the
relief valve may start to open. If we assume 200
May 2011 cheMicalprocessing.coM 40
CP1105_40_41_Puzzler.indd 40
psig steam is available, it must be reduced to a
safe limit, say, 180 psig.
Flow through a regulator is the same as
through a valve or orifice — it is an isenthalpic
process, not adiabatic as often is assumed. If we
ignore supersonic f low and assume it is unchoked,
the temperature drop will be slight. For real
gases, a drop in temperature resulting from throt-
tling is described by the Joule-Thompson (Kelvin)
coefficient: mJT = (dT/dP)H .
Throttling a wet gas produces a superheated
vapor. Using an online calculation program I
found by googling “superheat steam table,” I
estimated a temperature drop of 7.2°F for a drop
from 200 psig to 180 psig for a constant total
enthalpy of 1,119.3 BTU/lb, which is the total en-
thalpy of saturated steam at 200 psig. I solved the
problem by iterating with the program using the
superheated temperature as a variable and the en-
thalpy of 1,199.3BTU/lb as the target. The steam
starts with a saturated temperature of 387.8°F and
exits the regulator at 380.6°F — the saturation
temperature at 180 psig is 379.5°F. The tempera-
ture entering the heat exchanger is 380.6°F.
If I had mistakenly assumed an adiabatic
process, the temperature would be: (388 +
460)×[(14.7+180)/(14.7+200)](1.3-1)/1.3 = 829°R
(369°F). This is an error of only 3%. The pressure
drop is small, but the temperature difference is
significant: 12°F.
The original LMTD was: (253 – 153)/Ln
(253/153) = 198.8°F; ∆T1 = 353°F – 200°F =
153°F; ∆T 2 = 353°F – 100°F = 253°F, where 353°F
is the temperature of saturated steam at 125 psig.
The new LMTD with 180-psig steam would be:
(281-181)/Ln (281/181) = 227°F. Raising the steam
pressure increases the LMTD by 14%.
One serious problem with increasing the
temperature difference is its effect on thermal
expansion inside and outside the heat exchanger.
You will want a structural engineer to review the
piping; the exchanger manufacturer should look
at the effect a higher temperature will have on the
tubesheet, internals and the gaskets. Also, check
the maximum allowable operating temperature
(MAOP); usually 500°F is a convenient limit for
carbon steel, but verify.
4/26/11 2:36 PM

Heat Exchanger Modification
Oil to tubeside
Oil Steam
Shell baffle
TE TE
Oil T T
Add steam trap nozzles
Figure 1. Switching steam to the shell side requires some additions to the exchanger, suggests Norm Terrelg.
I considered switching to an oil but the heat
transfer coefficient would be in the 100–300
BTU/hr-ft 2 -°F range, well below the 1,000 BTU/
hr-ft 2 -°F expected with steam. With 500°F as a
maximum, thermal f luid is out. Electric heating
might be a possibility but this would involve a
serious overhaul and electric heaters cost about
170% more to operate compared to steam gener-
ated by methane.
Now, let’s consider some operational options.
Recycling the process f luid through for a second
pass might make sense if piping allows. This will
require new temperature controls to avoid over-
heating and allowances for thermal expansion of
oil trapped in isolated piping.
Another option would be to increase the
JULY’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 m 3/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 refinery 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
CP1105_40_41_Puzzler.indd 41
PROCESS PuzzlER
Steam
Switch from oil to steam
(was oil outlet)
TE
Add T/Cs
Notch for S-cond. TE
TE
TE
T
S-cond.
process f low velocity as high as possible. One
of the risks with this choice is tubesheet vibra-
tion, which can result in a number of corrosion
problems.
Dirk Willard, senior process engineer
Middough Consultants, Holland, Ohio
GO BACK TO THE SHOP
As a heat f lux of 1,500 BTU/hr-ft 2 -°F is reason-
able, I would move the steam to the shell side.
Put the oil through the tubesheet. Knock holes in
the baff les to allow steam condensate to escape
and add additional nozzles for steam traps. (See
Figure 1.)
Norman Terrelg, production engineer
BASF, Freeport, Texas
pump do you consider the best choice for this application?
Send us your comments, suggestions or solutions
for this question by June 10, 2011. We’ll include as
many of them as possible in the July 2011 issue and all
on CP.com. Send visuals — a sketch is fine. E-mail us at
ProcessPuzzler@putman.net or mail to Process Puzzler,
Chemical 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.
4/26/11 2:36 PM
 plant insites

