June 2012

SH EV
PR
June
O IEW
W
2012
PA
G
E
3
2
I-
1
www.che.com
Draining Process Vessels

AT THE VESSEL... MUCH LATER... MUCH, MUCH LATER...
HOW LONG
WILL IT
MEANWHILE, BACK AT
THE OTHER VESSEL...
TICK TICK TICK...
TA K E ?
PAGE 34
AND AT THE THIRD VESSEL? ... ZZZZZZZ...
ISOTHERMAL STEAM SYSTEM

PIPE FLOW CONTROL
CFD ANALYSIS OF SPRAY DRYING
HEAT TRANSFER PARAMETERS
FROM FLARES
EXPLOSION
DISTILLATION PROTECTION
STARTUP EQUIPMENT
CHE EDUCATION FOCUS ON
SOFTWARE
Fill one bulk bag per week or 20 per hour
at the lowest cost per bag
Flexicons extra-broad model range, patented innovations and performance enhancements
let you exact-match a filler to your specific cost and capacity requirements
FILLER FOR PALLET BULK BAG FILLER USES FILLERS WITH AUTOMATED COMBINATION
JACK BAG REMOVAL PLANT SCALE FEEDING SYSTEMS BULK BAG/DRUM FILLER
Low profile version of patented Full length forklifting tubes Every Flexicon filler is offered with Patented SWING-DOWN filler
TWIN-CENTERPOST filler allows allow positioning of this TWIN- pneumatic (shown) or mechanical features a fill head that lowers
removal of filled bags using a CENTERPOST filler model on a (bottom right) feeding/weighing and pivots down for safe, easy bag
pallet jack, eliminating the need plant scale as needed, allowing systems, as well as inlet adapters spout connections at floor level,
for a forklift or roller conveyor. you to fill by weight without to interface with and a swing-arm-mounted chute
Low cost standard models offered investing in load cells and optional overhead for automated filling and
with many performance options. automated controls. storage vessels. indexing of drums.
PATENTED CANTILEVERED BASIC FILLER FOR PATENTED

SWING-DOWN FILLER REAR-POST FILLER TIGHTEST BUDGETS TWIN-CENTERPOST FILLER
Fill head lowers, pivots and stops Offered with performance options A lighter-duty version of the Two heavy-gauge, on-center posts
in a vertically-oriented position, including: powered fill head economical TWIN-CENTERPOST boost strength and access to bag
allowing operator to safely and height adjustment, pneumatically filler, the BASIC FILLER reduces hooks while reducing cost. Standard
quickly connect empty bags at retractable bag hooks, inflatable cost further still, yet has an manual fill head height adjustment,
floor level and resume automated bag spout seal, dust containment inflatable bag spout seal and feed and feed chute vent for displaced dust.
filling and spout-cinching vent, roller conveyor, and vibratory chute dust vent as standard, and a Numerous performance options. First
operations. bag densification/deaeration system. limited list of performance options. filler to receive USDA acceptance.
.com
See the full range of fast-payback equipment at flexicon.com: Flexible Screw Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag Conditioners,
Bulk Bag Fillers, Bag Dump Stations, Drum/Box/Container Dumpers, Weigh Batching and Blending Systems, and Automated Plant-Wide Bulk Handling Systems
USA CHILE +56 2 415 1286

sales@flexicon.com UK +44 (0)1227 374710
1 888 FLEXICON AUSTRALIA +61 (0)7 3879 4180
AA-0658
SOUTH AFRICA +27 (0)41 453 1871
2012 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.
Circle 21 on p. 76 or go to adlinks.che.com/40268-21
Proven Process
Solutions for You
CT.39e-1
Yougetthebestfromourinnovativerangeoftechnologies: Sulzer Chemtech Ltd

Process Technology
distillation-evaporation-liquid-liquidextraction-crystallization-
4123 Allschwil, Switzerland
membraneseparation-hybridsolutions-polymerproduction. Phone +41 61 486 3737
contactpt@sulzer.com
Jointlywefullydevelopyourprocesssolutionfromfirstconcept www.sulzerchemtech.com
andpilottestingtoaninstalledplantwithguaranteedperformance.
Sulzer Chemtech USA, Inc.
Tulsa, OK 74131, USA
Whetheryouareactiveinthechemical,pharmaceutical,biofuelsor Phone +1 918 446 6672
food&beverageindustry,weareheretosupportyou. Sulzer Chemtech Pte. Ltd.
Singapore 629845
WeinviteyoutocomeandvisitusatACHEMAHall4.0BoothD48. Phone +65 6515 5500
WHEN THE HEAT IS ON, PUT THE
THERMINOL PERFORMANCE CREW

TO WORK FOR YOU.

In the heat transfer fluid race the competition can get pretty heated. Thats why you need the Therminol Heat
Transfer Fluid Performance Crew working for you. From start to finish, the Therminol TLC Total Lifecycle Care team
of seasoned professionals is ready to support you with everything you need to win. For your people, we provide
start-up assistance, operational training and a technical service hotline. For your facility, we offer system design,
quality Therminol products, sample analysis, flush fluid & refill and a fluid trade-in program*. We provide everything
you need to keep your heat transfer system at peak performance throughout its lifecycle. So join the winning team.
In North America call 1-800-426-2463 or in Europe 32.10.48.12.11. Youll see no other heat transfer fluid delivers
more proven comprehensive performance than Therminol.
www.therminol.com
Therminol TLC Total Lifecycle Care is a complete program of products and services from Solutia
designed to keep your heat transfer system in top operating condition through its entire lifecycle.
Solutia Inc. 2011. Therminol , TLC Total Lifecycle Care , Therminol logo, and Solutia and RADIANCE LOGO are trademarks of Solutia Inc.,
registered in the U.S. and in other countries. *Available only in North America.
JUNE 2012 IN THIS ISSUE VOLUME 119, NO. 6
Draining Process Vessels

AT THE VESSEL... MUCH LATER... MUCH, MUCH LATER...
www.che.com
HOW LONG
WILL IT
COVER STORY MEANWHILE, BACK AT
THE OTHER VESSEL...
TICK TICK TICK...
TA K E ?
34 Cover Story Draining Vessels Deter-
mine how long it will take to drain flat-,
cone- or dish-shaped units
NEWS
AND AT THE THIRD VESSEL? ... ZZZZZZZ...
11 Chementator Convert wastewater and
carbon dioxide into chemicals with this
technology; A non-crop-based sugar feed-
stock for bio-based chemicals and biofuels;
and more
20 Newsbriefs GE and Shenhua open
cleaner-coal-technology JV in China; CSB *ONLY ON CHE.COM
releases new safety video on Dupont hot More on Achema; Explosion
work explosion; Cybersecurity bill to ease Equipment; New Products; Lat-
information sharing passes House; and est news and more
more
22 Newsfront Education Evolution To 66 Engineering Practice A Novel Equa- DEPARTMENTS
prepare students for globalized industries, tion for Isothermal Pipe Flow A newly Letters . . . . . . . . . . . 6
chemical engineering departments are in- derived equation for isothermal gas flow in
Calendar . . . . . . . . 89
corporating new requirements, utilizing IT pipes yields improved mass-flux predictions
Whos Who . . . . . . . 78
and connecting with CPI companies
EQUIPMENT & SERVICES Reader Service . . . . 76
26 Equipment News Roundup Explo- 30 Focus on Software Plant-management Economic
sions: Are You Prepared?* Explosion software for increased integration, and Indicators . . . . . 7980
protection equipment can minimize dam- more; Track equipment health at large op-
age, but process understanding is key to erations; Enhancements for simulation of ADVERTISERS
optimized solutions batch reactors; and more Literature Review . . 69
32D-1 Show Preview Achema 2012 Held Product Showcase. . 73
ENGINEERING once every three years, Achema will take Classified
place June 1822 in Frankfurt, Germany. A Advertising . . . . 7475
33 Facts at Your Fingertips Spray Dry-
small portion of the products that will be ex- Advertiser Index . . . 77
ing Parameters This one-page reference
hibited on the show floor are discussed here
guide outlines the main considerations
involved in spray drying 32I-1 Show Preview II Achema 2012* COMING IN JULY
More of the products and services to be Look for: Feature Re-
42 Feature Report Dynamic Modeling exhibited at Achema are included: Tube-in- ports on Mixing; and
for Steam System Control Dynamic
tube design augments safety in these heat Corrosion; an Engi-
modeling fills in the gaps of steady-state
exchangers; A wear-resistant rotary valve for neering Practice arti-
modeling and provides a more complete,
abrasive bulk solids; and much more cle on Evaluating Green
reliable and efficient analysis
Projects; a You and
48 Engineering Practice Distillation: COMMENTARY Your Job article on
Avoid Problems During Tower 5 Editors Page Achema expected to ex- Working with the CSB
Startup Practical procedures for both ceed previous years results Attendance after an accident; Envi-
effective startup and problem analysis are at the largest exhibition congress for the ronmental Manager
discussed here for a depropanizer that chemical process industries is expected to articles on Guidelines
experienced downcomer seal loss outpace that of the previous (2009) event, for Safe Process Vacuum
which recorded 3,767 exhibitors and over Systems; and Overpres-
60 Engineering Practice CFD Analysis 173,000 visitors sure Protection; News
of Heat Transfer From Flares A way articles on Biogas; and
to obtain conservative estimates for the 72 The Fractionation Column A very con- Catalysts; and more
temperatures at the support structures of fined space This real-life experience reminds
a flare system us of how dangerous confined spaces can be Cover: David Whitcher
CHEMICAL ENGINEERING WWW.CHE.COM JUNE 2012 3

AC
H
EM H
Vi ll 8.
sit Bo 0
A a
us ot
at h #
D
24
,
Make the unpredictable
totally predictable.
Swagelok Pressure Regulators are now an even better choice for all
your pressure regulator needs. Why? Well, alongside our proven experience
and expertise, our range now covers sizes from 1/8 to 4 in. and all your
regulator needs high-flow capability, two-stage, back-pressure and
vaporizing models. With our regulators you get accuracy, sensitivity and
pressure stability. In short total predictability. Exactly what you would expect.
Visit swagelok.com/pressure.
2012 Swagelok Company
Winner of Eight Jesse H. Neal
Awards for Editorial Excellence
Editors Page
Published since 1902

An Access Intelligence Publication
Achema expected to exceed
PUBLISHER
BRIAN NESSEN
Group Publisher
ART & DESIGN
DAVID WHITCHER
Art Director/
previous years results
bnessen@accessintel.com Editorial Production Manager
his month, individuals from across the chemical process industries
T
EDITORS dwhitcher@che.com
REBEKKAH J. MARSHALL PRODUCTION (CPI) and the globe will gather together for the 30th time at Achema,
Editor in Chief the worlds largest exhibition congress on chemical engineering, envi-
rmarshall@che.com
STEVE OLSON
Director of Production & ronmental protection and biotechnology (June 1822; Frankfurt am Main,
DOROTHY LOZOWSKI Manufacturing
Managing Editor solson@accessintel.com Germany). Organizers at Dechema e.V. (Frankfurt; www.dechema.de) are
dlozowski@che.com
GERALD ONDREY (Frankfurt) JOHN BLAYLOCK-COOKE optimistic that the attendance and exhibitor totals will outpace those of
Senior Editor Ad Production Manager the previous (2009) event, which recorded a total of 3,767 exhibitors and
gondrey@che.com jcooke@accessintel.com
SCOTT JENKINS
over 173,000 visitors.
Associate Editor AUDIENCE Held once every three years, Achema is an event truly like no other.
sjenkins@che.com DEVELOPMENT
Starting several months before the event itself, Achema begins to take
CONTRIBUTING EDITORS
SARAH GARWOOD
Audience Marketing Director center stage on the schedule of every Chemical Engineering editor. The
SUZANNE A. SHELLEY sgarwood@accessintel.com first reason reflects the sheer number and impact of innovative technolo-
sshelley@che.com
CHARLES BUTCHER (U.K.)
GEORGE SEVERINE gies that are unveiled there. Examples of these technologies are scattered
Fulfillment Manager
cbutcher@che.com gseverine@accessintel.com throughout this issue, including our Chementator department (starting
PAUL S. GRAD (Australia) JEN FELLING on p. 11), our Focus on Software (pp. 3031) and the second installment of
pgrad@che.com
List Sales, Statlistics (203) 778-8700 our Achema Preview, which begins on p. 32 (and continues on our website
TETSUO SATOH (Japan) j.felling@statlistics.com
tsatoh@che.com at www.che.com/new_products_and_services/). The second reason drawing
JOY LEPREE (New Jersey) EDITORIAL our attention stems from over 900 lectures in the conference lineup that
jlepree@che.com ADVISORY BOARD
provide a fruitful ground for good technical manuscripts that we are al-
GERALD PARKINSON JOHN CARSON
(California) gparkinson@che.com Jenike & Johanson, Inc. ways seeking for the magazine.
INFORMATION SERVICES DAVID DICKEY The pinnacle, however, of a Chemical Engineering editors preoccupation
CHARLES SANDS MixTech, Inc. with Achema is in our production of the Achema Daily, a 64-page newspa-
Senior Developer per that is produced onsite every day of the show. Even with so many pages
MUKESH DOBLE
Web/business Applications Architect
IIT Madras, India
csands@accessintel.com to fill, we are only able to hit the highlights. Consider for a moment that if
MARKETING HENRY KISTER a person spent eight hours from Monday to Friday touring only the exhibit
Fluor Corp.
JAMIE REESBY halls and ignoring conference sessions, meals, walking time and interac-
Marketing Director TREVOR KLETZ
TradeFair Group, Inc. Loughborough University, U.K.
tion with other attendees, he or she would have less than 40 seconds to
jreesby@che.com spend at each exhibitor booth.
GERHARD KREYSA (retired)
JENNIFER BRADY DECHEMA e.V. The typical booth visit, of course, is much longer than that. Visitors
Marketing Coordinator
TradeFair Group, Inc. RAM RAMACHANDRAN come to have meaningful discussions with suppliers, often getting into
jbrady@che.com (Retired) The Linde Group the specification stages. After all, Achema has proven its ability to provide
HEADQUARTERS virtually every type of technology needed to build, operate and maintain
88 Pine Street, 5th Floor, New York, NY 10005, U.S. a chemical process plant, from suppliers across the globe. And, Thomas
Tel: 212-621-4900 Fax: 212-621-4694
Scheuring, CEO of Dechema, says With a proportion of around 50% of ex-
EUROPEAN EDITORIAL OFFICES
Zeilweg 44, D-60439 Frankfurt am Main, Germany
hibitors from abroad, Achema 2012 will be even more international than
Tel: 49-69-9573-8296 Fax: 49-69-5700-2484 all of its predecessors.
CIRCULATION REQUESTS: Of all the Achema exhibition groups, Scheuring says that two particu-
Tel: 847-564-9290 Fax: 847-564-9453 larly stand out: Instrumentation, Control and Automation Techniques
Fullfillment Manager; P.O. Box 3588,
Northbrook, IL 60065-3588 email: clientservices@che.com and Pharmaceutical, Packaging and Storage Techniques have achieved
ADVERTISING REQUESTS: see p. 76 impressive growth rates. Due to the completion of a new hall at the Frank-
For photocopy or reuse requests: 800-772-3350 or info@copyright.com furt Messe, Achema was able to offer both of these exhibition groups more
For reprints: Wrights Media, 1-877-652-5295, sales@wrightsmedia.com
scope for expansion, which he says was promptly snapped up. He adds
ACCESS INTELLIGENCE, LLC that demand in the two largest exhibition groups, Pumps, Compressors,
DON PAZOUR ROBERT PACIOREK Valves and Fittings and Laboratory and Analytical
Chief Executive Officer Senior Vice President,
ED PINEDO
Chief Information Officer Techniques, also remains gratifyingly stable. In fact,
Executive Vice President SYLVIA SIERRA the record total of 996 exhibitors (and growing) makes
& Chief Financial Officer Senior Vice President,
MACY L. FECTO
Corporate Audience Development Achema the largest pump exhibition in the world.
Exec. Vice President, MICHAEL KRAUS For those of you who cannot make it to Achema this
Human Resources & Administration Vice President,
HEATHER FARLEY
Production and Manufacturing time, we will be offering the Achema Daily in a digital
Divisional President, STEVE BARBER format. Meanwhile, our July and August issues will cer-
Access Intelligence Vice President,
Financial Planning and Internal Audit tainly contain more of the groundbreaking news that we
GERALD STASKO find there.
Vice President/Corporate Controller
Rebekkah Marshall
4 Choke Cherry Road, Second Floor
Rockville, MD 20850 www.accessintel.com CHEMICAL ENGINEERING WWW.CHE.COM JUNE 2012 5
Letters
Call for corrosion papers

The 2013 Corrosion Solutions Conference has issued a call
for papers for an event to be held September 1518, 2013
in San Diego, Calif. The conference will address the specific
needs and interests of professionals in materials, applica-
tion and equipment fabrication for chemical processing, oil
and gas, nuclear and other corrosion-related industries.
This conference is sponsored by ATI (Albany, Ore.; www.
atimetals.com), a producer of specialty metals, and has been
held every second year since 1997. The most recent confer-
ence (2011) attracted over 225 attendees from 13 countries.
Potential topics and areas of interest include, but are not
limited to, case histories, advances and other valuable in-
formation focused on corrosion in these applications:
Organics
Ethanol
Biofuels
Urea
Acetic acid
Hydrocarbon processing
Formic acid
Nitric acid
Sulfuric acid
Hydrochloric acid
Nuclear
Alternative energy
Other topics of interest include:
Preventative maintenance and repairs
Alloy development
Design and engineering
Fabrication advancements
Failure analysis
Equipment advances
Interested authors should submit an abstract with the
subject title, author name, position title and company
name, along with any coauthor names, position titles, and
Over 50 years of company names by November 1, 2012. Abstracts can be
uploaded to the conference website at:
experience www.aticorrosionconference.com/presenters
Each abstract will be reviewed and, if accepted, authors
will receive a notice of acceptance by February 1, 2013.
The Larox solid liquid Upon acceptance, authors will receive further infor-
mation regarding paper and presentation formatting.
separation equipment The conference registration fee for presenters will be
waived. For more information or to discuss a potential
is now available topic, contact Mr. Richard Sutherlin at (541) 967-6924
from Outotec. or richard.sutherlin@atimetals.com.
Every abstract received will be considered for inclusion
based on the technical content and relevance to the chosen
session topics. Abstracts that are promotional in nature
will not be considered. Final manuscripts will be due no
later than July 1, 2013.
Postscripts, corrections
www.outotec.com May 2012 (p. 14), Chementator: In the article, A new cata-
lyst enables room-temperature interconversion of CO2 and
formic acid, Brookhaven National Laboratory (BNL) was
referred to as Brookhaven National Institute. The corrected,
Circle 40 on p. 76 or go to adlinks.che.com/40268-40 online version of the article can be found at www.che.com.
6 CHEMICAL ENGINEERING WWW.CHE.COM JUNE 2012
Efficient Plant Management
COMOS Software Solutions
The software solution COMOS realizes throughout in-

tegrated and holistic management the entire life cycle
of a process plant. With its object orientation and uni-
fied data platform, COMOS ensures a seamless flow of
project-relevant data across all disciplines and project Pls. visit us
phases. This enables plant engineers and operators
to execute their projects faster and in higher quality.
in Hall 11,
Time to market is shortened and engineering costs are Stand C 3
reduced.
www.siemens.com/comos
Chemical Engineering e 1.2 Messe 86x123 2012
perfect
Calendar
ACHEMA
Frankfurt/Main
For
from 18.06.-22.06.2012
Hall 3.1 / Stand A75 NORTH AMERICA
methods
production
Semicon West. SEMI (San Jose, Calif.). Phone: 408-943-
6945; Web: semiconwest.org
San Francisco, Calif. July 1012
Energy Training & Electric Power Classroom

Seminars. PGS Energy Training (Hilton Head
Island, S.C.). Phone: 412-521-4737; Web: psgenergy.com
Seattle, Wash. July 1920
16th AFPM Cat Cracker Seminar. American

Handling equipment
Fuel and Petrochemical Manufacturers (AFPM;
Lifting, weighing, blending,
formerly the National Petrochemical and Refiners
pallet transfer
Assn.; Washington, D.C.). Phone: 202-457-0480;
Web: afpm.org
Mobile or stationary
Houston, Tex. August 2122
Manual or fully automatic
Loads up to 4000 kg handled
2012 ACEEE Summer Study on Energy Efficiency
Hygienic stainless steel
in Buildings. American Council for an Energy-Efficient
GMP-compliant design
Economy (Washington, D.C.). Phone: 202-507-4000;
ATEX conformity
Web: aceee.org
Mller GmbH - 79 618 Rheinfelden (Germany) Bloomington, Minn. August 1217
Industrieweg 5 - Phone: +49 (0) 76 23 / 9 69 - 0 - Fax: +49 (0) 76 23 / 9 69 - 69
A company of the Mller group
info@mueller-gmbh.com - www.mueller-gmbh.com
57th Annual Safety in Ammonia Plants and
Related Facilities Symposium. AIChE (New York,
Circle 37 on p. 76 or go to adlinks.che.com/40268-37 N.Y.). Phone: 646-495-1300; Web: aiche.org
Chicago, Ill. September 913
Low Flow Coriolis Auditing Management Systems ISO19011. BW

Precise and Compact Marguglio LLC (Cold Spring, N.Y.). Phone: 845-265-0123;
Web: hightechnologyseminars.com
Mass Flow Meters / Controllers
Memphis, Tenn. September 2425
2012 SOCMA Leadership Conference 2012.

now available with:
IECEx and ATEX approval SOCMA (Washington, D.C.). Phone: 202-741-4100; Web:
II 2G Ex d IIC T6 socma.com/leadership
Cambridge, Md. September 2527
WEFTEC. Water Environment Federation (Alexandria,

Va.). Phone: 703-684-24920; Web: weftec.org
New Orleans, La. September 29October 3
4th Regional Process Technology Conference.

AIChE (New York, N.Y.). Phone: 646-495-1300;
Web: aiche.org
League City, Tex. October 45
Fluid independent flow measurement and control
Gas or liquid flow rates: 100 mg/h to 30 kg/h ASME/STLE 2012 International Joint Tribology
Very compact: same footprint as thermal MFC Conference. American Society of Mechanical
High accuracy, excellent repeatability
Fast and stable control with integrated pump or regulation valve
Engineers (ASME) and the Society of Tribologists
IP65 design, with optional ATEX approval for Zone 1 or 2 and Lubrication Engineers (STLE; New York, N.Y.).
Phone: 800-843-2763 (U.S.); 973-882-1170 (outside
Innovation Experience Excellence the U.S.); Web: asme.org
Denver, Colo. October 710
Hall: 11.1
Booth: F3 AIChE 2012 Annual Meeting. AIChE (New York, N.Y.).
Phone: 646-495-1300; Web: aiche.org
I www.bronkhorst-cori-tech.com - E info@bronkhorst-cori-tech.com Pittsburgh, Pa. October 28November 2
Continues
3rd Annual ChemInnovations Conference &
Exhibition, co-located with Clean Gulf/
Industrial Fire, Safety and Security, and
Shale EnviroSafe Conference & Exhibitions.
The TradeFair Group (Houston). Phone:
713-343-1891; Web: cpievent.com
New Orleans, La. November 1415
EUROPE
The Scaleup of Chemical Processes. Scientific Visit us!
Update (East Sussex, U.K.). Phone: +44-1435-873062; ACHEMA, Frankfurt am Main
Web: scientificupdate.co.uk 18 22 June 2012
Milan, Italy July 912 Hall 3.0, Booth #F50
International Symposium on Chemical

Reaction Engineering (ISCRE22). European Federa-
tion of Chemical Engineering (Frankfurt am Main, Ger-
many). Phone: +32-3-260-0861; Web: iscre22.com
Maastricht, The Netherlands September 25
SOME THINK
3rd International Conference on Metal-
Organic Frameworks and Open Framework
Compounds (MOF2012). Dechema e.V. (Frankfurt
YOU CAN
am Main, Germany). Phone: +49-69-7564-277; Web:
mof-conf.org
Edinburgh, U.K. September 1619
Plastic Pipes XVI. Plastic Pipe Inst. (Budapest,

USE GENERIC
INSIGHT FOR
Hungary). Phone: +36-1-212-0056; Web: ppxvi.org
Barcelona, Spain September 2426
SPECIALIST
PPMA Show 2012. Reed Exhibitions (Surrey, U.K.).
Phone: +44-20-8910-7189; Web: ppmashow.co.uk
Birmingham, U.K. September 2527
4th Symposium on Continuous Flow Reactor

Technology for Industrial Applications. APPLICATIONS.
WE THINK
Teknoscienze S.r.l. (Milan, Italy). Phone: +39-02-26809375;
Web: teknoscienze.com
DIFFERENT.
Lisbon, Portugal September 2627
ASIA & ELSEWHERE

15th International Congress on Catalysis
(ICC2012). Dechema e.V. (Frankfurt am Main,
Germany). Phone: +49-69-7564-129; Web:
icc2012.org Packaging high-value, sensitive chemicals requires a whole
Munich, Germany July 16 di erent level of insight and innovation. At BEUMER, hands-on
experience working with chemical producers has let us develop
8th World Water Congress & Exhibition 2012. systems that strongly reect sector need. Our portfolio of
complete warehouse packaging and management systems
International Water Assn. (The Hague, The
includes some of the highest capacity systems on the market.
Netherlands). Phone: +31-70-382-0028;
Combined with a profound knowledge of your product and
Web: iwa2012busan.org
process, were able to maximise e ciency while maintaining
Busan, South Korea September 1621
a level of care and safety that makes all the di erence.
For more information, visit www.beumergroup.com
21st Annual Flexpo Conference Polyolefins and
Elastomers. Chemical Market Resources (Webster, Tex.).
Phone: 281-557-3320; Web: cmrhoutex.com
Bangkok, Thailand September 2627
Suzanne Shelley
Whats your
N
of conidence?
EXPERIENCE MATTERS W
O I
C ORION INSTRUMENTS
CHEMICAL P M W
O G E P R P P
B
M L MLI
T
REVEAL
S
S R MLI
G W
S
REVEAL
O V B B R L ORION
HART HART C F FOUNDATION F F Circle 39 on p. 76 or go to adlinks.che.com/40268-39
ISO 9001
Edited by Gerald Ondrey June 2012
Electrochemical reactor
CO2 Capture and Conversion
Convert wastewater and CO2 into e-
DC electricity
e-
chemicals with this technology Oxygen Hydrogen
E lectrochemical and chemical-precipitation

technology from New Sky Energy (Boul-
der, Colo.; www.newskyenergy.com) allows A
M
E
M
E
C
A
N T
the conversion of salty wastewater and CO2 M M Carbonates and
O H
from fluegas into valuable process chemi- B B carbon-negative
D O
R R products
cals, such as soda ash, calcium carbonate, E D
A A
sulfuric acid, bleach and other chemicals. Acid E Base
N N Carbon
New Skys customizable system is de- E E dioxide
signed to be installed onsite at a processing
from air or
facility to work with the chemistry of that flue gas
plants brine waste stream and CO2 exhaust. Salt
Onsite production of chemicals from readily
available waste streams reduces transporta- The tunable process is especially appropri-
tion costs and reduces CO2 emissions, says ate at battery recycling, oil and gas drilling, Metals recovery
Deane Little, New Sky CEO. glass or plastics manufacturing and min-
Dinnissen Process Technol-
The New Sky scheme includes a proprie- ing facilities. In economic studies of several ogy B.V. (Sevenum, The
tary electrochemical reactor in which Nafion cases, New Sky calculates the technology in- Netherlands; www.dinnissen.
ion-exchange membranes are stacked be- vestment for its technology would be repaid nl) has developed a purpose-
tween alternating anode and cathode plates, in 2.4 yr in the case of using produced water built system to recover
and a small voltage (3 V) is applied across the from oil and natural gas drilling to manu- valuable metals such as
cell. A salt solution entering the cell between facture sodium hypochlorite, and in 3.7 yr in chrome and molybdenum
the membranes is split into acid, base, hydro- the case of using waste brine to make soda from highly viscous residual
gen and oxygen. The base from this reaction ash for glass manufacturing. waste from the petrochemi-
cal industry. Such waste,
can be combined with CO2 and wastewater New Skys initial business model is to
which is often contaminated
to selectively precipitate a variety of magne- license its technology for incorporation at
with wood, stone and iron
sium, calcium and other metal salts. partner sites, as well as to provide consult- particles, has been almost
New Skys combined electrochemical-pre- ing services. The company has built two impossible to process, says
cipitation process generates a suite of poten- large prototypes, and plans a pilot facility the company.
tially useful chemicals, including carbonates, by the end of 2012, and a 34 ton/d modu- The thick, viscous tar mass
hydroxides, hydrochloric and sulfuric acids, lar production facility at a client site by the (from drums, containers and
sodium chloride, sodium sulfate and others. middle of 2013. bags) is first placed in tipper
units, which are vibrated and
shaken to empty the mass
A non-crop-based sugar feedstock into a scraper unit, which is
equipped with scrapers and
for bio-based chemicals and biofuels breakers. The scraper unit pro-
cesses the waste into a homo-
P roterro Inc. (Princeton, N.J.; www.

proterro.com) has demonstrated technol-
ogy for directly producing sucrose as a feed-
grown on the surface of a composite fabric
material, over which water is trickled. The
composite fabric acts as a wick, efficiently
geneous material, which is then
metered via a worm-wheel con-
veyor to an incinerator. There,
stock for bio-based chemicals and biofuels distributing a minimal amount of water waste products are completely
that avoids the need for cellulosic biomass over the growing surface. Surrounding the burned, leaving behind pure
and energy crops. Using a genetically engi- gravity-fed fabric surface is a transparent metal that is cooled in a silo
neered strain of photosynthetic cyanobac- enclosure into which CO2-enriched air is before being packed in bags.
More information about the
teria and a unique photobioreactor system, fed to serve as the carbon source for the
system will be available at the
Proterro is able to generate a clean, fermen- sucrose photosynthesis. companys Achema exhibition
tation-ready sugar at a cost competitive with Proterro CEO Kef Kasdin reports that (Hall 5.0, Stand D17).
sugarcane, corn or other energy crops. the company has successfully tested three
The freshwater cyanobacteria naturally photobioreactor systems in two regions of
secrete sucrose as an osmoprotectant in the U.S. Our system has more geographi-
Desulfurizing biogas
Last month, Lanxess AG
the presence of salt. They have been en- cal flexibility than the production of Bra-
(Leverkusen, Germany; www.
gineered and cultivated for maximum se- zilian sugarcane and other agricultural
lanxess.com) introduced
cretion of sucrose, while allowing the or- approaches, she says, adding that ethanol Bayoxide E 16, a highly ef-
ganisms to maintain all of their regular producers could be among the adopters of
metabolic functions. These organisms are Proterros sucrose. (Continues on p. 12)
Note: For more information, circle the 3-digit number
on p. 76, or use the website designation. CHEMICAL ENGINEERING WWW.CHE.COM JUNE 2012 11
C HEMENTATO R
Winning copper from low-grade ore (Continued from p. 11)
I ndia holds large reserves of low-grade

sulfide copper ore containing 0.3 wt.%
copper, which cannot be processed through
thiobacillus ferrooxidans. It employed a
method of repeated subculturing to acti-
vate the strain. During each subculturing
fective synthetic iron oxide
for reducing hydrogen sulfide
(H2S) in biogas that can be
conventional routes since the cut-off grade processes, 2 L of the full-grown media were added directly to the fer-
for treatment in concentrators is about centrifuged, to collect the total biomass to menter. Bayoxide E 16 reacts
0.45 wt.%. be used for the next experiments. After six directly with H2S to form iron
sulfide and sulfur, which
India is in short supply of copper and an sets of subculturing, a stable iron oxidation
together with the fermenta-
appropriate technology for processing low- rate of 500 kg/m3/h was achieved. tion residue, can be used to
grade ores would contribute to Indias econ- The team subjected impurity-free solution fertilize fields. Because of
omy. Accordingly, a team from the Institute of containing 43 g/L copper and 182 g/L of H2SO4 the additives nearly 100%
Minerals & Materials Technology (Bhubane- to electrowinning in a continuous mode at purity, it removes nearly all
swar, Orissa, India; www.immt.res.in), led a current density of 100 A/m2 and depletion of the H2S (typically around
by Professor Lala Behari Sukla, developed rate of 4 g/L copper to produce copper sheets 500 mg/m3, depending on the
a process flowsheet to recover copper metal of good morphology. About 35 m3 of electrolytic waste being fermented). As a
from the lean sulfide ore of copper available solution was processed. Cell voltage was about result, a metering system is
at Malanjkhand, Hindustan Copper Ltd. 2.2 V. The amount of copper deposited in the not required and the cost of
secondary biogas desulfur-
Copper-pregnant leach solution obtained continuous run of 3,515 h was 65.824 kg.
ization by activated carbon
from bio-heap leaching of chalcopyrite con- Smooth copper sheets were deposited at absorption is significantly
taining 0.3 wt.% copper was purified through the cathode during electrowinning with reduced, says the company.
solvent extraction for removal of impurities 99.96% purity. Removing the H2S directly in-
and then passed through activated carbon The team believes its process route is side the fermenter also helps
to produce an organic-free solution suitable technically feasible and environmentally avoid damage from corrosion
for copper electrowinning. friendly, and has the potential to replace caused by the formation of
The team used a mixed culture of aci- the conventional process, especially for the sulfuric acid, adds Lanxess.
dophilic bacteria, predominantly Acidi- treatment of lean copper sulfide ores.
Think Environmental Protection.

