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Cover Story
36 Part 1 Batch Drying with Vacuum Contact Dryers
Drying is a demanding unit operation where solvents need to be removed
without altering product chemistry. Vacuum contact dryers are essential
pieces of equipment for accomplishing this task
43 Part 2 Optimizing Analysis for Spray Drying
Precise control over spray-drying processes can be enabled
by modern measurement approaches that provide realtime
information on particle size and shape
In the News
9 Chementator
Algae printing ink has safety and sustainability benefits; Pilot project
captures rainwater for wine production; Award to lower costs
for flow-battery reactants and membranes; A quest for making
ammonia at moderate conditions; and more
16 Business News
Messer opens its largest CO2-recovery plant; Wacker expands
silicon-metal capacity at Norwegian production site; KBR awarded revamp
contract for LG Chem ethylene plant expansion; Worlds largest MTO plant 36
starts up in China; and more
18 Newsfront The Spread of Nitrogen Fertilizers
As price margins tighten, ammonia and urea producers are diversifying their
products, while new catalysts and process improvements boost capacities and
lower energy consumption
22 Newsfront The Future of Safety Sensors is Here Now
Wearable sensors enhance chemical plant worker safety and help close the
approaching skills gap 49
31 New Products
28 A compact compressor for H2-refueling stations; Save time and water with
this tank-cleaning machine; This range of diaphragm pumps is extended;
Predict product performance with a digital twin; Flow measurement at low
temperatures; This closed-system mixer requires no transfer steps; and more
Departments
5 Editors Page Designating a day for water
31
March 22 has been designated as World Water Day. Its observance brings
attention to global water resources and, this year, particularly to the need to
focus on wastewater
6 Letters
80 Economic Indicators
Advertisers
35 Hot Products
69 Solids Processing Special Advertising Section
76 Product Showcase
77 Classified
78 Reader Service
79 Ad Index
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Editor s Page
EDITORS ART & DESIGN
Designating a day for water
DOROTHY LOZOWSKI ROB HUDGINS
L
Editorial Director Graphic Designer ast month, special recognition to water-related issues was
rhudgins@accessintel.com
dlozowski@chemengonline.com given on March 22, the date designated by the United Nations
GERALD ONDREY (FRANKFURT) PRODUCTION as World Water Day. The first World Water Day was observed
Senior Editor
gondrey@chemengonline.com SOPHIE CHAN-WOOD in 1993, and has been celebrated every year since. The pur-
Production Manager
schan-wood@accessintel.com pose of the observance is to bring attention to our water resources
SCOTT JENKINS
Senior Editor INFORMATION and offer learning opportunities, as well as to inspire others to sustain-
sjenkins@chemengonline.com SERVICES ably manage those resources. This year, the theme of World Water
MARY PAGE BAILEY CHARLES SANDS Day was wastewater, to focus on the need to improve water reuse.
Associate Editor Director of Digital Development
mbailey@chemengonline.com csands@accessintel.com We cover water treatment regularly in our magazine, and I have
PUBLISHER, SALES & CONTRIBUTING EDITORS
written about its importance a number of times, yet each time I learn
MARKETING
SUZANNE A. SHELLEY
more, it impresses upon me how far-reaching the impact of water-
MATTHEW GRANT sshelley@chemengonline.com related issues is. The World Water Day website (www.worldwaterday.
mattg@powermag.com
CHARLES BUTCHER (U.K.) org) offers the following information in its Fact Sheet.