Find the Real Maximum Pressure

Always consider static head when assessing pressure vessels

CheMiCal Plant vessels serve many purposes, pressure. It includes the design conditions and the
including for storage and surge control and as reac- specific materials used, allowable materials stresses,
tors, fractionators, absorbers, strippers and crystal- testing conditions and other critical mechanical
lizers. Pressure is a key parameter for safe operation. details. That form (and any attachments stemming
Vessel operating and design pressures may appear from vessel modifications or repairs) defines the
in piping and instrumentation diagrams (P&IDs), operating limits. The vessel should be code stamped
specification sheets, operating instructions and fabri- with the same values shown on the U-1 form. While
Other paperwork cation drawings. useful and convenient, other paperwork doesn’t over-
Process safety analyses invariably address over- ride the U-1 form.
doesn’t override pressure protection. Such analyses generally rely on So, it’s important to understand how P&ID
the U-1 form. P&IDs for plant design information. The P&IDs design pressures compare to those on ASME U-1
usually include vessel maximum operating and forms and to know some common errors in P&ID
working pressures. But what do those pressures pressures.
mean? Are the P&ID pressures the ones we really Section VIII Division 1 of the ASME Code
must worry about? covers rules for construction of pressure vessels. Sub-
For vessels stamped as complying with the section UG-21 defines design pressure requirements:
American Society of Mechanical Engineers (ASME) “Each element of a pressure vessel shall be designed
Boiler and Pressure Vessel Code, the ASME U-1 for at least the most severe condition of coincident
form summarizes the vessel’s design temperature and pressure (including coincident static head in the nor-
mal operating position) and temperature expected in
Pressure Relief Valve Options normal operation.”
PRV The design pressure of a vessel is the maximum
Option 2
pressure that any part of the vessel can tolerate — it
Piping Elevation includes both system and static pressures. Design
67’-4” —
pressures may vary with temperature and vessels may
be stamped for multiple design temperature/pressure
Hydrocarbon Out
59’-4” —
combinations.
Common practice during hazard and operabil-
ity (HAZOP) reviews is to use pressure ratings on
P&IDs rather than referring back to U-1 forms. As
long as the values are correct and people properly
understand how to interpret them, this doesn’t cause
problems.
The U-1 form design values are for any point on
the vessel and must include static head in the pres-
sure evaluation. Too often, HAZOP and other safety
reviews look at operating pressure from a pressure
reading point and fail to consider the implications
Catalyst Out of static head. All vessels not under vacuum have a
20’-11” — PRV
PRV
Option 11 static head component of pressure.
Option
The static head may vary from insignificant for
Piping Elevation a horizontal vessel under vacuum to very high for a
— 12’-0”
tall liquid-filled vessel. As an example, let’s con-
sider a vessel that has a seam-to-seam height of 47
Feed
3’-3” —
ft. 8 in. and contains a mix of hydrocarbons and a
liquid ionic catalyst (hydrogen fluoride). The average
density of the liquid is 48.8 lb/ft3 at operating condi-
Figure 1. Location of the valve can markedly affect the maximum tions. The U-1 form indicates the vessel is designed
release setting.
to handle 165 psig at 250°F.

May 2011 cheMicalprocessing.coM 42

CP1105_42_43_InSites.indd 42 4/26/11 2:37 PM

 plant insites

Per the ASME code, the pressure relief device
must open at or before any part of the vessel reaches
the design pressure. Figure 1 shows the vessel layout
with the current pressure relief valve (PRV) location as
Option 1 and a new proposed location as Option 2.
The first common misconception often encoun-
tered is that a vessel’s rating allows operation at the
design pressure at the pressure measurement point.
PANEL This plant mythology is false. The ASME code
doesn’t specify the location of required pressure
DISCUSSION measurement points. The code specifies that the
system pressure plus the coincident liquid head must
WEBCAST be below the vessel design limit at all points on the
vessel. For our example, this limit is the lower edge
of the feed nozzle at the bottom of the vessel.
The feed nozzle centerline is at 3 ft. 3 in. above
grade. The lower edge of the nozzle is 9 in. lower, at
2 ft. 6 in. The PRV currently is located in a piperack
downstream of the vessel (Option 1). The PRV inlet
is at 12 ft. 0 in. At an operating density of 48.8 lb/
ft3 this gives 5 psi of static head (rounded up). The
maximum PRV relief setting is 161 psig (165 psig
design limit minus 4 psi static head).
A proposal “to take full advantage of the vessel
design pressure” would move the PRV to the Option
2 location. This idea stems from the thought that
the vessel’s top seam defines the design pressure.
This idea is wrong. It’s also very curious. Even if you
believe that the top seam defines the design pressure,
why move the PRV? Just reset it to account for the
correct static head.
What must happen if the PRV moves to the
Option 2 location? The elevation of the pipe is 67
ft. 4 in. and the PRV inlet is at 69 ft. 0 in. At an
operating density of 48.8 lbs/ft 3 this gives 23 psi
of liquid head (rounded up again). The maximum
PRV release setting is 142 (165 psig design limit
minus 23 psi static head).
The key point is that pressure relief devices must
protect all points of the vessel from exceeding design
pressure. Moving PRVs doesn’t change vessel design
pressures. Always go back to the U-1 forms when you
must verify design pressure. Other documentation,
while convenient and helpful, remains secondary to
the U-1 forms and related vessel code stamps.
andrew sloley, Contributing Editor
ASloley@putman.net

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

Additional 2011 CP Panel

Discussion topics include:
Dust Control - July
Next up!
CFATS - August
Alarm Management – June 16, 2011
Most plants have too many alarms, hampering operators’ ability to properly respond to Asset Management - August
issues. This discussion will look at proven methods to address the problems and alleviate Process Safety – Sept.
your alarm issues. Register now! Energy Efficiency – Oct.
Dry Materials Handling – Nov.