Think Cashco Vapor Control.
The full line of Vapor Control System from Valve Our vents are engineered to be fully modular in design
Concepts has established the industry standard for so they can be converted in design and function in the
engineered quality and in-ield adaptability. The ield. Any one of our vents can be changed to a pipe
engineered modular design enables us to reduce away, spring loaded, or even a pilot operated vent
capital outlay costs from 33% to 66% depending on without having to buy a whole new unit. Now thats
the model. innovation that VCI customers proit from.
www.cashco com
Innovative Solutions
Model 3100/4100 Model 3400/4400 Model 5200
Cashco, Inc.
P.O. Box 6, Ellsworth, KS 67439-0006
Ph. (785) 472-4461, Fax: (785) 472-3539
Focusing on your safety
We offer peace of mind when it comes to your process safety and
productivity. Metso is a single source for all your process control needs,
from automation systems to intelligent flow control solutions that are
proven in the toughest conditions. Our 30,000 professionals based in
over 50 countries deliver sustainability and profitability to customers
worldwide.
www.metso.com/oilandgas
C HEMENTATO R
The first synthesis and isolation of a heavy ketone

F or the first time, researchers from Riken
(Saitama, Japan; www.riken.go.jp) have
synthesized stable crystals (photo) of a so-
germanone could be reduced into an alco-
hol, as is observed with ordinary
ketones, and it also exhibits a
called heavy ketone a compound in which unique reactivity that is not ob-
the carbon of the C=O bond is replaced by Si, served with ordinary ketones, including the
Ge, Sn or Pb. These heavy ketones are highly reaction with acetone without using cata-
reactive and prone to polymerization, which lyst, and also the spontaneous trapping of
has made them difficult to synthesize and CO2 gas (at room temperature and 1 atm) to
isolate to study their properties. Computer provide a cyclic addition product.
studies have predicted such compounds may The researchers are now working to syn-
have applications for performing new acid thesize heavy ketones of silicon.
and base reactions, catalysis and for design-
ing new functional materials.
The researchers first compound is a ger-
manone, with the formula (Eind)2Ge=O,
where Eind is a bulky protection group
made of 28 carbon atoms and 45 hy-
drogen atoms (1,1,3,3,5,5,7,7-octaethyl-s-
hydrindacen-4-yl) which prevented the
intramolecular polymerization at the Ge=O
double bond (diagram). Computational stud-
ies and chemical reactions suggest that the
Ge=O double bond is highly polarized. The
ARE YOU RELYING ON FIKE IS COMMITTED TO RELIABLE SAFETY

SOLUTIONS THROUGH RESEARCH, NEW
SAFETY PRODUCTS TECHNOLOGIES, AND EXTENSIVE TESTING.
THAT SHOULD WORK? Comprehensive selection of ASME, CE and

3-A rupture/bursting discs
High performance explosion vents, specically
designed for sanitary applications
Complete line of products for CIP/SIP applications
Dedicated team of combustion engineers and
pressure relief experts
DONT LEAVE THE SAFETY OF YOUR

BUSINESS TO ANYTHING LESS THAN
THE MOST RELIABLE, PROVEN PRODUCTS.
VENTING SUPPRESSION RUPTURE DISCS TESTING
PROVEN PERFORMANCE, QUALITY

AND RELIABILITY FOR OVER 60 YEARS
1-866-758-6004 WWW.FIKE.COM
Heat-harvesting
A significant portion of generated energy is wasted as heat.
Strategically
Thermoelectric materials convert waste heat to electric-
ity, and could improve energy efficiency, but most existing Adapting
thermoelectric materials are expensive to manufacture and
difficult to install. Researchers at Purdue University (West
Lafayette, Ind.; www.purdue.edu) have collaborated with a
team at Jilin University (Changchun, China) in developing
a solution-phase deposition method for coating nanoscale
crystals of lead-tellurium (a thermoelectric material) onto
glass fibers. The techniques used in producing the flexible
coated fibers could point the way toward energy harvesting
materials that require less raw material and are amenable to
large-scale manufacture.
A less-expensive process to recover

CO2 from PSA offgas
A t Achema 2012 (June 1822; Frankfurt am Main, Ger-
many), Union Engineering A/S (Fredericia, Denmark;
www.union.dk) will be presenting its patented FlashCO2
process both at the exhibition (Hall 9.1, Stand E29)
and in a congress lecture (Monday, June 18th at 11:30
in the room Illusion 2). FlashCO2 enables liquid CO2 to
be produced from H2 plants at a direct operating cost of
around 2030/ton significantly lower than the 30
40/ton required using conventional chemical absorption
processes, says Michael Mortensen, Union Engineerings
chief sales officer.
Weadapt to your needs

FlashCO2 was developed to capture CO2 from the me-
dium-rich CO2 offgas being purged from pressure-swing
adsorption (PSA) units, which are typically used for prod-
uct purification in H2 plants. FlashCO2 (diagram) combines

conventional physical adsorption (using chilled methanol)
18 22 June 2012
and liquefaction technologies, and eliminates the require-
ment for steam stripping. Despite the relatively low CO2 Frankfurt am Main, Germany
concentration in H2 PSA offgas (4055%), the integrated
double-loop design makes the plant capable of producing Hall 11.1 Booth C75
food- and beverage-grade CO2 at costs competitive with
more conventional CO2 sources, such as ammonia and bio-
ethanol production. Also, the high concentration of H2 in
the purge from the FlashCO2 unit results in an increase of
H2 production by up to 10% a benefit not present using
traditional absorption processes, says the company.
The first commercial application of FlashCO2 was a 5 SAMSON AG MESS- UND REGELTECHNIK
ton/h beverage-grade CO2 plant for Indura SA (Santiago, Weismllerstrae 3
Chile; www.indura.net), which takes the PSA offgas from a 60314 Frankfurt am Main Germany
Phone: +49 69 4009-0 Fax: +49 69 4009-1507
major petroleum refinery in Conception, Chile and started
E-mail: samson@samson.de www.samson.de
up in 2007. SAMSON GROUP www.samsongroup.net
A01121EN
C HEMENTATO R
Chlorine dioxide single-stage NOx

scrubbing technology lowers costs
A new process for removing oxides of
nitrogen (NOx) from industrial foul-
air and cool combustion exhaust uses
reaction chamber. Requiring only 1.5
seconds of residence time within the
scrubbing vessel, the process uses chlo-
NO2, before being removed from a waste
gas stream. The PRDD process, which
has been demonstrated in two pilot-scale
ClO2 in a unique way to remove over rine dioxide to react with NO and NO2, facilities, employs reactions that occur
99% of both NO and NO2 with a single yielding nitric and hydrochloric acids. very quickly, allowing high removal ef-
scrubbing stage. The reaction vessel The mineral acid products of this reac- ficiencies for both NO and NO2.
is considerably smaller than those re- tion can be used elsewhere. The short residence times and simple,
quired by conventional wet-chemistry The PRDD NOx abatement process small single-stage reaction vessel design
NOx removal processes, and according is unique because it treats both NO in the PRDD process lowers equipment
to the technologys developer, Pacific and NO2 in a single scrubbing stage. costs, as well as operational costs, Rich-
Rim Design and Development (PRDD; Conventional wet-scrubbing processes ardson remarks, allowing companies to
Shingletown, Calif.; www.prdd.net), the require three-stage scrubbers to ac- cost-effectively meet regulatory require-
equipment is less expensive to install complish this, explains PRDD scientist ments for NOx emissions.
and operate than existing methods, and engineer Robert Richardson. In PRDD anticipates completing a full-
such as wet-scrubbing or selective cata- cases where waste gas streams contain scale facility in the third quarter of 2012
lytic reduction. primarily NO2, single-stage treatment that will be capable of treating 32,000
PRDDs patent-pending process em- is possible, but gas streams with sig- ft3/min of waste gas. The company is
ploys proprietary technology that pre- nificant levels of NO require multistage working on deals to license its technol-
cisely combines the ClO2 with NOx-con- scrubbers because the low-solubility NO ogy either as a retrofit, or to be built into
taining waste gas stream in a gas-phase must first be converted to water-soluble new facilities.
Need to predict emissions from a scrubbing

column and display real-time data? Were on it.
VISIT U
We make your challenges our challenges. ACHEM AT
S
A 2012
To see how CHEMCAD has helped advance engineering Frankfu
June 18
rt am M
-22
for our customers, visit chemstations.com/demos017. Hall 9.1 ain, Germ
| Stand any
C51
David Hill, CHEMCAD Support Expert
Engineering advanced
2012 Chemstations, Inc. All rights reserved. | CMS-322-1 6/12
C HEMENTATO R
An eye forfromdetail...
(Continued p. 15)
Aramid nanofibers
Teijin Techno Products Ltd., a Teijin group company (Tokyo,
Japan; www.teijin.co.jp) has developed the worlds irst
mass-producible aramid nanoiber. These uniformly sized
nanoibers are based on the companys proprietary Teijin-
conex heat-resistant meta-aramid, and will be marketed in
the form of non-woven sheets. Commercial production is
targeted for 2014.
These heat-resistant, aramid nanoiber sheets are said
to maintain their shape, even at 300C; are highly resistant
to oxidation; and have a high porosity and large surface
properties that make them especially suited for use as
separators in lithium ion batteries. Other potential applica-
Steel belts for
tions are being developed for the new aramid sheets, in-
cluding separators for capacitors and heat-resistant ilters.
challenging environments!
A new process for making screens In general materials used by Berndorf

Band offer high strength and corrosion
A fter eight years of R&D work, Inflotek B.V. (Beringe, The
Netherlands; www.) is now commercializing a range of
metal screens made with a proprietary, waterjet-cutting
resistance. Even for applications in
technology. Compared to conventional waterjet-cutting extremely aggressive atmosphere
methods, Infloteks process can reliably make hundreds of a newly developed steel grade is
perforations per hour, which enables the fabrication of in-
dustrial process screens with a large number of perforations available.
on a small surface. The screens can have virtually any pat-
tern that can be printed, with slots that are tapered (photo)
to reduce sensitivity for plugging, says Frank Stofmeel, sales Other features of Berndorf steel belts
manager at Inflotek. are precise tracking, perfect flatness
To make the screens,
and long lasting adhesion of vee-
a mixture of water
and very fine sand is ropes and product retainers.
passed through a pro-
prietary nozzle at high
pressure (4,000 bars).
The water beam (with
sand) emerges from
the nozzle at Mach 3,
and is narrower (100
m) than traditional
jets (400 m), enabling smaller slot kerfs with twice the cut-
ting tolerance, says Stofmeel. This much finer beam can cut
at speeds 23 times faster than a traditional waterjet, thus
significantly reducing production costs, he says. Screens
made with the micro-waterjet technology have the highest Visit us at:
open area of any screen thicker than 2 mm, with open areas
typically 50 to 200% greater than wedge wire screens for
ACHEMA, Frankfurt, Germany
slot widths below 400 , he adds. It can cut steel more than June 18 - 22, 2012
30 mm thick, without causing distortion, warping, work Hall 4.0, Booth A43
hardening or thermal stress.
Inflotek is initially focused on screens used in centrifuges
for separating solids from liquids, and the screens are cur-
rently being trialed in a range of industries, including pot-
ash, coal, food and chemicals. The company is also devel-
oping a range of screens for pulp processing, fluidized-bed
drying, high-wear coarse classification screens and others. Berndorf Band GmbH
The screens will make their commercial debut at Achema A-2560 Berndorf, Austria
2012 (June 1822; Frankfurt am Main, Germany; Hall 5.1, Phone: (+43)2672-800-0
Stand D8). Fax: (+43)2672-84176
(Continues on p. 19)
band@berndorf.co.at
www.berndorf-band.at
C HEMENTATO R
Compact, Lightweight,
High Quality
The GEM Plastic
Product Range
Manufacturing
bee silk with bacteria
GEM
components and
A partnership between Australian research agency
CSIRO (Melbourne, Australia; www.csiro.au) and Lonza
Group Ltd. (Basel, Switzerland; www.lonza.com), aims to
system solutions: market new insect silk products globally. Potential appli-
cations of insect silk include composite fibers for the avia-
For the chemical tion and marine industries, and medical applications such
industry and as wound repair, drug delivery, repairing and replacing
environmental human tissues such as membranes, ligaments, blood ves-
systems sels and cartilage.
For water treatment Production of silk at adequate yield and desirable prop-
erties including stability, lightness and tensile strength, as
For the processing
in natural silks, has been the aim of a group from several
industry
CSIRO divisions in Victoria and the ACT (Australian Capi-
tal Territory), and the Dept. of Biomedical Engineering,
Tufts University (Medford, Mass.; www.tufts.edu).
Many invertebrates, including silkworms, bees, spiders
and ants produce silk. Production of silkworm and spider
silks as biomaterials has posed problems due to the large
size and repetitive nature of the silk proteins. In contrast,
the silk of honeybees (Apis mellifera) is made of a family
of four small and non-repetitive fibrous proteins. An NMR
study reported that honeybee silk proteins have both a-
helix and b-sheet structures, and that a-helical conforma-
tion predominates.
The group has achieved recombinant production and pu-
rification of the four full-length unmodified honeybee silk
proteins in Escherichia coli bacteria at yields of up to 2.5
g/L the highest reported expression level of any recom-
binant silk protein. The previous highest level was the pro-
duction of a partial-length synthetic spider silk at a yield
of 0.36 g/L. Under suitable conditions the recombinant pro-
teins self-assemble to reproduce the native coiled structure.
Using a simple spinning system the group has succeeded in
producing recombinant silk fibers (photo) with the tensile
strength of the native material.
Visible photocatalyst
T he research groups of Masahiro Miyauchi at Tokyo In-
stitute of Technology (www.eim.ceram.titech.ac.jp) and
Kazuhiko Hashimoto at the University of Tokyo (www.
light.t.u-tokyo.ac.jp) have developed a photocatalyst that
ACHEMA For the handling of liquid is highly active for the destruction of volatile organic com-
hall 8, booth F4 media: poiunds (VOCs) using visible radiation. The catalyst, a
Large range of valve types
culmination of a five-year project supported by New En-
ergy and Industrial Technology Development Organization
Numerous body and seal (NEDO), opens the door for applications for photocatalyti-
materials cally destroying harmful VOCs in interiors of buildings and
PVC U ABS PP PVDF NBR cars with visible light.
FPM EPDM PTFE The researchers converted photochemically inactive, ox-
Various actuator and connection ygen-defective TiO2 made by the thermal-oxidation of a
www gemu-group com versions mixture of Ti2O3 and TiO2 in air into an efficient visible-
light-sensitive photocatalyst by grafting the TiO2 surface
(Continued from p. 15)
C HEMENTATO R
Green polymer
In cooperation with project partners from BASF, the Technical
University of Munich and the University of Hamburg, scientists
from Siemens global research unit Corporate Technology
have developed a competitive alternative to the standard ABS
(acrylonitrite-butadiene-styrene) polymer, which is frequently
used in consumer products. The new composite material is
a mixture containing polyhydroxybutyrate (PHB), which is
made from renewable materials such as palm oil and starch.
Because PHB is brittle, polypropylene carbonate (PPC) from
BASF is added to make it softer. PPC is 43 wt.% CO2, which
is obtained from power plant emissions using a separation
process. More than 70% of the new mixture is made of green
polymers. Bosch-Siemens-Hausgerte (BSH) has used the
new material for vacuum cleaner covers under series produc-
tion process conditions.
Detecting VOCs with a quantum-

tunneling composite
A sensor that detects volatile organic compounds (VOCs)
at levels of 10100 parts per million (ppm) is being
developed by Peratech Ltd. (Richmond, U.K.; www.perat-
ech.com), with collaboration from the University of Dur-
ham (U.K.; www.dur.ac.uk). The so-called Electronic Nose
is based on the companys quantum-tunneling composite
(QTC) material a composite of conductive nanoparti-
cles and a non-conductive polymer. The polymer content
of the granular QTC swells when exposed to VOCs, which
brings the conductive particles close enough to allow elec-
trons to flow between the particles an effect known as
quantum tunneling. The sensor is said to respond faster
than alternative sensing technologies, and rapidly (within
seconds) recovers once the VOCs have gone from the sur-
roundings. An additional feature of the QTC technology
is that it has very low power requirements, says the com- Everything under
pany. Peratech is now looking for companies interested in
licensing the technology.
Control
Compact, efficient and

with 23-nm clusters of amorphous cuperous oxide (CuO),
absolutely safe: these are
which serves as a co-catalyst. This catalyst shows a ten-
the properties of our new 18. - 22.06.2012
fold increase in reaction efficiency (with visible light) over FRANKFURT MAIN
conventional nitrogen-doped TiO2, and almost the same ecoforce generation HALL 4.0, STAND F44
sensitivity as the ultraviolet sensitivity of commercially of gas-tight decanters.
available anatase-type TiO2. For example, with the new
catalyst, gaseous 2-propanol is decomposed into CO2 under
visible radiation at a rate of 0.20 mol/h with a quantum
efficiency of 10.8%.
The chemists are planning to apply their achievement
GEA Westfalia Separator Group GmbH
for real applications, such as self-cleaning, easy to maintain
construction materials, as well as air-cleaning materials for Werner-Habig-Strae 1, 59302 Oelde, Germany
use at hospitals and airports. Materials have already been Phone: +49 2522 77-0, Fax: +49 2522 77-2828
developed as powders and coating solutions, and could be www.westfalia-separator.com
commercially applied within two years.
(Continues on p. 19)
engineering for a better world
CP-214-1-009
CSB RELEASES NEW SAFETY VIDEO ON
DUPONT HOT WORK EXPLOSION
Newsbriefs he U.S. Chemical Safety Board (CSB; Washington, D.C.;
U.S. House approves cybersecurity bill

T www.csb.gov) recently released a new safety video detailing
a fatal 2010 hot work accident that occurred at the DuPont
facility near Buffalo, N.Y.
The video, entitled Hot Work: Hidden Hazards, features a
to ease information sharing computer animation showing how hot work being conducted on
top of a tank led to a deadly explosion that killed one contractor
L ast month, the U.S. House

of Representatives voted
to pass the Cyber Intelli-
currently share these data
because the information is
classified and companies
and injured another.
In the video, CSB chairperson Raphael Moure-Eraso empha-
sized that hot work is often seen as a routine activity, but it can
gence Sharing and Protec- fear violating antitrust laws. prove deadly if fire and explosion hazards are overlooked.
tion Act (CISPA), a measure The bill would remove legal The 11-minute video details the events leading up to the ac-
that would ease informa- barriers, making it easier cident, noting that although DuPont personnel monitored the
tion sharing among chemi- for chemical firms, and atmosphere above the tank, no monitoring was done to see if
any flammable vapor was inside the tank. The CSB investigation
cal firms and other compa- other businesses, to do so.
found the hot work ignited the vapor as a result of the increased
nies with facilities that are The intelligence commu- temperature of the metal tank, sparks falling into the tank, or
vulnerable to cyberattacks. nity has the ability to detect vapor wafting from the tank into the hot work area.
The bill has been met with these cyberthreats, these The CSB released its final report and formal safety recommen-
much controversy: Presi- malicious codes and viruses, dation at a public meeting in Buffalo on April 19. The video is
dent Obama has threatened before they are able to at- available to stream or download at CSBs website or YouTube
a veto and the Senate has tack our networks, says channel (www.youtube.com/uscsb).
been circulating a different Ruppersberger. But right
bill aimed at cybersecurity, now, federal law prohibits
although no vote has been our intelligence community The Obama administra- ernments use of private
held in that chamber. from sharing classified cy- tion threatened a veto and information and restricting
Sponsored by Reps. berthreats with the compa- privacy and civil liberties which cyberthreat data can
Mike Rogers (R-Mich.) and nies ... that control the net- groups claim that, under be shared. The Obama Ad-
Dutch Ruppersberger (D- works the AT&Ts, the CISPA, what is defined as ministration is also seeking
Md.), CISPA would give Verizons, the Comcasts. consumer data and permit- regulatory mandates for crit-
businesses and the federal We have the ability to ted to be shared is overly ical infrastructure providers,
government legal protec- give them information to broad. The bills authors which are not contained in
tion to share cyberthreat protect us, yet we have to have added amendments CISPA, which is one of four
information with each other. pass a law to do that, the to appease concerns, such cybersecurity bills currently
The government does not Congressman added. as limiting the federal gov- under consideration.
GE and Shenhua open cleaner-coal-technology JV in China of the most widely deployed

in the industry.
G E (Atlanta, Ga.; www.

ge.com) recently an-
nounced the opening of GE
nologies with Shenhuas
expertise in coal gasifica-
tion and coal-fired power
distribution of commercial-
scale IGCC technology.
Gasification technology
Shenhua is one of the
worlds largest coal and
energy companies, with
Shenhua Gasification Tech- generation. The JV will sell has become a critical tool integrated coal production,
nology Co., a 50-50 joint industrial gasification tech- in the expansion of the power generation, railway,
venture (JV) with Shenhua nology licenses in China, Chinese economy, allowing port and shipping infra-
Group to advance the de- conduct research and devel- a wide variety of industrial structure. Shenhua also
velopment and deployment opment to improve cost and products and fuels to be has a national role in the
of cleaner coal technology performance of commercial- created from low-cost abun- development of new coal-
solutions in China. scale gasification and in- dant coal resources. With related technologies.
The new company com- tegrated gasification com- more than 50 licensed fa- China and the U.S. are
bines GEs expertise in bined cycle (IGCC) solutions cilities in China, GEs gas- the two biggest energy con-
industrial gasification tech- and work to advance the ification technology is one sumers in the world.
Jacobs receives contract from Evonik for new chemical plant

J acobs Engineering Group
Inc. (Pasadena, Calif;
www.jacobs.com) says it
polyamide-12 production
facility in Asia.
Officials did not disclose
based on Evoniks existing
plants in Germany. Mem-
bers of the integrated proj-
Mumbai, India.
Under a separate frame-
work contract signed in
was awarded a contract the contract value. Jacobs ect team are operating from 2011, Jacobs is providing
from Evonik Industries AG has been working closely Jacobs office in Leiden, The engineering services as
(Essen, Germany; www. with Evoniks project team Netherlands to undertake the owners engineer on
evonik.com) to provide basic in Marl, Germany to de- the FEED (front-end engi- Evoniks process industry
engineering services for an velop the conceptual design neering design) work, sup- projects worldwide.
investment in a grassroots for the new plant, which is ported by Jacobs' office in Edited by Scott Jenkins
Newsfront
EDUCATION
EVOLUTION engineering research was funded by
To prepare students for globalized industry, notes Dan Crowl, the Her-
bert Dow Professor for Chemical
industries, chemical engineering academic Process Safety at Michigan Technical
departments are incorporating new requirements, University (MTU; Houghton, Mich.;
www.mtu.edu). Whereas today that is
utilizing IT and connecting with CPI companies not the case. The modern relationship
between the academic and industrial
chemical engineering communities is
A
host of conditions, including glo- that generally, computer software and more diverse, dynamic and complex
balization of industry, expand- information management tools are than in the past, but there is a general
ing access to information and a keeping pace. For example, the use of sense that the academic and industrial
shifting workforce profile pres- computer-assisted design in engineer- chemical engineering worlds are not as
ent challenges for university chemi- ing is rising, he says. integrated as they should be.
cal engineering departments as they In education, access to information The disconnect between academia
prepare aspiring engineers for work. has never been greater, says Uni- and industry in chemical engineer-
To address the challenges, the educa- versity of Michigan (UM) chemical ing has never been greater, says
tional system for chemical engineering engineering collegiate lecturer Susan Sanat Kumar, chair of the chemical
is trying to strike the optimal balance Montgomery. This has both positives engineering department at Columbia
between new and traditional teach- and negatives for students. The wealth University (New York; www.columbia.
ing approaches, as well as between of online information allows unprece- edu). Its increasingly polarized.
core chemical engineering topics and dented access to the wide range of the Crowl suggests that an overall trend
modern engineering applications. latest technical information and ideas, within academia over the past several
Meanwhile, the academic chemical but also sources of temptation for stu- decades has been a generally reduced
engineering community and the world dents to take shortcuts. level of direct industry experience
of industrial chemicals are struggling, While most of the core topics taught on the part of the faculty members.
with mixed success, to forge connec- in chemical engineering courses have Theres been a drift away from the in-
tions and relationships. remained the same over several de- dustrial experience in U.S. education,
cades, the methods for teaching those he says.
Macro-level trends topics have changed somewhat, pri- There is a rising awareness, however,
A number of wider trends are having a marily through the wider use of in- that university departments must be
significant impact in shaping the edu- formation technology (IT). The use of connected more to industry, and must
cation enterprise in chemical engineer- information technology for teaching continuously foster those relationships,
ing. Information and the technology chemical engineering has been uni- say Mauricio Futran and Henrik Ped-
used to locate and organize it is at versal, but I still dont think universi- ersen, the current and past depart-
the heart of several high-level trends ties are taking full advantage of the IT ment chairs, respectively, of the chemi-
that have both positive and negative tools available, opines Richard Felder, cal engineering department at Rutgers
consequences for the education of engi- emeritus professor of chemical engi- University (Piscataway, N.J.; www.
neers. There has been a veritable ex- neering at North Carolina State Uni- rutgers.edu). Rutgers is somewhat
plosion of technical information avail- versity (NCSU; Raleigh; www.ncsu. unique in the number and breadth of
able, says Sasha Gurke, senior vice edu/effective_teaching) and longtime the industry partnerships that the de-
president and co-founder of Knovel, an champion of improved teaching. partment has made, Pedersen added.
online library of curated technical con- These include a catalysis consortium,
tent. And the growth of information is Bridging the gap a center for solid-organic particulate
still accelerating, while the Internet is In decades past, university chemi- matter, individual research collabora-
maturing, he adds. One result of that cal engineering programs have been tions and others. The partnerships are
is an ever-greater need for efficient closely tied to industrial chemical- driven by the expertise of the faculty,
and effective informatics tools for min- processing operations in their regions. which tends to be in areas of interest to
ing that information. Gurke suggests A large portion of academic chemical industry companies, Futran says.
In an example of how connections that the industry-academic gap is nel transferring practical engineer-
are made, many departments have real, despite the efforts on the part of ing knowledge on a person-to-person
established industry advisory boards individual universities, individual re- basis. Now, streamlined staffing and
that meet periodically to provide searchers and companies to establish the retirements of Baby-Boom-aged
input to university departments about links between the two sectors. Rela- engineers leave fewer opportunities
industrial needs, and other topics, tionships between universities and for in-depth mentoring. Citing an
MTUs Crowl points out. engineering-related companies cer- IEEE study that suggests over three-
Academics have to go out and seek tainly exist, but they are established quarters of the knowledge obtained by
connections to industry, because there and cultivated somewhat on an ad hoc engineers is acquired after graduation,
are not many good forums for the two basis. There is no national policy or Gurke says the reality is that young en-
communities to come together, Colum- leadership in this matter, he says. gineers have to obtain that knowledge
bias Kumar says. He recounts a recent Universities can and should do in other ways. And the relationships
effort to set up an industry-academic more to integrate practical industry between CPI players and engineering
discussion group at the New York Acad- knowledge into their courses, such schools will play a large role in how ef-
emy of Sciences in which academic as by setting up business incubators, fectively this is accomplished.
participation was far higher than in- participating in industrial R&D and University chemical engineering
dustry, by a 90/10% split, Kumar says. expanding internship programs with programs are exploring a wide range
So far, it seems like the themes we local companies, Gurke comments. of ways to foster improved connections
have picked bioprocessing, energy, The disconnect between academia with industry. An overriding educa-
big data have not resonated that and industry amplifies existing work- tional goal in the chemical engineering
strongly with industry, he says. force-related challenges. Gurke ex- program at MTU is to give students as
Knovels Gurke agrees that broader plains, The problem is that, in the much fundamental depth as possible,
leadership and coordination for aca- past, mentoring of young engineers while still relating the education to
demic-industry initiatives in chemical by older, experienced ones was more industrial practice, says MTUs Crowl.
engineering is lacking. He also agrees prominent, with experienced person- For example, in many cases, universi-
Visit us at ACHEMA
in Frankfurt, Germany
18 22 June 2012
Hall 4.0, Booth C26
Reliable Light Weight Construction
One Fits All

Compatible with existing The Component System
WPR2002 and KF Systems
Safer
Extended temperature and
pressure ratings
Simplified grounding
www.dedietrich.com Circle 15 on p. 76 or go to adlinks.che.com/40268-15

EVOLVING TEACHING APPROACHES
Newsfront ith a wide array of new technologies and a fuller understanding of the science behind
W how students learn, universities have an array of tools with which to engage their
young engineers. Students want an active learning environment, says MTUs Crowl.
Former N.C. State professor Felder cites the increasing use of inductive learning techniques,
universities have moved to- such as inquiry-based and problem-based learning, in which students are first presented with a
ward smaller unit operations challenge and learn the course material in the context of addressing that challenge, as an ex-
laboratory equipment that is ample of the disciplines movement toward more experiential hands-on instructional strategies.
Also, making expectations clear to students about what problems they are expected to solve
not as reflective of industrial
is important. Going forward, there will be an increasing use of learning objectives, where
environments, says Crowl. On instructors articulate what skills should be mastered at different points in the class.
the other hand, MTU students For the past 21 years, Felder has led a popular, three-day workshop for chemical engineer-
work on a pilot-scale, three- ing instructors known as the National Effective Teaching Institute (NETI).
story distillation tower with The successful workshops have exposed more than 1,000 chemical engineering instructors
an Emerson control system. from over 200 institutions to the latest information from the cognitive science field about how
Its an example of how were students learn. NETI is also designed to provide instructors with new tools to foster that learn-
trying to make the academic ing, Felder says.
experience connect to the in- The chemical engineering department at Manhattan College has utilized a large number
dustrial world, Crowl noted. of teaching tools and techniques, but has found that its students responded better to a more
traditional lecture-based approach.
Other faculty members, such
One thing I think departments need to be careful of is changing things just for the sake
as UMs Montgomery and Ann of change, says Annmarie Flynn, chemical engineering department chair at Manhattan
Marie Flynn, chemical engi- College. Its important to establish a balance between the traditional teaching style and
neering department chair at the more experiential, inductive approaches, which are challenging to run effectively in
Manhattan College (Riverdale, practice, Flynn remarks. Formal lecture, with repetition of concepts, remains important,
New York; www.manhattan. Columbias Kumar adds.
edu Flynn say that it is impor- The chemical engineering department at Rutgers strives to teach fundamental topics in a
tant to have faculty with in- classroom setting, while still using Web-based tools that are available.
dustrial experience, especially
to teach the product- and pro-
cess-design courses. that a survey of chemical engineering Ancillary skills
alumni at UM identified a number of Despite the difficulty in fitting mate-
Curriculum changes topics where recent graduates were rial into the traditional chemical engi-
A major ongoing challenge faced by somewhat lacking in their preparation neering curriculum, departments are
university chemical engineering fac- for the workplace. These included sta- still making an effort to provide their
ulty is how to maintain the core chem- tistics, six-sigma manufacturing and students with not only technical engi-
ical-engineering curriculum, while also process equipment troubleshooting. neering knowledge, but also skills that
including key ancillary skills and intro- Weve been hearing a lot from indus- are not specific to engineering, and yet
ducing students to new technologies. trial engineers that critical thinking important for modern workplace suc-
Theres a deep-seeded conservatism skills are important, especially when cess. These include writing, presenta-
in the world of chemical engineering, applied to troubleshooting processes tion, language and others.
which means that there is a consid- and equipment problems, says UMs Communications-related skills have
erable resistance to change, Kumar Montgomery. In response to the input emerged as a focus in many engineer-
says. Its actually quite remarkable from alumni in industry positions, UM ing departments. At the University of
that so little has changed in the chem- developed in conjunction with the Michigan, members of the technical
ical engineering curriculum. alumni board a required one-credit communications faculty are also in-
In most ways, the curriculum has class covering chemical engineering volved in the laboratory and design
remained very much the same; what process economics. courses in the chemical engineering
may be different are the examples Others pointed to additional areas department, notes Montgomery.
used to illustrate the topics, Kumar that should be addressed more in Students at Manhattan College are
says. Its these examples that will chemical engineering education. For required to take a communications
bring in some of the newest technolo- example, sustainability and risk anal- class, in which they discuss topics
gies and latest applications and be ysis are becoming more important in such as technical presentations, email
reflective of modern technologies. framing engineering problems. Risk writing, technical communications
Futran and Pedersen, of Rutgers Uni- management and risk analysis are and others, Flynn explains.
versity agree, saying the core chemical important for engineering design, and At Columbia, Kumar notes that
engineering topics remain the same should become more prominent in en- communications skills are integrated
after decades of teaching. The problem gineering education, says Gurke. across the board in the undergradu-
is that there is very little, if any, room Reflecting the importance of comput- ate curriculum, so chemical engineer-
in the curriculum for new topics, Crowl ing and informatics, Columbia chemi- ing students are required to deliver
says. Its very difficult to fit everything cal engineering students are required multiple oral presentations and sub-
in, adds Manhattans Flynn. to complete a class in programming mit several written reports. Rutgers
Despite the difficulty, chemical engi- methods. In addition, they must com- takes a similar approach.
neering departments are feeling pres- plete a two-semester chemical engi- Aside from communication skills,
sure to add more material to their cur- neering design series, where product other non-engineering-specific topics
ricula. For example, Montgomery says design is the second-semester subject. have also emerged as ones that will
help engineering students in their ca- chemical hazards education. The ad- chemical engineering departments in
reers. For example, all Columbia engi- ditions are a result of new accredi- the U.S. Universities are addressing
neering students are also required to tation requirements introduced in this need in a number of ways.
take a core program of general edu- 2012 by the Accreditation Board for Most university departments are in-
cation requirements. Engineering and Technology (ABET; corporating process safety and chemi-
At Michigan, we try to give students Baltimore, Md.; www.abet.org) to in- cal hazard information in the context
more opportunities to take general clude teaching on chemical process of other classes. At Rutgers, we have
electives and pursue minors in their safety and process hazards as part of embedded that material into multiple
degree program. Theres also a uni- all university chemical engineering courses, Pedersen says.
versity-wide initiative in international curricula. At Manhattan, Flynn says the de-
education, Montgomery points out. One of the factors that led to the partment has incorporated in its labo-
Knovels Gurke also recommends a new ABET chemical hazards ac- ratories a number of safety features
more comprehensive approach to teach- creditation requirements was the instituted at an industrial cosmetics
ing informatics in university engineer- U.S. Chemical Safety Boards (CSB; engineering facility at Loreal Corp.,
ing courses even suggesting man- Washington, D.C.; www.csb.gov) inves- with which they have a relationship.
datory informatics classes. Everyone tigation of a 2007 explosion at the T2 It helps to establish a culture of
has visits by a university librarian to Laboratories facility in Jacksonville, safety among the students, she says.
explain resources, but more emphasis Fla. The CSB investigation concluded They are also looking at an accident
should be placed on how to learn and that one of the causes of the accident and emergency management class.
how to do it efficiently, Gurke says. was that engineers did not have suffi- At MTU, Crowl says the depart-
cient instruction on reactive chemical ment has established a student-run
Process hazards requirement hazards. One of the CSBs recommen- safety program in laboratories there
Another area in which additions to dations was to change the accredita- that helps students take responsibil-
the chemical engineering curriculum tion requirements to add education on ity for safety.
have been made is process safety and process hazards to the curriculum of Scott Jenkins
HEXOLOYSILICONCARBIDE

The Name No other company in the world has more expertise with silicon carbide than

That Makes Saint-Gobain Ceramics. Our Hexoloy sintered alpha silicon carbide is the
material of choice for high performance applications in a variety of chemical
A World processing industries throughout the worldwide market. Hexoloy compo-
Of Difference nents are custom made and offer excellent performance at temperatures
up to 1650C (3000F), universal corrosion resistance, excellent wear
resistance, high strength, and high thermal conductivity. Wherever
youre located in the global market, specify Hexoloy silicon carbide, the
name that delivers performance you can count on.
Saint-Gobain Ceramics Telephone: 716-278-6233