cbutcher@chemengonline.com
AUDIENCE
DEVELOPMENT
Over 80% of wastewater generated by society goes back into the
PAUL S. GRAD (AUSTRALIA) ecosystem without being used or recycled. High-income countries
SARAH GARWOOD pgrad@chemengonline.com
Audience Marketing Director treat around 70% of wastewater, and the percentage drops dra-
sgarwood@accessintel.com
TETSUO SATOH (JAPAN)
tsatoh@chemengonline.com
matically in lower-income countries
JESSICA GRIER
Marketing Manager
1.8 billion people are at risk for life-threatening diseases because of
jgrier@accessintel.com JOY LEPREE (NEW JERSEY) contaminated sources of drinking water
jlepree@chemengonline.com
GEORGE SEVERINE The portion of the worlds population living in cities is expected to
Fulfillment Manager
gseverine@accessintel.com
grow from 50% to 70% by 2050, while many cities are not equipped
to address growing wastewater management needs
JEN FELLING
List Sales, Statlistics (203) 778-8700
j.felling@statlistics.com The CPI contributes
EDITORIAL ADVISORY BOARD Industrial production accounts for nearly 25% of global water con-
sumption, according to a statement released in conjunction with
JOHN CARSON JOHN HOLLMANN
Jenike & Johanson, Inc. Validation Estimating LLC World Water Day by Lanxess (www.lanxess.com). The chemical
DAVID DICKEY HENRY KISTER process industries (CPI) are well equipped to provide solutions to in-
MixTech, Inc. Fluor Corp. dustrial, as well as municipal water- and wastewater-treatment chal-
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EUROPEAN EDITORIAL OFFICES
And new technologies are being developed around the world. See
Zeilweg 44, D-60439 Frankfurt am Main, Germany for example, the Chementator article in this issue about a group in
Tel: 49-69-9573-8296
Fax: 49-69-5700-2484 Singapore who are working on removing pollutants from water with
CIRCULATION REQUESTS: iron hydroxides (p. 12), and the work in Korea on developing a new
Tel: 847-564-9290 water-treatment adsorbent reported last month (A New Adsorbent for
Fax: 847-564-9453
Fullfillment Manager; P.O. Box 3588, Wastewater Treatment, Chem. Eng. March 2017, p. 11).
Northbrook, IL 60065-3588
email: chemeng@omeda.com
Written for engineers by engineers, Chemical Editors note: Thank you for pointing out the errors in
the column. Regarding the definition of enthalpy, you are
Engineering delivers solid engineering essentials correct the inclusion of temperature for volume was
and developing industry trends to keep its readers a typographical error. Regarding the discussion of water
films on heat-transfer surfaces, the author was trying to
abreast of everything they need to keep their condense a longer explanation, and it was indeed flawed.
facilities running smoothly. Thank for you clarifying this. The online version has been
updated to reflect these corrections, and can be found
at www.chemengonline.com/steam-concepts/.
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Chementator
Algae printing ink has safety and
sustainability benefits Edited by:
Gerald Ondrey
S
cientists at Liv- Algae-to-ink process
ing Ink Technol- EFFICIENT DISTILLATION
ogies (Denver,
Toyo Engineering Corp.
Colo.; www. (Toyo; Chiba, www.toyo-eng.
livinginktechnologies. co.jp) has completed con-
com) have developed struction for an energy-sav-
biodegradeable print- ing distillation system used in
ing ink made from natu- a project for Maruzen Petro-
ral cyanobacteria and 1. Species 2. Cultivation 3. Harvest 4. Ink 5. Print
chemical Co. (Tokyo, Japan;
algae as a sustainable www.chemiway.co.jp). This
and non-toxic alterna- system, tradenamed Su-
tive to conventional petroleum-derived and simple, because Living Ink uses the perHIDiC, has achieved an
energy saving of over 50%
printing inks. whole cell for the ink, rather than extracting
compared with conventional
Living Inks method involves using sun- pigments from the cells with downstream distillation, says Toyo.
light and carbon dioxide to grow a variety processing steps, explains Scott Fulbright, The newly installed sys-
of algae and cyanobacteria species that are the companys co-founder and CEO. For tem was designed with the
colored by pigmented molecules they pro- the ink strains, We needed to find the aim of providing large en-
duce. For example, green ink comes from right combination of pigment color, ability ergy savings for the methyl
chlorophyll produced by the cells, while to grow effectively in industrial settings and ethyl ketone (MEK) pro-
other strains result in red, yellow and or- cell size, which is on the order of 15 mi- duction plant at Maruzen
ange inks. Living Ink is also working on a crons, Fulbright adds. Petrochemical site in Chiba
genetically engineered algae strain that can Living Ink is targeting the packaging ink Prefecture, and is the first
commercial application of a
be used for black-colored ink. and stationery markets initially. The com-
SuperHIDiC system.