CP Discussions Now
Available On-Demand:
For more information on each of these exciting 60-minute Webcasts,
Condition Monitoring
to watch on demand Webcasts and to register, go to: Energy Efficiency
www.ChemicalProcessing.com/cpseries Emissions

CP_PanelSeries_Half_1105.indd 1 4/26/11 10:43 AM

CP1105_42_43_InSites.indd 43 4/26/11 2:38 PM

 equipMent & services
Pin Mill Fits Compact
Spaces
The 18-in. diameter centrifugal
impact mill model CIM-18-SS
provides coarse to fine (400 mesh)
grinding of friable materials into
controlled particle sizes, as well asdiagnostic and predictive failure
de-agglomerating and conditioning
of dry solids. A direct drive system
reduces the unit’s footprint to about 262-512-2291
half of that required by a belt-driven www.rockwellautomation.com
machine, allowing installations in
restricted areas. Setting the infi-
nitely variable rotor speed between
several hundred rpm and 5,400 rpm
provides the flexibility to use the
machine for coarse grinding and
de-agglomerating as well as for fine
grinding. The 15-hp unit reportedly
produces tight particle-size distribu-
tion at any given rotor speed setting,
and sanitizes rapidly.
Munson Machinery Company, Inc.
800-944-6644
www.munsonmachinery.com
MCCs Come With
Embedded EtherNet/IP
Allen-Bradley Centerline low-volt-
age motor control centers (MCCs)
are now available with EtherNet/
May 2011 cheMicalprocessing.coM
CP1105_44_47_E&S.indd 44
IP. A single, standard network current and immediately switches
can help simplify communica- off the power supply. In micro-
tion for the entire enterprise and seconds energy from the electrical
provide users with the flexibility system is reduced to a safe level.
to control, configure and collect Pepperl+Fuchs
data from any point in the system. 330-486-0002
Remote access via Ethernet al- www.pepperl-fuchs.us
lows personnel to safely monitor,
troubleshoot and diagnose the
MCC without exposing them to
potentially dangerous conditions
and power equipment. With em-
bedded IntelliCenter technology,
the MCCs use a pre-configured
and pre-tested network with
integrated hardware and software.
This plug-and-play set up is said
to reduce installation time and
minimize downtime by providing
information. Filter Suits Oval-Style Dust
Rockwell Automation Collectors
The HemiPleat NoOval replace-
ment filter features an “oval to
round” configuration that fits into
down-flow-style dust collectors
that use oval filters. It is claimed to
be ideal for improving overall per-
formance or solving problems such
as short filter life with existing dust
collectors. The new filter features a
nano-fiber media that is said to be
strong enough to handle difficult
dust challenges. Its open-pleat
design allows greater media utiliza-
tion for more effective cleaning and
Power Supply Maintains lower pressure drop — reportedly
Intrinsic Safety resulting in greatly extended filter
The Dynamic Arc Recognition life and energy savings. All models
and Termination System (DART) replace 26-in.-long oval filters and
is a power supply and control sys- are available to fit straight-style or
tem for intrinsically safe fieldbus triangular-style yokes.
installations. The device is said Camfil Farr Air Pollution Control
to increase the power available to (800) 479-6801
field devices in explosion hazard www.farrapc.com
areas, while maintaining intrinsi-
cally safe energy levels. During Detector Monitors Low-
normal operation, a DART Level Hydrogen Leaks
power supply feeds full nominal The TS4000H Intelligent Hydro-
power of 8 to 50 watts. Should a gen Gas Detector detects hydrogen
fault occur the potential spark re- at 0–500 ppm levels. It features a
mains non-incendive, and DART precision electrochemical hydrogen
detects the resulting change in sensor that has a T90 response of
44
4/26/11 2:39 PM