23 Acheson Drive Fax: 716-278-2373
Niagara Falls, New York 14303 scd.sales@saint-gobain.com www.hexoloy.com
Fike
Equipment News Roundup
EXPLOSIONS:
ARE YOU PREPARED?
Explosion protection
equipment can
minimize damage,
but process
understanding is
key to optimized
solutions
Fike
A
n explosion is defined as a Designed for use with square or rect-
rapid increase in volume and angular explosion vents, FlamQuench
SQ technology consists of various lay-
release of energy in an extreme ers of high temperature stainless steel
manner, and is usually ac- that absorb heat produced during
companied by high temperature gen- combustion. This allows conventional
eration and gas release. Flammable venting to be done indoors with no
gases, vapors, dusts and ambient release of flame
oxygen all present in chemical pro- An ECARO-25 (photo, top right) clean
cessing facilities can react to cause agent fire-suppression system is suit-
an explosion that essentially creates able for protecting electronics and
a shock wave. high-value assets, thus reducing the
threat of needless downtime and busi-
As a result of modern production ness interruption Pepperl+Fuchs
technologies and increased produc-
tion capacity, an explosion is a threat (Princeton, N.J.; www.chilworth.com).
chemical processors confront daily, When it comes to explosion protec- For industrial signal transmission many
users insist on single loop integrity.
says Gerd Mayer, president of Rembe tion, what youre saying is that you Others need compact mounting. With a
(Charlotte, N.C.; www.rembe.com). are anticipating that an explosion will module width of only 12.5 mm and single
While there are Occupational Safety occur, but you have designed your pro- channel functionality, the new KC-Mod-
and Health Admin. (OSHA; Washing- cesses and equipment in such a way ules of the K-System combine these two
requirements, making them suitable for
ton, D.C.; www.osha.gov) standards that when an explosion does occur, use in hazardous areas
and industry guidelines namely people wont be harmed and the facil-
OSHAs Combustible Dust National ity wont be damaged.
Emphasis Program and NFPAs 654, And, he continues, in order to do of ignition of the flammable gas, vapor
68 and 69 chemical processors are this, operators need to have a clear or dust cloud atmosphere is impera-
still often confused when it comes to understanding of their operations and tive, he says.
selecting and installing explosion pro- processes, as well as the chemicals In addition, the objectives of the fa-
tection systems. being used and the associated risks cility owners must be evaluated, says
Protection is very different than they create. Knowledge of the maxi- Bruce McLelland, national accounts
prevention, explains Vahid Ebadat, mum pressure and the severity of the sales manager for explosion protec-
CEO of Chilworth North America explosion that could occur as a result tion with Fike Corp. (Blue Springs,
ACHEMA 2012
18.-22. June, Hall 4.0
Booth A68
Mo.; www.fike.com), such as how much injected into the dust or vapor cloud to
Fatty Acid
damage is tolerable and what kind of quench and stop an explosion. While Industry
changes the facility owner is willing to this is a viable solution, it can be an ex-
make for protection. Is it acceptable pensive option because detectors and
if, at the end of an event, a vent has sensors, control systems and battery
worked properly and protected against backup equipment are required and
the worst case scenario, but the pro- must be regularly maintained.
cessing equipment is destroyed by fire Explosion relief venting. Compared
after the explosion? he asks. Its good to the first two options, venting is usu-
that there wasnt flying debris or inju- ally the simplest solution. It consists
ries or loss of facility, but there is still of a panel or door that will rupture
a loss of equipment and there will be or open and release the explosion
a significant loss in process downtime. products (pressure and flame). The
Processors need to look at all types of problem here, however, is that vents
available explosion protection equip- cant normally open inside a building
ment and determine what is accept- and must be routed to a safe location
able loss to them. outside the building, which requires
Mayer agrees. He suggests consid- proximity to an outside wall. And, it is
ering three basic requirements when not an option when the chemical being
selecting a solution: profitability (the released could cause an environmen-
protection solution has to be economi- tal hazard.
cal to implement, operate and main- There have been some advances in
tain), reliability (the protected facility explosion protection solutions, includ-
has to remain permanently and opti- ing suppression systems that offer
mally available for production) and optical detection to improve the speed
safety (people and machines must be of response and stability of detection,
ensured of an explosion-protected en- and indoor venting systems, referred
vironment through constructive and to as particulate retention and flame-
s
Liquid
effective directives). arresting devices, that, under some
circumstances, make venting possible
to m
Equipment types when equipment has no easy access
In addition to the use of appropriately to an outside wall. And, these can all
rated electrical equipment and intrin- be used in conjunction with intrinsi-
sically safe instruments and devices in cally safe instrumentation, the use
hazardous areas, there are three main of which helps reduce but not al-
types of explosion protection solutions, ways eliminate the need for explo- for example:
each with its own set of pros and cons. sion protection equipment in some
Solutions include the following: installations, says Robert Schosker, Tall oil distillation
Containment. Process equipment product manager of intrinsic safety
Lecithin drying
can be designed to withstand the with Pepperl+Fuchs Inc. (Twinsburg,
maximum explosion pressure. How- Ohio; www.pepperl-fuchs.us). Monoglyceride
ever, containment can be an expensive However, experts agree that what Glycerin recovery
option because of the special engi- might seem like the best solution may
neering and strength required. Often, not actually provide the best protec-
once the equipment is built, access to tion for a given facility. It is highly
the vessel for routine maintenance is recommended that chemical proces-
cumbersome. And, it is necessary to sors seek a risk assessment that can
maintain the pressure integrity of classify the hazardous areas, deter-
the vessel for life. Corrosion or other mine the risks and, based upon that
wear and tear can weaken the equip- information, select the explosion pro-
ment over time. In practice, this op- tection solution or solutions that will system solutions
tion is usually considered for small protect employees, equipment and for evaporation and biopharma
vessels or where highly toxic chemi- processes in accordance with the fa-
Processing Partners:
cals must not be released. cility owners objectives.
Explosion suppression. Like a fast- Ultimately, the best solution is www.gigkarasek.at
acting fire extinguisher, suppression the one that provides life safety and www.incontech.com
systems kick in when an explosion enables the facility to maintain their
starts to develop. When explosion con- business with the least interruption
ditions are detected, a suppressant is possible, says McLelland. Circle 26 on p. 76 or go to adlinks.che.com/40268-26

Equipment News
EXPLOSION-
RELATED
PRODUCTS
Yokogawa
Install these lights in
hazardous environments
The portable tower and re-
movable lamp assembly de-
sign of the EPL-QP-1X150-100
explosion-proof halogen light tower
(photo) provides 1,500 ft2 of work
area coverage with 1,520 lumens of
light output. It is designed to pro-
vide operators in hazardous
locations with a pow-
erful portable light- Newson Gale
ing solution. Equipped

with a 150-W halogen bulb
Defining the limit as standard that produces illumination in
Larson Electronics
a wide flood pattern, the ex-

plosion-proof lamp housing is suitable
Actuators for the for wet areas. Larson Electronics
oil and gas industry LLC, Kemp, Tex.
www.magnalight.com
AUMA offer a comprehensive range of explosion-
proof actuator and gearbox types combined with
Verify grounding with
suitable actuator controls for the oil and gas
this system Oseco
industry.
The Earth-Rite static electricity
monitoring system (photo) provides a sure in the event of deflagration, pre-
AUMAs modular concept margin of safety when Type C FIBCs venting a large explosion. It can also
ensures perfect integration or similar static dissipative contain- be used on bulk storage units and in
Reliable corrosion protection ers are used to transfer bulk powdered ductwork applications requiring a
and other solid materials in hazardous- square explosion vent. The vent fea-
Suitable for all conventional area applications. The system includes tures a high vacuum rating to help
eldbus systems an enclosed, intrinsically safe power extend the life of the vent in applica-
Approved worldwide supply and an electronic monitor. It tions where high vacuum pressure
Please visit us
continuously verifies the existence exists. Its lower burst pressures pro-
www.auma.com at our booth
8.0 C23
of a low-resistance path between the vide users with the ability to get the
containers static dissipative or con- required relief area without having to
ductive fibers and a known grounding use a larger vent size. It can operate in
point, typically through a mechanical temperatures up to 450F and meets
grounding clamp affixed to a flexible OSHAs Combustible Dust National
tab. Newson Gale Inc., Jackson, N.J. Emphasis Program and NFPA 68.
www.newson-gale.com Oseco, Broken Arrow, Okla.
www.oseco.com
An explosion vent with
extended life This suppression system meets
The MV-RD explosion vent (photo) NEP requirements
provides extended in-service life and Type IPD chemical isolation and sup-
lower burst pressure in smaller sizes. pression system (photo, p. 29) provides
The vent is designed for high cycling explosion protection for facilities han-
AUMA Riester GmbH & Co. KG applications, such as in dust collectors dling combustible powders. Installed,
P.O. Box 1362 79373 Muellheim, Germany and baghouses that experience vac- the system meets the requirements
Tel. +49 7631 809-0 riester@auma.com uum pressures up to 12 psig (24.4 in. of OSHA Combustible Dust National
Hg). The vent mounts on enclosures Emphasis Program (NEP), as well as
AUMA Actuators Inc. where dust explosions may occur, and NFPA 654, 68 and 69. System compo-
100 Southpointe Blvd. Canonsburg, PA 15317, USA
will activate to safely relieve pres- nents include a power supply and bat-
Tel. +1 724-743-AUMA (2862) mailbox@auma-usa.com
BS&B Safety Systems,
the FM-approved, loop- during maintenance or when trouble-

powered indicators are in shooting a malfunction. The MLX con-
potentially hazardous en- tains a six-digit numerical and alpha-
vironments in the chemical industry. numeric displays for engineering units
They provide an additional view of the and a 20-segment bar graph indicating
measured value between a field instru- 0100% of full scale. Yokogawa Corp.
ment and the control room. This local of America, Newnan, Ga.
indication of flow, pressure, liquid level www.yokogawa-usa.com
or temperature can provide assistance Joy LePree
Safe
Solutions For Handling
Dangerous
Chemicals.
ACHEMA
June 18th - 22nd, 2012
Volkmann
. Frankfurt, Germany
l ows
tery backup, a monitoring module in- F
dicating system status/drive external tion
va
relays, a unitized sensor to detect ex-
In no
plosion onset and suppression cannons
e re
that deliver a safe sodium bicarbonate Wh
suppression agent into the protected
equipment. The cannons compact size
and low mass simplify installation
and allow the unit to be installed at
any angle. There is no need for heavy
extension piping and nozzles for sup-
pressant dispersion. BS&B Safety
Systems, Tulsa, Okla
www.bsbsystems.com
Vacuum conveying system

By using a sophisticated, nitrogen
purging function, the INEX vacuum
VISIT US AT HALL 8.0 / Booth L79
conveying system (photo) reduces oxy-
gen content within the unloaded batch Award-winning Almatec E-Series Plastic AODD pumps
to below 7% (or lower when required), provide safe and reliable performance when handling
maintaining the materials inert safety, the most dangerous acids, solvents and caustics.
while providing dust-free transport.
Solid block CNC machining
The INEX features a closed station that
can be flushed from within by sucking Polyethylene and PTFE materials, conductive also
in the washing liquid, or through clean- available for explosion environments (ATEX)
in-place. Standard lightweight and
pressure-rated systems are available Ring design structure for improved product containment 22069 Van Buren Street
with INEX functionality. Volkmann, Grand Terrace, CA 92313-5651 USA
Optional features available (e.g. barrier chamber system) O: +1 (714) 396-1502
Inc., Hainesport, N.J. for further safety requirements
www.volkmannusa.com Carl-Friedrich-Gau-Str. 5
47475 Kamp-Lintfort, Germany
Dry run ability, self-priming, gentle fluid handling, no O: +49/2842/961-0
This loop-powered indicator rotating parts, no shaft seals F: +49/2842/961-40
provides local data info@almatec.de
The MLX loop-powered indicator www.almatec.de
(photo, p. 28) incorporates the LCD
from the companys EJX pressure
transmitter into a NEMA 4X alumi-
num housing. Typical applications for
Focus
FOCUS ON
Software
Plant-management software for
increased integration, and more
This company has expanded its Comos
software solution for plant engineer-
ing and operation to include consider-
ably enhanced functionality. Comos 10
now provides an enterprise platform
for plant engineers and operators that
can handle even the largest volumes
of data. New functions allow project Siemens Industry Sector
teams to collaborate with each other
across different systems and locations,
enabling parallel processing of differ-
ent work packages. Comos 10 also al-
lows further integration of Comos in
the Simatic PCS 7 process-control sys-
tem (photo). A new interface ensures
a consistent, bidirectional exchange
of information between both systems,
which allows previously serial engi-
neering processes to be organized in
parallel. Initial pilot projects have
produced time savings of up to 11
weeks (or 12.5%), and up to 315 fewer
person-weeks. Cosmos 10 is being
released in several stages, the first
version became available last month.
Achema Hall 11.0, Stand C3 Sie-
ProSim
mens Industry Sector, Industry Auto-
mation Div., Nuremberg, Germany Track equipment health Enhancements for simulation
www.siemens.com at large operations of batch reactors
In February, this company intro- Released earlier this year, this new
Major updates of gSolids for duced Proficy SmartSignal Shield version of BatchReactor (photo)
process design and operation 4.0 software for the oil-and-gas and combines detailed equipment mod-
Last month saw the release of gSolids, power industries. The Shield soft- eling, reaction engineering and ad-
a second-generation, integrated drag- ware helps operators detect equip- vanced numerical methods to create
and-drop graphical flowsheet environment problems early and avoid a state-of-the-art simulation envi-
ment for model-based engineering and surprise equipment failure, thereby ronment for chemists and chemical
optimization of solids processes. New in increasing productivity while mini- engineers. By providing a complete
gSolids is the ability to handle multiple mizing costs. This software solution understanding of the production
solid phases, each with its own parti- provides early warning of impend- recipe, the new simulation software
cle-size distribution. There are also en- ing equipment problems, diagnostic enables users from the pharmaceuti-
hancements to a large number of the guidance and prioritized actionable cal and fine-chemicals industries to
softwares capabilities, such as the use intelligence. The Shield softwares test alternative synthesis routes and
of dynamic modeling to handle batch, diagnostic algorithms combine ob- new production strategies through
continuous and hybrid processes; ad- servations on multiple individual effective use of simulation in paral-
vanced parameter estimation and op- sensors to pinpoint failure effects. lel with laboratory and pilot-plant
timization capabilities; and integration Beyond vibration and thermal anal- experiments. The software features
with the companys gCrystal modeling ysis, the solution uniquely models an efficient thermodynamic package
software and gas-liquid process models. all data on all critical rotating and and relies on proven and efficient
Hall 9.2, Stand C9 Process Systems non-rotating equipment. GE Intel- numerical methods. Hall 9.1, Stand
Enterprise Ltd., London, U.K. ligent Platforms, Chicago, Ill. E66a ProSim, Toulouse, France
www.psenterprise.com www.ge-ip.com/smartsignal www.prosim.net
30 CHEMICAL ENGINEERING WWW.CHE.COM JUNE 2012 Note: For more information, circle the 3-digit number
on p. 76, or use the website designation.
Save man-hours with this lation to a wider range of new users, heat exchanger thermal and mechani-
electrical-design software says the company. Users can now ex- cal design products, says the company.
This completely new Electrical soft- perience a fully integrated simulation Process engineers can also jump-start
ware application is said to be a fea- environment to easily access other as- projects and optimize operations by
ture-rich design solution for electrical penONE Engineering products. This efficiently finding and accessing mod-
engineers and designers in the plant enables easy and intuitive access to els and data throughout the Aspen
environment. Pre-released customer the comprehensive physical-proper- Search tool. Aspen Technology, Inc.,
testing has demonstrated man-hour ties database, the capital-cost estimat- Burlington, Mass.
savings of up to 30% when compared ing product and the most-complete www.aspentech.com
to traditional design applications,
says the company. It is quick and easy
to deploy, and has a very open inter-
face, allowing it to be used with design
applications from other vendors or as
part of this companys Integrated En-
gineering & Design approach. Electri-
cal can be used on both new projects,
as well as on brownfield activities
where the integration legacy data is
critical. Hall 9.2, Stand C29 Aveva,
free zone
Solutions Ltd., Cambridge, U.K
www.aveva.com
A new version of a smart plant

design and modeling solution
Last month, this company launched
CADWorx Plant Professional 2013, the
newest version of its AutoCAD-based in-
telligent 3D plant design and modeling
solution. The software features a power-
ful new pipe routing engine in which the
piping components operate as a single
system. This allows a plant designer to
move, resize and change the specifica-
tion as a single line without the need
to modify each component individually. Plant Process Product
Another new feature is the Assembly
View Pallette. The assembly builder lets
the designer build and save a complete Dry processing or processing in the concentrated
assembly of a piping system that can phase is efcient, economical, ecological.
be reused in the future parametrically,
thereby boosting the efficiency of the
design by allowing for common assem-
blies used throughout a project to be Energy savings
designed, developed and modeled once, High efciency operations
then reused quickly in different areas of Lower cost of ownership
the plant system. Hall 9.2, Stand D28
Intergraph Corp., Huntsville, Ala.
www.intergraph.com
Consistent product quality
High degree of processing exibilities
This release enables more users
to perform simulations
The new release of Aspen Plus soft- ACHEMA 2012 | Frankfurt am Main
ware, launched in March, is said to sig- June 18 to 22, 2012 | Hall 5.1 | Booth D92
nificantly improve the user experience
in process simulation. The completely
redesigned user interface and work-
flow improve engineering productivity www.list.ch
and enable the use of process simu- www.list.us
www.list.sg
Focus
A tool to test for used by this foundation to verify and ancillary files needed to facilitate
HART compliance validate compliance of host products HART DDL/EDDL host testing. Hall
In April, the new enhanced HART submitted for HART registration. 11.V, Stand B29 HART Communi-
DDL/EDDL (electronic device de- The new Suite v.2.0 includes: im- cation Foundation, Austin, Tex.
scription language) Host Test Suite proved Encoded Test DDs updated to www.hartcomm.org
v2.0 was released. The test suite is align with the current Test Specifi-
used by suppliers and developers of cations; test report spreadsheets for Save energy at data centers
host products to test compliance of documenting test results; new and and more with this suite
their HART implementation and is improved Xmtr-MV v2.5; and other In December, this company intro-
duced its Decathlon suite including
software, hardware and services for
data centers to provide a single view
of IT, facilities and energy manage-
Total Project Delivery

ment information for improved data
access and use, while making data
centers themselves more reliable and
energy efficient. Decathlon is said to
enable better control and proactive
maintenance of data center opera-
tions, with access to information from
multiple systems, and provides po-
tential energy savings of 10 to 50%.
Decathlon provides realtime equip-
ment health status to ensure reliabil-
ity and proactive maintenance. It also
transforms energy consumption data
into valuable information so that data
center operators can optimize power
use while maintaining high levels of
productivity and reliability. Hall 11.1,
Stand A61 ABB Warminster, Pa.
www.abb.com
With a Reputation for Excellence A tool to help design
heat-trace systems
In today's challenging economic climate, creative thinking, accurate
Released at the end of last year,
cost estimates and a commitment to technical excellence are crucial to
TraceCalc Pro version 2.5 is an in-
the success of capital projects. Mustang has a superior reputation for
dustrial heat-trace-system design
providing owners with total project delivery, from feasibility analysis and
software that provides users with a
front-end engineering to facility startup.
step-by-step process to design an ef-
fective and efficient heat-trace sys-
Whether a project is grassroots, revamp, expansion or modernization,
tem for pipes and vessels. Users can
Mustang has the experience and capability to successfully execute
input their heat-trace design param-
your project to achieve the desired results.
eters (such as pipe size and material,
insulation type and thickness, service
Contact Mustang today!
voltage, maximum exposure temper-
ature, pipe length, the number and
size of valves and more) into Trace-
Calc Pro. The software then provides
the information needed to complete
the heat-trace-system design process,
such as the amount of heat loss from
the pipe, types of heat-trace products
required, number of circuits used, and
processplants@mustangeng.com electrical and thermal performance of
www.mustangeng.com the system. Tyco Thermal Controls,
Houston, Tex.
www.tycothermal.com
Gerald Ondrey
Show Preview
Funke Wrmeaustauscher
Apparatebau
The benefits of
solvent-free processing
Dry processing processing in the
concentrated phase, with minimal or
zero use of solvents is efficient, eco-
nomical, and ecological, according to
this company. Applications in polymer
processing include polymerization
and direct devolatilization. Oper-
ating at viscosities up to 100,000 Zeppelin Systems
Pas, the firms Kneader Reac-
tor process technology (photo)
ensures consistently high prod-
uct quality and eliminates or
at least significantly reduces
costs of solvents and recycling.
The result is a technology offer-
ing a high degree of process flex-
ibility and lower total cost of owner-
ship. Excellent mixing behavior, low
shear rates and plug flow contribute
to a wide operational window and con-
Kreisel
sistent product quality, even at high Umwelttechnik
capacities. The closed system ensures List
environmentally friendly operation,
with residual monomer contents below suitable for the treatment of sludges and are said to increase service life by
10 ppm. Hall 5.1, Stand D92 List AG, and pastes. The FB in this horizontal a factor of 10 to 20 compared to steel
Arisdorf, Switzerland dryer is produced mechanically by a valves (depending on the material
www.list.ch rotating paddle system. For processes being conveyed). Hall 6.0, Stand
under atmospheric pressure, steam B82 Kreisel Umwelttechnik GmbH
Reliable feeding and discharge can be applied as an additional heat- & Co. KG, Krauschwitz, Germany
under extreme conditions transfer medium and also serve as in- www.kreisel.eu
The Rotary Feeder CFH 630 (photo) ertization. In the CFT dryer, the wet
has been designed to ensure reliable product is immediately encapsulated Tube-in-tube design augments
feeding and discharge of product, even by the dry product, is evenly distrib- safety in these heat exchangers
at pressures and temperatures of 6 uted throughout the dry product and In addition to plate heat exchangers
bars and 200C. The feeder housing is is dried efficiently. By encapsulating in bolted, brazed, semi- and fully-
sealed from the process while material the wet feed, sticky phases or forming welded designs, this company will
is conveyed at rates of up to 100 ton/h. crusts on the wall are largely avoided. exhibit several products from the
Normally, high temperatures and Hall 4.0, Stand B24 Buss-SMS- shell-and-tube heat-exchanger de-
pressures cause different expansion Canzler GmbH, Butzbach, Germany sign. A highlight is the refined safety
and deformation of the rotor and the www.sms-vt.com of the SWP shell-and-tube exchanger
housing. To compensate for these fac- (photo), which is based on a tube-
tors, the CFH 630 housing is heated A wear-resistant rotary valve for in-tube combination that creates a
by an integrated temperature control abrasive bulk solids safety space and prevents the op-
system, which helps to minimize the This company has developed a hy- erating media from mixing. Also at
gap and thus the air leakage. Hall 6.0, gienically pure and safe conveyor Achema will be two special types of
Stand A52 Zeppelin Systems GmbH, system for metering and transporting plate heat exchangers: the FPG, with
Friedrichshafen, Germany bulk materials. Capable of transport- two plates welded together into a cas-
www.zeppelin-systems.com ing more than 100 ton/h over dis- sette; and the FPDW, with the two
tances of over 1 km, every system is plates welded together at the potring
Dry sludges and pastes energy-optimized and adapted to the to form a leakage space between the
two ways with one unit users requirements. Also being ex- plates. Hall 4.0, Stand G24 Funke
The Combi Fluidization Technology hibited are the wear-resistant rotary Wrmeaustauscher Apparatebau
(CFT) combines contact and fluidized- valves (photo), which deliver high- GmbH, Gronau/Leine, Germany
bed (FB) drying, and is especially performance and high throughput, www.funke.de
Note: For more information, circle the 3-digit number CHEMICAL ENGINEERING WWW.CHE.COM JUNE 2012 32D-1
on p. 76, or use the website designation.
Georg Fischer Piping Systems
Show Preview
Thermo Fisher
Scientific
Phoenix Contact
Distributed signals with

a single turn in the field
The new Radioline wireless system
(photo) is designed for wireless signal
transmission at large facilities. input/
output (I/O) mapping is one feature
that distributes signals from up to 250
stations within the system without
any software. Input signals receive
I/O addresses via thumb wheels, with
these addresses being mapped to cor- Rembe
responding output modules. Because
identical signals can be outputted Vega Grieshaber
several times, it is possible to set up
smart distribution and signal multi- Moving-object simulations im- Designed to meet the demands of the
plication in the field. Hall 11.1, Stand proved with this new version bulk solids industry, the device can de-
A27 Phoenix Contact GmbH & Co. This company recently released STAR- tect the limit level under adverse en-
KG, Blomberg, Germany CCM+ v7.02, a new version of its mul- vironmental conditions, such as dust,
www.phoenixcontact.com tidisciplinary engineering simulation fog or high temperatures. It consists of
solution. The release features a new a VegaMIP T61 transmitter and a re-
Perform multiple spectroscopies Overset Mesh capability that allows ceiver, which measures the attenuation
with a single touch users to generate an individual mesh of the received microwave signal and
The Nicolet iS50 FTIR (Fourier trans- around each moving object, which can generates a switching signal. For hard-
form infrared) spectrometer (photo) is then be moved at will over a back- to-reach or dangerous areas, there is
said to be the first research-grade FTIR ground mesh. The Overset Mesh capa- now the receiving unit R62 with re-
with one-touch operation. The device bility is fully compatible with the full mote control, which allows the control
features integrated Raman for an ac- range of unstructured mesh options in unit to be placed in a safe, accessible
cessible and cost-effective compliment STAR-CCM+. With no need to worry location. Hall 11.1, Stand C63 Vega
to IR characterization, dedicated NIR about interconnecting meshes or cell Grieshaber KG, Schiltach, Germany
(near infrared) designed to assist de- distortion, Overset Mesh brings genu- www.vega.com
velopment of quality control methods ine moving object simulation within
for bulk samples and touch points for the grasp of all engineers, says the A rupture disc for
collecting, analyzing and reporting re- company. Hall 9.2, Stand C10 CD- pristine processing applications
sults with one-touch simplicity. Users adapco, London, U.K. One of the highlights at this companys
can initiate attenuated total reflection www.cd-adapco.com stand is the new TC(R)-KUB reverse-
(ATR), Raman and NIR modules at acting bursting disc with Gylon gasket
the touch of a button, enabling access A level detector for (photo), which utilizes the synergies
to these techniques without manually hard-to-reach areas from both the inspected and proven
changing system components. Hall The microwave barrier VegaMIP R62 KUB Technology (reverse-acting burst-
4.2, Stand B7 Thermo Fisher Scien- (photo) is a non-contact sensor that ing disc) and the high-tech develop-
tific, Dreieich, Germany can detect the limit level of solids and ment found in a Gylon Gasket. This
www.thermoscientific.com liquids in poorly accessible locations. new bursting disc can be installed in
32D-2 CHEMICAL ENGINEERING WWW.CHE.COM JUNE 2012
any industrial or chemical area requir- has been adapted for the dos-
ing absolute sterility and permeability, ing of tanks with volumes of 100
for example in the pharmaceutical, bio- to 1,000 L. Four different modes
technological and food-processing in- of operation are provided by the
dustries. Hall 9.1, Stand C26 Rembe electronics, and the speed can be
GmnH, Brilon, Germany adapted for different viscosities. The
www.rembe.de agitators are suitable for both batch
and intermittent operation. Hall 8.0,
Many parameters are handled by Stand K63 sera ProDos GmbH,
Flowserve
a single transmitter Immenhausen, Germany
The new Signet 9900 SmartPro www.sera-web.com
Transmitter (photo, p. 32D-2) features while maintaining reduced inventory
multi-parameter capabilities, flexible levels, says the company. The 9900 is This ANSI pump now has
modularity and an auto-sensing, back- available in both panel or field-mount an ISO companion
lit display with at-a-glance visibility, versions. Hall 8.0, Stand E64 Georg An expanded range of this companys
even in dark conditions. The transmit- Fischer Piping Systems Ltd., Schaff- Durco Mark 3 ISO chemical-process
ter provides a single-channel interface hausen, Switzerland pumps (photo) will be launched at
for many different parameters, includ- www.piping.georgfischer.com Achema. The Durco Marc 3 ISO pump
ing flow, pH/ORP, conductivity/resis- range is fully compliant with ISO
tivity, pressure, temperature, level, A top-mounted agitator with 2858 (dimensional) and ISO 5199 (de-
salinity and other sensor types that smart electronics sign) criteria, and is designed using
output a 420-mA signal. This single- The new Type MU electric agitator state-of-the-art hydraulic and model-
channel, multi-parameter capability combines efficient agitator technol- ing software with knowledge gained
and field-upgradable modularity allow ogy with the advantages of modern from more than 30 years of experience
users to increase their service level electronics. The controllable agitator with the companys ANSI/ASME B73.1
PROTECT PUMPS
DRY RUNNING CAVITATION BEARING FAILURE OVERLOAD
MONITOR PUMP POWER COMPACT EASY MOUNTING

Best Sensitivity Only 3.25" x 6.25" x 2"
Digital Display Starter Door Panel
Raceway Wall
TWO ADJUSTABLE SET POINTS
Relay Outputs UNIQUE RANGE FINDER SENSOR
Adjustable Delay Timers Works on Wide-range of Motors
Simplies Installation
4-20 MILLIAMP ANALOG OUTPUT
WHY MONITOR POWER INSTEAD OF JUST AMPS? PUMP POWER

VALVE CLOSING
PUMPING
POWER
AMPS
VALVE OPENING NO FLUID

No Sensitivity
Power is Linear-Equal Sensitivity For Low Loads
at Both Low and High Loads
NO LOAD FULL LOAD NO LOAD FULL LOAD
CALL NOW FOR YOUR FREE 30-DAY TRIAL 888-600-3247

WWW.LOADCONTROLS.COM
CHEMICAL ENGINEERING WWW.CHE.COM JUNE 2012 32D-3
Mller
Show Preview
Durco Mark 3 ANSI pump. Both ANSI connections for inside and outside
and ISO pump versions feature the IPS washing enables a reduction of
Beacon condition monitoring device water consumption. The units are
a data acquisition, logging and visual constructed of stainless steel with
alert device that is designed to moni- EPDM seals. Hall 3.1, Stand A75
tor vibration in addition to tempera- Mller GmbH, Rheinfelden,
ture. Constructed of stainless steel and Germany
mounted on top of the bearing housing, www.mueller-gmbh.com
the IPS Beacon delivers early warning
notification to users, allowing them This established machine
to take proactive measures to extend now bags even faster
bearing life and mechanical seal of the The Haver Adams will be the cen-
pump. Hall 8.0, Stand A64 Flowserve terpiece of this firms exhibition.
Corp., Irving, Tex. Since its launch six years ago, this
www.flowserve.com packaging system, which uses the
Form-Fill-Seal principle, has been
This washing machine cleans improved to meet users demands
drums in a few minutes for speed and product variety. Today, extended storage times in wind and
The Drum Washing Machine DCM products with poor flow properties weather, a guaranteed cleanliness
(photo) cleans the inside and outside of and powder-type products with granu- along the entire supply chain and an
30200-L drums, with a washing cycle lar components and micro-granulates improved price-to-benefit ratio, says
of 510 min. Cleaning nozzles within can be packed into compact, sealed, the manufacturer. Hall 3.0, Stand F38
the system can be connected directly weather-tight bags at the rate of 2,000 Haver & Boecker, Oelde, Germany
to a facilitys water loop (2 bars pres- bags per hour. The advantages of this www.haverboecker.com
sue, 35 L/min flowrate), and separate kind of durable packaging include Gerald Ondrey
Get Chemical Engineerings plant

cost index to improve plant cost
estimatesand delivered in advance
of the print edition!
For more than 37 years, chemical process industries
professionals- engineers, manager and technicians,
have used Chemical Engineerings Plant Cost Index
to adjust process plant construction costs from one
period to another.
This database includes all annual archives (1947 to
present) and monthly data archives (1970 to present).
Instead of waiting more than two weeks for the print or
online version of Chemical Engineering to arrive,
subscribers can access new data as soon as its calculated.
Resources included with Chemical Engineerings Plant

Cost Index:
Electronic notification of monthly updates as soon as

they are available
All annual data archives (1947 to present)
Monthly data archives (1970 to present)
Option to download in Excel format
17817
Subscribe today at www.che.com/pci
32D-4 CHEMICAL ENGINEERING WWW.CHE.COM JUNE 2012
Spray Drying
Parameters
Department Editor: Scott Jenkins
GEA Niro
mong the most widely used technolo- (usually compressed air) through
A gies in the chemical process industries