To make the inks, algae is grown in con- pany has partnered with algae produc- SuperHIDiC is based on
trolled containers, then concentrated in a tion company Cellana Inc. (Kailua, Ha- the heat-integrated distilla-
harvesting step (photos). Other plant-based waii; www.cellana.com) for high-volume tion column (HIDiC) tech-
materials are added to the cells to complete production of algae, and was recently nology, which has been
the ink formulations, which can then be awarded a Small Business Innovation researched for many years
printed onto paper, cardboard and cotton Research (SBIR) grant from the U.S. Na- by companies, universities
textiles using conventional printers. tional Science Foundation to further de- and research institutions
The ink production process is low-cost velop the algae-based inks. around the world. Toyo has
further refined this technol-
ogy (Chem. Eng., Janu-
A pilot project to capture rainwater for ary, p. 10), in collaboration
with the National Institute
wine production of Advanced Industrial Sci-
ence and Technology (AIST;
A
pilot project set up by the Univer- pilot system, which captures and trans- Tokyo, www.aist.go.jp), and
sity of California Davis (UC Davis; ports rainwater from the roofs of several plants to expand commer-
Davis, Calif.; www.ucdavis.edu), UC Davis campus buildings to a hold- cial applications.
GE Water & Process Technolo- ing tank. After subsequent filtration, the
gies (Trevose, Pa.; www.gewater.com) and water is pumped into 45,000-gal feed SOLAR STEAM
wine-industry service provider Winesecrets tanks for the water-treatment process. Queen Mary University of
LLC (www.winesecrets.com) seeks to cap- Most of what the membrane technology London (QMUL; www.qmul.
ture rainwater for use in wine production, separates from the rainwater are the dust ac.uk) and industry partner
specifically for cleaning the winemaking and particulate matter that settles on the Larkfleet Ltd. (Bourne, U.K.;
equipment. Collected rainwater represents roofs and in the gutters between rainfalls, www.larkenergy.co.uk) have
received 800,000 (about
an attractive source for water, especially says Hertel.
$98,000) in funding to further
in areas that swing from extreme rainfall UC Davis has been operating the pilot develop a concentrated-
to drought, explains GEs sales manager system at its discretion since commission- solar-thermal technology for
Ryan Hertel. Since rainwater naturally has ing was completed in December 2016, producing industrial steam.
little alkalinity or mineral content, the water- reportedly treating about 7,000 gal/d of The funding for the two-year
treatment requirements to achieve com- water. With the extremely wet and rainy project, provided by Innovate
parable purity are much less complex and season California has recently experi- UK, the Newton Fund and the
costly than drawing water from traditional enced, the system has been running a National Science and Tech-
sources, such as wells, aquifers or rivers. lot, comments Hertel. For the projects nology Council in Mexico, will
GE provided a reverse-osmosis mem- next phase, UC Davis plans to livestream allow an already developed
prototype of the solar collec-
brane system and equipment for total- the analytics from the treatment system di-
oxygen-content (TOC) analysis to the rectly over the Internet. (Continues on p. 10)
U
Developed and patented by nited Technologies Research Cen- that was originally used in phosphoric-acid
Larkfleet, the solar collectors ter (UTRC; East Hartford, Conn.; fuel cells. The simple, porous ionic separator
use plastic Fresnel lenses in- www.utrc.utc.com) has been is doped with sulfuric acid and may obviate
stead of conventional glass awarded a $2.7-million cooperative the need for more expensive ion-exchange
reflectors. The Fresnel lenses research agreement to further develop two membranes in stationary flow batteries.
frame rotates to track the technologies aimed at lowering the capital Such a membrane could lower the cost of
movement of the sun using a cost of flow batteries for electrical grid-en- that component by a factor of five, says
fully automatic system, which
ergy storage. UTRC researcher Michael Perry.
allows for the concentration
of maximum levels of solar ra-
UTRC will lead the U.S. Department of In addition, the award will support devel-
diation on the collector tubes, Energys ARPA-E (Advanced Research opment work on lower-cost flow-battery
says the company. The new Projects Agency Energy) Integration and reactants. Currently, most flow-battery reac-
design is lighter than glass Optimization of Novel Ion-Conducting Sol- tants are based on vanadium or other tran-
systems, which makes it ids (Ionics) program. Other participants in sition metals, but the research team will be
transportable and potentially the Ionics program include Harvard Univer- screening engineered organic molecules for
easier to manufacture. sity, Lawrence Berkeley National Labora- new reactant possibilities. These organic-
The technology is said to tory, the University of South Carolina and based reactants, or iron-ligand complexes,
be ideal for medium-temper- Advent Technologies. could lower flow-battery reactant costs while
ature applications, such as
The research team will seek to build upon maintaining electrochemical performance,
the manufacturing of textiles,
chemicals and medicines,
UTRCs work on a polar polymer membrane Perry suggests.