under 30 sec-
onds and mini-
mal zero shift
across its operat-
ing environmental
conditions. An explosion-proof
housing protects the electronics,
and the gas sensor may be remote
mounted up to 2,000 ft (610
meters) from the electronics. The
interface module’s galvanically
isolated, intrinsically safe design
supports sensor field replacement
without special tools or hot work
permits. In addition to monitor-
ing for low hydrogen levels, the
TS4000H can be configured to
detect a variety of other toxic gases.
General Monitors
800-330-9161
www.generalmonitors.com
Sliding Vane Pumps
Feature Electric Heating
Three models of NP Series sliding
vane pumps now are available
with optional electric heating.
A 4-in. model joins the previously
upgraded 2.5-in. and 3-in. models.
Electric heating may be used in
place of jacketed heads for applica-
tions that normally require jackets,
such as handling bitumen, molasses,
lube oils, etc. The company will
continue to offer jacketed heads for
customers who need pumps with
steam and hot-oil capabilities. The
pumps are said to offer maximum
versatility for handling a variety of
clean, non-corrosive liquids, includ-
ing fluids of varying viscosities and
temperatures.
Blackmer
616-241-1611
www.blackmer.com
CP1105_44_47_E&S.indd 45
Ball Valve Delivers
Corrosion-Resistance
The PE100 ball valve is considered
ideal for gas, sewer and water ap-
plications where metal ball valves
have typically been installed. It
is 50% lighter than comparable
metal valves and offers corrosion-
resistant internal and external
parts. The ball valve’s two-step
planetary gear system is said to
ensure smooth valve opening and
closing, thereby eliminating water
hammer. The PE100’s SDR11
spigot ends are approved for maxi-
mum operating pressures of 230
psi for water and 150 psi for air or
gas. Valves are available in 1–6 in.
sizes and in both metric and IPS
pipe sizes.
Asahi/America, Inc.
781-321-5409
www.asahi-america.com
Ultrasonic Transmitter
Measures Solid Levels
The Series ULB is
a direct-install
level transmit-
ter designed for
non-contact
measurement
of solid levels.
It utilizes
ultrasonic tech-
nology paired
with automatic
temperature
compensation to
provide reliable and
accurate measure-
ments in virtually
all conditions, says
the company. An integrated
LCD screen and four responsive
push buttons allow for quick and
easy programming via a simple
45
equipment & services
menu structure. The ULB also
features diagnostic capabilities
and a failsafe output signal that
are considered ideal for critical
applications.
Dwyer Instruments, Inc.
800-872-9141
www.dwyer-inst.com
Filters Boast Porous Metal
Elements
The 7710 Series of HyPulse
HyLine filters is designed to ac-
commodate lower pressure liquid
and gas filtration applications at
a value price point. Porous metal
elements are 10-in. long, 316L
stainless steel cartridges in either
a double open-ended or 1-in.
NPT connection configuration.
The stainless steel housing comes
standard with a Buna N housing
seal. Other seals and “O” rings are
available to support applications
requiring higher temperature or
corrosion resistance. The filters are
designed for maximum operating
pressures of 300 psi (housing)
and include a ¼-in. NPT housing
drain, ¼-in. NPT gauge ports and
1-in. FNPT line connections.
Mott Corporation
860-747-6333
www.mottcorp.com
Pressure Transmitter
Uses HART Technology
The TX200H smart pressure
transmitter provides field adjust-
ment while communicating asset
management data utilizing HART
7. A 10:1 turndown on pressure
ranges from 0 to 15 psi (0 to 1 bar)
up to 0 to 25,000 psi (0 to 1,724
bar) allow users to range the trans-
mitter as application requirements
change. Real-time diagnostics
chemicalprocessing.com may 2011
4/26/11 2:39 PM
 equipMent & services
report device health status and pro-
cess performance, helping reduce
maintenance costs. The TX200H
is constructed of 316 stainless steel,
welded and hermetically sealed to
meet enclosure type 4X and IP66
requirements. It can be mounted
directly onto the process or within
the control panel.
United Electric Controls
617-926-1000
www.ueonline.com
Compressors Offer
Maximum Leakage Control
T791 and T891 compressors are
oil-free machines for applications
requiring maximum leakage
control. Each piston rod has three
sets of packing that form two
distinct distance pieces or barriers
to the atmosphere. Because each
distance piece has its own line
connections that can be separate-
ly pressurized, purged, padded
or vented, the compressors offer
a wide range of flexibility for
controlling external leak-
age. The T791 is a two-stage
compressor with a working
pressure of 615 psia (42.4 bar)
while the T891 is a single-stage
compressor with a working pres-
sure of 465 psia (32.1 bar). Both
are double-acting machines with
piston displacement just over 100
cfm (169.9 m3/hr).
Corken
405-946-5576
www.corken.com
Meters Provide Accurate
Data, Billing Recording
EngyCal RH33 Btu meter and
RS33 steam meter provide data
recording and billing information
for custody transfer, steam measure-
ment, and energy flow calculations.
The RH33 Btu meter was devel-
oped for custody transfer applica-
tions with liquids such as water,
water/glycol mixtures or thermal
oils. It calculates enthalpy (hot
May 2011 cheMicalprocessing.coM
CP1105_44_47_E&S.indd 46
diagnostic information, permit-
ting monitoring of instrument
maintenance conditions to help
reduce plant downtime.
ABB
www.abb.com
and cold), energy (thermal flow),
density and mass flow based on the
measured flow value and tempera-
ture differential. For recording and
billing steam mass and energy flow,
the RS33 calculates enthalpy and Meters Withstand Extreme
energy as well as the density and Conditions
mass flow based on the measured The Dura Meter series is designed
flow value, temperature or pressure.for severe environmental conditions
Endress+Hauser across multiple industries such as
800-642-8737 chemical, oil and gas, utilities, water
www.us.endress.com treatment and food processing. The
first meter in the series, an elapsed
Wireless Adapter Gets time meter, combines time meter
Stranded Data assembly with a die cast aluminum
The FieldKey wireless adapter pro- NEMA 4X housing. The Dura Me-
vides access to all the information ter series meets ANSI Specification
held within HART instrumenta- C39.1, is water and dust resistant
tion of any make. Added, point and UL rated. Standard options in-
by point, to existing 4-to-20-mA clude horizontal vs. vertical mount-
HART instruments and networks, ing, hours vs. minutes, reset vs.
FieldKey wirelessly relays process, non-reset and voltage and frequency
diagnostic and configuration rating. Additional options include
information back to a host electrical connection, customer con-
system. As a result, Field- figuration, stainless steel tag, and
Key unlocks the unused epoxy resin or polyurethane-epoxy
information held within in- combination paint.
stalled 4-to-20-mA HART Yokogawa Corporation of America
instruments. Users can 800-888-6400
wirelessly monitor addi- www.yokogawa-usa.com
tional process information
that may include tempera- Filter Elements Speed
ture, pressure, flowrate, Maintenance
level, and density, as well The Balston vacuum pump inlet
as receive and exhaust filter product line
feedback now includes models offering
from valve replaceable filter elements. The
positioners. filter element reportedly is easy to
They can change out in less than one minute
also access without the need for any tools. The
46
4/26/11 2:39 PM
 EQUIPMENT & SERVICES