(CPI), spray drying involves dispersing
a liquid or slurry in a hot gas to produce
a two-fluid nozzle to accomplish
the atomization. Particle size is
controlled by adjusting the ratio of
a dry powder product. A wide range of the compressed air to the feed. Two- (a) (b)
pumpable solutions, suspensions and emul- fluid pneumatic atomization is used
sions can be used as spray-drying feeds. primarily in smaller drying systems.
Spray drying allows processors to gener- Sonic atomization. For applica-
ate powders with precisely defined proper- tions requiring fine droplets at low
ties. By controlling process parameters flowrates, sonic atomization can be
including the characteristics of the liquid used. In this technique, the feed liq-
feed, the method of atomization, the con- uid is passed over a surface that is FIGURE 1. Rotary atomizers (a) produce a liquid mist
figuration of the dryer and others chemi- vibrated at ultrasonic frequencies. It horizontally from the atomizer wheel. Atomization by
cal makers can control the shape, flow is employed in small-capacity dryers nozzle (b) often leads to a narrower
properties and porosity of the solid particles when a highly uniform particle-size particle-size distribution
produced. Here, the major considerations distribution is required.
of spray drying are outlined. FIGURE 7. This spray drying
Dryer configuration system is equipped with a heat
Atomization To allow the liquid to evaporate, recovery unit
Several methods for atomizing the liquid the flow patterns of the droplets
feed in a spray-drying system are available and the gas through the dryer
(Figure 1). For most atomization equipment, must provide enough contact
the liquid leaves the atomizing head as a time. Therefore, the size and
thin liquid film. The film fragments upon geometry of the spray-drying
leaving the atomizing head, and droplets chamber and gas disperser
form immediately, driven by the surface become important parameters.
tension of the liquid. Because of this, In many spray-drying systems,
droplet formation depends heavily on the the atomizer is installed at the
rheological properties of the liquid and its roof of a large-diameter drying
interaction with the heated drying medium chamber, and the heated gas
just outside the atomizing device. is introduced through a roof-
Rotary. In centrifugal (rotary) atomization, mounted air or gas disperser GEA Niro
the most common method used in spray around the atomizer. This cre-
dryers, a rotating disc or wheel breaks the ates a co-current flow of gas
liquid stream into droplets. A liquid mist is and droplets and particles. The chambers airflow patterns and temperature distribu-
formed horizontally from the atomizer wheel. height must allow particles sufficient retention tions within the drying chamber. For most
Centrifugal atomizers rotate in the range of time to dry. Larger particle sizes require applications, the gas disperser has adjust-
5,000 to 25,000 rpm. The size of the drop- larger-diameter drying chambers. able guide vanes that allow for fine-tuning.
lets produced is roughly inversely propor- The residence time should be selected Industrial radial fans are used to move the
tional to the peripheral speed of the wheel, based on the experience of the products gas through the system. Sizing of system
or disc, which typically have diameters in the known drying characteristics and on the components can be based on gas flow.
range of 5 to 50 cm. The use of variable- desired particle size. This allows direct
speed drives can make the control of the calculations of the drying chamber volume. Evaporation rate
droplet size straightforward. The smallest Another configuration involves installing Inside a spray dryer, the evaporation rate
rotary atomizers handle 110 kg/h of liquid the pressure nozzle at the bottom of the is directly proportional to the temperature
feed in the laboratory, while the largest com- chamber, so that the spray shoots upward difference from input to outlet multiplied by
mercial units, driven by 1,000-kW motors, from the bottom. This configuration is used the mass flow. Values for the outlet temper-
can handle more than 200 metric ton/h. in cases where the product is a coarse pow- ature are usually determined experimen-
Nozzle. Atomization with a pressure der and the production rate is lower. tally, since they depend on the materials
nozzle involves pressurizing a liquid using equilibrium isotherm, and true equilibrium
a pump, and forcing it through the orifice or Collecting dried solids is never actually reached. The inlet tem-
a nozzle. Typical orifice sizes are 0.53.0 Coarse powders are most easily collected perature is also determined experimentally,
mm, which limits the capacity of the nozzle directly from the bottom of the drying cham- and should be as high as possible without
to 7501,000 kg/h of liquid feed, depend- ber. For fine powders, cyclones or bag filters risking product degradation.
ing on pressure, viscosity and solids content become the primary collecting points. The
of the feed. Larger pressure drops across particles must be separated from the drying Safety
the orifice produce smaller droplets, so to media, which is cooler (due to evaporation) In spray-drying operations, safety proce-
reduce particle size for a given feedrate, a and more humid than before drying. dures related to dust explosions must be
smaller orifice and higher pump pressure considered carefully, including determina-
must be provided to maintain the same Gas flow tion of dust explosion pressure rise (Kst), the
mass flow. Although simple, the pres- Heating the drying gas that flows through maximum dust explosion pressure (Pmax),
sure nozzle is often difficult to maintain, the spray dryer may be accomplished by minimum ignition energy (MIE), minimum
especially in multiple-nozzle systems. Most direct combustion of natural gas, by indirect ignition temperature (MIT), and minimum
of the difficulty results from plugging, as heating with shell-and-tube heat exchang- auto-ignition temperature (MAIT).
well as wear of the nozzle insert, which can ers, or by electric heaters (used in small
Editors note: The material in this Facts at Your Fin-
change the characteristics of the nozzle. spray dryers). Most gas dispersers are gertips was adapted from the article cited here: .
Two-fluid pneumatic. In this type of atomiza- configured with the help of computational Moller, J.T. and Fredsted, S., A primer on spray dry-
tion, the feed interacts with a second fluid fluid dynamics (CFD) analysis to define ing. Chem. Eng., November 2009, pp. 3440.
Feature
Cover Story
Report
Draining Vessels D
Pt
Determine how long it will take for units h 1
with flat, cone- or dish-shaped bottoms Z1
hL
Edward H. Steve
Chemical Engineer Z X
FIGURE 1. In a vertical
T
hroughout the chemical process
industries (CPI), the need to cylindrical, lat-bottom
Z2
tank, liquid is lowing Tank side wall
drain a tank or process vessel into the outlet nozzle
arises. In batch-type plants, it is (point 1) located at x distance above 2
a regular occurrence and is one factor the bottom of the tank and through a Pt
that affects the total cycle time per pipeline to some terminus (point 2)
batch and ultimately the entire pro-
Tank bottom
duction capacity of the plant itself. size of the pipeline is the same size as
Some operations rely on draining a the outlet nozzle and does not change
freely flowing Newtonian liquid from between points 1 and 2. The pressures
a process vessel to another vessel or to above the liquid in the tank and at the
elsewhere without the assistance of a terminus are both Pt. FIGURE 2. If the inside sur- Drain nozzle
pump. This article develops the equa- Before draining begins, the liquid face of the outlet nozzle is
tions that a process engineer can use fills the tank to some initial height (hi) aligned with the inside surface of the
tank bottom as shown here, distance x is
to easily estimate the time required above the outlet nozzle. If the inside 0 and hi incorporates the entire contents
for draining a vertical, cylindrical pro- surface of the outlet nozzle is aligned of the tank
cess vessel with a flat bottom, a cone with the inside surface of the tank bot-
bottom or an ASME F&D (dish) bottom as shown in Figure 2, distance x static pressure represented by Z +
tom. Unlike other articles on the sub- is zero and hi incorporates the entire h. Note that hL also decreases dur-
ject [1], this one includes the effect of contents of the tank. As draining pro- ing draining because differentiating
the connected drain line. gresses, h decreases. Equation (3) gives the following:
Using the equations and the ex- The Bernoulli Equation applies to
dhL = dh (4)
amples in this article, the reader can the flow in the pipeline between points
construct an Excel spreadsheet for 1 and 2: A basic material balance applies to de-
repeating the calculations to estimate veloping the equation needed to pre-
the approximate drain times for a se- dict the drain time for the tank:
ries of cylindrical, cone-bottom and In Out = Accumulation
dish-bottom tanks. (1) Because no liquid is being added to
Tanks with other head styles and This article assumes isothermal flow, the tank, In = 0.
horizontal and non-cylindrically so the liquid density remains un- Out is the rate of liquid discharge
shaped tanks are not considered here. changed; because the pipeline size does from the outlet pipeline and is given
Meanwhile, this article does not deal not change, the velocities at points 1 by [3]:
with special fluids such as slurries or and 2 are the same. Thus, Equation (1)
Q = 19.65 d2 (hL/K)0.5 (5)
non-Newtonian liquids. can be rearranged as follows:
Because hL decreases during draining,
hL = Z + [(144 / ) (P1 P2)] (2)
FLAT BOTTOM Q decreases as well. Therefore, the
Equation and its basis The Z term is the change in eleva- Reynolds Number (NRe) in the pipe-
Figure 1 shows the height of liquid tion of the discharge pipeline and is a line also changes during draining.
(h) above the outlet nozzle of a verti- fixed value. The K in Equation (5) is the total re-
cal cylindrical flat-bottom tank dur- Because P1 = Pt + (h/144) and P2 = sistance to flow and is the sum of four
ing draining. The liquid is flowing into Pt, Equation (2) becomes: individual resistances:
the outlet nozzle (point 1) located at x
hL = Z + h (3) K = KEntrance + KValves&Fittings
distance above the bottom of the tank
+ KPipe + KExit (6)
and through a pipeline to some termi- Equation (3) indicates that the friction
nus (point 2). Equations in this article caused by flow in the pipeline between The values for two of the resistances
are based on the assumption that the points 1 and 2 consumes the entire in Equation (6) are found in the litera-
0.06
AVERAGE PIPELINE FRICTION FACTOR
0.05
Friction factor (f)

he upper plot in Figure 3 results when calculated values of friction
T factor [8] for 3-in., schedule-40 pipe with roughness 0.00015

are plotted as a function of NRe on arithmetic coordinates. The
lowest value for NRe is 2,000. Note the sharp decrease in f at values
0.04
0.03
0.02
much less than 500,000 NRe.
0.01
Inspection of the data shows that the value of f drops by approxi-
mately 0.002 between 100,000 and 300,000 NRe; it drops only 0
0.0005 between 300,000 and 500,000 NRe. Because the value 0 500,000 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000
of f at fully turbulent flow (fT) is given as 0.018 [9], and the value NRe
is 0.0181 at 500,000 NRe, no significant reduction in f occurs at 0.06
values greater than 500,000 NRe. 0.05
The lower plot in Figure 3 shows f as a function of NRe up to 500,000
NRe. The superimposed Excel Trendline indicates that the equation of 0.04
the curve for that plot is y = 0.1804x0.1822. The fit of the Trendline is 0.03 y = 0.1804x
not perfect, but is sufficient for calculating an average f.
The average friction factor (fAVE) can be calculated by determining 0.02
the area under the plot and dividing by the included range of NRe. 0.01
For the lower plot in Figure 3, the basic mathematics are:
0
0 100,000 200,000 300,000 400,000 500,000 600,000
(B1-1) NRe
FIGURE 3. These plots show calculated values of friction
Integrated and expanded with values for NRe gives: factor (f) for 3-in. schedule-40 pipe with roughness 0.00015
plotted as a function of NRe. The top graph shows no sig-
niicant reduction in f at >500,000 but a sharp decrease at
values <<500,000. The bottom graph narrows in on NRe up to
500,000 and provides a suitable, itted trendline equation for
calculating an average f
(B1-2)
Plots like Figure 3 were constructed for schedule-40 pipe in sizes of the fAVE value as well as the range of NRe used and the plot
1, 1.5, 2, 3, 4, 6 and 8 in. After judging what should be the value equation for each pipe size; the friction factor at complete turbu-
for NRe2 for each pipe size, fAVE was calculated. Table 1 presents lence from the literature [9] is also indicated for reference.
ture [4] and are accepted as indepen- TABLE 1. AVERAGE FRICTION FACTOR FOR SCHEDULE 40 PIPE
dent of NRe: (ROUGHNESS = 0.00015)
KExit = 1 Pipe size, in. NRe1 NRe2 f vs. NRe plot equation fAVE fT
For a sharp edged opening: 1 2,000 500,000 y = 0.1323x0.1411 0.0241 0.023
KEntrance = 0.5 1.5 2,000 300,000 y = 0.1722x0.1764 0.023 0.021
Values for other entrance conditions 2 2,000 300,000 y = 0.1903x0.1858 0.0222 0.019
3 2,000 500,000 y = 0.1804x0.1822 0.0201 0.018
can be found in Ref. 4.
4 2,000 500,000 y = 0.1933x0.1908 0.0194 0.017
However, values for the other two 6 2,000 740,000 y = 0.1904x0.1908 0.0178 0.015
resistances (KPipe and KValves&Fittings) 8 2,000 1,200,000 y = 0.1815x0.1869 0.0163 0.014
must be found through some analysis.
In general, the resistance to flow changes during draining, average val- Equation (8):
through straight pipe is given by [5]: ues can also be used when determin-
ing KValves&Fittings. The box, Average
KPipe = f (Lpipe/Dpipe) (7)
resistance to flow in valves and fittings (9)
For a given length of pipe with a given (p. 37), discusses an approach to calcu- Substituting Equation (4) into Equa-
inside diameter, the (Lpipe/Dpipe) ratio lating these averages, and Table 2 lists tion (9) gives the following:
is constant no matter what the flow the results for various sizes of several
might be. The friction factor (f), how- types of valves and fittings that could
ever, is a function of NRe so KPipe is be part of a drain line. (10)
not constant as the flow decreases Obviously, K can then be calculated Putting the pieces of the basic mate-
during drainage. A way to avoid itera- for the variable flow in the drain line rial balance together yields the math-
tive calculations is to use an average by summing the values of the four ematical version with flow units of
friction factor (fAVE) in Equation (7) to individual resistances according to gal/min:
calculate KPipe. The box, Average pipe- Equation (6).
line friction factor (above) discusses Returning to the basic material bal-
that approach to calculating fAVE and ance, Accumulation is the rate of vol- (11)
Table 1 lists the results for various ume reduction in the tank. The volume Equation (11) can be re-arranged into
sizes of schedule 40 pipe. (gallons) in the tank above the outlet a form that can easily be integrated:
The literature reports [6, 7] that a nozzle at any time is given by:
three-constant (3-K) method should be
VCY = 7.48(D2h)/4 (8)
used to calculate the resistances to flow
(12)
through valves and fittings because The volume decreases with time ac-
they vary with NRe. Because the flow cording to the first derivative of Using the following model:
Cover Story
TABLE 2. AVERAGE RESISTANCE TO FLOW IN VALVES AND FITTINGS

Item Dn, in. Ki Kd Ki(1+Kd/ K1 NRe1 NRe2 K1/NRe Kf Kf [10]
Dn0.3) ave ave
Tee, flow-through 1 0.05 4 0.2500 150 2,000 300,000 0.0025 0.2525 0.460
(flanged) 1.5 0.05 4 0.2476 150 2,000 300,000 0.0025 0.2501 0.420
2 0.05 4 0.2459 150 2,000 300,000 0.0025 0.2484 0.380
3 0.05 4 0.2435 150 2,000 300,000 0.0025 0.2460 0.360
4 0.05 4 0.2419 150 2,000 300,000 0.0025 0.2444 0.340
6 0.05 4 0.2395 150 2,000 300,000 0.0025 0.2421 0.300
8 0.05 4 0.2379 150 2,000 300,000 0.0025 0.2404 0.280
90-deg. elbow 1 0.091 4 0.4550 800 2,000 1,200,000 0.0043 0.4593 0.690
(flanged) 1.5 0.091 4 0.4506 800 2,000 1,200,000 0.0043 0.4549 0.630
2 0.091 4 0.4475 800 2,000 1,200,000 0.0043 0.4518 0.570
3 0.091 4 0.4432 800 2,000 1,200,000 0.0043 0.4475 0.540
4 0.091 4 0.4402 800 2,000 1,200,000 0.0043 0.4444 0.510
6 0.091 4 0.4360 800 2,000 1,200,000 0.0043 0.4402 0.450
8 0.091 4 0.4330 800 2,000 1,200,000 0.0043 0.4373 0.420
45-deg. elbow 1 0.071 4.2 0.3692 500 2,000 1,200,000 0.0027 0.3719 0.368
(threaded, 1.5 0.071 4.2 0.3656 500 2,000 1,200,000 0.0027 0.3683 0.336
standard) 2 0.071 4.2 0.3631 500 2,000 1,200,000 0.0027 0.3657 0.304
3 0.071 4.2 0.3595 500 2,000 1,200,000 0.0027 0.3622 0.288
4 0.071 4.2 0.3571 500 2,000 1,200,000 0.0027 0.3597 0.272
6 0.071 4.2 0.3536 500 2,000 1,200,000 0.0027 0.3563 0.240
8 0.071 4.2 0.3512 500 2,000 1,200,000 0.0027 0.3538 0.224
Gate valve 1 0.037 3.9 0.1813 300 2,000 740,000 0.0024 0.1837 0.184
(standard) 1.5 0.037 3.9 0.1796 300 2,000 740,000 0.0024 0.1820 0.168
2 0.037 3.9 0.1783 300 2,000 740,000 0.0024 0.1807 0.152
3 0.037 3.9 0.1766 300 2,000 740,000 0.0024 0.1790 0.144
4 0.037 3.9 0.1754 300 2,000 740,000 0.0024 0.1778 0.136
6 0.037 3.9 0.1737 300 2,000 740,000 0.0024 0.1762 0.120
8 0.037 3.9 0.1726 300 2,000 740,000 0.0024 0.1750 0.112
Ball valve 1 0.017 4 0.0850 300 2,000 740,000 0.0024 0.0874 0.069
(standard) 1.5 0.017 4 0.0842 300 2,000 740,000 0.0024 0.0866 0.063
2 0.017 4 0.0836 300 2,000 740,000 0.0024 0.0860 0.057
3 0.017 4 0.0828 300 2,000 740,000 0.0024 0.0852 0.054
4 0.017 4 0.0822 300 2,000 740,000 0.0024 0.0846 0.051
6 0.017 4 0.0814 300 2,000 740,000 0.0024 0.0838 0.045
8 0.017 4 0.0809 300 2,000 740,000 0.0024 0.0833 0.042
Example calculation Step C. Using Table 2, KGATE VALVE

As an example, consider a 2,000-gal, is 0.1807 and K90DEG-ELBOW is 0.4518;
(12A) vertical flat-bottom cylindrical vessel the value for KVALVES & FITTINGS is,
with a 7-ft inside diameter (D) that therefore, (0.1807 + 3 3 0.4518) or
And integrating between the initial initially contains 1,000 gal of liquid. 1.5361.
and the final values yields: The outlet nozzle is 2-in., schedule Step D. Summing up yields the fol-
40 (d = 2.067 in.), located as illus- lowing K portion:
trated in Figure 2. A 2-in. gate valve K = 0.5 + 1.5361 + 2.577 + 1
is mounted on the nozzle; the drain = 5.6131
(13)
line contains 20 ft of 2-in., sched- K1/2 = 2.369
Drain-time equation for a verti- ule-40 pipe and three 90-deg. elbows, Step E. From Equation (14A):
cal, cylindrical tank with a flat and the change in elevation (Z) is 3 hL1 = Z + hi
bottom. Clearing the minus sign ft (pipe length is included in the 20 = 3 + 3.47
and combining the constants gives ft). The draining time is found with = 6.47 ft
the equation for the drain time from the following steps: hL11/2 = 2.5436
a vertical cylindrical tank with a flat Step A. Because hi incorporates the Step F. From Equation (14B):
bottom (in minutes): entire contents of the tank, Equation hL2 = Z
(8) is re-arranged to solve for the value = 3 ft
of hi: hL21/2 = 1.732
hi = (4VCY) / (7.48D2) = 3.47 ft Step G. Using Equation (14), the esti-
(14) Step B. For the 20 ft of 2-in. pipe, mated drain time is 13.2 min.
For a flat bottom tank, note that: LPipe/DPipe is 20/0.17225 or 116.1. Note that when the bottom of the
When multiplied by the appropriate cylindrical tank is not flat, the deri-
hL1 = Z + hi (14A)
fAVE from Table 1 (0.0222), KPipe is vation of the drain time equation be-
hL2 = Z (14B) 2.577. comes more complicated.
AVERAGE RESISTANCE TO FLOW IN VALVES AND FITTINGS
he literature reports [6, 7] that the resistance to flow in a valve
T or a fitting should not be considered constant as had been

previously reported [5] but should be considered to vary with
Reynolds Number (NRe) according to [7]:
0.4000
0.3000
1 in.
1.5 in.
2 in.
3 in.
4 in.
6 in.
8 in.
Kf = (K1/NRe) + Ki [1 + (Kd/Dn0.3)] (B2-1)

There is a set of three constants K1, Ki and Kd for each specific valve 0.2000
Kf
or fitting. The table in Ref. 7 should be the source of the values be-
cause the constants have been updated from those given in Ref. 6. 0.1000
Note that (K1/NRe) is variable; the Ki [1 + (Kd/Dn0.3)] term is con-
stant for any given pipe size. As the influence of the variable part 0.0000
becomes small (approaches zero), Kf becomes equal to the constant. 200,000 400,000 600,000 800,000
An average value for Kf can be calculated by adding an average NRe
value of the variable part of the equation to the constant part.
0.08
The first plot in Figure 4 shows calculated values of Kf for vari-
ous sizes of a flow-through-tee, plotted as a function of NRe on 1 in. Power (1 in.)
0.06
arithmetic coordinates. The lowest value for NRe is 2,000 while
K1/NRe
the largest value is the estimated beginning of fully turbulent flow
from a Moody chart [5]. Note the sharp decrease in Kf for all 0.04
sizes at low NRe due to the variable part of the equation becom- y = 150x 1
ing less significant. 0.02
Inspection of the (K1/NRe) data for the flow-through-tee shows that
the value decreases by 0.0015 between 50,000 and 100,000 NRe; 0
it drops 0.001 between 100,000 and 300,000 NRe and 0.0003 0 100,000 200,000 300,000 400,000
between 300,000 and 740,000 NRe. Based on those differential NRe
data, no significant reduction occurs above 300,000 NRe. FIGURE 4. Resistance to low in a low-through tee (Kf, irst
The lower plot in Figure 4 shows K1/NRe for the flow-through- graph) decreases sharply for all sizes at low NRe because
tee as a function of NRe up to 300,000 NRe; K1 is 150. The the variable part of the equation (Kf/NRe, second graph) be-
superimposed Excel trendline confirms that the equation of the comes less signiicant
curve is y = 150x1.
The average value of K1/NRe can be calculated by determining is related to the type of fitting or valve, not to the size.
the area under the plot and dividing by the included range of The average value of Kf for any size flow-through tee is then
NRe. For the lower plot in Figure 4, the basic mathematics are: (K1/NRe)ave plus the constant related to that size.
After judging what should be the value for NRe2 for each fitting
and valve, (K1/NRe)ave was calculated for a flow-through tee,
90- and 45-deg. elbows, and a gate and a ball valve. After cal-
(B2-2) culating the constant part of Equation (B2-1), the average value
Integrating and expanding with values for NRe gives: for Kf was easy to determine.
Table 2 presents the applicable constants, the range of NRe
(K1/NRe)ave = [150 (ln 300,000 ln 2,000) ] = 0.0025 (B2-3) used and the average Kf value for each pipe size of the various
(300,0002,000) fittings and valves listed; the constant Kf value from the literature
Note that this average value applies to all pipe sizes because K1 [10] is also indicated for reference.
CONE BOTTOM der and a cone are different, so are FIGURE 5. Here,
the volume of
Figures 5 and 6 depict a vertical pro- the individual drain times. The total a partially illed
cess vessel comprised of an upper right drain time for the tank, therefore, is cone is illustrated
circular cylinder and a lower circular the sum of the times required to drain
right cone. This article assumes that both portions. Each time must be cal-
there is a liquid level in the upper por- culated separately.
tion, as shown, before draining begins. Cylindrical portion. For draining
D
While liquid is still in the upper the cylindrical portion, Equation (14) Rc Pt
part during draining, the liquid fills applies because the geometry is iden-
R
the cylinder to some height (h) and the tical to a flat bottom tank. But, the h hC
Z1
entire cone to height hC; the height of initial and final values for hL1 and hL2
liquid above the outlet nozzle located must be defined carefully: 1
hL
at the bottom of the cone is (h +hC).
hL1 = hi + hC + Z (14C) Z
Liquid drains from the outlet nozzle
(point 1) to some terminus (point 2) as hL2 = hC + Z (14D)
Z2
discussed above. The reader can reason
that hL = Z + h + hC and that Equa- Because the value for hi is related only 2
tion (4) is still valid for the cylinder. to the volume of the liquid in the cylin- Pt
During draining, the height of liquid drical portion, the volume in the cone
in the cylinder decreases, and the liquid must be subtracted from the total vol- lowing discussion can be adapted to a
surface descends into the cone; then both ume in the tank before calculating hi cone tank by itself, if appropriate.
the cross-sectional area and the height with Equation (15). The volume of liquid (gallons) con-
of the liquid in the cone decrease. Cone portion. Figure 5 depicts the tained in the circular right cone shown
Because the geometries of a cylin- cone bottom only. Note that the fol- in Figure 5 is given by the following:
NOMENCLATURE
a radius of a spherical hL loss of static pressure P2 pressure at outlet of VCY liquid volume in a cylin-
sector, ft due to fluid friction, ft drain pipeline, psi drical tank, gal
d inside diameter of outlet hL1 initial loss of static pres- Pt pressure above liquid x height of outlet nozzle
nozzle and drain sure due to fluid flow, ft in tank and at outlet of above flat bottom, ft
pipeline, in. hL2 final loss of static pres- drain pipeline, psi Z1 elevation of outlet noz-
D inside diameter of sure due to fluid flow, ft Q rate of liquid discharge, zle, ft
tank, ft K total resistance coeffi- gal/min Z2 elevation of outlet of
Dn nominal pipe size, in. cient* RC radius of a right circular drain pipeline, ft
Do outside diameter of Kd resistance coefficient in cone, ft Z change in elevation of
tank, ft 3-K method related to RD radius of spherical por- drain pipeline, ft
DPipe inside diameter of outlet diameter of valve or fit- tion of an ASME F&D cone angle, deg.
pipeline, ft ting, in.0.3 head, ft total time to drain a tank
f friction factor* Kf resistance coefficient for RS radius of sphere used to with a cone or a dish
fAVE average friction factor* valve or fitting* describe spherical sector, bottom, min
fT friction factor at fully de- Ki resistance coefficient in ft c time to drain a cone bot-
veloped turbulent flow* 3-K method related to v1 fluid velocity at inlet of tom, min
g acceleration due to grav- type of valve or fitting* outlet nozzle, ft/s B time to drain an ASME
ity, ft/s2 K1 resistance coefficient in v2 fluid velocity at outlet of F&D (dish) bottom, min
h height of liquid, ft 3-K method related to drain pipeline, ft/s f time to drain a flat bot-
hB depth of an ASME F&D NRe* vS depth of a spherical sec- tom tank or a cylinder,
head, ft LPipe length of drain pipeline, tor, ft min
hC height of liquid in a right ft VB liquid volume in a 1 density of liquid at inlet
circular cone, ft NRe Reynolds number* dished head, gal of outlet nozzle, lb/ft3
hi initial height of liquid in P1 pressure at inlet of outlet VC liquid volume in a cone, 2 density of liquid at outlet
cylindrical portion of a nozzle, psi gal of drain pipeline, lb/ft3
tank, ft * Dimensionless
VC = 7.48[(R2h)/3] (16) material balance for the cone gives the FIGURE 6.
Note that determining the radius of mathematical version with flow units Tanks with a
cone bottom
the liquid in the cone is a matter of of gal/min: are comprised
trigonometry: of an upper
R = h/(tan ) (17) right circular
The value of angle is a function of the cylinder and a
lower circular
construction of the cone so it remains right cone
constant; Equation (17), therefore, cor- (22) D
relates the height and radius of liquid Equation (22) can be rearranged into
in the cone during draining. a form that can easily be integrated: Pt
Liquid drains from the outlet nozzle
(point 1) to some terminus (point 2)
as discussed above. Again, the reader
can reason that hL = Z + h and that h
Equation (4) is still valid for the cone. (23)

Substituting Equation (17) into
hC
Equation (16) gives the following: Equation for a cone-bottom. Inte- Z1
grating Equation (23) between hL1
VC = 7.48h3/[3(tan )2] (18) hL
and hL2, clearing the minus sign, Z
1
The rate of volume reduction in the combining the constants and group-
cone during the draining process is ing items of like exponents gives the Z2
given by the first derivative of Equa- expression for the drain time from a
2
tion (18) with respect to time: cone bottom: Pt
of liquid. The tank inside diameter is

7 ft (D), the height of the bottom cone
(19)
is 3.5 ft (hC) and the bottom nozzle is 2
But hL = Z + h, so h = hL Z and: in., schedule 40 (d = 2.067 in.). A 2-in.
gate valve is mounted on the nozzle.
h2 = hL2 2hLZ + Z2 (20)
The drain line contains 20 ft of 2-in.
Substituting Equation (4) and Equa- (24) schedule-40 pipe and three 90-deg.
tion (20) into Equation (19) then gives: An example will show how the total elbows, and the change in elevation
drain time is calculated for a cone bot- (Z) is 3 ft (pipe length is included in
tom tank. the 20 ft). To determine the total drain
time, the calculations are:
(21)
Example calculation Step A. Using R = RC (which = D/2)
The 2,000 gal, cone-bottom tank and h = hC in Equation (16), the total
Putting together the pieces of the basic shown in Figure 6 contains 1,000 gal volume in the cone bottom is 336 gal.
Spherical
portion
FIGURE 7. An CL
ASME F&D (dish) s
bottom tank is co-
prised of an upper
D right circular cyl-
inder and a lower
Pt dish bottom
hB RD 2
Tangent line
h Rs Rs
DC
Cylindrical portion
(not included in
FIGURE 8. The surface and volume
ASME dish head is of head) FIGURE 9. Here, the geometry of a
Z1
composed of a central spherical sector is illustrated
1 spherical section bor-
hL dered by knuckle por-
hB
Z tions that provide the bordered by knuckle portions that
transition between the provide the transition between the
spherical shape and spherical shape and the cylindrical
Z2
the cylindrical shape shape of the vessel; the radius of the
of the vessel
2 spherical portion (RD) is approxi-
Pt mately equal to the inside diameter
Step B. The initial volume in the cylin- (dish) bottom. While liquid is still in of the tank (D) and the depth of the
drical portion is 1,000 336 or 664 gal. the upper part during draining, the dish to the tangent line (hB) is ap-
Step C. Using Equation (15): liquid fills the cylinder to some height proximately 0.169 D. Per the calcu-
hi = 2.307 ft (h) and the entire dish to height hB; lation in the box, Assuming dish is
Step D. The same K applies (as in the the height of liquid above the outlet spherical (p. 40), modeling the entire
previous, flat-bottom tank example nozzle is (h +hB). head shape with a spherical sector
calculation) Liquid drains from the outlet nozzle introduces only a small error into
K1/2 = 2.3692. (point 1) to some terminus (point 2) the draining theory.
Step E. For the cylinder: as discussed above. Once again, the Using the basic Equation (B3-1) (see
1. hL1 = hi + hC + Z reader can reason that hL = Z + h + Assuming dish is spherical, p. 40) with
= 2.307 + 3.5 + 3 = 8.807 ft hB and that Equation (4) is still valid vS = h and RS = D, the volume of liquid
hL11/2 = 2.5436 for the cylinder. (gal) contained in the partially filled
2. hL2 = hC + Z During draining, the height of liquid dish shown in Figure 10 is given by:
= 3.5 + 3 = 6.5 ft in the cylinder decreases, and the liquid VB = 7.48[(Dh2) (h3/3)] (25)
hL21/2 = 2.5495 surface descends into the dish; then both As with the other shapes, the rate of
3. Using Equation (14), f = 6.8 min the cross-sectional area and the height volume reduction in the dish during
Step F. For the cone: of the liquid in the dish decrease. the draining process is given by the
1. tan = hC/RC = 3.5/(7/2) = 1 Because the geometries of a cylin- first derivative of Equation (25) with
[(tan )2] = 1 der and the dish are different, so are respect to time:
2. hL1 = hC + Z = 3.5 + 3 = 6.5 ft the individual drain times. The total
hL1 2.5 = 107.717 drain time for the tank, therefore, is
hL11.5 = 16.572 the sum of the times required to drain (26)
hL10.5 = 2.5495 both portions. Each time must be cal- Liquid drains from the outlet nozzle
3. hL2 = Z = 3 ft culated separately. (point 1) to some terminus (point 2) as
hL22.5 = 15.588 Cylindrical portion. For draining discussed above. The reader can reason
hL21.5 = 5.196 the cylindrical portion, Equation (14) that hL = Z + h and that Equation (4)
hL20.5 = 1.732 applies because the geometry is iden- is still valid for the dish. Because hL =
4. Using Equation (24), c = 4.03 min tical to a flat bottom tank. But, the Z + h, the following are true:
Step G. Total drain time for the entire initial and final values for hL1 and hL2
tank is: must again be defined carefully: h = hL Z (27)
= f + c = 6.8 + 4.0 = 10.8 min hL1 = hi + hB + Z (14E) h2 = hL2 2hLZ + Z2 (28)
Calculating the drain time for a pro- hL2 = hB + Z (14F)
cess vessel with an ASME F&D (dish) Because the value for hi is related only Substituting Equation (4), Equation
bottom head requires a similar pro- to the volume of the liquid in the cylin- (27) and Equation (28) into Equation
cedure, but the time for draining drical portion, the volume in the dish (26) then gives:
the bottom head requires a different must be subtracted from the total vol-
mathematical expression. ume in the tank before calculating hi
with Equation (15).
ASME F&D (DISH) BOTTOM Dish portion. As Figure 8 (see As-
Figure 7 depicts a vertical process ves- suming dish is spherical, p. 40) (29)
sel comprised of an upper right circu- shows, an ASME F&D head is com- Putting together the pieces of the basic
lar cylinder and a lower ASME F&D posed of a central spherical section material balance for the dish gives the
ASSUMING DISH IS SPHERICAL
s Figure 8 [11] shows, the shape of an ASME F&D (dish) head is spherical up to the
Cover Story
A extremities where knuckle portions make the transition from sphere to the cylindrical
shape of the vessel shell. The radius of the spherical portion is the outside diameter
of the tank [12]. To simplify the mathematics of draining with an error of less than 5%,
the ASME F&D head can be considered a spherical segment as explained below.
FIGURE 10. The volume of the spherical segment with one base shown in Figure 9 is given by
Here, the volume
Equation (B3-1) [13]:
in a partially
illed dish is il- VB = (/3) vS2 (3RS vS) (B3-1)
lustrated
For an ASME F&D head, vS is approximately 0.169D [12]; RS can be approximated by
D the inside diameter of the tank because the thickness of the head is small by comparison.
Substituting these values into Equation (B3-1) and solving for VB gives:
VB = 0.08467D3, ft3 (B3-2)
Z1
1 hL
VB = 0.6333D3, gal (B3-3)
h
Z
hB Because the actual volume (in gallons) in a dish head is approximately 0.606D3 [12],
Z2
the error due to assuming that the head is a spherical sector is as follows:
%ERROR = [(0.6333/0.606) 1]100 = 4.51% (B3-4)
2
Pt
mathematical version with flow units Example calculation = 1.183 + 3 = 4.183 ft

of gal/min: An example will show how the total hL21/2 = 2.045 ft
drain time is calculated for a tank 3. Using Equation (14), f = 9.55 min
with a dish bottom. Step G. For the dish:
The 2,000 gal dished bottom tank 1. hL1 = hB + Z
shown in Figure 7 contains 1,000 gal = 1.183 + 3 = 4.183 ft
of liquid; the diameter is 7 ft (D) and hL12.5 = 35.787 ft
the bottom nozzle is 2-in., schedule 40 hL11.5 = 8.555 ft
(30) (d = 2.067 in.). A 2-in. gate valve is hL10.5 = 2.045
Equation (30) can be re-arranged into mounted on the nozzle. The drain line 2. hL2 = Z = 3 ft
a form that can easily be integrated: contains 20 ft of 2-in., schedule-40 hL22.5 = 15.588
pipe and three 90-deg. elbows. The hL21.5 = 5.196
change in elevation (Z) is 3 ft (pipe hL20.5 = 1.732
length is included in the 20 ft). The 3. Using Equation (32), B = 3.16 min
drain time is calculated by the follow- Step H. Total drain time for the entire
ing steps: tank is:
(31) Step A. The total volume in the dish is = f + B = 9.55 + 3.16 = 12.7 min
Equation for a dish-bottom. Inte- 0.606D3 (see Assuming dish is spheri- Edited by Rebekkah Marshall
grating Equation (31) between hL1 and cal, above) or 208 gal.
hL2, clearing the minus sign, combining Step B. The initial volume in the Acknowledgements
the constants and grouping items of cylindrical portion is 1,000 208 or Thanks to Professor Ron Darby, of
like exponents gives the expression for 792 gal. Texas A&M, for providing the table
the drain time from a dish: Step C. Per Equation (15), hi is 2.75 ft of 3-K constants from his book.
Step D. hB = 0.169D = 1.183 ft Thanks also to Van Zhao, process en-
Step E. The same K applies (from the gineer at IPS, for critically reviewing
flat bottom tank); so K1/2 = 2.3692 the manuscript.
Step F. For the cylinder:
1. hL1 = hi + hB + Z Author
= 2.75 + 1.183 + 3 = 6.933 ft Edward H. Steve (esteve41@
(32) hL11/2 = 2.633 ft comcast.net) is a chemical en-
gineer who works with com-
2. hL2 = hB + Z panies on an as-needed basis.
He has 46 years of design and
operating experience in the
chemical, chemical specialty,
References renewable energy, pharma-
ceutical chemical, pharma-
1. Foster, Thomas C., Time required to empty a 8. Serghides, T.K., Estimate friction factor accu- ceutical, electronics, consumer
vessel, Chem. Eng., May 4, 1981, p. 105. rately, Chem. Eng., Mar. 5, 1984, pp. 6364. goods and biotechnology in-
2. Crane Company, Flow of Fluids, Technical 9. Crane, op. cit., p. A-26. dustries. He is the author of
Paper 410, Stamford, CT, 1991, pp. 15. 17 other articles on unsteady state heat transfer
10. Crane, op. cit., p. A-27ff. in process vessels, fluid flow and solids storage.
3. op. cit., pp. 34. 11. Dimoplon, William, Jr., How to determine In addition to wide process engineering experi-
4. op. cit., pp. A-29. the geometry of pressure vessel heads, Hy- ence, Steve has management experience as COO,
5. op. cit., pp. 28. drocarbon Process., August 1974, adaptation department head, team leader and production
of Figure 2, p. 71. supervisor in large and small companies. He
6. Darby, Ron, Correlate Pressure Drop through has a B.Ch.E. degree from Cornell University, is
Fittings, Chem. Eng., July 1999, pp. 101104. 12. op. cit., p. 73.
a registered professional engineer in Pennsylva-
7. Darby, Ron, Chemical Engineering Fluid 13. Tuma, Jan J., Engineering Mathematics nia and New Jersey, is an emeritus member of
Dynamics, 2nd Ed., Marcel Dekker, New Handbook, McGraw-Hill, New York, 1970, p. AIChE and a member of Chemical Consultants
York, 2001, Table 7-3, pp. 210211. 30. Network (www.chemconsultants.org).