for cooking, or any other
processes requiring temper-
atures up to 250C. A quest for making ammonia
at moderate conditions
OXIDATION CATALYST
T
Last month, BASF SE (Lud- oday, am- NH3 High prerssure, P < 10 bars N2
wigshafen, Germany; www. monia con-
basf.com) launched Camet tinues to Porous Ru
catalyst layer
ST, a new sulfur-tolerant oxi- be manu- 3H2 + N2 2NH3
dation catalyst for controlling factured by the
CO emissions from natural- Haber-Bosch pro-
gas-fired power plants. Camet cess an energy- H2 dissociation BCC metal (Nb, V & alloys)
ST builds on the companys H diffusion
intensive process Catalyst (5100 nm)
standard Camet oxidation
catalyst technology, while
that operates at
also improving the ability of high temperatures H H H H H H
Dissociative H2 H-H
the catalyst to perform in and pressures adsorption H-H
the presence of most forms (above 400C and H-H H-H
of sulfur contamination with 100 bars). For de-
minimal deactivation. In ex- cades, researchers around the world have conventional Haber-Bosch synthesis, says
tended full-scale trials, BASF been looking for alternative routes to making Way. We use a niobium or vanadium foil
Camet ST catalyst maintains NH3, such as those based on electrochem- membrane which is several orders of
performance while the com- istry, but for now, industrial efforts are pre- magnitude less expensive than palladium
petitive catalyst rapidly deac-
dominantly focused on process and catalyst coated with an H2-dissociation catalyst on
tivated, says BASF. Camet ST
is currently deployed in several
refinements for Haber-Bosch synthesis (see one side, and a nanostructured N2-dissocia-
commercial units where sulfur the Newsfront article on pp. 1821). tion catalyst on the other side.
contamination previously re- A new approach is being investigated by In proof-of-concept experiments, a ruthe-
sulted in excessive downtime researchers at the Colorado School of Mines nium catalyst was used for N2 dissociation,
and frequent cleaning. (Golden, Co.; www.mines.edu), as part of an but other materials are being examined as
Ideas project funded by the U.S. Dept. of part of the project, says Way. With ruthenium,
3-D PRINTING BNNT Energys ARPA-E program. The 11.5-year the researchers have demonstrated NH3
Researchers at the Institute project aims to demonstrate the feasibility synthesis at 0.8 bar and 500C, achieving
for Frontier Materials, Dea- of a low-cost membrane reactor for synthe- a higher rate (6 105 mol/m2.s) than that
kin University (Waum Ponds, sizing NH3. The concept uses a hydrogen- achieved by solid-state electrochemical pro-
Australia; www.deakin.edu. permeable metallic membrane to transport cesses, and without the need for supplying
au/ifm) have achieved a atomic hydrogen to the other side of the an external voltage. Ultimately, the membrane
world-first in successfully membrane where the NH3 synthesis reac- reactor has the potential to increase the NH3
3-D printing a boron nitride
tion occurs (diagram), explains professor J. flux to more than 0.1 mol/m2.s by optimizing
nanotube/titanium (BNNT)
composite. BNNTs are an
Douglas Way, the project coordinator. This the N2-dissociation catalyst, says Way. A pat-
advanced new nanomaterial makes it possible to decouple the two dis- ent has been filed on the membrane reactor
sociation reactions of H2 and N2, which concept, and Way would welcome hearing
(Continues on p. 12) compete for active sites on the catalyst of from potential industrial partners.
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Circle 06 on p. 78 or go to adlinks.chemengonline.com/66427-06
with many unique properties, Hydronium ions as charge carriers
explains professor Ying (Ian)
Chen, chair in Nanotechnol-
S
cientists at Oregon State University (rather than single protons) were incorporated
ogy. They are ultralight, super (Corvallis; www.oregonstate.edu) into the PTCDA crystal lattice, indicating a
strong and incredibly resistant
have for the first time demonstrated new chemistry for charge storage, Ji explains.
to heat, he says.