exhaust filters are said to SIL Relays Boast Fail-Safe

remove 99.9% of 0.1-mi-
cron oil mist and smoke
particles, eliminate
oil accumula-
tion in duct-
work, recover
expensive
lubricating oils
and forestall
potential
OSHA and
EPA violations.
Balston Grade 30
vacuum pump inlet filters prevent
oil backstreaming from the pump
to the evacuated chamber, and
protect the pump from damage by
submicron particles (at relatively
low concentrations).
Parker Hannifin Corporation
800-343-4048
www.balstonfilters.com
Water Jet Pump Varies
Operating Pressures
The 605 series of water jet pump
units now gives users a combina-
tion of ultra-high pressure and
high horsepower in a unit that can
convert to a variety of operating
pressures. The range of the units has
been expanded to include eight op-
erating pressures from 4,000 psi to
40,000 psi (275 bar to 2,800 bar),
with engines of up to 600 hp (447
kW). Diesel and electric models are
available. They offer flows as low as
20 gpm (83 lpm). These units can
be converted from one pressure to
another in about 20 minutes.
NLB Corp.
248-624-5555
www.nlbcorp.com
Controls
The PSR-FSP2/2x1 and PSR–
FSP/2x1 relays are designed to
operate with fail-safe controls
in process applications. The
PSR-FSP/2x1 can be used in
applications up to a Safety
Integrity Level (SIL) 3, and
the PSR-FSP2/2x1 for up
to SIL 2, according to IEC 61508.
They have two normally open safe
outputs. Outputs for the PSR-
FSP/2x1 are internally redundant,
while outputs for the PSR-FSP2/2x1
are not. Both have a normally closed
status contact that can be wired to
a SIL-rated controller to perform an
automated “proof test” to ensure the
targeted SIL level is maintained.
Phoenix Contact
800-322-3225
www.phoenixcontact.com

CLASSIFIED PRODUCT SPOTLIGHT

CP0902_Autocon_R1.pdf 1 2/26/09 3:27 PM

GYRO
Equipment TM

The OS10 CONTINUOUS Bin Activating Feeder

DryBlender/Solid-Liquid CALL FRAIN LAST! For Dry Bulk SoliDS
MIXER
Frain has more Pre-Owned
THE OS10 IS
EFFICIENT! Packaging & Processing
LESS HP – LESS SPACE
MORE OUTPUT machinery than any
THE OS10 IS competitor at the
FRIENDLY!
NO MECH. SEAL OR
GEARBOX TO
MAINTAIN
LOWEST
THE OS10 IS
CLEAN!
PRICE!
EASY DISASSEMBLY
SELF-PURGING

THE OS10 IS
GUARANTEED!
• Up to 400 to 1 turndown ratio
THOROUGH!
COMPLETE WET-UP CALL FRAIN GROUP • Uniform material feeding
AND EVEN DISPERSION
30” X 30” X 14” - 10 HP - 600+ lb/minute 630-629-9900 •
•
Reliable material discharge
Infinitely adjustable feed rates
Autocon Mixing Systems, Inc. www.used-packaging.com • Prevents material segregation
www.theosten.com • 800 225 6192
• Prevents material from compacting
• Positive material cut-off

LOOKING TO ADVERTISE?
Contact Polly Dickson at pdickson@putman.net or 630-467-1300 x396 +1 651 484-2900 • www.dynamicair.com

47 CHEMICALPROCESSING.COM MAY 2011

CP1105_44_47_E&S.indd 47 4/26/11 2:40 PM

 CLASSIFIED

Equipment

A Leader in Plant Dismantling and Demolition

Boilers.
• Nationwide Service
• We self-perform every project with trained,
Nationwide.
experienced crew
• Surplus Equipment Dealer Learn more about
• Top Ranked Specialty Contractor our total solutions:
1-800-227-1966
• Highly Specialized Equipment www.nationwideboiler.com
• Superior Safety Performance
• $22 million insurance

MIDWEST STEEL COMPANY, INC.