Feature Report Investigate
Dynamic Modeling for Model

Steam System Control
Dynamic modeling fills in FUNDAMENTAL INVESTIGATIVE Plan
QUESTIONS
the gaps of steady-state To understand a systems behavior, start by gathering as
modeling and provides a much information as possible. Ask fundamental questions,
such as these:
more complete, reliable 1. What units are the big users?
and efficient analysis

2. What units are the big producers?
3. How does steam demand change for different operating
Implement
scenarios?
4. Are there any equipment limitations?
Ali Bourji, David Ballow 5. What is the nameplate capacity of each major system
and Martha Choroszy component? FIGURE 1. An
WorleyParsons 6. Are there limitations to achieving nameplate capacity? effective control
7. Has the root cause of any limitation been determined? strategy can be bro-
ken down into four
O
ne of the most energy-intensive 8. In the case of commonly occurring upsets, do they have a stages
utilities for many facilities in pattern or connected event?
the chemical process industries
(CPI) is the steam system. Tra-
ditionally, steam-use optimization has endpoints providing a more complete tive exercise may still prove valuable
centered on efficient heat transfer and analysis. With potentially billions of for the complex. It is still necessary to
eliminating waste [1]. Further optimi- dollars in capital investment depend- draw on the knowledge of experienced
zation can involve a broader look at ing on a reliable supply of steam, operators who have run similar sys-
how steam supply and consumption employing dynamic modeling during tems in the past. Supplementing their
interact dynamically throughout a the design development of integrated knowledge and experience with the
large complex. This type of optimiza- systems is worth the extra effort. This appropriate process engineering and
tion often results in increased inter- article breaks down the task of setting modeling techniques will allow for suf-
connectivity and interdependency. up a control strategy into four basic ficiently accurate system emulation.
Many CPI facilities have a central steps (Figure 1).
steam-production area containing boil- Model
ers and boiler feedwater treatment, as Investigate In the typical workflow of modern
well as additional steam generators In order to properly control any sys- process design, a steady-state model
scattered throughout the facility (for tem, a thorough understanding of the is usually developed to facilitate
example in the petroleum refining interactions within the system (the the creation of utility balances and
sector there are ethylene and catalytic system behavior) is essential. Under- to study various operating cases.
cracking units). If a facility is built standing system behavior begins with A wide array of modeling software
in several stages, as is often the case, gathering as much information as pos- has been developed [2] and is in use
steam generating systems may be sible about a given process or facility. within the CPI. When choosing the
separated by considerable distances. Ask some fundamental questions, such platform for the steady-state model,
Over these distances, the stability of as those outlined in the box above. keep in mind the potential for run-
the integrated steam system could be For an existing operational facility, ning the model dynamically.
jeopardized by inappropriate control there is no better resource to answer Steady-state modeling is essential,
strategies. How should one go about these questions than the senior opera- but a plant will never truly achieve
setting up a control strategy and veri- tions staff. They have direct knowl- steady state. To achieve a reliable and
fying that it is stable and appropriate edge of how the system behaves in stable steam supply throughout the
for a particular complex? realtime during real upsets under real complex, the fully integrated steam
Steady-state modeling and steam conditions. Defining these upsets will system must be analyzed in a dy-
balances only show the endpoints of become an essential input to dynamic namic state to understand the prob-
system behavior. Dynamic model- model development. able interactions between the system
ing fills in the space between these For new facilities, this investiga- components. Operating facilities are
Source
3 Source
3 pipe User A User A
Source Source 1 pipe FC
1 piping piping out Source
Common 3 out User A User A Sink
Source header 1 Total production pipe out FV A
1 Source
2 piping Combined Common
Mix-
Pri source header Mix-101 To users A
Source Source 2 100 out 1
2 piping out Common
header
pipe 2
FIGURE 2. This example is used to demonstrate a steady- TEE-100 User B User B
pipe FC
state model flowsheet (Pri used in the figures stands for
primary) Common To
header User B User B Sink
users pipe out FV B
out 2 B
Master PC Source 3 FC
SP 300.0 psig SP 50000 lb/h
PV 298.7 psig PV 50000 lb/h
OP 24.94 % OP 50.00 %
OP 24.94 % Rate limiter 3
OP 24.94 % User A pipe out User A FC
Rate limiter 1
Source Temperature 474.8 F SP 1.000e+005 lb/h
PV value 24.94 $
3 FC Pressure 297.6 psig PV 9.973e+004 lb/h
OP value 4.985e+004 lb/h Master Mass flow 5.977e-004 lb/h OP 50.03 %
Rate limiter 1 PC Source
3 Source Total production
3 pipe Temperature 475.0 F User A User A
Source Source 1 Pressure 298.6 psig pipe FC
1 piping piping out Source Mass flow 1.497e-005 lb/h
Common 3 out User A User A Sink
Source header 1 Total production pipe out FV A
1 Source Source 2
2 piping piping out Combined Common User B FC
Mix- header Mix-101
100 Pri source To users A SP 5.000e+004 lb/h
Source out 1
2 PV 4.988e+004 lb/h
Common OP 24.84 %
header
Rate limiter 2 Combined Phi source pipe 2
Temperature 475.0 F TEE-100 User B User B
Pressure 298.7 psig pipe FC
Rate limiter 2
Mass flow 9.970e+004 lb/h Common
PV value 24.94 $ To User B User B Sink
OP value 4.985e+004 lb/h header users
out 2 pipe out FV B
B
User B pipe out
Temperature 475.0 F
FIGURE 3. A flowsheet that is ready for dynamic mode is illustrated here Pressure 298.5 psig
Mass flow 4.991e+004 lb/h
generally not able to risk a major steam header, while a third source sits gained from the operators, the design
shutdown in order to test system re- close to the process user areas. engineer must account for the time
sponses to the upsets of interest. The This same simulation flowsheet can factors involved in transitioning from
next best option is to model the sys- be adapted for dynamic evaluation by normal to alternate operation. For this
tem dynamically. The dynamic model adding some basic controls as shown example, users in Area B are reducing
becomes a testing platform on which in Figure 3. demand to reach the alternate operat-
control concepts can be proven and Using this source-sink model of a ing mode. Through consultation with
adjusted if necessary [3]. steam distribution header, some of the operators, it becomes clear that
Dynamic process simulations fill the aspects of the system behavior this demand reduction normally takes
the gap between different steady- can be explored. The system may have place over a 2-min period. Figure 4 is
state operating cases, showing a two design cases that result in differ- a graph of what this may look like in a
more complete picture of system be- ent steam balances. The steady-state dynamic simulation.
havior. Using the knowledge gained model gives a snapshot of what is Starting from a steady state cor-
during the investigative process, a happening when everything is stable. responding to normal operation, the
model can be constructed that will be Table 1 shows what these data may demand reduction begins at 120 sec-
useful for testing the system under look like. onds. The User B demand is ramped
changing conditions. Switching to a dynamic analysis steadily downward for the prescribed
Example. Suppose the system to be gives a more complete picture of the two minutes. The source-steam flow
modeled consisted of three sources and system behavior in the time between controllers initiate a correspond-
two users of steam. The steady-state the two operating cases. At this point, ing reduction in steam production
model flowsheet may look like Figure the previous consultation with op- to maintain the system balance.
2. In this example system, two sources erators who understand the system This production decrease is typically
of steam exist on one end of a main comes into play. Using the knowledge achieved through some type of master
TABLE 1. STEADY-STATE RESULTS FOR TWO OPERATING SCENARIOS
Feature Report
Name Normal operation Alternate operation
Pressure Mass Flow Pressure Mass Flow

pressure controller. The master pres- (psig) (lb/h) (psig) (lb/h)
sure controller senses the steam dis-
tribution-header pressure and drives Source 1 300.0 125,000 300.0 50,000
the steam producer to increase or Source 2 300.0 75,000 300.0 50,000
decrease production to maintain the
Source 3 299.6 50,000 300.3 50,000
desired header pressure.
A major limiting factor in controlling Total production 299.1 250,000 299.8 150,000
steam header pressure is the response
To users in A 298.0 100,000 298.7 100,000
time of the steam generating source.
These sources respond very slowly due To users in B 298.7 150,000 299.7 50,000
to the mass of water and steel that
must absorb and release energy to af-
fect a change in the system flow. This 120,000
Source 1
thermal inertia can cause differing 100,000 Mass flow, lb/h
response times on flow increases and
Mass flow, lb/h
80,000
decreases at different capacities.
In this example, the Source 1 and 60,000 Source 2
2 characteristics are such that their Mass flow, lb/h
40,000
response is limited to a rate of 10%
of total capacity per minute. Figure 20,000
User B pipe out
5 shows a plot of the pressure at the 0 Mass flow, lb/h
main sensing point for Sources 1
and 2. 0 100 200 300 400 500 600
Again starting from steady state Time, s
and introducing the disturbance at
120 seconds, the header pressure ini- FIGURE 4. The dynamic behavior of steam sources during transition, as discussed
in the example, is shown here
tially rises due to the slow response
time of Sources 1 and 2. The sluggish
340
nature of these steam sources also con-
tributes to the overcompensation and 320
severe drop in header pressure. The
Pressure, psig
300
sources are eventually able to compen-
sate for the change in steam demand, 280
Combined Pri
but a large oscillation has been expe- 260 source
rienced in the interim. These types of pressure, psig
240
oscillations can cause process upsets
throughout a large facility. Note that 220
this example is for illustrative pur- 200
poses only and some of this lag can be 0 100 200 300 400 500 600
attenuated with careful tuning. Time, s
A validation step is essential to ver-
ify the models ability to emulate the FIGURE 5. This plot shows the dynamic response of main header pressure as
system behavior. Typically, a model given in the example
review is performed involving key
personnel from engineering and oper- Once validated, the model will pro- magnitude can be made during the op-
ations departments. The information vide valuable insight into system be- eration of a facility. The magnitude of
gained during the investigative step havior and interactions. It is the high the change need only be greater than
regarding common upset events is degree of interconnectivity in facilities the noise band of the target dependent
particularly useful at this stage. Ide- that results in greater efficiencies, but variable. Proper planning and prepa-
ally, the model is put through a series can lead to unexpected interactions. A ration is essential for this type of test-
of known scenarios, and the result- well-constructed dynamic model can ing, since there is a risk of upsetting
ing predicted response is compared lead to the discovery of these interac- an operating unit. All test parameters
to the known response. Any required tions and will allow a facility time to must be documented and agreed upon
fine tuning can be implemented, and develop a plan for controlling the inte- prior to testing.
the model can be used for subsequent grated system.
analysis with a reasonable degree If the model is emulating an exist- Plan
of confidence. The model can also be ing system, step testing can be used to Using the developed and validated
used to predict system behavior under develop actual system behavior data. system model, a master control strat-
new conditions. Incremental changes of a tolerable egy can be developed. Using engineer-
MASTER CONTROL STRATEGY KEY CONSIDERATIONS
In assembling a preliminary control strategy for steam systems, the following key con-
siderations should be included:
1. How will the header pressure be measured and maintained?

2. Is it better to maintain a set point target at one position in the complex header be gained by rerunning the previous
system, or to maintain an average pressure based on multiple readings across model cases using the tuned model
the header? and planned control strategy. Perturb-
3. Should all boilers be fired symmetrically at the same load? ing this model using upsets from model
4. Should boilers be fired in groups with the same load selected for each boiler in development will show the effective-
a group? ness or ineffectiveness of the proposed
5. Are some boilers better left base loaded at a fixed firing rate? control scheme. Initial tuning param-
eters can be developed along with any
6. Are there any waste streams being fired?
adjustments to sensing locations and
7. What constraints need to be incorporated into the control strategy? final control-element characteristics
(such as control valve sizes). The dy-
namic model can then be used to pre-
ing judgment and insights gained steam users need to be shed in order dict reactions to more severe upsets
throughout the model development to recover from an upset scenario. that are not reasonable to attempt in
and testing, a preliminary control The input of experienced operations an operating unit.
strategy is assembled. Some key con- personnel is essential in developing
siderations in such a strategy include a ranking of the major steam users Implement
those shown in the box above. that can be shed. This ranking will Implementation of the control scheme
The control strategy will likely be allow the development of steam shed is the final step. All of the modeling,
a combination of traditional propor- actions resulting from steam-header checking and rechecking should re-
tional-integral-derivative (PID) con- pressure loss [3]. sult in confidence in the new master-
trollers and logic triggered actions. Once the preliminary control strat- control scheme and provide useful
Steam load shedding is an example egy is established, it can be incorpo- predictive data for implementation
of logic triggered actions. Load shed- rated into the dynamic model. Con- in a new facility or for navigating an
ding can be implemented if major fidence in the selected controls will existing facilitys management-of-
Need Tube Bundles or Heat Exchangers?
s ude
Tube Bundleof any existing bundle to incl.
Duplication materials and performance
dimensions,
gers
Heat Exchan or replacement exchangers
Design new
ication.
for your appl
Coils t or new.
Replacemen
1-800-339-7991
Available in stainless steel.
www.MultiThermCoils.com
Heat Transfer Fluids Industrial Coils HVAC Equipment
Feature Report
change (MOC) procedures. either hazards or operability. This is References

The planned scheme must first typically done within the framework 1. Jaber, David, McCoy, Gilbert A., and Hart,
be documented in all relevant en- of an established plant or project Fred L., Follow these Best Practices in
Steam System Management, Chem. Eng.
gineering documents. Piping and hazard-analysis procedure, such as Prog., December 2001.
instrument diagrams, process flow an MOC procedure or a hazard and
2. Currie, Jonathan, and others, Steam Util-
diagrams, control narratives and operability study (HAZOP). ity Systems are not Business as Usual for
instrument loop diagrams are ex- Prior to activating the new control Chemical Process Simulators, AIChE Ar-
chived Presentations, March 15, 2011.
amples of these documents. Once all scheme, all components, including the
documentation is in place, a thor- software components, must be tested 3. Bourji, Ali, Ballow, David, and Choroszy,
Martha, Find Benefits in Automating
ough review will take place to en- to ensure proper functionality. Boiler Systems, Hydrocarbon Proc., Octo-
sure nothing has been overlooked in Edited by Dorothy Lozowski ber 2011.
Authors
Ali Bourji is a senior techni- David Ballow is a principal Martha Choroszy is a chief
cal director at WorleyParsons process engineer at Worley- process engineer at Worley-
(6330 West Loop South, Bel- Parsons (6330 West Loop Parsons (6330 West Loop
laire, TX 77401; Email: ali. South, Bellaire, TX 77401; South, Bellaire, TX 77401;
bourji@worleyparsons.com; Phone: 713-407-5000) and is Phone: 713-407-5000). She
Phone: 713-407-5000). Bourji a professional engineer. He received a B.S.Ch.E. from
received his B.S.Ch.E. and received a B.S.Ch.E. from the Massachusetts Institute
M.S.Ch.E. from the Univer- Louisiana Tech University of Technology and an M.B.A.
sity of Houston and his Ph.D. and is a member of AIChE. from Tulane University. She
from Lamar University. He is a licensed professional en-
is a professional engineer gineer in Texas and a mem-
and a member of AIChE and ber of AIChE and NFPA. She
AFPM (formerly NPRA). Bourji is the author is the author of numerous publications, a re-
of numerous publications and serves on the cipient of Tulanes Allen Vorholt Award and has
Chemical Engineering Ph.D. Advisory Council served as a Blue Ribbon Panel Member to define
at Lamar University. the national agenda for the U.S. Core Combus-
Spencer_ACHEMA_Specials_Ad_7x4.875_051512:Layout 1 5/16/12 8:12 AM Page 1
tion Research Program.
In the process industry, Spencer applies more than 120 years of industry
air and gas handling equip- technology leadership to engineer, design and
ment must perform awlessly manufacture solutions for extreme air and gas
under very tough requirements: handling challenges. Our custom blowers and gas
Corrosive, toxic and other gases boosters are unique and engineered for their target
such as suldes, nitrogen, halogens, application. We fabricate from special metals and
acids, cyanides, hydrogen and ammonia utilize corrosion-resistant coatings, restrictive shaft
Temperatures to 1100 F (593 C) sealing and leak-tight designs.
Casing design pressures to 1000 psig (6895 kPa) Only Spencer offers the process industry more choices,
Inlet pressures to 500 psig (3447 kPa) more options and more experience in providing air
Differential pressures to 20 psig (138 kPa) and gas handling equipment for hot, high-pressure
Volumes to 30000 icfm (50977 m 3/hr) or corrosive gases.
Leak-tight performance
The Spencer Turbine Company 600 Day Hill Road, Windsor, CT 06095 USA 800-232-4321 860-688-8361 Fax 860-688-0098 www.spencerturbine.com
Visit us at ACHEMA 2012 - Stand D81 in Hall 9.0 in Frankfurt am Main, Germany, June 18-22.
MAGNETROL Do your high-pressure vessel environments get you steamed? Rely on
the Eclipse Model 705 for liquid level detection that delivers precise
ECLIPSE readings in saturated steam applications up to 2250 psi at 650F.

Our steam probe technology utilizes both a patented mechanical
steam target and patented rmware algorithms for continuous
MODEL 705 compensation control of the signal propagation delay through the
vapor space.
First in guided wave radar. The Eclipse Model 705 introduced guided wave radar technology to
Foremost in steam applications. industrial control applications and was the rst to pioneer steam
compensation measurement. Make it your foremost choice for high-
pressure performance.
When things get hot, depend on SIL 3 Certified Eclipse Model 705
and Magnetrol, the level control experts. www.magnetrol.com
1-800-624-8765 info@magnetrol.com
1-800-624-8765 info@magnetrol.com
Feature Report
Engineering Practice
Distillation: Avoid Problems

During Tower Startup
C3s to methyl
Practical procedures for Depropanizer
acetylene,
propadiene
1
both effective startup 22
converters
Condenser
and problem analysis 34

Reflux
drum
are discussed here for 38
39
a depropanizer that External

43
experienced downcomer C4's

62
Reboiler
seal loss
Condensate
stripper
bottoms
Andr Bernard To debutanizer From C3
NOVA Chemicals (Canada) Ltd. Deethanizer rerun tower
bottoms
A
variety of performance problems
FIGURE 1. Shown here is a schematic process low diagram of the depropanizer
can arise in distillation towers and its ancillaries
during startup. Many are caused
by equipment, hardware or pro- water, are also known to cause prob- are effective and the least invasive to
cess conditions. Hardware issues may lems during distillation, or in some process operations. Specifically, the use
be related to instrumentation, tower cases may result in pressure surges. of diagrams that define the tray-stabil-
internals or ancillaries. Instrumenta- Meanwhile, oxygen-freeing prac- ity limits and expected operating lines,
tion malfunctions are also common tices, and methodologies to intro- and support effective startup planning,
during startup and are predominantly duce the feed stream can lead to cold can help to demystify the analysis of
related to liquid level indicators, on- temperatures that are below the mini- poor tower performance.
line analysis of key components and in mum allowable temperature of the This article illustrates the use of
some cases, flowmeters. If not properly piping or tower material. Unstable these practical tools through a trouble-
compensated, flowmeters can mislead thermosyphon or reboiler stalling, shooting exercise with a depropanizer
the operator on streams operating caused by low loads or prema- tower at NOVA Chemicals Corunna
outside the normal design envelope. ture start of the reboiler, can also site. The Corunna site is an olefins
Vessel-isolation blinds, valve align- cause tower instability. Similarly, plant with a front-end crude unit
ments or unexpected obstructions in tray or packing hydraulic loads and a back-end aromatics unit. The
valves can also restrict or misdirect that are outside the equipment ca- plant has the flexibility to crack naph-
flows. Any of these issues could lead to pability can significantly impact tha and heavy atmospheric gas oil
hazardous conditions and ultimately fractionation efficiency by allowing (HAGO), produced by the crude unit.
process incidents. either flooding or operation It also has the capability of cracking
Anomalies in tower internals, such below turndown. natural gas liquids (NGLs).
as obstructions, mechanical damage Although some of these problems ul-
or poor installation can also cause timately require the process to be shut Depropanizer description
towers to perform poorly. Meanwhile, down so that the tower can be inspected The depropanizer is a 147-ft tower
issues related to process conditions internally, that should be the last re- with a diameter of 7.5 ft and a total of
could arise in all operations conducted sort. Good startup planning and pro- 62 trays. The first 33 trays (from the
from the point of shutdown to getting cedures can go a long way toward pre- top) are conventional two-pass sieve
the tower ready for startup, during venting operating problems in the first trays. Trays 34 to 62 are high-capacity
the startup itself, and ultimately dur- place. If problems do arise, appropriate trays. Heat is supplied to the bottom
ing steady-state operation. The pres- knowledge of the system is essential for reboiler by low-pressure steam. Pro-
ence of unexpected impurities, such as identifying the corrective actions that pylene refrigeration (3C) provides
Liquid reinjection CGC = Charge gas compressor NOMENCLATURE
Condensate stripper PFO = Pyrolysis fuel oil
RPG = Raw pyrolysis gasoline AE = Pipe-equivalent slot area, ft2
AD = Pipe-equivalent of downcomer
H2 CH 4
Acid C2 area, ft2
gas Fractionator
Ah = Hole area, ft2
Charge Chill aD = Downcomer area, ft2
Quench gas
Charge area
train C = Constant given by Equation (9)
dryer
gas Cv = Discharge coefficient, unitless
CGC Deq = Equivalent diameter, ft
PFO RPG Liquid Acetylene F1 = Factor, equivalent to unity
dryer
Water and
converters (F1 = 1) for most tower larger
condensed
Demethanizer than 4 ft in diameter [6]
hydrocarbons F2 = Factor given by Equation (11)
(1st three stages) g = Gravitational acceleration,
32.2 ft/s2
Condensed
Condensate Deethanizer K1 = Constant (0 for sieve deck)
hydrocarbons
(4th and 5th stages) Stripper K2 = Dry pressure drop coefficient,
in./(ft/s)2
KC = Number of velocity head lost
C3 + to C3+ to
depropanizer depropanizer
LD = Downcomer liquid rate, lb/h
lD = Downcomer length, ft
Nslot = Number of downcomer slots
FIGURE 2. This low diagram shows the liquid re-injection mode and condensate P1 = Lower tray pressure,
stripper operating mode in. of liquid
P2 = Upper tray pressure,
Rectifying section Stripping section in. of liquid
(2-pass sieve trays) (high-capacity trays) PD = Downcomer pressure drop, in.
of liquid
1 55
PT = Tray deck pressure drop, in. of
2
56 liquid
3 V = Total vapor rate, lb/h
4 57 VD = Downcomer vapor rate, lb/h
5 (VD)cr = Downcomer critical vapor rate,
58
6 lb/h
7 59 VT = Tray vapor rate, lb/h
8 = Pipe friction factor, unitless
9
60 n = Fraction of VD flowing to the
61
downcomer n
10
V = Vapor density, lb/ft3
11
62 L = Liquid density, lb/ft3
12
13
the depropanizer overhead product.
14
Feed to Tray 39 is cooled against cool-
15
15A ing water. Without cooling, the feed
Relative density would enter the tower with a signifi-
Relative density cant vapor fraction, which would shift
Startup condition
Normal rates the tray loads from the stripping to
the rectifying section.
FIGURE 3. This gamma scan of the depropanizer compares normal operating load
From a startup standpoint, the liq-
to the startup conditions
uid re-injection configuration (Figure
cooling to the overhead condenser. pressors 4th and 5th stage are dried 2), offers two advantages. First, given
As shown in Figure 1, the tower has in liquid dryers and can either be pro- the low feedrate during startup, this
two main feed points at Tray 34 and cessed by the condensate stripper or arrangement provides more load on
Tray 39. The feed is distributed by mixed with dry charge gas, upstream the deethanizer and depropanizer,
trough distributors at those locations. of the chill train (liquid re-injection which helps in meeting turndown. Sec-
A third minor feed point, which accom- path [1]). Re-injection of this liquid ond, the movement of material from
modates a small recycle stream from stream to the charge gas enhances the front to the back end of the plant is
the C3 rerun tower is located on Tray condensation in the first propylene sequential. As such, the depropanizer
22. The tower normally receives feed chiller. Process loads are then reduced does not see any feed until the deetha-
from the deethanizer bottoms at Tray in the chill train but increased in the nizer has been inventoried. The plant
34 and the condensate stripper bottoms deethanizer and depropanizer. is therefore normally started with the
at Tray 39. External C4s can be pro- In the liquid re-injection configu- liquid re-injection configuration.
cessed from time to time and are mixed ration, the depropanizer is entirely
with the condensate-stripper feed. The fed from the deethanizer bottom. Be- Depropanizer startup problems
olefins unit has the ability to run with cause of nozzle size and distributor Sequence of events. Feed from the
or without the condensate stripper. limitations the feed is split between deethanizer to the depropanizer
As shown in Figure 2, condensed hy- Tray 34 and Tray 39. Tray 34 feed is started ramping up roughly 15 h
drocarbons from the charge-gas com- cooled through cross exchange with after the charge gas compressor was
TABLE 1. PRE- AND POST-SHUTDOWN OPERATING CONDITIONS
Pre-shutdown Post-shutdown
Engineering Practice (at time of Gamma Scan)

Feed from the deethanizer, 112.8 105.6
thousand lb/h
Feed from the condensate 63.0 72.8
brought to minimum governor speed. stripper, thousand lb/h
Steam to the reboiler was started
External C4s, thousand lb/h 0 5 (off-spec C4s)
10 h later. The depropanizer was oper-
ated in the liquid re-injection mode for Reflux rate, thousand lb/h 98.9 94.3
the following 12 h. Throughout this pe- LP steam to reboiler, thousand 24.2 26.3
riod, several moves were made on the lb/h
reflux and reboil rate. Since these op- Tower pressure, psig 123 122
erations were unsuccessful in bringing Tower pressure drop (in. H2O) 111 112
the tower bottom within specification,
the operation mode was transitioned
TABLE 2. PROBLEM ANALYSIS
to the condensate stripper scheme.
Furthermore, roughly 5,000 lb/h of off- Deviation: Depropanizer bottom stream C3s outside specification
spec C4s from storage was fed to the Is Is not Differences Changes Probable
cause
depropanizer through the external
C4s feed point to help load the tower. What Object: Object: Feedrates Low
Depropanizer Deethanizer Properties rates in
The tower was still performing poorly bottom Process C3 area
and process engineering support was stream conditions
then requested by operations. Composi-
Depropanizer troubleshooting. Defects: Defects: tion
C3s outside Bottom Trays
Prior process engineering work [2] product spec- specifica-
done on startup conditions highlighted ification tion
the risks associated with operating
high-capacity trays below their mini- Where Depropanizer Depro- Tray type Low High capac-
mum liquid limit. There was concern stripping panizer Composi- rates in ity tray turn-
that the tray load might not be suf- section rectifying tion C3 area down not
section Hydraulic met
ficient to seal the downcomers. How- load
ever, an initial high-level review of the Temperature
operating conditions did not reveal Properties
anything abnormal. When Startup Pre-shut- Path to low- Low Stripping
As described in Table 1, the tower down rate opera- rates in section tray
operating conditions were not sig- tion C3 area downcomer
unseal
nificantly different from the pre-shut- Stripping
down ones. Plant data also suggested section tray
that the upper section was working weeping
fine, since reflux changes and over-
head composition were varying as ex- comer operation. Based on the work for pre-shutdown operation. As for
pected. The stripping section, however, done by Urbanski and others [3], it is the sieve tray, the startup conditions
was performing poorly. assumed that tray weeping cannot be showed loads slightly higher than pre-
Simulation work and a gamma scan determined by the gamma scan. shutdown.
on the tower were then conducted. The tower was simulated with in- Tray loading calculations were con-
The Operations Dept. was asked to puts reflecting operating conditions sistent with the gamma scan results,
maintain stable conditions, regardless sustained at the time of the scan. The which supported the conclusion that
of performance, for the duration re- intent of the simulation was first to the trays were not flooded but rather
quired to conduct the gamma scan on ensure that the trays were operating were operating at low rates. Some of
the tower. The intent of the scan was within their hydraulic capabilities. the key information gathered was
to determine if any mechanical anom- The operating point relative to flood- structured into a problem analysis ma-
alies were present inside the tower ing was calculated using the Kister trix, as shown in Table 2. The concept
and to assess the tray-loading profile. and Haas correlation [4] for the sieve of problem analysis is to look at what,
The gamma scan results (Figure 3) tray section. where and when the problem is and
indicated no mechanical anomalies and The operating point for the high- is not and to look at differences and
no sign of flooding. Vapor-liquid disen- capacity trays was plotted on the tray changes, as well. It was clear from
gagement looked better compared to a operating window obtained from the Table 2 that the main change was the
previous scan done at a normal plant tray vendor. The simulation results low feedrates in the C3 area. A review
rate. Many of the high-capacity trays estimated the sieve tray operation at of previous startups concluded that
showed a clear vapor space equivalent 7273% of flood, which compare to the plant had never been brought up
to the vapor space above the reboiler 6870% of flood for the pre-shutdown to steady-state conditions at such low
return and the bottom tray. Scanning operation. The high-capacity tray op- rates. A light feed slate similar to pre-
across the tray could not provide any erating points are shown on Figure 4 shutdown conditions explained the
information with regard to the down- and compared against loads calculated lower rates to the C3 and C4 area. This
A B C
Downcomer
Maximum vapor
Tray deck Tray deck
Vapor load
Minimum liquid Maximum liquid

Inlet weir
Outlet weir
Startup loads
Pre-
shutdown
loads Outlet weir
Minimum vapor Downcomer holes

Conventional tray Conventional tray
with outlet weir with inlet and High-capacity tray
Liquid load outlet weir with dynamic seal
FIGURE 4. This diagram shows the high-capacity trays oper- FIGURE 5. Typical downcomer arrangements for conventional
ating limits, with the pre-shutdown and startup operating points and high capacity trays are shown here. The downcomer posi-
tive seal is shown on (A) and (B), while the downcomer dy-
namic seal is shown on (C)
Conventional one-pass Typical high-capacity tray Pipe equiva- Equivalent Kc

sieve tray lent diameter fittings
DE Entrance 0.5
Vapor flow path DE 45 elbow 0.2
er DD 45 elbow 0.2
om
nc DD Straight lD/DD
w
Do length
Vapor DD Exit 1
flow path
Pipe equiva- Equivalent Kc

lent diameter fittings
DE Entrance 0.5
which will ensure a constant liquid
head regardlessStraight
D D of rates andwhether
lD/DD
Active area or not the tray length
deck is sealed. In the
DD of an outlet
absence Exit 1
weir (and inlet
FIGURE 6. These illustrations compare
the vapor low path across a conven-
tional, one-pass tray (left) and a typical
explained, to a certain degree, why difference that explains why the prob- high-capacity tray (right) with a pipe-
itting analogy for estimating the down-
this problem had never been experi- lem occurred in the stripping section comer pressure drop
enced before. and not in the rectifying section. As
The tray type and the path to low- shown on Figure 5, high-capacity tray weir), or if the outlet weir height is
rate operation were two other key downcomers differ from those of con- less than the downcomer clearance,
components to this analysis, which ventional trays in the way the down- the downcomer seal becomes dynamic.
led to the conclusion that the probable comer seals itself. In a high-capacity In this case, the two-pass sieve trays
cause was an unsealed downcomer or tray, liquid falls on the active area of have a downcomer design similar to
a tray weeping problem in the strip- the tray below through a number of the one described Figure 5A.
ping section. slots in the bottom of the downcomer. As indicated on the problem anal-
When a tray is turned down from Sufficient liquid flow is required to ysis summarized in Table 2, this
high to low rates, the downcomers maintain a positive liquid head over problem did not occur in the deetha-
and the tray deck are already sealed. the slots (this is a dynamic seal). nizer. The deethanizer tower is also
However, at the early stage of starting Insufficient liquid causes the down- equipped with high-capacity trays;
up a distillation tower, vapor tends comer to run empty, which opens however, the potential for under load-
to flow through the downcomers and up the slots. Vapor is then free to ing the deethanizer was recognized
liquid weeps down the holes on the flow upward through the slots of when evaluating startup conditions.
tray deck. To break this path, a good the downcomer. Startup material balances were devel-
balance between vapor and liquid In conventional trays, mechanical oped to ensure sufficient load on the
flowrates needs to be established, so barriers ensure a constant inventory deethanizer, especially the stripping
that sufficient vapor seals the tray of liquid in the downcomer. If the out- section. Feed pre-heat to the deetha-
deck and sufficient liquid seals the let weir height exceeds the clearance nizer was bypassed until reaching full
downcomers. As such, turndown con- of the downcomer, the liquid head in plant rates. Operators were also re-
ditions will differ between a tray being the downcomer cannot drop below the minded to maximize reflux.
brought from high to low rates, and a outlet weir height when the tray deck Performance of the deethanizer
tray brought from a cold startup. is sealed. tower was also carefully monitored
The tray type is another significant An inlet weir can also be present, throughout the startup as it is a key
Tray operating window
minimum liquid rate
Vapor rate, lb/h