However, in the 20 years
the use of hydronium ions (H3O+) as The researchers also found that H3O+ ions
since the materials discovery, charge carriers. The research opens another diffuse at higher rates than K+ or Na+ ions
it has only been possible to avenue of exploration for high-power, sus- through the electrode structure, suggesting
produce it in small amounts, tainable batteries for stationary power-stor- that H3O+ has lower migration-activation
which has seriously limited its age applications. energy, Ji says. Although the reason for this
practical use in product devel- The research team, led by professor Xiulei low-friction property is not yet clear, it could
opment. Our novel and scal- Ji, demonstrated that hydronium ions can eventually give rise to higher-power batteries.
able manufacturing process be reversibly stored in an organic crystal- The next stage of research in this area may
can effectively eliminate this line material, perylenetetracarboxylic dianhy- be to focus on identifying cathode, anode
production bottleneck and un-
dride (PTCDA), which has been used as an and electrolyte materials for a battery system
leash the real power of BNNTs
into the marketplace.
electrode in lithium-ion and other batteries. using H3O+ as a charge carrier.
Using dilute sulfuric acid as the electrolyte, The research was published in a recent
(Continues on p. 13) the researchers confirmed that the H3O+ ions issue of Angewandte Chemie, Intl. ed.
A
suitable catalyst for splitting also less stable in an alkaline envi- Ru and C2N, a two-dimensional gra-
water to make hydrogen ronment. Catalysts made of inex- phene-like structure, to verify its per-
must exhibit high H2-con- pensive, non-noble metals corrode formance as a water-splitting catalyst.
version efficiency, excellent rapidly under acidic conditions and To synthesize the Ru@C2N catalyst,
durability, and must operate well operate at very high voltages, which the team mixed the ruthenium salt
under low voltage. For an efficient limits productivity. (RuCl3) with the monomers that form
H2-evolution reaction, the catalyst Now, researchers from Ulsan the C2N. The catalyst was then pro-
must be able to trigger proton re- National Institute of Science and duced through reduction and heat-
duction with minimal overpotential Technology (UNIST; Ulsan, South treatment processes.
and must have fast kinetics. Cur- Korea; www.unist.ac.kr), led by The researchers used the same pro-
rently, the most efficient catalysts professor Jong-Beom Baek, have cesses to produce M@C2N (M = Co,
in acidic media are platinum-based, developed a ruthenium-based Ni, Pb, Pt) catalysts. The Ru@C2N
because the strength of the PtH water splitting catalyst that acts catalyst exhibited the highest perfor-
bond is associated with the fastest almost as effectively as platinum, mance at the lowest overvoltage. It
reaction rate for the H 2-evolution but is less expensive and is not af- exhibits high turnover frequencies at
reaction. However, the Pt-based fected by the water pH. 25 mV, as high as Pt, and can be used
catalysts are expensive, and are The UNIST team has synthesized in any environment.
R
esearchers from the Agency lutants. If iron particles are turned nanoparticles to maintain a high
for Science, Technology into nanomaterials their, active sur- active surface area for effective
and Research (A*STAR, face areas are increased, which pollutant removal.
Singapore; www.a-star. enhances their chemical adsorp- The researchers observed that this
edu.sg) have developed low-cost, tion capability. However, it remains material safely traps and removes
environmentally friendly iron-hy- difficult to separate iron hydroxide contaminants by immersion in dirty
droxide coatings with unique fin-like particles from water, which is nec- water, and can then be regener-
shapes that absorb large amounts essary due to their toxicity. ated by means of a simple chemical
of pollutants, such as dyes, from To overcome this drawback, the treatment. For example, they tested
drinking water, by means of a sim- researchers synthesizing iron-hy- the material in water contaminated
ple dipping procedure. droxide coatings with a hierarchy by a Congo red dye. Within 30 min.,
Iron hydroxides are being in- of structural features, from nano- the water turned almost colorless,
creasingly used instead of con- to micrometer scales, by electro- with more than 90% of the dye at-
ventional activated charcoal (AC), deposition of aqueous metal ions tached to the special coating. Even
because AC does not easily re- onto nickel foam at mild voltages. though these coatings have some
move heavy metals and bulky or- Electron microscopy shows that of the highest capacities ever re-
ganic compounds from water. Ion the coatings nanostructure has ported, they are only operating at a
hydroxides, on the other hand, can elongated, fin-like protrusions, fraction of their theoretical capacity,
form stable bonds to those pol- which enable the immobilized the researchers say.