MIDWEST-STEEL.COM - (713) 991-7843
New X Clean ad May_Layout 1 4/15/2011 11:38 AM Page 1

Integrity. Dependability.
Real Customer Service.
The industrial strength solution to remove oil and grease Rentals | Sales | Leasing
• Environmently safe • Water based
• NSF Registered A8 and C1
• Biodegradable
For information call or e-mail:
RodneyR@klsummit.com
800.749.5823
Sublime ad May CP_Layout • www.klsummit.com
1 4/15/2011 1:30 PM Page 1
R AT
EB
CEL

IN

Capper For Sale 1931 Capper For Sale 2010

G

Dept. of the Navy approved for cleaning seawater systems 1 8o 8 0 - 2 0 1 0

ffami n
ly traditi
o

Your trusted resource for

equipment solutions for 130 Years

equipment sales, purchases, rentals & leasing

auction & liquidation services
Certified Market Appraisals
asset based loans
DISSOLVES LIME SCALE
It is safe for employees, 130 Acres for 130 YeArs - To learn about Loeb’s
equipment and the environment. carbon offset project and watch our progress in
reaching 130 acres of rainforest conservation, visit:
NSF A3 approved • Biodegradable • Non-Corrosive, www.loebequipment.com
Non-Flammable • Changes color when spent.
For information : RodneyR@klsummit.com
800.749.5823 • www.sublimedescaler.com (800) 560-LOEB (773) 548-4131
saLEs@LOEBEquipmEnt.cOm
12/14/10 12:04 PM

LOOKING TO ADVERTISE?
Contact Polly Dickson at pdickson@putman.net or 630-467-1300 x396

MAY 2011 CHEMICALPROCESSING.COM 48

CP1105_48_49_CLASS.indd 48 4/26/11 11:04 AM

 classified

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

Equipment Custom Services
AADVANCED MACHINERY INC.
• •
• BOILERS • WANTED TO BUY
•
FOR SALESELL • RENT• LEASE •
• - 24 / 7 - • OLD PLASTIC
• EMERGENCY SERVICE •
ablet/Compacting Briquetting Presses
tzmills, J, D-6
icropulverizer, 1-SH • • MOLDING PREFORM
• 40 e.f.
K Blenders, Lab up to 30 cu.ft.
• PRESSES
atterson Dbl. Cone Blender,
rich Mixers, RO2VAK, R-7• • Baldwin Defi ance #20, #45
• sizes and materials
ttleford Mixers, FM-130, FKM-300, FKM-600
ar, Bal, Pebble Mills, many • Defiance #20, #45
• IMMEDIATE DELIVERY
nion Process Attritors, 60-S • Stokes Machines - All Models
•
weco Grinding Mills, DM-1, DM-3, Urethane
•
• CALL: 800-704-2002
Sales offices
•
tokes Oscillating Grinders KOMAGE #K-15, #K50
ay Pony Mixer, 25 gal. 55 PubliShing hEadquartErS
• 2hp, L550
eyers Dual shaft disperser, 10HP TO 250,000#/hr • Bipel Preformers
/T-4, R/R-4 •
eplacement parts for Stokes Presses F/F-4,
250,000#/hr
150,000#/hr
Nebraska
Nebraska
750 psig
1025 psig
750OTTF
900OTTF • ANY CONDITION
• Oscillating
eplacement parts for Stokes 150,000#/hr
150,000#/hr
Nebraska
Nebraska
750 psig
350 psig
750OTTF
• Aadvanced Machinery
555 W. Pierce Road, Suite 301

• •
Itasca, IL 60143
ranulators 115,000#/hr Nebraska 350 psig Phone: 630-467-1300 • Fax: 630-467-1109
80,000#/hr Nebraska 750 psig (586) 790-1717
ALL EQUIPMENT • IN STOCK!
80,000#/hr
75,000#/hr
Erie City
Nebraska
2000 psig
350 psig
800OTTF
• Fax. (586) 790-1871
Web site: www.chemicalprocessing.com

• 70,000#/hr
60,000#/hr
Nebraska
Nebraska
750 psig
350 psig
750OTTF
• Email:www.aadvancedmach.com
Service@aadvancedmach.com
brian Marz, Publisher
E-mail: bmarz@putman.net
AADVANCED MACHINERY, INC.
• Dr.
40,000#/hr
35044 Automation
20,000#/hr
Nebraska
Erie City
350 psig
200 psig • Phone: 630-467-1300, x411

• 10-1000HP
Clinton Township, Michigan 48035 Firetube 15-600 psig
• Carmela Kappel, Assistant to the Publisher
Phone: 630-467-1300, x314
•
Tel. (586) 790-1717 Fax. (586) 790-1871
ALL PRESSURE AND TEMPERATURE COMBINATIONS
Email: service@aadvancedmach.com • Fax: 630-467-0197