Downcomer critical
vapor rate
element for bringing the ethylene FIGURE 7. This igure Tray operating window
shows the post-event minimum vapor rate
product within specification. analysis of a tray-stability
diagram Tray deck
Corrective actions seal point
The troubleshooting exercise de-
Liquid rate, lb/h
scribed above revealed that the high-
capacity trays downcomers were not
sealed. It was also believed that, since 1 2 3 4 5 6
a fair chunk of vapor was flowing
through the downcomers, not enough Gamma
was left to seal the tray deck. As a scan
result, poor vapor-liquid contact was

causing the lack of fractionation that
was observed.
Increasing the liquid load and forc-
ing it down the tower to seal the down-
comers was believed to be one reason-
able solution to this problem. The
action plan called for an increase of
offspec C4s rate from 5,000 to 25,000
lb/h, increasing reflux and reducing 0 10 20 30 40 50 60 70 80
the reboil rate for a few hours. The re- Time, h
duction in reboil rate was done to en- Feedrate from Reflux Feedrate from Reboil rate C3 analyzer
condensate rate deethanizer
sure that liquid would flow down the stripper
tower. The reboil rate would be re-es-
FIGURE 8. The trends of the key process variables are shown here for the depro-
tablished once the tower showed signs
panizer startup. Period 1, 2, 3, 4 and 6 show the C3 composition trending down. As
of recovery. The tower bottom C3 com- shown, steady conditions were maintained during Period 5 to enable a gamma scan
position met the specification within to be performed on the tower
the hour that followed the changes
described above. The pressure balance is provided by tween a one-pass sieve tray and a typi-
Equation (2): cal high-capacity tray downcomer with
Quantifying tray seal limits regard to the pipe-analogy concept. In
Use a tray stability diagram. The the high-capacity tray, vapor flows
(2)
analysis described above was able to upward from the active area, directly
determine the cause of the problem. For startup conditions, the pressure through the slots of the downcomer
However, the tray seal limits had drop across the tray can be assumed to (pipe entrance), then flows through
not been determined quantitatively. be equivalent to the tray dry pressure the downcomer (straight pipe length),
Rather, the action plan was based on drop, which is determined by a varia- and exits the downcomer (pipe exit).
intuition, and its success relied on tion of the orifice Equation (3): The conventional tray forces the
good problem analysis, and a little bit vapor flow to change direction twice
of luck. Tower stability during startup (2 x 45-deg pipe elbow) and therefore
has been discussed by Kister [4, 5] who causes more resistance to vapor flow
(3)
promotes the use of a startup stability than the high-capacity tray. In both
diagram. Such a stability diagram is For the sieve tray deck, the value of cases, the pressure drop through the
based on a liquid-vapor rate plot that K1 = 0 and K2 = 0.186/Cv2. straight length of the downcomer is in-
shows the tray-deck seal limit and The pressure drop for vapor flow- significant and therefore not included
downcomer critical velocity. ing up the downcomer is estimated by in the equation.
The downcomer critical velocity is modeling the downcomer as a pipe. The The multiple slots and number of
defined as the vapor velocity at which geometry of the different components downcomers on the high-capacity tray
liquids can no longer descend freely of the downcomer is converted into a add to the complexity of developing the
through the downcomer but become pipe-equivalent diameter through the downcomer pressure-drop relationship.
entrained by vapor instead. The vapor following expression: Knowing that the pressure drop across
flow distribution between the tray each downcomer is equal, the calcu-
deck and the downcomer must be un lation can then be limited to a single
derstood to establish those limits. The downcomer. The pressure drop calcula-
(4)
vapor balance across the tray can be tion was broken down by elements. For
described by Equation (1).* Figure 6 shows the differences be- the downcomer entrance, the pressure
* All terms are defined in the Nomenclature box
drop was established based on the di-
(1) on p. 49. mension of a single slot.
Period 1 and 2 Period 4 Period 6 Trays 44 to 54 Trays 55 to 62
Period 3 Period 5
44
55
Downcomer Transition zone
backup 45
56
Downcomer critical 46
Vapor rate, lb/h
vapor rate 57
47
58
Operating line Better
overlap 48
at time of scan 59
between
Minimum vapor rate normal 49
60
and
startup 50
61
Tray deck
seal point 51
62
Liquid rate, lb/h
!
52 Gap
C3s trending up between
53 normal
Downcomer and
backup 54 startup
Downcomer critical
Vapor rate, lb/h
vapor rate Relative density Relative density
Startup condition
Normal rates
Minimum vapor rate FIGURE 10. This gamma scan shows a suspected entrainment of liq-
uids on startup from the bottom trays to trays 45, 47, 48 and 49
Tray deck
seal point ADn. n can then be deter- the critical downcomer vapor velocity
Liquid rate, lb/h mined using Equation (6): limit. Figure 7 also includes the mini-
mum stable liquid and vapor rate ob-
FIGURE 9. This igure shows the oper- (6)
tained from the tray vendor.
ating data (of the critical vapor-rate and
tray seal-point) on the stability diagram The ratio of Equation (3) and Equa- Key process variables applied on
for the different periods described on tion (5) provides the relationship be- the depropanizer are plotted against
Figure 8. Uncorrected data (red dashed tween VT and VD. time (Figure 8). The tower pressure is
curves), and data corrected for 20% re- not plotted, as it remained relatively
duction in the perforation area (red solid
curves) are shown
constant throughout this period. For
(7) simplicity of presentation, the time
Assuming even distribution within scale starts at 0 hour just before the
one downcomer, the total downcomer C3 analyzer started reading.
vapor flow, VD, was divided by the (8) The plot is subdivided in time in-
total number of slots and multiplied terval periods, where Periods 1, 2, 3,
by factor 1, as described by Equation Where: 4 and 6 show the C3 composition in
(5A). Factor 1 represents the fraction the bottom of the depropanizer trend-
of VD flowing to a single downcomer. ing down. Period 5 represents the
AE represents the pipe-equivalent slot conditions sustained during the
area, based on the slot-equivalent di- (9) gamma scan.
ameter. The pressure drop from vapor Using plant data, the bottom tray
exiting the downcomer can be calcu- Using the value of VT, the tray-deck load was calculated from the tower
lated from Equation (5B). The total seal limit was determined from the bottom product and low-pressure (LP)
downcomer pressure drop can be ob- correlation in Ref. [4, 5]. The down- steam flowmeters. The actual bottom-
tained by the summation of Equations comer critical vapor rate was deter- tray vapor rate was estimated by
(5A) and (5B). mined by Equation (10). multiplying the ratio of the simulated
bottom-tray vapor to LP steam rate by
(5) the actual measured rate of LP steam
(10) to the reboiler. The liquid load of the
bottom tray was estimated by adding
F1 = 1 and F2 is given by: the above calculated vapor rate to the
actual tower bottoms flowrate.
(5a) The data were segregated by peri-
ods, as shown in Figure 8, and plotted
(11)
on two stability diagrams. The first
Where LD is assumed equal to L. diagram in Figure 9 shows the data
(5b) The stability diagram, as shown in selected for the time when the depro-
Figure 7, is built by plotting the total panizer bottom C3 composition was
Writing the above equations for each vapor and liquid rate corresponding to trending down and also includes the
downcomer will provide correspon- the seal deck limits established from gamma scan time interval. The bot-
dence between the fraction of VD (ex- Prince and Chans correlation. The tom diagram plots the data for which
pressed by n, where n = downcomer total vapor and liquid rate correspond- the depropanizers bottom C3 composi-
number) and the pipe-equivalent area ing to Equation (10) and (11) provides tion was trending up.
The downcomer critical vapor-rate

limit and tray-deck seal point previ-
ously calculated are illustrated by the
Below downcomer Within stability
red dashed line on Figures 8 and 9. backup zone
Note that those limits were calculated
with the assumption of clean trays.
However, this tower is known to foul, 0 5 10 15 20 25 30
especially in the bottom section. The Time, h
tower had been in service for more Feedrate from Reflux Feedrate from Reboil rate C3 analyzer
than three years and this startup was condensate rate deethanizer
stripper
the result of an unplanned outage.
To account for fouling, the total FIGURE 11. The historic trends of key process variables for the depropanizer
perforation area on the tray deck (Ah startup are shown here for the subsequent startup
in Equation (3) was reduced until
the stability limits aligned with the in liquid-reinjection mode up to the is intended to feed the depropanizer
depropanizers bottom C3 composition end of Period 3, as shown on Figure 8. at Tray 39. To avoid dilution and ben-
behavior. This exercise suggested that Near the end of Period 3, the tower op- efit from the pre-fractionation work
roughly 20% of the perforated area eration mode was transitioned to the done by the condensate stripper, the
was plugged. This moves the stability condensate stripper configuration. deethanizer bottoms must feed the
limits down (see the solid red lines). While the tower was operated in depropanizer at Tray 34 only. If not
Note that as those limits are moving, liquid-reinjection mode, the operat- done properly, the transition of the
so will jet flood. As a result, the trays ing points, as shown on Figure 9, were feed could upset the tower and cause
are expected to flood prematurely. (In spread on each side of the downcomer the downcomer to go dry.
other words, if the lower operating backup limit. Most of the operating Experience demonstrated that
limit is lower, then the jet flood limit data falls within the stable region feeding the depropanizer to a single
would also be lower; under these condi- for Period 1, 2 and 3 and the tower feed point when operating in liquid-
tions, if the tray were pushed, it would C3 composition trends downward. reinjection mode can cause the vapor
flood at a lower load than expected). The reduction in reflux and reboil rate to exceed the system limit at the
Assuming clean downcomers, the min- rates near the end of period 2 causes feed location. It is suspected that the
imum liquid load defined by the ven- the C3 composition to trend up again. deethanizer stream feeding at Tray 39
dor operating window should remain This transition aligns with the operat- was re-directed to Tray 34 before the
unchanged. This limit is identified on ing points suddenly falling below the condensate stripper started to offload
Figure 9 as downcomer backup and is downcomer backup limit. Similarly, the deethanizer. As such, the full flow
defined by the liquid rate in the down- the increase of reflux and reboil rates would have gone to Tray 34, causing
comer that ensures a sufficient liquid at the beginning of Period 3 brings significant vapor entrainment and de-
level over each downcomer slot. the operating points above the backup priving liquid on the trays below the
A transition zone for C3 composi- limit, which is also associated with a feed point.
tion has been identified on the plot, in drop of C3s. The above suspicion is supported
which the trend was found to go either The operating point ramped from by the liquid level in the tower sump,
way. The minimum vapor rate defined the backup limit to slightly above the which dropped from 76 to 40% over a
by the tray operating window should, minimum vapor rate limit, and stayed one-hour period. A spike in the over-
in theory, move down if the perforation within the stable region for more than head product flow, which is controlled
area is reduced. However, this limit two hours. It is believed that the tray from the reflux drum level in a level
was found to not play a major role in sealed itself during that period. Be- to the flow-cascade loop, also supports
this event and data were insufficient cause the tray was sealed, the critical this suspicion. The transition matches
for evaluating the change. A drop sim- vapor rate limit of the downcomer no the time at which the C3 composition
ilar to the seal point of the tray deck longer applied and the tower should spiked up and then started dropping
would be the best estimate. have recovered efficiency. Proper ad- again in Period 3, just before the first
Except for the critical vapor limit of justment of reflux and reboil rates at pounds of material from the conden-
the downcomer, all other limits shown that stage should have been all that sate stripper were fed to the depro-
on Figure 9 always apply, regardless of was required to bring the bottom panizer. At this point, the downcomers
the operating mode. However, the criti- stream within its C3 specification. of the high-capacity trays are assumed
cal vapor limit of the downcomer only However, as the C3 composition was to be relatively dry with the operat-
applies during startup. Vapor is forced trending down, the operation mode ing point above the critical vapor-rate
to flow across the tray deck once a suf- was transitioned to the condensate- limit of the downcomer. The only way
ficient amount of liquid seals the down- stripper scheme. Initially in the tran- to re-seal the downcomer was to drop
comer. The max vapor rate then be- sition, the deethanizer bottoms fed the the operating point back into the sta-
comes limited by the onset of jet flood. depropanizer at Tray 34 and Tray 39. ble area until the downcomer sealed
Note that the tower was operated The bottom of the condensate stripper itself. At this point, process conditions
could be re-established for a stable sitioned to condensate stripper mode The cluster of operating points plot-
and on specification operation. once stable. Figure 11 shows the key ted on the stability diagram shows
As shown on Figure 8, operation process variable progression over a normal load progression. Initially,
was kept relatively stable while a time, and Figure 12 provides the op- vapor and liquid flows through both
gamma scan was being performed on erating points and expected operating the holes of the tray deck and the
the tower (Period 5). The cluster of line. The key process variables on Fig- downcomers resulting in poor
data representing this period is right ure 11 progress in a more controlled fractionation. Then, as feedrates are
on the critical vapor-rate limit. This fashion than those observed in the increased, vapor and liquid traffic in-
suggests that the downcomer was not previous startup (Figure 8). creases in the tower. A liquid level is
sealed but operated close to the condi-
tions that were required to seal it.
The extent of liquid entrainment is
limited and cannot be easily identi-
fied on the scan. Figure 10 compares Thermal Processing Solutions for High Quality Products.
the gamma scan between Trays 44 Product uniformity, efficiency, durability. Bhler AeroDryTM
to 54 and to that for the region from conveyor and fluid bed dryers provide these critical elements to
Trays 55 to 62. A larger gap exists fine chemical and polymer processors around the world.
when comparing the startup and nor-
mal rate scan on Tray 55 to 62, which
suggests lower froth height with the
startup condition.
The normal and startup gamma
scans overlap better on Trays 45, 47, Buhler Aeroglide, 100 Aeroglide Drive, Cary NC 27511 USA, Tel +1 919 851 2000, Fax +1 919 851 6029
48 and 49, suggesting a potential liq- aeroglide.sales@buhlergroup.com, www.aeroglide.com/chemicals
uid backup from the lower trays at

the startup condition. Given the lower
rates, the entrained liquid might not
show signs of flooding but might cause
an internal recirculating loop to form
inside the tower.
Figure 8 shows that a small reduc-
tion in reboiler duty and a small in-
crease in reflux kicked off a huge drop
in the tower bottoms C3 composition.
The reboil rate was further reduced
one hour later, but the tower down-
comers had already sealed themselves.
This confirms that the conditions sus-
tained during the gamma scan were
relatively close to being within the
stability zone. As shown on Figure 9,
the cluster of operating points is well
within the stable zone for Period 6.
Subsequent startup
An unplanned outage occurred within
a few weeks from the above startup. Visit us at ACHEMA
Again, during this period, no work or Booth C20 Hall 6
18 - 22 June
vessel entry was done on the depro-
panizer. The same startup procedure
and feed slates were followed again on
the plant restart. However, additional
steps were added on the procedure to
ensure feed cooling and reflux maxi-
mization on the depropanizer.
Proper feed locations and transi- Innovations for a better world.
tion between operating modes was
re-emphasized. The tower was started
on liquid-reinjection mode and tran-
Downcomer Transition zone
backup Operating line
Engineering Practice Downcomer critical
Vapor rate, lb/h

vapor rate
eventually established in the dowcom- initially attributed to

ers and seals them forcing vapor to the low feedrates in the Minimum vapor rate
flow across the tray deck. Vapor flow- C3 area. However, by the
ing across the holes of the tray deck time the depropanizer was Tray deck
provides sufficient pressure to prevent started up, feed rates were seal point
Liquid rate, lb/h
liquid from falling through the holes. ramped up to planned
At that point the tray is considered production rates, which FIGURE 12. This igure shows the operating data on
sealed and within the stability zone. were low but similar to the stability diagram for the subsequent startup
By following this path, the critical pre-shutdown levels. The
vapor-rate limit for the downcomer tower could not fractionate properly the stable zone, the downcomers criti-
becomes irrelevant. as those rates were met. Intuition sug- cal vapor-rate limit should become ir-
Note how well the operating points gested that even with the operating relevant, as the downcomer is already
follow the simulated operating line for point is within the vendors tray-oper- sealed when crossing this limit. If the
loads above the downcomer backup. ating window the downcomer was tower load is quickly brought up above
The cluster of data is more sparse and still unsealed. the downcomers critical vapor veloc-
does not line up as well with the op- The theory at the time relied on the ity, the downcomer might not seal it-
erating line at loads below the down- path to low rates on the tray. Estab- self and liquid would be entrained out
comer backup limit. This makes sense lishing the tray-stability diagram clar- of the downcomer.
because the tower loses efficiency ified what had actually happened. The The most effective way to correct
when operated below its downcomer low liquid limit identified as down- this problem is to move the operating
backup limit. comer backup will apply, whether the point down within the stability zone.
tray is brought to that limit from high The problems encountered during the
Analysis to low, or from low to high loads. If the first startup are not attributed to feed
The poor performance of the depro- tray load progresses smoothly from rates but rather to the feed-lineup se-
panizer during the first startup was below the downcomer limit through quence during the transition to the
Tower inspection
More than two years after this inci-
dent, the depropanizer was opened
and inspected during a scheduled
plant turnaround. The inspection re-
vealed no mechanical anomalies. The
FIGURE 13. Shown here is photographic proof of the reduced effective hole diam-
sieve trays in the rectifying section
eter on the depropanizers high-capacity trays located in the stripping section
were found to be clean.
condensate-stripper operating mode. until the condensate stripper bot- However, in the stripping section,
Plant data suggest that the downcom- tom stream is fully operational. This a thin layer of polymer was found on
ers were sealed prior to the transition. will temporarily affect the tower ef- the surface of the tray. The polymer
An inappropriate feed-lineup sequence ficiency, but will ensure a smooth was hard and strongly bonded to the
is believed to have caused significant transition and prevent unsealing metal surface (Figure 13), coating the
liquid entrainment at the feed point, the downcomers. circumference of the holes and reduc-
which caused the downcomers of the The deethanizer is also equipped ing each holes effective area.
trays below that feed point to empty with high-capacity trays. Process work The post-event analyses described
out. At that time, the operating point done around startup conditions high- earlier suggested a 20% reduction of
was above the critical vapor rate, and lighted conditions required to satisfy the perforation area. This represents
tray stability could only be re-estab- the minimum liquid limit on the ven- a reduction in diameter of around 1/16
lished by reducing the tray load. The dor-specified tray operating window. in. for 1/2-in. holes, or equivalent to a
deethanizer bottom stream, which The tower load ramped up smoothly layer of approximately 1/32 in. cover-
feeds the depropanizer at the same lo- from below the minimum liquid limit ing the circumference of each hole. The
cation as the condensate stripper bot- to a point within the tray window. As polymer was scraped off a small area
tom stream, should not be switched to such, the downcomers critical vapor of the tray deck to highlight the poly-
the other deethanizer bottom stream rate limit has never been a concern. mer layer covering the circumference
PLASTIC CONTROL VALVES FOR

ALL YOUR CORROSIVE APPLICATIONS
Collins plastic control valves are
highly responsive control valves
designed for use with corrosive
media and/or corrosive atmos-
pheres.
Collins valves feature all-plastic
construction with bodies in PVDF,
PP, PVC and Halar in various body
styles from 1/2" - 2" with Globe,
Angle or Corner configurations and
many trim sizes and materials.
Valves may be furnished without
positioner for ON-OFF applications.
Call for more information on our
plastic control valves.
P.O. Box 938 Angleton, TX 77516

Tel. (979) 849-8266 www.collinsinst.com
of the holes, which is illustrated on the in fractionation. drop and poor fractionation, is a strong
left side of Figure 13. The un-scraped However, a reduction or loss of frac- indicator of unsealed downcomers.
area in the same picture would sug- tionation itself, even though symptom- The use of a tray-stability diagram
gest little fouling at first sight. How- atic, is not sufficient to conclude that a could replace the need for a gamma
ever, the polymer coating over the tray loss of downcomer seal has occurred. scan. However, as demonstrated with
also covered the circumference of all Flooding will also cause a significant the depropanizer example, certain
the holes with a layer thickness more reduction in fractionation. These two conditions like fouling could mislead
or less similar to the one displayed on operational anomalies can be distin- the investigators, where a gamma
the scraped area. The fouling was more guished by differences in tower pres- scan would provide the missing link
severe on some trays, as shown on the sure drop. In general, a loss of down- for proper diagnosis.
right-end side of Figure 13. On aver- comer seal will be associated with low In summary, the loss of a downcomer
age most of the trays had a reduction tower pressure drop, while high pres- seal is very likely if:
in hole area of approximately 20%. sure drop is indicative of flooding. Poor or no fractionation is observed
The combination of poor fraction- The tower has low pressure drop
Downcomer seal-loss symptoms ation and low pressure drop suggests Operating points are outside the
When downcomers become unsealed, unsealed downcomers but could also tray-stability diagram, and
a significant portion of the vapor flows be the result of mechanical anoma- The gamma scan is showing little to
through the downcomer and bypasses lies, such as tray manways left open no froth and doesnt show signs of
the active area of the tray. Depending or damaged tray panels. Gamma scan any mechanical anomalies
on the extent, there might not be suf- of the tower will help in ruling out me-
ficient vapor flowing across the tray chanical anomalies and will provide Re-establish a downcomer seal
deck to prevent weeping or dumping additional information with regard to It is one thing to recognize unsealed
of liquids. As such, little contact oc- flooding. For instance, a scan showing downcomers, but quite another to im-
curs between vapor and liquid, which very little froth and no mechanical plement a suitable remedy. Any situ-
is evidenced by a significant reduction anomalies, along with low pressure ation where one tower is incapable of

meeting product specifications puts a violated. Operation below the down- from the stability limits, allowing for
high level of stress on the engineering comer backup limit requires an in- proper direction in the magnitude of
decision makers. Even if the diagnosis crease in tray load to ensure a proper the change required for sealing the
is accurate, plant management can downcomer seal. This can be accom- downcomers. The absence of a stabil-
easily lose faith if the remedy does plished either by increasing through- ity diagram leaves the troubleshooter
not provide positive results in a timely put or by false loading the tower with to a trial-and-error approach, which
fashion. This leads to further trouble- reflux and reboil. On the opposite could become time-consuming. In
shooting and eventually shutdown end, operation above the downcomers such case, one approach is to pro-
and tower entry, once all options have critical vapor rate requires a reduc- ceed with a tower slump followed by
been exhausted. tion in load to reseal the downcomer. a smooth transition to loads histori-
The tray-stability diagram is a This is accomplished by reducing cally demonstrated. This should re-
powerful tool that not only helps to throughput or by a temporary slump establish tray efficiency.
diagnose a problem, but also reveals of the tower. The stability diagram Edited by Suzanne Shelley
which one of the limitations has been also helps to quantify the deviation
Author
Andr Bernard is a process
References 4. Kister, H.Z., Distillation Design, McGraw- engineer with NOVA Chemi-
Hill, 1992. cals (Canada) Ltd. (Email: ber-
1. Bernard, A., and R. Hayden, Planning and nara@novachem.com; Phone:
Designing the Modernization of the Recov- 5. Kister, H.Z., When tower startup has prob- 519-862-2911 ext. 2350). He
ery Area of a Flexible Cracker, AIChE Spring lems, Hydrocarbon Proc., February 1979. has more than 20 years of ex-
Meeting, Ethylene Producers Conference, 6. Kister, H.Z., Distillation Operation, perience in plant operations
April 2004, New Orleans, La. McGraw-Hill, 1990. and process design. He holds
2. Bernard, A., Post-revamp startup planning 7. Kister, H.Z., Distillation Troubleshooting, B.S.Ch.E. and M.S.Ch.E. de-
and support, Petroleum Tech Quarterly, Q4 Wiley-Interscience, 2006. grees from lcole Polytech-
2007. nique de Montral in Canada.
8. Summers, D,R., Performance diagrams All He is a member of the Ameri-
3. Urbanski, N., and others Gamma Scanning Your Tray Hydraulics in One Place, Annual can Institute of Chemical Engineers, and regis-
a Column Containing Closely Spaced Trays, Meeting AIChE 2004. tered professional engineer in the provinces of
Annual Meeting AIChE 1999, Dallas, Tex. Ontario and Qubec in Canada.
Feature Report
CFD Analysis of Heat

Transfer From Flares Flare tip 1
A way to obtain conservative estimates
for the temperatures at the support
structures of a flare system
Z
400 m Y X
Tushar Bhad, Sumanta Sarkar and 00 m
3
Arvind Kaushik
Hydrocarbon IC, Larsen & Toubro Ltd.
Inlet
145 m
Outlet
A
gas flare is an elevated vertical Flare boom-1
conveyance found accompany- Bridge-1
ing oil wells, gas wells, drilling Bridge-2
Flare tip 3
rigs, petroleum refineries, chem- Flare boom-2 Flare tip 2
ical plants, natural gas plants and so
on. Although modern flare systems FIGURE 1. This diagram
are specifically designed to reduce shows the computational
the thermal radiation, pollution and domain used for the CFD
acoustic impact of a flare, a consider- analysis presented in the
text. A close up of the three
able amount of radiation is neverthe- flares is also shown
less emitted by an operational flare as
a result of burning large quantities of
combustible gases. The emitted radia-
tion increases the temperature of the combustible gases. Therefore, correct ages are available for predicting the
flare support structure and nearby estimation of the predicted tempera- radiation intensity around a flare, only
structures. Therefore, it is essential to ture is very difficult unless a detailed CFD takes account of the geometrical
correctly estimate heat transfer from mathematical modeling of the entire aspects, process variables, ambient air
the flares to the structures when de- system is carried out. direction and temperature, combus-
signing structures, selecting their ma- Computational fluid dynamics tion reactions and all modes of heat
terials of construction (MoC), selecting (CFD) is the best tool to model such a transfer in a 3D domain to accurately
protective paints and so on. system, incorporating all of the com- predict temperature of structures as-
Flare vendors sometimes provide plexities to predict how flares will sociated with flare systems, and thus
temperature data on structures vis-- perform under realistic operating con- eliminates the uncertainties associ-
vis distances from the flare tip based ditions with respect to different wind ated with designing those structures.
on predictions from their proprietary speed and direction. This is generally In the current study, a comprehen-
software, experimental data or cor- not possible with less-sophisticated sive CFD analysis combining the ef-
relations. In most of the cases, these software packages. fects of fluid flow, combustion and
predictions are based on two-dimen- This article presents a CFD analy- heat transfer including radiation
sional (2D) planes, and detailed tem- sis for predicting the temperatures has been carried out for an off-
perature data on three-dimensional of neighboring structures of flares. shore oil-and-gas process complex
(3D) geometries of the structures are Designing structures associated with having multiple flares, handling dif-
not available. flares is traditionally done based on ferent gas compositions and mass
In reality, the temperature of a flare industry practices. However, this may flowrates. The adopted methodology
support structure and the surround- lead to over- or under-designing of the is generic in nature and applicable to
ing structures depends on several structures depending on the antici- any flare system that may be present
factors, such as the ambient air veloc- pated temperature of the structures in any plant in the chemical process
ity and direction, the geometry of the when flares are under full load opera- industries (CPI).
flare tip and the composition of the tion. Although several software pack- Four cases were studied for four
a. Case I b. Case II
FIGURE 2. The
influence of the
wind direction
and velocity can
be seen in the
temperature path
lines for the four
c. Case III d. Case IV cases discussed
in the text
different ambient conditions involv- the combustible components of the dif- ploys two partial differential equa-
ing two wind directions and two wind ferent gases were converted to equiva- tions to estimate the velocity length
speeds to find out the maximum tem- lent methane and a single-step meth- scales of turbulence:
perature of the structures under full- ane-combustion reaction (CH4 + 2O2 =

load operation of flares. Steady-state CO2 + 2H2O) was modeled using eddy
t
( k ) +
xj
u j k( )
heat-transfer analyses were carried dissipation model. Radiation was mod-
out using a general-purpose, commer- eled using the P1 model. The ideal gas ( l + t ) k (3)
cial CFD code. To take care of the ef- law is used to determine density as a = P +
x j k x j
fects of convective and radiative heat function of temperature. Heat trans-
transfer from flares to the structures, fer from the structural members to

combustion and radiation were also
modeled. All of the combustible com-
the ambient is modeled by providing
a wall heat-transfer coefficient and t
( ) +
xj
(
u j )
ponents of the different gases were ambient temperature. Four different
converted to equivalent methane, and cases were studied involving two wind P 2 ( l + t )
= C 1 C 2 +
a single-step methane-oxidation reac- directions and two wind speeds. k k x j k x j
tion was modeled to limit the number
of species present in the domain. The Mathematical model (4)
maximum temperature of the flames Gas phase equations. The steady- In the above two equations, P repre-
was predicted to be around 1,900C. state continuity and momentum equa- sents the production term given by
Also, it will be shown that even at tion of the gas phase are given as Equation (5).
full load operation and for the most Equations (1) and (2). The source term,
adverse ambient conditions, tempera- Sp, results from combustion. The com- u u j 2 U m ij u j 2
P = t i + k ij
ture for the support structures and ponent of velocity in coordinate direc- x j xi 3 xm x j 3
the connecting bridges would be well tion x is given in Equation (2), which
within the maximum allowable limit includes pressure, gravitational force (5)
of structural steel. (buoyancy effects), and the general- The energy equation used to solve for
ized source term. Equations for the y enthalpy is given by Equation (6). The
Analysis approach and z components are similar. source term, Sh, in the energy equa-
In the current study, CFD analyses tion includes combustion and radia-
are carried out for an offshore oil-
xi
( u i ) = S p tion heat-transfer rates:
and-gas process complex having three (1)
h
flares. These flares are disposed to at-
xi
( i h ) = h
xi xi
+ Sh
mosphere through tripods. The 3D do- p ij (6)
main are comprised of the two flare tri-
xj
( )
ui u j = +
xi c j
+ gi + Fi + S p
pods and the interconnecting bridges. Owing to a higher temperature of the
Steady-state heat-transfer analyses (2) flame, radiation is the predominant
were carried out using a general- mode of heat transfer from the flame
purpose, commercial CFD code con- Model for turbulence. The model to the structures. In the current model-
sidering a rectangular computational employed in the present simulation ing, radiation has been modeled using
domain. Although the three flares are is the standard k- model proposed a commercial code. In the commercial
supposed to burn different gases, all by Launder and Spalding. This em- radiation model, radiation flux (qr) is
FIGURE 3. a. Case I b. Case II

Shown here (1,200C) (627C)
are iso-surface
plots for the four
cases. For Case I
(iso-temperature
1,200C) repre-
sents the flame
shape. Those for
Cases IIIV (iso-
surface for 627C)
represent the di-
rection and spread
of the fluegas
plume c. Case III d. Case IV
(627C) (627C)
defined by Equation (7), as follows: product species, YR is the mass frac- Boundary conditions
tion of a particular reactant, A is an The following boundary conditions
qr = aG 4 an 2 T 4
(7) empirical constant equal to 4.0 and B were used for performing the CFD
is an empirical constant equal to 0.5. analyses:
Where G is the incident radiation, a In Equations (8) and (9), the chemi- 1. The mass-flow inlet boundary con-
is the absorption coefficient, n is the cal reaction rate is governed by the dition was used at the air inlet cor-
refractive index of the medium and large-eddy mixing time scale, k/. responding to air velocity of 15 knots
is the Stefan-Boltzmann constant. Combustion proceeds whenever tur- (7.6 m/s).
The expression for radiation flux can bulence is present (k/ > 0), and an 2. The ambient air temperature was
be directly substituted into the energy ignition source is not required to ini- taken as 300K.
equation to account for heat sources tiate combustion. 3. The pressure outlet boundary condi-
(or sinks) due to radiation. tion was specified as zero gauge pres-
Fuel combustion has been modeled Modeling and meshing sure at the outlet boundaries.
using the eddy dissipation model. Geometry modeling and meshing 4. The side walls and lower wall of
Combustion of methane is rapid and are carried out using a commercial computational domain are modeled as
the combustion is said to be mixing- CAD (computer aided design) tool. free slip walls.
controlled, hence chemical kinetic The model consists of a rectangular 5. The mass flow inlet boundary con-
rates can be safely neglected. The domain (420 m 300 m 145 m) as ditions used at the tips of the three
commercial code provides a turbu- shown in Figure 1. Bridges and flare flares are as follows:
lence-chemistry interaction model support structures have been mod- Flare tip 1: 7 kg/s
(eddy dissipation model), based on the eled at their respective locations Flare tip 2: 17 kg/s
work of Magnussen and Hjertager [1]. considering only the main load-bear- Flare tip 3: 146 kg/s
The net rate of production of species ing members. This domain has been 6. The wall heat-transfer coefficient
due to reaction r, Ri,r, is given by the aligned with the wind direction. At was calculated by Morgan co-relation,
smaller (that is, the limiting value) of the lower side, the domain boundary which was used to model the convec-
the two expressions below, Equations has been considered at a distance of tive heat transfer.
(8) and (9). 7 m from the bottom of the bridges. 7. The structural elements were mod-
YR Close-up views of the flares along eled as thin surfaces with a thickness
Ri ,r = i,r M w,i A min R with the inclined support structures of zero.
k R ,r M w, R
(8) are shown as insets to Figure 1. The
geometry has been meshed using Case studies
pY p a combination of structured (hexa- A total of four different cases have
Ri ,r = i,r M w ,i AB
k N j ,r M w, j hedral) and unstructured (tetrahe- been studied for four different ambi-
j
(9) dral) elements with total number of ent conditions. The objective is to as-
Where Yp is the mass fraction of any volume elements as 2.7 million. certain the maximum possible tem-
FIGURE 4.
The tempera-
tures of the
supporting
structure is
shown here for
Case I. Temper-
atures at dis-
creet points for
Cases IIV are
summarized in
Table 1
TABLE 1. SUMMARY OF RESULTS FOR CASE IIV NOMENCLATURE

Case Number I II III IV P Pressure
Wind direction Normal Normal Opposite Opposite u, v, wVelocity components in the x, y,
z directions
Wind speed, knots 15 30 15 30 x, y, z Three spatial directions
Bridge 1 temperature, C 29 28 30 30 S Volumetric rate of heat generation
T Static temperature
F-2 Boom temperature, C 60 61 60 54
t Time
F-2 Platform temperature, C 121 122 126 135 k Turbulent kinetic energy
Bridge 2 temperature, C 62 39 54 52 Dissipation rate of kinetic energy
Specific property, dependent
F-1 Boom temperature,C 182 195 187 164 variable
F-1 Platform temperature, C 282 352 332 321 Symbol for partial differential
Density
perature (or worst case scenario) on iso-surface, the temperature will be Diffusion coefficient
less than 1,200C. Dynamic viscosity
the structures in the presence of com-
C Specific heat
bined convective and radiative heat The steady-state temperature pro-
D Mass Diffusion coefficient
transfer with different wind speeds file of the structures nearest to the (x) Divergence of the variable x
and wind directions. flares are shown in Figure 4. The e Internal Energy per unit mass
Case I: Normal wind direction, maximum temperature on the F-1 G Rate of generation of turbulent
wind velocity at 15 knots. Figure 2a platform is calculated to be 282C, energy
shows the path-line plots for plumes whereas the same for F-2 is calcu- h Specific enthalpy
coming from the flares. These lines are lated to be 121C. From the contour 2D Two dimensional
the steady-state temperatures on the plot it can be seen that the maximum 3D Three dimensional
path-lines of plumes. Owing to the low temperature of 282C is limited to a
mass flowrate of Flare 1 (low momen- very small region near the corner ad- sented in Figures 2c and 3c. Streamline
tum, subsonic flow), one sees that the jacent to the Flare 3. plot for Case II shows similar temper-
plume is diverted almost immediately The first column of Table 1 summa- ature and dispersion of the plume as
along the direction of air flow. The rizes the maximum predicted temper- the base case with the only difference
maximum temperature is found to be atures of the structural elements. being in the direction of plume.
limited to within a very small region Case II: Normal wind direction, Column 3 of Table 1 summarizes
near the tip of Flare 1 due to dissipa- wind velocity at 30 Knots. The pa- the predicted temperatures on the
tion of heat from the hot plume to the rameters for Case II are the same various support structures of the
large ambient surroundings. as Case I except the wind speed has platforms for Case III.
For Flare 2 and Flare 3, the mass been doubled. Path line plots for tem- Case IV: Opposite wind direction,
flowrate of the combustible gas is perature and the contour plot for wind velocity at 30 knots. For this
much higher, and flow velocity comes temperature on iso-surface are shown final case, the parameters are the same
in the sonic to supersonic region. This in Figures 2b and 3b. There one sees as Case II except the wind direction
leads to the generation of steeper that the higher ambient-air velocity is reversed. The stream line plot for
plumes that are not as easily deflected causes the fluegas plumes to become temperature and contour plot for iso
by the ambient air flow. Also, due to horizontal more quickly as compared temperature of 627C are presented in
the higher mass flowrate of combus- to the base case (Case I). The tem- Figures 2d and 3d. The streamline plot
tible gas, a larger region is covered peratures predicted for the support for Case IV shows that the combined
under the high temperature zone. The structures are presented in column 2 plume of Flare 2 and Flare 3 is di-
maximum temperature of the flames of Table 1. verted toward the living quarter plat-
is calculated to be around 1,900C. Case III: Opposite wind direction, form owing to the higher wind speed.
Figure 3a presents an iso-surface wind velocity 15 knots. For this case, However, the plume gets dissipated as
(a surface having the same property the parameters are the same as Case it moves away from the F-1 platform
everywhere) of the flares for 1,200C. I except the direction of the wind is because of turbulence. The last column
This plot gives an idea about the flame reversed. The stream line plot for tem- of Table 1 summarizes the predicted
region having a temperature greater perature and the contour plot for iso- temperatures on the support struc-
than 1,200C. Anywhere outside the temperature of 900K (627C) are pre- tures and platforms for Case IV.
Temperature profile of horizontal members on flare boom
Wind speed: 2/sec; Case: Scenario 1
250
200
Temperature, C
Validation of results FIGURE 5. This
150
Owing to limited or non-existing graph plots the tem-
perature variation
availability of actual field data, it is along the boom 100
very difficult to validate results for length predicted by
this analysis. However, it has been at- a flare-modeling
tempted to compare the CFD analysis software for a past 50
project
results with data from some past proj-
ects for comparable mass flowrates of 0
the combustible gas as given below: 20 40 60 80 100 120 140 160
CFD predicted maximum tempera- Structure elevation, m
ture compared (gas load: 146 + 17 =