12 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM APRIL 2017
Peltier refrigeration expands While BNNTs have a structure
into untapped applications similar to carbon nanotubes
and share the same extraordi-
nary mechanical properties and
W
hen compared to traditional re- for scalability in terms of the amount of heat
thermal conductivity, they are
frigeration cycles, Peltier (ther- removed. As you apply an electric current
able to withstand double the
moelectric) technology has across a semiconductor chip, one side gets temperatures (up to 800C).
many benefits, including no hot and one side gets cold. The application This superior heat tolerance is
moving parts and no hazardous refrigerant of that coldness determines the commercial critical for surviving the extreme
chemicals. However, it has not yet been efficacy, he explains. However, the key to a temperatures involved in melt-
widely adopted into large-scale industrial robust thermoelectric cooling system is not ing and liquefying powders dur-
processes (due to poor efficiency, inabil- the chip itself, but the incorporation of the chip ing the 3-D printing process for
ity to scale cooling and high costs) until into a thermal system that can handle high metal matrix composites.
now. Phononic Inc.s (Durham, N.C.; www. heat flux with low parasitic losses. The me- BNNTs also have greater
phononic.com) line of Peltier-cooled refrig- chanical system design is just as important as chemical stability and elec-
trical insulation properties,
erators known as Evolve have been the semiconductor chip itself, Atti comments.
the ability to shield against
deployed into the healthcare and life-sci- Phononics thermal design involves com- neutron and ultraviolet radia-
ences sectors. The company is also cur- bining active and passive heat-transport tion and to generate electrical
rently investigating the integration of Peltier systems, that when integrated with the ad- current when subjected to
systems into industrial chilled-water loops. vanced semiconductor chips, result in per- mechanical stress.
Phononic has built working prototype refrig- formance metrics that are competitive with Deakin has patented its
erators for augmenting chilled-water loops compressor-based refrigeration systems. BNNT production technol-
in data-center cooling, and has conducted Depending on the application, the Peltier ogy, which is ready to be
successful benchtop demonstrations. units may consume 1030% less energy scaled up to meet the increas-
Phononics patented semiconductor chips than compressor cycles, says Atti. Phonon- ing demand for BNNTs, and
plans to build a commercial
deliver a large temperature gradient between ics current product offerings include 1.8-
BNNT pilot plant at its Waurn
the hot and cold side while simultaneously and 5.5-ft3 pharmacy-grade refrigerators, Ponds campus to produce
pumping a tremendous amount of heat per as well as household wine coolers. Later BNNTs in kilogram quantities.
unit area, says Tony Atti, Phononic founder this year, the company plans to release the
and CEO. This combination of traits allows worlds first solid-state freezer. (Continues on p. 14)
A
glassy solid-state electro- glass-electrolyte battery systems.
ten hardeners, ten binding agents, ten pigments
and ten additives are to be taken into account in
lyte (SSE) developed by re- The new SSEs compatibility with
the development of a coating formulation, this searchers from the University lithium, sodium and potassium en-
results in 10,000 combinations. And this does of Texas at Austin (UT; www. ables the use of these alkali metals
not even include variations in proportions. With utexas.edu) will aid in the evolution on anodes, which isnt possible with
its new, fully automated plant for testing coating of safer, longer-lasting rechargeable traditional batteries. Furthermore, the
formulations, Evonik Resource Efficiency GmbH batteries. A major concern with the SSE is also universally compatible with
(Essen, Germany; www.evonik.com) can now use of lithium- and sodium-ion bat- off-the-shelf cathodes, enabling its
accelerate the search for optimal formulations. teries is the formation of dendrites, use as a drop-in replacement for liquid
In the first step, the plant dispenses raw ma- which can interfere with liquid and electrolytes, according to Murchison
terials automatically and formulates them into
crystalline electrolytes, causing bat- and Braga. The SSE is produced via
coatings. In the second step, the substrates are
coated with the formulations, dried, and then
tery short-circuits or worse, ex- wet chemistry, in a process the team
transported to the test stand. At the test stand, plosions and fires. UTs glassy elec- believes could be readily scaled up.