•
www.aadvancedmach.com
SUPERHEATED AND SATURATED
• SalES

• RENTAL FLEET OF MOBILE

TRAILER-MOUNTED BOILERS • Faith dalton, District Manager
Digital Sales Manager
• 75,000#/hr Optimus 750 psig 750OTTF • Email: fdalton@putman.net

• 75,000#/hr
60,000#/hr
Nebraska
Nebraska
350 psig
350 psig • Phone: 630-467-1300, x485

• •
50,000#/hr Nebraska 500 psig MiChaEl Connaughton, Account Executive
40,000#/hr Nebraska 350 psig Email: mconnaughton@putman.net

• 30,000#/hr
75-300HP
Nebraska
Firetube
350 psig
15-600 psig • Phone: 630-467-1300, x804

• ENGINEERING
ALL BOILERS ARE COMBINATION GAS/OIL • ProduCt SPotlight/ClaSSiFiEdS/ad-litS

• • START-UP •FULL LINE OF BOILER

AUXILIARY SUPPORT EQUIPMENT. • Polly diCKSon, Inside Sales Manager
E-mail: pdickson@putman.net
• Electric Generators: 50KW-30,000KW • Phone: 630-467-1300, x396

• WEB SITE: www.wabashpower.com •

Fax: 630-364-4175

• 847-541-5600 • FAX: 847-541-1279 •

rEPrintS
Foster Reprints
• E-mail: info@wabashpower.com • 866-879-9144

• • www.fostereprints.com

• wabash POWER
EQUIPMENT CO. • advErtiSEr indEx

• •
advErtiSEr Pg #
444 Carpenter Avenue, Wheeling, IL 60090
Arizona Instrument 20
Baldor Electric Co. 52

AADVANCED MACHINERY INC.

HEAT EXCHANGERS BASF Catalysts LLC
Bete Fog Nozzle
17
3

Liquid Cooled Brooks Instrument 37

▼

Dupont Personal Protection 51

Quality & Service First Endress + Hauser 2
BUY & SELL MACHINERY
Fike Corporation 6
586-790-1717 • service@aadvancedmach.com
Inpro/Seal 23
WWW.AADVANCEDMACH.COM
Load Controls 26
Material Transfer & Storage 32
Air Cooled
▼

NLB 19
Centrifuges
Horizontal Peeler Centrifuges Inverting Filter Centrifuges
FOR GASES & LIQUIDS! Nordfab
Paratherm
28
29

Vertical Basket Centrifuges

Newly acquired Comber Nutsche Talk Directly with Design Engineers! Putman Media 43
Filter-Dryers available Blower Cooling Vent Condensing Siemens Process Automation 4
856-467-3399
Spraying Systems 25
www.heinkelusa.com
TriStar PetroServ 33
UBM Canon Communications 39
(952) 933-2559 info@xchanger.com