163 kg/s) with the results of a flare The predictions from this CFD anal- The combination of both high- and
modeling software predicted tem- ysis for temperatures on the flare and low-speed flows may be encoun-
perature (for 133 kg/s gas load) for a boom are believed to be conservative tered depending on a flares design.
similar flare boom values for the designing of struc- This results in a convergence problem
Maximum temperature predicted tures influenced by radiation from Getting a converged solution for a
by CFD analysis was 352C for the flares system involving both combustion
F1 platform while the predicted and radiation modeling in the large
temperature for the reference case Challenges domain is challenging
was 228C, as shown in Figure 5. The following are some of the general Multi component systems involving
The reference case temperature was challenges encountered while model- multiple species require high com-
lower owing to the relatively lower ing a flare system: putation time
mass flowrate of combustible gas The handling of a considerably large Multiple case runs to arrive at the
(133 kg/s versus 163 kg/s for the size domain and therefore a rela- maximum possible temperature on
case under consideration) tively large mesh count the structures for safe design be-
Comprehensive Expertise
ITS EASY TO
Experience the variety of our high grade steel CONTROL NOISE with SoundPLANs
solutions at the ACHEMA 2012. noise evaluation and mapping software
Spun Castings
HAVE NOISE PROBLEMS? Whether its where workers
Static Castings ur
out o need hearing protection or overall city noise management,
Investment Castings more ab
to learn lopments:
Join us l d e ve SoundPLAN helps you solve your noise issues.
Services: teria
new ma Mo
Machining and Welding, oy G 45
Centrall G 21-02 As the global leader in noise modeling software, we deliver:
Research and Development, a ll o y
Centr Fast data processing
Metallurgical Consulting,
Project Management and many more Superb documentation & graphics
High Grade Special Steels Highly accurate results
Duplex and Super-Duplex
Ni-based Alloys
SoundPLANs software
Schmidt + Clemens GmbH + Co. KG
Edelstahlwerk Kaiserau is available in many languages with expert
Kaiserau 2, 51789 Lindlar, Germany ACHEMA local support in 48 countries.
Phone: +49 2266 92-0 18 22 June 2012
Fax: +49 2266 92-370 Frankfurt am Main/ Call or download our FREE demo
Germany
www.schmidt-clemens.com Hall / Booth 11.0 / C43 +1 360 432 9840 www.soundplan.com
Circle 46 on p. 76 or go to adlinks.che.com/40268-46 Circle 49 on p. 76 or go to adlinks.che.com/40268-49
Tushar P. Bhad is an assistant
manager, Hydrocarbon IC, R&D,
Larsen & Toubro Ltd. (Mum-
bai 400072, India at Larsen &
comes time consuming References Tourbo Ltd. Mumbai, India;
Email: tushar_bhad@lntenc.
There is a limited availability of ex- 1. Improving the Safety Standard of an Offshore com). He has over three years
Platform, Fluent News Letter, Spring 2001. of experience in the area of CFD
perimental and field data for flares, modeling of thermal and fluid
2. Stephen Ferguson, Computer Flow Simulation
which makes validation of results Provides New Insight into Hurricane-resis- systems having various appli-
tant Platform Design, Exploration & Produc- cations involving modeling of
rather difficult tion: The Oil & Gas Review 2006. multi-phase flow, turbulence,
combustion and heat transfer. At present his areas
3. ANSYS Fluent user manual. of interest include fluid flow, heat transfer, and mod-
Broader applications eling of multi-phase flow, combustion and radiation
The methodology adopted to carry out modeling using CFD. He has published papers in the
Authors CFD conferences and jointly filed for an Indian Pat-
the current study is generic in nature ent in the year 2010. Bhad is a post graduate thermal
Arvind Kaushik is senior engineer from WCE Sangli, India.
and the same steps can be followed to deputy general manager
(R&D) at Larsen & Toubro Sumanta Sarkar is deputy general manager
perform CFD analysis of any flare sys- (R&D) at Larsen & Toubros Hydrocarbon IC
Ltd. (Email: arvind_kaushik@
tem and associated structures for any lntenc.com). He has over 23 (Email: sumanta_sarkar@lntenc.com). He is a post
years of experience in the graduate (M. Tech.) chemical
chemical process plant, refinery, oil- design of thermal equipment, engineer from ITT, Kharagpur,
and-gas production facility and so on. process optimization, en- and has 17 years of experience
ergy conservation in process in the areas of CFD analysis,
The same modeling technique is ap- plants, dynamic simulation design & rating of thermal
plicable to predict temperature around of process and power plants, equipment and systems, opera-
commissioning and trouble- tion, technical services, project
any hot gas stack, for example fluegases shooting in India and overseas. He leads a team execution, feasibility studies
of mechanical and chemical engineers in the and technology evaluation.
from incinerators, furnace stack, DG set His current areas of interest
Thermal Engineering Group of R&D for inno-
stack and so on. However, this would vations in design of waste heat recovery equip- are troubleshooting and design
ment. His areas of interest include solar thermal analysis of fluid & thermal
not require modeling of the complex energy, low temperature thermal desalination, systems through CFD modeling, involving multu-
combustion reactions since the fluegas thermal energy storage systems, dynamic simu- phase flow, turbulence, reaction and heat transfer
lation of power plants, energy optimization of with combustion and radiation. He is a recipient of
composition and the temperature data industrial processes and commissioning and the Outstanding Young Chemical Engineer Award
are often made available by the vendor trouble-shooting of process equipment. Kaushik (IIChE) in 2007 and has published several papers
is a post graduate (M.Tech) chemical engineer in various CFD forums in India and abroad. He
or designer of the combustion system. from Indian Institute of Technology (IIT; Kan- has jointly filed for an Indian Patent for Horizontal
pur, India), since 1990. Heat Recovery Unit in the year 2010.
Edited by Gerald Ondrey
Visit HTRI at ACHEMA 2012 (Hall 4.0, Stand A62)

and 2012 Global Petroleum Show (Booth 2121)
Now reads Honeywell

UniSim Heat Exchangers and
AspenTech .EDR case files!*

HTRI Xchanger Suite is an integrated,
easy-to-use suite of tools that delivers
accurate design calculations for
shell-and-tubeheatexchangers
jacketedpipeheatexchangers
hairpinheatexchangers
plate-and-frameheatexchangers
spiralplateheatexchangers
firedheaters
aircoolers
economizers
tubelayouts
vibrationanalysis
It also interfaces with many process simulators

and physical property packages either directly
Were changing the future of heat transfer. or via CAPE-OPEN.
www.htri.net
*Service Pack 3 includes functionality to load and convert files from Honeywells UniSimDesignShell-TubeExchangerModelerfiles(.STEI),aswellaslegacyHTFSandAspenShell&TubeExchanger
(.TAIand.EDR)files.HoneywellandUniSimaretrademarksofHoneywellInternational,Inc.HTFSandAspenShell&TubeExchanger are trademarks of Aspen Technology, Inc. HTRI, the
HTRIlogo,theH2logo,WerechangingthefutureofheattransferandXchangerSuitearetrademarksofHeatTransferResearch,Inc.Thesemarksmayberegisteredinsomecountries.
Feature Report
A Novel Equation for

Isothermal Pipe Flow
A newly derived equation for NOMENCLATURE
a,1,b stations P absolute pressure, Pa
isothermal gas flow in pipes yields D pipe inside diameter, m R universal gas constant,
f Fanning friction factor 8314.47 Pa-m3/kg-
improved mass flux predictions G mass flux, kg/s-m2 mole-K
Gc critical mass flux, kg/s- T absolute fluid tempera-
m2 ture, K
Jung Seob Kim, SK E&C USA, Inc. L pipe length, m u velocity, m/s
and Navneet Singh, Bayer CropScience LP M gas molecular weight v specific volume, m3/kg
Ma Mach number arithmetic difference
N overall loss coefficient, fluid density, kg/m3
4fL/D + K (total flow
C
ompressible flow in pipes is common in the chemical
process industries (CPI) and is typically associated resistances of fittings)
with density changes in gases that are subjected to
pressure variations. Gas flow conditions can be de-
scribed using an adiabatic or isothermal flow equation.
G
For conservative piping design, the isothermal model is fa- Pa Pb D
Ta =Tb
vored, but it overpredicts mass flux through pipes. Ta Tb
The conventional isothermal model is relatively simple
and more applicable to long, uninsulated pipelines. Flow
conditions in long pipes and the flow of fluids with a low N , 4fL/D + K
specific heat ratio (~1.0) are approximately isothermal. The
temperature of the fluid is essentially constant and equal FIGURE 1. Parameters for typical isothermal flow of ideal
to the originating station temperature. gases in pipes include friction and fitting losses
The homogeneous equilibrium model improved (HEMI)
for pipe flows, developed by Kim and Dunsheath to better ac- Isothermal pipe flows
count for the change in density along the entire pipe length The novel isothermal pipe flow equation described in this
has been presented for all fluids [1]. Kim and Dunsheath article better represents the nature of isothermal pipe flow.
noted that the term dP within the flow equation would re- Typical isothermal flow of ideal gases in a pipe with fric-
sult in somewhat higher mass flux than would be expected. tion is shown in Figure 1. An ideal gas is one that obeys the
This finding can be applied to the isothermal flow equation equation of state for ideal gases. The compressibility fac-
of ideal gases by manipulating the Bernoulli equation. tor (Z) of ideal gases is 1. The overall loss coefficient (N)
This article describes a novel isothermal pipe flow equa- includes pipe friction losses, in terms of 4fL/D, as well as
tion that better represents the properties of gas flow in all fitting losses of K. The loss coefficient of a frictional ele-
a pipe and yields more accurate predictions of mass flux. ment can be included either as the equivalent length or the
The article also compares the calculation results of the two number of velocity heads. The temperature for isothermal
isothermal equations (novel versus conventional) using an flow is constant across the entire pipe length, and flow at
example piping system. The newly derived, isothermal flow constant temperature is very convenient to model. Eleva-
equation presented here is called the novel isothermal tion changes in pipelines can be neglected if gas densities
pipe flow equation for ideal gases (to differentiate it from are relatively small. In the problems presented here, there
the conventional isothermal pipe flow equation). are no elevation changes for horizontal pipes (Figure 1).
One of the reasons for the preferential use of the isother-
mal flow equation, as compared to the adiabatic equation, Conventional equation
is that the mass flux predictions are conservative. How- The designer of pipe flow systems favors an isothermal pipe
ever, inappropriate calculations of average density using flow equation because it is simple and conservative. There
the conventional isothermal equation leads to non-conser- are numerous isothermal equations, but all are analogous
vative results, in terms of piping design. These results can to Equation (1) [211]. The mass flux (G) is determined from
lead to piping systems that lack the capacity to handle the the calculated value of G2. The choking conditions set a
mass flow. The novel isothermal equation yields more con- limit on the maximum pipe mass flux for a given set of pipe
servative results and correctly sized piping systems. flow conditions. This means that lowering the pipe outlet
3,000 3 3,000 3
Mass flux, kg/m2-s 2,500 G 2.5 2,500 G 2.5
Mass flux, kg/m2-s

Gc Gc
Mach number
Mach number
2,000 Mach No. 2 2,000 Mach No. 2
1,500 1.5 1,500 1.5
1,000 1 1,000 1
500 0.5 500
0.5
0 0 0 0
0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1
Pb/Pa Pb/Pa
FIGURE 2. Mass flux predictions with the conventional iso- FIGURE 3. With the same piping system and inlet conditions
thermal flow equation tend to be higher because the equation as in Figure 2, the novel isothermal equation yields a smaller
does not correctly account for gas density changes mass flux
pressure does not increase the mass flux. The choked mass 1,200 9
Average density, kg/m3

flux is defined as Equation (2). Mach number is the ratio of 1,000 8
Mass flux, kg/s-m2

the gas velocity to the velocity of sound in the gas under the 7
given conditions and can be defined as Equation (3). 800
6
600
G_Conv 5
400 G_Novel 4
Avg. density_friction
200
(1) Avg. density_kinetic 3
0 2
1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1
(2)
Pb/Pa
FIGURE 4. Mass flux and average density plots can help

(3) determine whether the novel or conventional isothermal flow
equation should be used
For the plot in Figure 2, an ideal gas of molecular weight 20
and specific heat ratio 1.0 is flowing through a constant-area plot in Figure 3 is created for the same inlet conditions and
piping system of N = 5. The gas pressure and temperature piping system as Figure 2. Figure 3 shows that choking
at the pipe inlet are 1,013,500 Pa and 300K, respectively. occurs at a lower pressure ratio Pb/Pa (0.327 versus 0.352)
Figure 2 shows that the mass flux decreases slightly with than in the conventional isothermal flow equation.
a further decrease in outlet pressures after the flow chokes The calculated choked mass flux (940 kg/s-m2) is smaller
at the maximum mass flux. This means that the isother- than that calculated by the conventional isothermal flow
mal flow equation does not correctly account for the density equation (1,009 kg/s-m2). It is interesting to note that Equa-
changes in a pipe, and tends to overpredict the mass flux for tion (4) does not achieve the maximum mass flux at choked
the same pressure drop or underpredict the pressure drop conditions. On the other hand, the maximum mass flux is
for the same mass flux (see next section). But this has not reached at choked conditions for the conventional isother-
been examined in the past because supersonic flow is not mal pipe-flow Equation (6). As expected, the novel isother-
typically of interest to the piping system designer. mal pipe-flow equation shows significant mass flux decrease
after choking. Proper accounting for the variation in density
Novel isothermal equation at low pressure ratios is responsible for this difference.
For the conventional isothermal flow equation, the calcula-
tion results have been found to overpredict mass flux, so Differences between models
there is a need to correct this deficiency. This fundamental The average density along the pipe can be determined
drawback can be resolved by applying a physically real flow by two different equations [Equations (5) and (6)]. One is
equation. A somewhat complicated Equation (4) represents based on arithmetic average density and the other is based
the novel isothermal pipe flow equation developed based on arithmetic average specific volume. An inappropriate
on the Bernoulli equation. The derivation of this equation selection of the equation affects the mass flux prediction.
is given in the box on p. 70. As shown in Figure 4, there are significant differences in
mass flux at low pressure ratios (Pb/Pa). The difference in
mass flux increases as the pressure ratio (Pb/Pa) decreases.
From these results, it is considered unlikely that the con-
(4) ventional isothermal pipe flow equation predicts conserva-
tive mass flux calculations. However, for most operating
Equation (4) is not perfect in the way it accounts for all conditions in industry, the two flow equations give similar
the changes during flow in pipes. One of the pressure drop mass flux results.
terms, expansion loss (Pexpansion = Ptotal Pkinetic There are also apparent similarities between the two
Pfriction), can be accounted completely when the calcu- graphs of the mass flux and average density. Therefore, the
lation is started from the stagnation pressure. However, mass flux difference between two equations is due to the
Equation (4) provides conservative results because the different definition of average density along the pipe. The
changes in the expansion loss term will be smaller when average density for the conventional isothermal flow equa-
the calculation is started from the stagnation pressure. The tion is obtained using Equation (5) for both friction losses
G1
Engineering Practice Pa Ta =Tb Pb

Ta Tb
FIGURE 5. Split-
and kinetic losses. ting the pipe from
On the other hand, the novel isothermal flow equation is one segment (top
obtained using the average density for friction losses and diagram) into two N=5
the average density for kinetic losses using Equations (5) segments (two-step
and (6), respectively. Applying the arithmetic average den- pipe flow; bottom
diagram) can help G1 G2
sity for the friction losses is appropriate because the inte- Pb
determine which Pa P1
gration is based on N (pipe length), not on pressure. How- equation version is Ta = T1 T1 = Tb Tb
Ta T1
ever, the arithmetic average density for the kinetic losses better for a particu-
is not appropriate here because the integration is based lar case
N =5 N =0
on pressure, not on pipe length. The

arithmetic average density is only
a mathematically convenient solu-
tion that does not represent the ac-
tual average density for the kinetic
loss term. Equation (6) is based on a
density mixing rule to estimate the
correct average density in pipe flows.
The reciprocal of the arithmetic-av-
erage specific volume is both mathe-
matically and physically satisfactory.
This definition is much more repre-
sentative of the average density for a
kinetic loss term. In some cases, the
arithmetic average density ends up
September 29 October 3, 2012 with non-conservative calculation
New Orleans Morial Convention Center results.
New Orleans, Louisiana
(5)
So many new features this year,
you won't want to miss it!
If you want to know what will be important to you in the future, go to
WEFTEC. If you want to see what equipment you will be using in the (6)
future, go to WEFTEC. If you want to know how to effectively deal with Selecting the right model
The evaluation procedure outlined
the multitude of issues confronting the water/wastewater industry, then
below examines the nature of the
you simply MUST go to WEFTEC. WEFTEC is The Answers Event. pipe flow for the assumed flow con-
ditions. The mass flux calculation
WEFTEC 2011 Attendee is extended to supersonic flow to
maximize the effect of the arithmetic
average density that results in the
overprediction of mass flux. There-
fore, the calculation results are sup-
posed to provide a clue as to which
flow equation is better or more ap-
plicable for cases involving short
pipes with large pressure drops.
There are two different pipe out-
let pressure locations for equivalent
mass flux (Figure 4). The pipe outlet-
pressure location, 101,350 Pa, is se-
lected as one of them. Decreasing the
pressure ratio (Pb/Pa) below choking
conditions causes gas density to sig-
TABLE 1. EVALUATION RESULTS FOR DETERMINING THE BETTER ISOTHERMAL FLOW MODEL
Conventional (Equation 1) Novel (Equation 4)
Mass Flux (G1) with N = 5 for Pa to Pb 921 kg/s-m2 557 kg/s-m2
Irreversible Friction Losses (P1) at G1 and N = 5 for Pa to Pb 474,871 Pa 173,527 Pa
Pressure (P1) 630,206 Pa 908,450 Pa
Mass Flux with N = 5 for Pa to P1 921 kg/s-m2 557 kg/s-m2
Irreversible Friction Losses (P2) at G1 and N = 5 for Pa to P1 322,083 Pa 100,628 Pa
P1 P2 152,788 Pa 72,899 Pa
Mass Flux (G2) with N = 0 for P1 to Pb 921 kg/s-m2 605 kg/s-m2
nificantly decrease, which in turn increases the pressure using Equation (1) or (4) for N = 0. The calculated mass
drop. Using Equation (1) or Equation (4), the mass flux flux G2 should be greater than G1 if the flow equation
(G1) for the one-step pipe flow path from Pa (1,013,500 is correct, because there is a net driving force the dif-
Pa) to Pb (101,350 Pa) sketched in Figure 5 (top diagram) ference of the friction losses (P1 P2,) that causes
can be calculated. One can also calculate irreversible fric- greater mass flux than G1.
tional losses (P1) for the one-step flow path using Equa- Table 1 exhibits the calculation results for the two
tion (7). pipe-flow equations. For the conventional isothermal flow
equation, G2 is not greater than G1. This means that the
one-step pipe flow path from 1,013,500 to 101,350 Pa
(7) results in same mass flux, even though the irreversible
frictional losses are greater. The conventional isothermal
Another location for the equivalent mass flux shown in equation overpredicts mass flux. Note that the direction of
Figure 4 is located using Equation (1) or Equation (4) by the arithmetic average density is to overpredict mass flux.
changing Pb until the calculated mass flux equals G1. For In addition, two different irreversible frictional losses at
another flow-path case sketched in Figure 5 (bottom dia- the equivalent mass flux are contradictory. On the other
gram), the pipeline is split into two pipe segments. The hand, a novel isothermal flow equation gives a value of G2
first pipe segment from Pa to P1 is a frictional section. The that is greater than G1. This means that the novel isother-
second pipe segment from P1 to Pb is a non-frictional sec- mal pipe flow equation obeys the fundamental principles
tion. Irreversible frictional losses (P2) for the two-step of flow in pipes. Therefore, it is evident that the novel iso-
flow path can be calculated using Equation (7). The mass thermal equation represented by Equation (4) yields bet-
flux G2 for the non-frictional pipe section is calculated ter results than the conventional isothermal equation.
JUNE 2012
CHE.COM
Literature Review
Featuring Brochures and Catalogs of Products and Services for the CPI
Visit CE Lit Online
at che.com
Place Your Ad Here! EquipNet provides asset management ser-

Advertise in Chemical Engineer- vices to world-class chemical companies
ing Literature Review, a special Our offerings include asset evaluation
bound-in-the-magazine supplement and appraisal, site reconfiguration con-
that can showcase your latest catalogs, sulting, project management, and sales
brochures, and spec sheets. Reach over and marketing. These services yield
266,700 engineering professionals who a large supply of high-quality process
turn to Chemical Engineering for this kind equipment and unused MRO parts avail-
of production information. able for sale at the EquipNet Market-
Contact: Diane Hammes Place, the largest website of its kind.
Chemical Engineering, Contact: John Cote, Managing Director:
11000 Richmond Ave, Houston, TX 77042 Chemical (781) 821-3482 x2103
E-mail: dhammes@accessintel.com jcote@equipnet.com
Tel: (713) 444-9939 www.EquipNet.com/chem
www.che.com Circle 291 on p. 76 or go to adlinks.che.com/40268-291

DERIVATION OF THE NOVEL, ISOTHERMAL HORIZONTAL-PIPE-FLOW EQUATION
On the basis of the Bernoulli equation, if there is no ever, the kinetic loss term includes an expansion loss
friction, a general mechanical-energy equation for hori- term. For an actual pipe flow, a friction loss term is re-
zontal pipe flow can be written as: quired to be included in Equation (A-5).
Since the friction loss term is , Equation
(A-1) (A-5) can be written as:
Since = , Equation (A-1) can be written as:
(A-6)
(A-2)
Since and , Equation (A-2) can be Since and
written as:
(A-3)
,
Integrating Equation (A-3) between stations a and b Equation (A-6) can be written as:
gives:
(A-4)
For an isothermal flow of ideal gases , Equa- (A-7)

tion (A-4) becomes: Rearranging Equation (A-7) for G 2 gives:
(A-5)
Equation (A-5) is defined as a kinetic loss term. How- (A-8)
Concluding remarks since the variation of density with pressure changes in

Conservative pipe design considerations favor the use of a pipe is nonlinear. Unfortunately, the use of arithmetic
the isothermal flow equation over the adiabatic flow equa- average density in the conventional isothermal equa-
tion. However, the conservative results of conventional iso- tion has not previously been identified in the literature.
thermal flow equation are no longer true because the arith- However, the novel isothermal pipe-flow equation em-
metic average density used in the conventional isothermal ploys the arithmetic-average specific volume for the ki-
pipe-flow equation tends to overpredict the mass flux in netic loss term. This enables the novel isothermal flow
pipes. Although the mass flux overprediction of vapor flow equation to better represent the nature of flow in a pipe
is not significant, the definition of average density in a pipe and to accurately predict mass flux results without any
affects mass flux if the pipe pressure drop is greater than constraints. Therefore, conservative and safer design
40% of the inlet pressure. considerations favor the use of the novel isothermal
It should also be noted that the arithmetic average pipe-flow equation.
density does not represent the flow behavior in a pipe, Edited by Scott Jenkins
References 8. Flow of Fluids through Valves, Fittings, and 10. Kern, R., How to Size Piping and Compo-
Pipe, Crane Technical Paper No. 410, 1988. nents as Gas Expands at Flow Conditions,
1. Kim, J.S. and Dunsheath, H.J., A Homoge- Chem. Eng., October, 1975, pp. 125132.
neous Equilibrium Model Improved for Pipe 9. Pressure-relieving and Depressuring Sys-
Flows, Proceedings of World Congress on tems, ANSI/API Standard 521, pp. 104110, 11. Walters, T., Gas-Flow Calculations: Dont
Engineering and Computer Science 2010 Vol. January 2007. Choke, Chem. Eng., January 2000, cover
II WCECS 2010, October 2022, San Fran- story.
cisco, pp. 733738, 2010.
2. Shapiro, A.H., The Dynamics and Thermody- Author
namics of Compressible Fluid Flow, Vol. 1,
The Ronald Press Company, New York, 1953. Jung Seob Kim is a senior Navneet R. Singh is a Se-
process engineer at SK E&C nior Process Engineer at
3. McCabe, W.L. and Smith, J.C., Unit Opera- USA Inc. (1401 Enclave Bayer CropScience LP (8400
tions of Chemical Engineering, McGraw- Parkway Suite 100, Houston, Hawthorne Road, Kansas
Hill, New York, 1976. TX 77077; Phone: 281-258- City, MO 64120; Phone : 816-
2619; Email: jkim3@sk.com) 242-2738; Email: navneet.
4. Crowl, D.A. and Louvar, J.F., Chemical Pro- where he is responsible for singh@bayer.com) where he
cess Safety: Fundamentals with Applica- designing petrochemical and is responsible for process de-
tions, Prentice-Hall, Englewood Cliffs, N.J., refinery plants. He has more sign, process modeling and
1990. than 25 years of experience emergency relief system de-
5. Saad, M.A., Compressible Fluid Flow, Pren- in different roles within the sign. He holds M.S. and Ph.D.
tice-Hall, Englewood Cliffs, N.J., 1985. petrochemical process indus- degrees from Purdue Univer-
try including with Bayer Technology Services, sity and a B.S.Ch.E. degree from the Institute
6. Holland, F.A. and Bragg, R., Fluid Flow for Samsung BP Chemicals and Samsung Engineer- of Chemical Technology, Mumbai. He is a Senior
Chemical Engineers, Elsevier Inc., Amster- ing. He holds a B.S.Ch.E. from the University of member of AIChE and an engineer intern in the
dam, 1995. Seoul, is a member of AIChE, and is a registered State of West Virginia.
7. Green, D. and Perry, R.H., Perrys Chemical professional engineer in the State of Texas.
Engineers Handbook, McGraw-Hill, 2008.

presents the 3rd Annual
November 14 - 15, 2012

NEW ORLEANS, LA | ERNEST N. MORIAL
CONVENTION CENTER
ChemInnovations, the leading

process industries event in the
Americas focused on Chemical,
Petrochemical and Rening.
How can you maximize
your time and money
at ChemInnovations 2012?
Take advantage of
The Americas has a hotbed of activity! Over $10.3
ChemInnovations billion is expected in Capital and Maintenance projects
SHOW SPECIAL for for 2012 in North America that is over 990 plants with
in the Chemical Process Industries.
ACHEMA participants. Conference Content planned by the industry for the industry.
Conference tracks focused on Chemical Process Industry
challenges for Primer/Entry Level and Intermediate/
Visit us at Management Level.
ACHEMA in Hall See over 150 new technologies and solutions on the
ChemInnovations show floor alone.
9.0, Stand E2
www.cpievent.com
Contact Carley Ziober,
+1-713-343-1884
C O - L O C AT E D W I T H :
How is natural gas changing
or Petra Trautes, the CPI? The United States
+49 (69) 58604760 has become competitive for
investments with the recent
development from shale gas.
Find out at the co-located event
Shale EnviroSafe the latest on regulatory issues, how costs are
affecting feedstock, chemicals that are being provided to the
oil & gas industry for fracking and much more.
EnvironmentalColumn
Fractionation Manager
A very confined space

irca 1978, Reese and I visited a inspection. I went down first. Reese
C petrochemical plant in Corpus

Christi, Texas. Primarily, our
job was to inspect trays that had
been installed in three columns. Each
of those columns was about 10 ft in
followed (above me). At each succes-
sive tray, I checked the installation
and took a few measurements. Above
me, Reese took notes. The trays were
spaced 2 ft apart. The manway cross-
diameter and 100 ft tall. section was only 17 in. by 17 in. This
Our first mistake: We tried inspect- made descents, and ascents, difficult.
ing all three columns on the same day. After about one hour, Trays 1 to 30
By the time we got to the third col- were sufficiently inspected, and there
umn we were physically drained. Nev- were just 10 more trays to go, but I
Mike Resetarits is the technical director
ertheless, with shaky legs and arms, began to feel light-headed and weak. at Fractionation Research, Inc. (FRI; Still-
we climbed up the outside of the third Reese was just above me, but I could water, Okla.; www.fri.org), a distillation
column. We entered the top of the col- only see his feet. I said, Hey Reese, research consortium. Each month, Mike
umn via a 24-in. dia. manhole. how are you feeling. He called down, shares his first-hand experience with CE
Our second mistake: We told no I feel like stretching out on one of readers
member of the plant staff that we these trays and falling asleep. I said,
were entering the third column. Per Me too. I can barely speak and think. focus to muster the strength to climb
our instructions, the deck manways Somethings wrong! Lets get out of up through the 30 trays that we had
on the 40 trays had been left open. here! Actually, at that moment, we already inspected. We could not see
This afforded us a path downward were not sure that we could. It took each others face but we spoke con-
through the stack of trays, for our all of our energy and our complete stantly. The sentences were differ-
ent but each had the same inherent
meaning: Keep going!
The next 20 minutes seemed like
20 hours. Reese reached the top tray
ADVANCED PROCESS SOLUTIONS and then exited the column. I was
LEADING WORLDWIDE IN MIXING TECHNOLOGIES just inches and minutes behind him.
The outside air smelled and felt good.
After about 15 min we both felt well
again well enough to climb down
the outside of the column. Before
reaching the ground we stopped at
Deck 1, about 20 ft up.
There it was, our third and biggest
mistake: The lower column manhole
was not open. Air was not circulating
through the column while we were in
Having advanced to world market leader, the EKATO GROUP has been providing their
it. Whatever we were breathing inside
customers with the technical excellence and experience for more than 75 years. The
the column, down low in the column,
companies within the EKATO GROUP offer a broad spectrum of mixing technologies.
was not air. It was possibly gasoline
vapors. It was probably deficient in
From modulary designed industrial agitators to turnkey oxygen. Had we stayed in the column
production plants, the EKATO GROUP provides a range of just a few more minutes, a rescue team
engineering services and custom-made solutions for the would have been needed to pull our life-
most challenging customer applications. The synergies less bodies out through the manways,
within the EKATO GROUP ensure reliable and cost-effective assuming that the rescue team did not
solutions that meet the highest quality standards for every make the same mistakes that we did.
application. This is supported by a global service network. Back in the 1970s, safety training
HALL 5.0, STAND D42
was too-often defined as an annual
PPE [personal protective equipment]
transparency presentation. Back
Your contact in Europe
Tel.: +49 7622 29-0
GROUP Your contact in the USA
Tel.: +1 201 825 4684 then, and now, confined spaces are
e-mail: info@ekato.com www.ekato.com e-mail: usa@ekato.com very dangerous places.
Mike Resetarits
resetarits@fri.org
RZ_AnzChemEng2012.indd 1 09.02.12 15:38
PRODUCT SHOWC ASE
Clean tanks
ENGINEERING WITH INNOVATIVE IDEAS...
Manufacturers & Exporters of :-
fast, in 3-D Protect pressure or vacuum

instruments from clogging,
corrosion and damage.
orrent 3-D Compact and Economical, Plast-O-Matic
T head cleans
tanks quickly
Gauge Guards prevent dangerous leaks and
allow dependable instrument readings from
CENTRIFUGE FLUID BED DRYER
full vacuum to 250 psi.

while personnel PTFE or FKM
stay safely diaphragms.
outside. Rotating PVC, Polypro or
water jets (up PVDF bodies.
VACUUM TRAY DRYER ROTO CONE VACUUM DRYER
to 10,000 psi, Available with

150 gpm) are or without
powerful and gauges.
eco-friendly. Gauge
Shields for
harsh environments.
DOUBLE CONE BLENDER NAUTA VACUUM DRYER
Call NLB today or
download our free
Other Machines
AN ISO 9001 : 2008
Since 1979 CERTIFIED COMPANY
Dryers - Tray Dryer, Rotary Vacuum Paddle Dryer
white paper at Blenders - Conical / Octagonal/ Ribbon Blender
www.nlbcorp.com. Liquid Ointment & Cream Section - Liquid / Oral Manufacturing Plant, Sparkler Filter
Tablet Section - Mass Mixer, Multi Mill, Micro Pulveriser, Vibro Shifter, Coating pan
NLB. The Leader in Customized Equipments - cGMP Reaction Vessel, Heat Exchanger, Tanks
Water Jet Productivity Know more us at:
PLAST-O-MATIC VALVES, INC.

www.shivshaktiequipments.com | www.shivshaktiequip.in | www.apipharmaequipment.com
(248) 624-5555 CEDAR GROVE, NJ 07009 SHIV SHAKTI PROCESS EQUIPMENT PVT. LTD
nlbmktg@nlbusa.com (973) 256-3000 Fax: (973) 256-4745 407, S hivam C hambers, S .V.Road, G oregaon ( West), M umbai-104 I NDIA
www.plastomatic.com info@plastomatic.com Tel:91-22-2678 8480 / 2679 8554 Fax : 91-22 2679 8284 Cell:91 - 9821633589
E-mail : sales@shivshaktiequipments.com / sspepl@gmail.com
Circle 201 on p. 76 or go to Circle 202 on p. 76 or go to Circle 203 on p. 76 or go to
adlinks.ce.com/40268-201 adlinks.ce.com/40268-202 adlinks.ce.com/40268-203
The Chemical Engineering bookstore offers a

variety of industry topics you will come to rely on.
Environmental Management: Air-Pollution Control

Environmental Management: Wastewater and Groundwater Treatment
Fluid Handling
Gas-Solid and Liquid-Solid Separation
Liquid-Liquid and Gas-Liquid Separation
Managing Bulk Solids
17792
For a complete list of products, visit the Chemical

Engineering bookstore now. http://store.che.com/product/book

Intelligen Suite
The Market-Leading Engineering Suite for Modeling, Evaluation,
Scheduling, and Debottlenecking of Multi-Product Facilities
SuperPro SchedulePro
Use SuperPro Designer to model, evaluate, and Migrate to SchedulePro to model, schedule,
optimize batch and continuous processes and debottleneck multi-product facilities
Easy production tracking, conflict Tracking demand for resources Managing inventories for input,
resolution and rescheduling (e.g., labor, materials, utilities, etc.) intermediate, and output materials
SuperPro Designer is a comprehensive process simulator that facilitates modeling, cost analysis, debottlenecking, cycle
time reduction, and environmental impact assessment of integrated biochemical, bio-fuel, fine chemical, pharmaceutical
(bulk & fine), food, consumer product, mineral processing, water purification, wastewater treatment, and related processes.
Its development was initiated at the Massachusetts Institute of Technology (MIT). SuperPro is already in use at more than
500 companies and 900 universities around the globe (including 18 of the top 20 pharmaceutical companies and 9 of the top
10 biopharmaceutical companies).
SchedulePro is a versatile production planning, scheduling, and resource management tool. It generates feasible
production schedules for multi-product facilities that do not violate constraints related to the limited availability of equipment,
labor, utilities, and inventories of materials. It can be used in conjunction with SuperPro (by importing its recipes) or
independently (by creating recipes directly in SchedulePro). Any industry that manufactures multiple products by sharing
production lines and resources can benefit from the use of SchedulePro. Engineering companies use it as a modeling tool to
size shared utilities, determine equipment requirements, reduce cycle times, and debottleneck facilities.
Visit our website to download detailed product literature and

functional evaluation versions of our tools
INTELLIGEN, INC. 2326 Morse Avenue Scotch Plains, NJ 07076 USA

Tel: (908) 654-0088 Fax: (908) 654-3866
Email: info@intelligen.com Website: www.intelligen.com
Intelligen also has offices in Europe and representatives in countries around the world

NEW & USED EQUIPMENT
www.EquipNet.com/chemical :: 781.821.3482 :: Sales@EquipNet.com
Chemical Processing Equipment

from Merck
236018 Alloy Fab 5000 Gallon 316L Stainless Steel Reactor
235923 Wiped Film Evaporator System
235909 Westfalia Separator
235912 Ross 42N Double Ribbon Blender in 316L Stainless Steel
235977 Hull Tray Dryer with SIHI Vacuum Skid
236029 Tolan 1500 Gallon 316L Stainless Steel Reactor
RemoveTrampAd-ChemEng_Layout
Circle 242 on p. 761or1/30/12 5:
go to adlinks.che.com/ 40268-242
Remove CONTROL
Tramp Metals SYSTEMS
ProGrade Magnets Recipe-controlled systems
for all process applications!
Low Cost High Power
Continuous & batch processes
Plates from Hazardous & non-hazardous locations
$ 248 Fast design and start-up
Designed, built, installed and supported
by the process experts at Ross!
Grates from
$85 1-866-797-2660
Toll Free
Circle 244 on p. 76 or go to www.rosssyscon.com
adlinks.che.com/40268-244
9100
Metal Separator Circle 245 on p. 76 or go to
WABASH SELLS & RENTS adlinks.che.com/40268-245
Boilers Detects & Rejects:
20,000 - 400,000 #/Hr. - Aluminum - Steel
Diesel & Turbine Generators - Brass/Copper - Stainless
50 - 25,000 KW
Gears & Turbines
25 - 4000 HP
GET CONNECTED TODAY
We stock large inventories of:
Air Pre-Heaters Economizers Deaerators
Pumps Motors Fuel Oil Heating and Pump Sets
Valves Tubes Controls Compressors
Pulverizers Rental Boilers & Generators
www.che.com
24/7 Fast Emergency Service
800-704-2002
888-300-3743 HEAT EXCHANGERS

Phone: 847-541-5600 Fax: 847-541-1279
Liquid Coole
www.wabashpower.com call
wabash visit www.eriez.com

POWER EQUIPMENT CO.