the properties of the formulations are character- trolytes are non-flammable and allow Another potential benefit of batter-
ized. All steps are carried out automatically ac- for homogenous plating on the cath- ies employing the new SSEs is the
cording to a precisely defined program that can ode and anode, which eliminates ability to operate at much lower tem-
be reproduced at any time. the formation of dendrites, say UT peratures. The glass electrolyte has
The plant consists of 52 elements that are com- researchers Andrew Murchison and low activation energy for the conduc-
bined in 30 functionalities; each functionality is de- Helena Braga. Furthermore, the elec- tion of the working ions. Therefore,
signed to handle a specific task (for example, to trolyte will not oxidize at the voltages we think it will be able to work at low
apply a coating formulation to a substrate). The 52
needed to charge and discharge the temperatures, says Murchison. The
elements are connected by a rail system that goes
through all parts of the plant; on the rail systems,
electrodes that are currently available team has tested cells at temperatures
containers and substrates are transported via on the market. Simplified battery-cell as low as 20C, and in experiments,
shuttle. In addition, there are 13 robots that carry fabrication, high volumetric energy the glass electrolyte has performed
out various activities, such as loading the shuttle density and faster rates of recharge considerably better than other SSEs
or placing coated substrates in the oven. are among the other benefits of the at temperatures below 60C. n
Circle 17 on p. 78 or go to adlinks.chemengonline.com/66427-17
14 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM APRIL 2017
Circle 22 on p. 78 or go to adlinks.chemengonline.com/66427-22
Business News
LINEUP Plant Watch which has doubled the companys catalyst
SNC-Lavalin wins EPC contract for manufacturing capacity in India.
ABENGOA
ammonia plant in Oman
AMEC FOSTER March 9, 2017 SNC-Lavalin (Montreal, Ingleside Ethylene starts up
WHEELER Que., Canada; www.snclavalin.com) has been ethylene cracker in Texas
ARKEMA awarded a contract by Salalah Methanol Co. March 1, 2017 Ingleside Ethylene, LLC, the
LLC (SMC) for the engineering, procurement 50/50 joint venture (JV) between Mexichem
BASF and construction (EPC) of an anhydrous liquid S.A.B. de C.V. (Tlalnepantla, Mexico; www.
CEPSA ammonia plant, including its utilities and offsite mexichem.com) and OxyChem (Dallas, Tex.;
infrastructure, in the city of Salalah, located in www.oxychem.com), begun operation of its
ENI ethylene cracker at OxyChems Ingleside, Tex
the Sultanate of Oman. Closing of financing
EVONIK by SMC is expected to occur in June 2017. site. The cracker has the capacity to produce
550,000 m.t./yr of ethylene.
GE WATER
Messer opens its largest
GRUPO IDESA CO2-recovery plant Arkema to increase PEKK production
March 8, 2017 Messer Group (Bad Soden, in France and the U.S.
HENKEL
Germany; www.messergroup.com) recently February 24, 2017 Arkema (Colombes,
HONEYWELL UOP opened its largest CO2-recovery plant on the France; www.arkema.com) recently doubled
globe. Located in Nanjing, China, the plant the capacity of its poly-ether-ketone-ketone
KBR
has a capacity of 150,000 metric tons per (PEKK) product line in France, and confirms
LG CHEM year (m.t./yr). Messer is now recovering a its future investment at its Mobile, Ala. site in
MESSER total of 300,000 m.t. of CO2 from industrial a world-scale PEKK plant expected to come
processes per year in China. In addition to the onstream in the second half of 2018. These
MEXICHEM CO2 recovery plant, Messer is also building a investments will serve the growing needs of
OXYCHEM new technology center for gas applications the composites and 3-D printing markets.
in Nanjing.
PERSTORP KBR awarded revamp contract for
ROYAL DSM Wacker expands silicon-metal LG Chem ethylene plant expansion
capacity at Norwegian production site February 23, 2017 KBR, Inc. (Houston;
SNC-LAVALIN www.kbr.com) was awarded a technology
March 8, 2017 Wacker Chemie AG (Munich,
SUEZ Germany; www.wacker.com) is expanding licensing and basic engineering design
the capacity of its silicon-metal site in Holla, revamp contract by LG Chem (Seoul, South
SYNTHOMER Korea; www.lgchem.com) for its ethylene
Norway. The company is constructing an
WACKER additional world-scale plant in Holla, with plant in Daesan, South Korea. KBR will
capital expenditures of around 85 million provide services to expand ethylene capacity
budgeted for the capacity increase and for by 230,000 m.t./yr, resulting in a total capacity
expanding local infrastructure. Completion of 1,270,000 m.t./yr through the addition of two
of the plant is expected during the first half new furnaces and other system modifications.
of 2019.