49 chemicalprocessing.com may 2011

CP1105_48_49_CLASS.indd 49 4/26/11 11:05 AM

 enD poinT
Bio-chem Industry Gets Social
Industry report shows companies that adapt to social networking are more successful
FaceBook, TwITTer, LinkedIn and other so-
cial networks are synonymous with changing human
social interaction. However, it now appears that such
networks are also driving corporate collaborations.
This is especially true in the field of bio-based ma-
terials and chemicals (BBMC), which is benefiting
from increasing ties between start-ups, corporations,
Social networking universities and investors.
So says a report from Lux Research, Boston, Mass.,
can help smaller a company that specializes in providing strategic advice
players navigate and ongoing intelligence for emerging technologies.
In “Green Materials’ Social Networks,” Lux
new paths to Research points out that making plastics, catalysts,
market. solvents and other industrial chemicals from re-
newable sources requires an exceptional degree of
interdisciplinary science, and bringing them to market
cuts across industries ranging from agriculture to au-
tomotive. So without thriving social networks, these
important new products will fail, it says.
The report maps the relationships that define and
drive open innovation in today’s BBMC industry and
provides strategic guidance for successful future col-
laborations, internal activities and market initiatives.
It also presents a method for analyzing the impact of
business partnership networks on products, industries
and competitors. The report largely indicates the stron-
ger a technology developer’s commercial partnerships
are, the stronger the company tends to perform overall.
“Financial backers and academic collaborators
help new green materials get started,” says Mark
Bünger, a Lux Research director and the report’s lead
author. “But too many promising technologies stop at
that stage. Only multiple, active commercial relation-
ships with other businesses will turn these technolo-
gies into mature processes and products that actually
have a commercial and environmental impact, and a
return for their investors.”
In preparing the report, Lux Research interviewed
more than 80 BBMC technology developers as well
as select businesses with which they partner, and
complemented its findings with secondary research.
The analysis also drew on research into human and
organizational social networks to apply it to the specif-
ic companies and clusters in the renewable chemicals
space. In addition to assessing each company’s indi-
vidual social network, the firm found patterns across
the field that reveal new insights.
The first of three key findings highlights that
BBMC encourages interdisciplinary partnering more
May 2011 cheMicalprocessing.coM 50
CP1105_50_EndPoint.indd 50
than other fields. Compared to other markets, BBMC
demands a broader diversity of expertise, ranging
from biochemistry, industrial scale-up, and even con-
sumer marketing and branding. Thus, it encourages
more cross-industry partnerships. While collaboration
between a drug-maker like Merck and a carmaker like
Ford would be unthinkable, writes Bünger, both of
those firms have relationships with companies in the
BBMC field (Codexis and Merquinsa, respectively).
The report also finds that successful BBMC devel-
opers sustain several strong, significant partnerships.
Like gregarious humans, leading technology start-ups
tend to be prolific networkers. For example, BTG-
BTL has Akzo Nobel, DSM and Shell, among others,
on its list of friends; Elevance counts Cargill and
Dow Corning; Algenol Biofuels has Dow Chemical
and Linde; and little Lignol works with Novozymes,
Huntsman, PPG and Pacific Ethanol. The report says
these partnerships do more than help validate smaller
companies — they provide technology advice and
engineering expertise, and open paths to market that
would be difficult for small players to navigate alone.
The last finding notes that the strongest clusters of
relationships form at intersections in the value chain.
Like people, companies don’t form relationships
randomly. In the case of BBMC, the value chain —
feedstocks, products and applications — is strongly
associated with almost every aspect of a company’s
identity. Compared even with seemingly fundamental
factors like a company’s technology, size or geographic
location, the partnerships it forms within the value
chain overwhelmingly determine its success or failure.
The report concludes that examining individual
relationships as well as the collective “social network”
of the bio-based industry as a whole reveals oppor-
tunities and threats for everyone: “Relationships in
the bio-based materials and chemicals field have been
deepening over the past few years, showing that com-
mercial maturity is near and that consolidation in the
space will accelerate, and inter-industry partnering is
more common in BBMC than other spaces. To build
a stronger corporate social network, companies should
reconnect with prior partners on new terms, use cor-
porate networking to increase personal productivity
and morale, and use existing networks to help coordi-
nate actions, especially in feedstock and finance.”
Seán oTTewell, Editor at Large
sottewell@putman.net
4/26/11 11:04 AM
 This isn’t the There’s only one Tyvek®, and it’s made by DuPont. That’s why workers across industries
and the people who protect them insist on the genuine article. Whether performing
place to wonder asbestos abatement, cleaning up after a flood or applying insulation, every worker
if you’re wearing deserves protection, even from the particles they can’t see. DuPont scientists know the
risks your people face. They created DuPont™ Tyvek®, which resists particles down
DuPont ™ Tyvek . ®
to 1 micron in size with built-in protection that can’t be worn away like some other
protective materials. They offer products like ProShield® NexGen® that help protect
against a range of hazards and deliver non-hazardous light-liquid splash protection.
And our Tyvek® garments are engineered with a comfort-fit design for more flexibility
and to reduce the number of rips and tears. Beyond attire, we continue to innovate,
bringing you cutting-edge solutions like the new SafeSPEC™ 2.0, the powerful digital
tool that helps you find the suitable garment for your hazard or application.
Visit safespec.dupont.com

TYV
E

EK
B

®
.

R
Y

E AD
Copyright © 2011 DuPont. All rights reserved. The DuPont Oval Logo, DuPont TM, Tyvek ®, ProShield ®, NexGen ® and SafeSPEC TM
are registered trademarks or trademarks of E. I. du Pont de Nemours and Company or its affi liates.

CP1105_full page ads.indd 51 4/26/11 10:57 AM

 A Better IEEE 841
Super-E® windings meet or exceed NEMA
Premium® efficiency standards
High strength cast iron frame, endplates,
conduit box and fan cover are designed
to reduce vibration and assure accurate
mounting dimensions

All internal rotor, stator

and shaft surfaces Oversize bearings on each end
are epoxy coated to for long life
prevent corrosion

Insulation system meets Inpro/Seal™ VBXX Bearing

requirements of NEMA Isolators at both ends assure
MG 1, Part 31.4.4.2 for protection from contamination
VFD use and considered
inverter-ready

Two-part epoxy primer Exclusive PLS® (Positive

inside and out, plus Lubrication System)
epoxy finish coat to assures proper bearing
prevent corrosion lubrication in all
mounting positions

All joints gasketed and sealed for added

Foot flatness within 0.005 inches for
protection against contaminant entry
precision alignment to driven equipment

Inside and Out

®
Baldor•Reliance 841XL severe duty motors are • Energy Efficient
engineered and built to meet or exceed the most rigid
severe duty service standards. You’ll find Baldor•Reliance
severe duty motors hard at work around the world in some
of the most brutal conditions you can imagine, like petro- • Unmatched Quality
chemical, pulp & paper and mining operations.

So, no matter how you look at it, you can always count on
Baldor•Reliance severe duty motors to perform under the • Superior Reliability
most extreme conditions...inside and out.

Exceeds IEEE Std. 841-2009 requirements.

baldor.com 479-646-4711 • Quickest Delivery Available

©2011 Baldor Electric Company

CP1105_full page ads.indd 52 4/26/11 10:58 AM