444 Carpenter Ave., Wheeling, IL 60090
Circle 243 on p. 76 or go to
SOFTWARE ADVERTISE IN Air Cooled

THE CLASSIFIED FOR GASES & LIQUIDS!

Contact Diane Hammes Talk Directly with Desig
Tel: 713-444-9939 Blower Cooling Vent Co
Fax: 512-213-4855
Email:
(952) 933-2559 info@xchanger.com
Circle 241 on p. 76 or go to
dhammes@accessintel.com Circle 247 on p. 76 or go to
adlinks.che.com/40268-241 adlinks.che.com/40268-247

New Product Information June 2012
JustFAXit! or go to www.che.com/adlinks
Fill out the form and circle or write in the number(s) go on the web and ill out the

below, cut it out, and fax it to 800-571-7730. online reader service card.
name Title
Company
address
City State/Province Zip/Postal Code
Country\ Telephone Fax
email | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | |
FREE PRODUCT INFO 14 engineering, Design & Construc- 29 10 to 49 employees 47 Pollution Control equipment
(please answer all the questions) tion Firms 30 50 to 99 employees & Systems
15 engineering/environmental Ser- 31 100 to 249 employees 48 Pumps
YOUR INDUSTRY
vices 32 250 to 499 employees 49 Safety equipment & Services
01 Food & Beverages
16 equipment manufacturer 33 500 to 999 employees 50 Size reduction & agglomeration
02 wood, Pulp & Paper
17 energy incl. Co-generation 34 1,000 or more employees equipment
03 inorganic Chemicals
18 other YOU RECOMMEND, 51 Solids handling equipment
04 Plastics, Synthetic resins
JOB FUNCTION SPECIFY, PURCHASE 52 Tanks, Vessels, reactors
05 Drugs & Cosmetics (please circle all that apply)
20 Corporate management 53 Valves
06 Soaps & Detergents 40 Drying equipment
21 Plant operations incl. mainte- 54 engineering Computers/Soft-
07 Paints & allied Products 41 Filtration/Separation equipment
nance ware/Peripherals
08 organic Chemicals 42 heat Transfer/energy Conserva-
22 engineering 55 water Treatment Chemicals
09 agricultural Chemicals tion equipment
23 research & Development & equipment
10 Petroleum reining, 43 instrumentation & Control Sys-
24 Safety & environmental 56 hazardous waste management
Coal Products tems
26 other Systems
11 rubber & misc. Plastics 44 mixing, Blending equipment 57 Chemicals & raw materials
12 Stone, Clay, glass, Ceramics EMPLOYEE SIZE 45 motors, motor Controls 58 materials of Construction
13 metallurgical & metal Products 28 less than 10 employees 46 Piping, Tubing, Fittings 59 Compressors
1 16 31 46 61 76 91 106 121 136 151 166 181 196 211 226 241 256 271 286 301 316 331 346 361 376 391 406 421 436 451 466 481 496 511 526 541 556 571 586
2 17 32 47 62 77 92 107 122 137 152 167 182 197 212 227 242 257 272 287 302 317 332 347 362 377 392 407 422 437 452 467 482 497 512 527 542 557 572 587
3 18 33 48 63 78 93 108 123 138 153 168 183 198 213 228 243 258 273 288 303 318 333 348 363 378 393 408 423 438 453 468 483 498 513 528 543 558 573 588
4 19 34 49 64 79 94 109 124 139 154 169 184 199 214 229 244 259 274 289 304 319 334 349 364 379 394 409 424 439 454 469 484 499 514 529 544 559 574 589
5 20 35 50 65 80 95 110 125 140 155 170 185 200 215 230 245 260 275 290 305 320 335 350 365 380 395 410 425 440 455 470 485 500 515 530 545 560 575 590
6 21 36 51 66 81 96 111 126 141 156 171 186 201 216 231 246 261 276 291 306 321 336 351 366 381 396 411 426 441 456 471 486 501 516 531 546 561 576 591
7 22 37 52 67 82 97 112 127 142 157 172 187 202 217 232 247 262 277 292 307 322 337 352 367 382 397 412 427 442 457 472 487 502 517 532 547 562 577 592
8 23 38 53 68 83 98 113 128 143 158 173 188 203 218 233 248 263 278 293 308 323 338 353 368 383 398 413 428 443 458 473 488 503 518 533 548 563 578 593
9 24 39 54 69 84 99 114 129 144 159 174 189 204 219 234 249 264 279 294 309 324 339 354 369 384 399 414 429 444 459 474 489 504 519 534 549 564 579 594
10 25 40 55 70 85 100 115 130 145 160 175 190 205 220 235 250 265 280 295 310 325 340 355 370 385 400 415 430 445 460 475 490 505 520 535 550 565 580 595
11 26 41 56 71 86 101 116 131 146 161 176 191 206 221 236 251 266 281 296 311 326 341 356 371 386 401 416 431 446 461 476 491 506 521 536 551 566 581 596
12 27 42 57 72 87 102 117 132 147 162 177 192 207 222 237 252 267 282 297 312 327 342 357 372 387 402 417 432 447 462 477 492 507 522 537 552 567 582 597
13 28 43 58 73 88 103 118 133 148 163 178 193 208 223 238 253 268 283 298 313 328 343 358 373 388 403 418 433 448 463 478 493 508 523 538 553 568 583 598
14 29 44 59 74 89 104 119 134 149 164 179 194 209 224 239 254 269 284 299 314 329 344 359 374 389 404 419 434 449 464 479 494 509 524 539 554 569 584 599
15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 300 315 330 345 360 375 390 405 420 435 450 465 480 495 510 525 540 555 570 585 600
if number(s) do not appear above,

please write them here and circle: Fax this page back to 800-571-7730
ADVERTISING SALES REPRESENTATIVES
North America Jason Bullock, Dan Gentile Diane Hammes
Eric Freer, District Sales Manager District Sales Manager District Sales Manager Inside Sales Manager
Chemical Engineering Chemical Engineering Tel: 512-918-8075 Chemical Engineering;
11000 richmond ave, Suite 690, houston, TX 77042 8325 Broadway, Ste. 202/PmB 261 E-mail: dgentile@che.com 11000 richmond ave, Suite 690,
Tel: 713-343-1904 E-mail: efreer@che.com Pearland, TX 77581 Indiana, Illinois, Iowa, houston, TX 77042
Alabama, Alaska, Canada, Connecticut, Delaware, Florida, Tel: 281-485-4077; Fax: 281-485-1285 Minnesota, Wisconsin Tel: 713-444-9939
Hawaii, Idaho, Kentucky, Maine, Maryland, Massachusetts, E-mail: jbullock@che.com; E-mail: dhammes@che.com
Michigan, Mississippi, Montana, Nebraska, New Hampshire, Arkansas, Arizona, California, Product Showcase,
New Jersey, New York, North & South Carolina, North & South Colorado, Georgia, Kansas, Literature Reviews,
Dakota, Ohio, Oregon, Pennsylvania, Rhode Island, Tennessee, Louisiana, Missouri, New Mexico, Classiied Display
Utah, Vermont, Virginia, Washington, D.C., West Virginia, Nevada, Oklahoma, Texas, Advertising
Wyoming, Latin America Washington
International Dipali Dhar Ferruccio Silvera Rudy Teng

Chemical Engineering Chemical Engineering Sales Represntative
Petra Trautes
88 Pine Street, 5th loor, new York, nY 10005 Silvera Pubblicita Chemical Engineering;
Chemical Engineering
Tel: 718-263-1162 Viale monza, 24 milano 20127, italy room 1102 #20 aly 199 Baiyang road
Zeilweg 44
E-mail: ddhar@accessintel.com Tel: 39-02-284-6716; Pudong Shanghai 201204
D-60439 Frankfurt am main
India Fax: 39-02-289-3849 China
germany
E-mail: ferruccio@silvera.it/www. Tel: +86 21 50592439
Phone: +49-69-58604760 Katshuhiro Ishii
silvera.it Fax: +86 21 50592442
Fax: +49-69-5700-2484 Chemical Engineering
Andorra, France, Gibraltar, Greece, mP: +86 13818181202
email: ptrautes@che.com ace media Service inc., 12-6, 4-chome
Israel, Italy, Portugal, Spain E-mail: rudy.teng@gmail.com
Austria, Czech Republic, Benelux, nishiiko, adachi-ku, Tokyo 121, Japan
Asia-Paciic, Hong Kong, Peoples
Eastern Europe, Germany, Scandinavia, Tel: 81-3-5691-3335; Fax: 81-3-5691-3336
Republic of China, Taiwan
Switzerland, United Kingdom e-mail: amskatsu@dream.com
Japan
76 ChemiCal engineering www.Che.Com June 2012

Advertisers Index
Advertiser Page number Advertiser Page number Advertiser Page number Advertiser Page number
Phone number Reader Service # Phone number Reader Service # Phone number Reader Service # Phone number Reader Service #
A Box 4 U 59 Fike Corporation 14 * Lewa GmbH 32I-6 Samson AG 15

1-877-522-6948 1-866-758-6004 49 7152 14-0 49 69 4009-0
adlinks.che.com/40268-01 adlinks.che.com/40268-20 adlinks.che.com/40268-32 adlinks.che.com/40268-45
Abbe, Paul O. 32D-4 Flexicon SECOND List AG 31 Schmidt & Clemens
1-800-524-2188 Corporation COVER adlinks.che.com/40268-33 GmbH & Co. KG 64
adlinks.che.com/40268-02 1-888-FLEXICON 49 2266 92-0
Load Controls 32D-3
* Alfa Laval adlinks.che.com/40268-21 1-888-600-3247 adlinks.che.com/40268-46
Copenhagen A/S 32I-12 * GEA Niro 32I-3 adlinks.che.com/40268-34 Siemens AG I IA&DT CC 7
adlinks.che.com/40268-03 45 39 54 54 54 Magnetrol 47 adlinks.che.com/40268-47
adlinks.che.com/40268-22 1-800-624-8765
Almatec Maschinenbau Solutia, Inc. 2
GEA Westfalia Separator adlinks.che.com/40268-35 1-800-426-2463
GmbH 29
1-714-396-1502 Group GmbH 19 Metso Corporation 13 adlinks.che.com/40268-48
adlinks.che.com/40268-04 49 2522 77-0 adlinks.che.com/40268-36 SoundPLAN
AUMA Riester Mller GmbH 8 International LLC 64
GmbH & Co. KG 28 * GEA Wiegand GmbH 32I-8 49 (0) 7623/969-0 1-360-432-9840
49 7631 809-0 49 7243 705-0 adlinks.che.com/40268-37 adlinks.che.com/40268-49
MultiTherm LLC 45 Spencer Turbine 46
Berndorf Band GmbH 17 GEM Gebr. Mller 1-800-339-7991 1-800-232-4321
43 2672 800-0 Aparatebau GmbH adlinks.che.com/40268-38 adlinks.che.com/40268-50
adlinks.che.com/40268-06 & Co. KG 18 Sulzer Chemtech AG 1
Orion Instruments 10
Beumer Group adlinks.che.com/40268-25 1-866-55-ORION 41 61 486 3737
GmbH & Co. KG 7 GIG Karasek GmbH 27
adlinks.che.com/40268-07 adlinks.che.com/40268-26 Outotec Oyj 6 Swagelok Company 4
Bronkhorst - * Haver & Boecker 32I-11
High Tech B.V. 8 49 2522 30-271 * Phoenix Contact 32I-7 TLV Corporation 41
adlinks.che.com/40268-09 adlinks.che.com/40268-27 495 235 349494 1-704-597-9070
Buhler Aeroglide 55 Heat Transfer
1-919-851-2000 Research, Inc. 65 * Pompetravaini 32I-10 * Uhde GmbH 32I-9
adlinks.che.com/40268-08 adlinks.che.com/40268-28 39.0331.889000 adlinks.che.com/40268-54
* Buss-SMS-Canzler Hytorc 32a-32d WEFTEC 68
GmbH 32I-14 1-877GUN-2-GUN * R. Stahl Schaltgerte adlinks.che.com/40268-55
49 60 3385-0 adlinks.che.com/40268-29 GmbH 32I-15 Wood Group Mustang 32
adlinks.che.com/40268-10 * Italvacuum 32I-4 49 7942 943-0 adlinks.che.com/40268-56
39 011 470 4651 adlinks.che.com/40268-43
Cashco VCI 11 * Zeppelin Silos
1-785-472-4461 adlinks.che.com/40268-30 Saint Gobain Ceramics 25
adlinks.che.com/40268-11 1-716-278-6233
& Systems GmbH 32I-15
* KSB AG 32I-5 adlinks.che.com/40268-57
Chemstations, Inc. 16
Clean Harbors 56 Advertisers
1-800-422-8998 Classiied Index June 2012 Product Showcase . . . . . . . . . 73
Collins Instrument Co. 57 Computer Software . . . . . 7475
1-979-849-8266 Advertiser Page number Advertiser Page number
Phone number Reader Service # Phone number Reader Service # Equipment, New & Used . . . . 75
De Dietrich Process Applied e-Simulators Intelligen Inc. 74
1-908-654-0088 Advertiser Page number
Systems GmbH 23 Software 75 Phone number Reader Service #
adlinks.che.com/40268-15 adlinks.che.com/40268-241 adlinks.che.com/40268-240
Dupre Logistics 21 Equipnet Direct 75 NLB Corp. 73 Shiv Shakti Process

1-800-356-3658 1-781-821-3482 1-248-624-5555 Equipments Pvt. Ltd. 73
adlinks.che.com/40268-16 adlinks.che.com/40268-242 adlinks.che.com/40268-201 91-22-2678-8480
Edwards Ltd. 58 Eriez Manufacturing Co. 75 Plast-O-Matic Valves, Inc. 73
adlinks.che.com/40268-17 1-973-256-3000
Wabash Power
1-888-300-3743
adlinks.che.com/40268-243 adlinks.che.com/40268-202 Equipment Co. 75
Ekato Rhr- und 1-800-704-2002
Mischtechnik GmbH 72 Indeck Power Ross, Charles adlinks.che.com/40268-246
49 7622 29-0 Equipment Co. 75 & Son Company 75
adlinks.che.com/40268-18 Xchanger, Inc. 75
1-847-541-8300 1-800-243-ROSS 1-952-933-2559
EPI Engineering FOURTH adlinks.che.com/40268-244 adlinks.che.com/40268-245 adlinks.che.com/40268-247
1-800-551-9739 COVER
Send Advertisements and Box replies to: Diane Hammes
Equipnet Direct 69
1-781-821-3482 Chemical Engineering, 11000 Richmond Ave, Houston, TX 77042
E-mail: dhammes@che.com Tel: 713-343-1885
* International Edition See bottom of next page for advertising sales representatives' contact information
People
WHOS WHO
Lindenhayn MacCleary Goodrich Little Exton
Archer Daniels Midland Co. keting and business development Steven Little becomes chair of the
(Decatur, Ill.) names Kyle James activities in the NAFTA region. department of chemical and petro-
general manager of glycols. leum engineering at the
Jim Rowland joins Watlow (St. University of Pittsburghs
Christian Lindenhayn joins Orion Louis, Mo.), a maker of thermal sys- (Pittsburgh, Pa.) Swanson School
Engineered Carbons (Kingwood, tems, as vice president of operations. of Engineering.
Tex.) as senior vice president of Meanwhile, Victoria Holt, president
the rubber business line. and CEO of Spartech (Clayton, Mo.), Dow Polyurethanes (Midland,
joins Watlows board of directors. Mich.) names Mark Bassett global
Jerry MacCleary becomes president vice president.
for the NAFTA region of Bayer Toray Plastics (America), Inc.
MaterialScience LLC (Pittsburgh, (North Kingstown, R.I.) names Ralph Exton is named chief market-
Pa.), succeeding Greg Babe, who is Lauritz Goodrich national sales ing officer of GE Power & Water
retiring. MacCleary will retain his manager for the companys Torayfan (Trevose, Pa.).
leadership of the polyurethanes mar- Polypropylene Film Div. Suzanne Shelley
SUBSCRIBE SUBSCRIBE SUBSCRIBE SUBSCRIBE SUBSCRIBE SUBSCRIBE SUBSCRIBE SUBSCRIBE SUBSCRIBE

July
2008 Incorp
SUBSCRIBE SUBSCRIBE SUBSCRIBE SUBSCRIBE

B S C SUBSCRIBE
R I B E SUBSCRIBE
T O SUBSCRIBE SUBSCRIBE SUBSCRIBE
oratin
www. So g
Into lids
6
che.c Liquid
S U
om s
Focus
on Ga
New s De
Engine tection
ering
Closed Mater
Liquid ials
Dispen
Findin sing
g the
To Fit Right
the Ap Gloves
Facts plicatio
at You n
r Fin
Vacuum gertips:
Pump
Flowm s
eter
News
Augu
st
2008
www. Sterili
8
che.c zation
Written for engineers, by engineers

om PAG
E 34
r
More and more, business in the Chemical Process Industries (CPI) is not
Rever
se
PAG Osmo
E 34 sis
Heat
Transf
er
Fluids
Hydro
car
local, its global. To keep up with this rapidly evolving marketplace, you
Proper bon
ties
Focus
Filtrat
on
need a magazine that covers it all, not just one country or region, not just
ion
one vertical market, but the whole CPI.

Facts
at You
r Lesson Finger
tips:
r
System s-Learned Valve
s s
Preven
ting
Cakin
g
With editorial offices in Europe, Asia, and North America, CHEMICAL

ENGINEERING is well-positioned to keep abreast of all the latest innovations
in the equipment, technology, materials, and services used by process
plants worldwide. No other publication even comes close.
The #1 choice
of worldwide To subscribe, please call 1-847-564-9290
CPI organizations or visit clientservices@che.com
www.che.com

Economic Indicators
BUSINESS NEWS
the modern membrane process in Frankfurt- in the manufacturing of highly concentrat-
PLANT WATCH
Hchst, Germany, and has commissioned ed omega-3 fatty acids. With the acquisition,
Outotecs EOS process is selected for ThyssenKrupp Uhde GmbH (Dortmund, Ger- BASF extends its portfolio of omega-3 prod-
sinter project in India many; www.uhde.eu) to design and supply ucts for the pharmaceutical and dietary
May 14, 2012 Outotec Oyj (Espoo, Finland; the membrane cells.The new plant will in- supplement industries with a new offering of
www.outotec.com) has been selected by crease production capacity by around 50% highly concentrated omega-3 fatty acids.
Bhushan Power & Steel Ltd. (BPSL) to design to 250,000 m.t./yr of chlorine and 275,000 The integration is expected to be completed
and deliver technology for a new iron-ore m.t./yr of caustic soda solution. Commis- by the end of 2012.The companies have
sintering plant that will be built in Rengali in sioning is scheduled for the 4th Q of 2013. agreed not to disclose financial details of
the state of Orissa.The contract value is ap- the transaction.
proximately 20 million.The sintering facility Chevron Phillips Chemical selects site for
is expected to produce 2.45 million metric new polyethylene facilities
tons (m.t.) per year of iron-ore sinter, which is Solazyme and Dow to accelerate
May 1, 2012 Chevron Phillips Chemical
used as a raw material in steel production. commercialization of bio-based fluids
Co. LP (The Woodlands,Tex.; www.cpchem.
May 2, 2012 Solazyme, Inc. (San Fran-
com) has announced that the two polyeth-
Evonik plans to expand its L-threonine cisco, Calif.; www.solazyme.com) and The
ylene facilities planned as part of the com-
capacity in Europe Dow Chemical Company (Midland, Mich.;
panys U.S. Gulf Coast (USGC) Petrochemi-
May 14, 2012 Evonik Industries AG (Essen, www.dow.com) have entered into a con-
cals Project, will be located on a site nearby
Germany; www.evonik.com) plans to in- tingent offtake agreement in which Dow
the Chevron Phillips Chemical Sweeny
crease the capacity of L-threonine at Evonik has agreed to purchase from Solazyme
facility in Old Ocean,Tex.The two facilities
Agroferm Zrt. (Kaba, Hungary), a 100% af- all of its requirements of non-vegetable
will each have a capacity of 500,000 m.t./
filiated company of Evonik.The nameplate microbe-based oils for use in dielectric fluid
yr and will utilize Chevron Phillips Chemi-
capacity is expected to be expanded to applications through 2015, contingent
cals proprietary Loop Slurry Technology.The
30,000 m.t./yr of L-threonine (feed grade upon Solazymes ability to supply such oils.
estimated completion date for the USGC
98.5%), which represents an increase of Concurrently, Solazyme and Dow have
Petrochemicals Project is 2017.
10,000 m.t./yr.The new capacity is sched- entered into a Phase 2 Joint Development
uled to come on stream in the 3rd Q of 2013. Agreement (JDA2), a multi-year extension of
Largest LNG plant in northeast China to
L-threonine, which Evonik markets under the current joint-development agreement
feature B&Vs patented technology
the brand name ThreAmino, is an essential including accelerated commercialization
April 23, 2012 Black & Veatch (B&V; Over-
amino acid for animal feed. timelines. JDA2 enables additional applica-
land Park, Kan.; www.bv.com), in partnership
tion development work to be conducted
with Chemtex, has been selected by Jilin
Honeywell Green Diesel to be produced by Dow. Consumption of Solazymes algal
Qianyuan Energy Development to deliver
from biofeedstocks in U.S. facility oil feedstocks is expected to significantly
a liquefied natural gas (LNG) facility. Once
May 8, 2012 UOP LLC (Des Plaines, Ill.; exceed the minimum estimated volumes of
completed in late 2013, the 500,000-Nm3/d
www.uop.com), a Honeywell company, has 8.5 million gallons (29,000 m.t.) starting in
plant will be the largest of its kind in north-
signed an agreement to license technol- the 2nd half of 2013 and through 2015.
east China and will feature B&Vs patented
ogy to Emerald Biofuels LLC to produce Prico LNG technology.
Honeywell Green Diesel at a facility in Loui- BASF acquires
siana. Emerald is expected to use UOPs Eni BASF to invest in new chemical Novolyte Technologies
Ecofining process technology to produce production site in India April 26, 2012 BASF SE has purchased
85-million gal/yr of Honeywell Green Diesel. April 11, 2012 BASF India Ltd. (Mumbai; Novolyte Technologies (Cleveland, Ohio).
For more on Green Diesel, see Chem. Eng., www.basf.com) will invest 150 million in a from Arsenal Capital Partners (New York, N.Y.;
May 2007; www.che.com/news/3251.html. chemical production site at the Dahej Pe- www.arsenalcapital.com), a U.S.-based
troleum, Chemicals and Petrochemicals In- private equity firm.The companies have
BASF to build formic acid plant vestment Region located in Gujarat.The site agreed not to disclose financial details of
in Louisiana will be an integrated hub for polyurethane the transaction.The acquisition comprises
May 4, 2012 BASF Corp. (Florham Park, manufacturing and will also house pro- Novolytes energy storage activities focused
N.J.; www.basf.us) has announced plans duction facilities for surfactants, largely for on developing, producing and marketing
to build a state-of-the-art production plant home and personal care applications, and performance electrolyte formulations for lith-
for formic acid at its integrated facility in polymer dispersions for coatings and paper. ium-ion batteries. BASF has also purchased
Geismar, La. Slated to start up in the 2nd Q of Production startup is planned for 2014. Novolytes performance materials business.
2014, the new plant will have a capacity of Additionally within the framework of the ac-
more than 50,000 tons/yr. quisition, BASF will continue a joint venture
MERGERS AND ACQUISITIONS of Novolyte with Korean partner Foosung, a
Uhde supplies chlor-alkali electrolysis BASF acquires fatty-acid global producer of the high-purity specialty
technology to AkzoNobel maker Equateq Ltd. salt lithium hexafluorophosphate (LiPF6), a
May 2, 2012 AkzoNobel (Amsterdam, May 9, 2012 BASF SE (Ludwigshafen, Ger- key material for manufacturing lithium-ion
the Netherlands; www.akzonobel.com) is many; www.basf.com) has announced the battery electrolytes.
converting an amalgam electrolysis plant to acquisition of Equateq Ltd., a global leader Dorothy Lozowski
FOR ADDITIONAL NEWS AS IT DEVELOPS, PLEASE VISIT WWW.CHE.COM

June 2012; VOL. 119; NO. 6
Chemical Engineering copyright @ 2012 (ISSN 0009-2460) is published monthly, with an additional issue in October, by Access Intelligence, LLC, 4 Choke Cherry Road, 2nd
Floor, Rockville, MD, 20850. Chemical Engineering Executive, Editorial, Advertising and Publication Offices: 88 Pine Street, 5th Floor, New York, NY 10005; Phone: 212-621-4674, Fax:
212-621-4694. Subscription rates: $149.97 U.S. and U.S. possessions, $166.97 Canada, and $269 International. $20.00 Back issue & Single copy sales. Periodicals postage paid
at Rockville, MD and additional mailing offices. Postmaster: Send address changes to Chemical Engineering, Fulfillment Manager, P.O. Box 3588, Northbrook, IL 60065-3588.
Phone: 847-564-9290, Fax: 847-564-9453, email: clientservices@che.com. Change of address, two to eight week notice requested. For information regarding article reprints,
please contact Wrights Media, 1-877-652-5295, sales@wrightsmedia.com. Contents may not be reproduced in any form without written permission. Canada Post 40612608.
Return undeliverable Canadian Addresses to: PitneyBowes, P.O. BOX 25542, LONDON, ON N6C 6B2
FOR MORE ECONOMIC INDICATORS, SEE NEXT PAGE CHEMICAL ENGINEERING WWW.CHE.COM JUNE 2012 79
Economic Indicators 2010 2011 2012
DOWNLOAD THE CEPCI TWO WEEKS SOONER AT WWW.CHE.COM/PCI
CHEMICAL ENGINEERING PLANT COST INDEX (CEPCI)

650
(1957-59 = 100) Mar. '12 Feb. '12 Mar. '11
Annual
Prelim. Final Final
596.1 596.3 575.9
Index:
CE Index 600
Equipment 729.9 730.6 698.7 2004 = 444.2
Heat exchangers & tanks 686.6 689.9 657.5 2005 = 468.2
550
Process machinery 680.7 677.7 662.1 2006 = 499.6
Pipe, valves & fittings 934.8 933.5 862.8 2007 = 525.4
Process instruments 433.9 433.8 438.7 500
2008 = 575.4
Pumps & compressors 922.2 919.6 898.5
2009 = 521.9
Electrical equipment 513.6 514.2 499.4 450
Structural supports & misc 772.1 772.9 738.6
2010 = 550.8
Construction labor 323.0 321.7 324.3 2011 = 585.7
400
Buildings 526.3 524.4 514.2
J F M A M J J A S O N D
Engineering & supervision 327.8 328.4 334.3
CURRENT BUSINESS INDICATORS LATEST PREVIOUS YEAR AGO
CPI output index (2007 = 100) Apr. '12 = 89.0 Mar. '12 = 89.0 Feb. '12 = 89.8 Apr. '11 = 87.3
CPI value of output, $ billions Mar. '12 = 2,182.9 Feb. '12 = 2,180.4 Jan. '12 = 2,144.8 Mar. '11 = 2,072.8
CPI operating rate, % Apr. '12 = 76.9 Mar. '12 = 76.9 Feb. '12 = 77.6 Apr. '11 = 75.3
Producer prices, industrial chemicals (1982 = 100) Apr. '12 = 329.6 Mar. '12 = 329.5 Feb. '12 = 318.1 Apr. '11 = 332.0
Industrial Production in Manufacturing (2007=100) Apr. '12 = 94.6 Mar. '12 = 94.1 Feb. '12 = 94.5 Apr. '11 = 89.5
Hourly earnings index, chemical & allied products (1992 = 100) Apr. '12 = 159.2 Mar. '12 = 157.2 Feb. '12 = 157.3 Apr. '11 = 155.1
Productivity index, chemicals & allied products (1992 = 100) Apr. '12 = 105.1 Mar. '12 = 105.4 Feb. '12 = 106.8 Apr. '11 = 107.3
CPI OUTPUT INDEX (2007 = 100) CPI OUTPUT VALUE ($ BILLIONS) CPI OPERATING RATE (%)
120 2500 85
110 2200 80
100 1900 75
90 1600 70
80 1300 65
70 1000 60
J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D
Current Business Indicators provided by IHS Global Insight, Inc., Lexington, Mass.
CURRENT TRENDS
apital equipment prices, as reflected in the CE Plant Cost gions. Production slipped in the Mid-Atlantic and West Coast
C Index (CEPCI; top), were relatively flat from February to
March (the most recent data).
and was flat in the Northeast.
Using a three month moving average, comparable to the
Meanwhile, all of the Current Business Indicators from IHS U.S. CPRI, production gains were seen in nearly all chemical
Global Insight (middle), were relatively flat from March to segments, except fertilizers, ACC says. Some of the largest
April. According to the American Chemistry Council (ACC; gains were in man-made fibers, adhesives, industrial gases,
Washington, D.C.; www.americanchemistry.com), the U.S. inorganic chemicals, and pesticides. Compared to March
Chemical Production Regional Index (U.S. CPRI) rose by 0.1% 2011, total chemical production in all regions was up 1.3%
in March, following a revised 1.0% gain in February, the and remained ahead year-over-year in all regions.
fourth consecutive gain. Regionally, chemical production rose Visit www.che.com/pci for more information and other tips
in the Gulf Coast, Midwest, Ohio Valley and Southeast re- on capital cost trends and methodology.

Come visit Chemical Engineering
in Frankfurt at ACHEMA the
leading international event for the
chemical process industries!
ChE.com
As a joint effort with Vogel Business
Media, we will once again be the official
show daily producers of the ACHEMA
DAILY, highlighting the current news,
trends, special programs, and events
during the show.
Visit us in Hall 9.0, Stand E2

See you in Germany June 18th-22nd!
READY FOR THE NEXT
WATER SHORTAGE?
Total Facility Water Optimization
Maximize the efficiency of plant water use by improving condensate return and energy recovery, improve steam work
efficiency and excessive condensate production, optimize boiler and cooling tower blowdowns, and eliminate steam
vents all while developing a strategic water shortage contingency plan with a Total Facility Water Study.
Copyright 2012. EPI Engineering, Inc. All Rights Reserved.

E P I
Engineering TM

June 2012

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

June 2012

Uploaded by

Copyright:

Available Formats

SH EV

Draining Process Vessels

AND AT THE THIRD VESSEL? ... ZZZZZZZ...

ISOTHERMAL STEAM SYSTEM

PATENTED CANTILEVERED BASIC FILLER FOR PATENTED

USA CHILE +56 2 415 1286

SOUTH AFRICA +27 (0)41 453 1871

Yougetthebestfromourinnovativerangeoftechnologies: Sulzer Chemtech Ltd

TO WORK FOR YOU.

Draining Process Vessels

CHEMICAL ENGINEERING WWW.CHE.COM JUNE 2012 3

Published since 1902

Call for corrosion papers

The software solution COMOS realizes throughout in-

Energy Training & Electric Power Classroom

16th AFPM Cat Cracker Seminar. American

Low Flow Coriolis Auditing Management Systems ISO19011. BW

2012 SOCMA Leadership Conference 2012.

WEFTEC. Water Environment Federation (Alexandria,

4th Regional Process Technology Conference.

International Symposium on Chemical

Plastic Pipes XVI. Plastic Pipe Inst. (Budapest,

4th Symposium on Continuous Flow Reactor

ASIA & ELSEWHERE

chemicals with this technology Oxygen Hydrogen

E lectrochemical and chemical-precipitation

P roterro Inc. (Princeton, N.J.; www.

Winning copper from low-grade ore (Continued from p. 11)

I ndia holds large reserves of low-grade

Think Environmental Protection.

Model 3100/4100 Model 3400/4400 Model 5200

The first synthesis and isolation of a heavy ketone

ARE YOU RELYING ON FIKE IS COMMITTED TO RELIABLE SAFETY

THAT SHOULD WORK? Comprehensive selection of ASME, CE and

DONT LEAVE THE SAFETY OF YOUR

VENTING SUPPRESSION RUPTURE DISCS TESTING

PROVEN PERFORMANCE, QUALITY

A less-expensive process to recover

Weadapt to your needs

uct purification in H2 plants. FlashCO2 (diagram) combines

Chlorine dioxide single-stage NOx

Need to predict emissions from a scrubbing

David Hill, CHEMCAD Support Expert

A new process for making screens In general materials used by Berndorf

Detecting VOCs with a quantum-

Compact, efficient and

U.S. House approves cybersecurity bill

L ast month, the U.S. House

GE and Shenhua open cleaner-coal-technology JV in China of the most widely deployed

G E (Atlanta, Ga.; www.

Jacobs receives contract from Evonik for new chemical plant

Reliable Light Weight Construction

One Fits All

www.dedietrich.com Circle 15 on p. 76 or go to adlinks.che.com/40268-15

Saint-Gobain Ceramics Telephone: 716-278-6233

Equipment News Roundup

CHEMICAL ENGINEERING WWW.CHE.COM JUNE 2012 27

ing solution. Equipped

a wide flood pattern, the ex-

the FM-approved, loop- during maintenance or when trouble-

Vacuum conveying system

A new version of a smart plant

Total Project Delivery

Distributed signals with