CyPlus Idesa inaugurates
Amec Foster Wheeler wins EPC contract sodium cyanide plant in Mexico
from Eni for steam-reforming plant February 22, 2017 CyPlus Idesa, a JV
March 8, 2017 Amec Foster Wheeler between Evonik Industries AG (Essen,
(London, U.K.; www.amecfw.com) was Germany; www.evonik.com) and Grupo
awarded an EPC contract in excess of 50 Idesa S.A. De C.V. (Mexico City, Mexico;
million by Eni S.p.A. (Rome, Italy; www.eni.com) www.grupoidesa.com), officially opened its
for a new steam-reforming plant for hydrogen new production plant for sodium cyanide in
production to be built at Enis petroleum refinery Veracruz, Mexico. The new plant has capacity
in Gela, Italy. Amec Foster Wheeler will also to produce 40,000 m.t./yr of sodium cyanide.
support Eni during commissioning, startup
and testing. The companys role is expected Worlds largest MTO
to be completed in the fourth quarter of 2018. plant starts up in China
February 22, 2017 Honeywell UOP (Des
BASF inaugurates catalyst Plaines, Ill.; www.uop.com) announced that
manufacturing site in Chennai Jiangsu Sailboat Petrochemical Co. started
March 3, 2017 BASF SE (Ludwigshafen, up its methanol-to-olefins (MTO) unit during a
Germany; www.basf.com) inaugurated its new 10-day test to confirm successful operation.
mobile-emissions-catalysts manufacturing site When the full unit goes online, it will have
in Chennai, India. The site includes a new a production capacity of 833,000 m.t./yr,
Look for more 47,000-m2 production plant, which replaces reportedly making it the largest single-train
latest news on an existing BASF plant in Chennai, and is the MTO unit in the world. The facility utilizes UOPs
chemengonline.com culmination of a three-year expansion project, process technology and catalysts.
16 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM APRIL 2017
Mergers & Acquisitions Packaging Technologies (Cambridge, Germany; www.covestro.com) has
Evonik and Royal DSM form JV Mass.) business for $1.05 billion. Darex agreed to sell its North American
for algae-based omega-3 fatty is a supplier of high-performance spray polyurethane foam business to
acids sealants and coatings that generated Accella Polyurethane Systems LLC
March 8, 2017 Royal DSM (Heerlen, sales of around $300 million in 2016. (www.accellacorp.com). The sale is
the Netherlands; www.dsm.com) Darex operates 20 production sites scheduled to be completed in the second
and Evonik plan to establish a JV for in 19 countries. quarter of 2017. Financial terms have
omega-3 fatty acid produced from natural not been disclosed. Covestros spray
marine algae. The companies will build Covestro agrees to sell spray polyurethane-foam business is located
a commercial-scale production facility polyurethane-foam business in Spring, Tex.
in the U.S. at an existing Evonik site, February 22, 2017 Covestro (Leverkusen, Mary Page Bailey
which is expected to come onstream
in 2019. The JV plans to invest around
$200 million in the facility.
IN BRIEF
DIVERSIFICATION
SAVING ENERGY
NEW CATALYSTS
S
ince the start of shale-gas boom FIGURE 1. This facility in Tatarstan, Russia has a nameplate
capacity of 2,050 m.t./d of ammonia in a single train, and can
in 2012, the U.S. has been moving be operated to co-produce up to 668 m.t./d of methanol and
toward becoming an exporter of 1,382 m.t./d of ammonia using Haldor Topsoes IMAP Am-
fertilizer after decades of importing monia process
most of its fertilizers. New production plants
are beginning to come onstream some- in sustainable and energy-efficient production,
thing the country has not seen for 35 years. in part driven by stricter environmental regu-
The startup of new large facilities in major lations. Currently, three new ammonia plants
importing nations, like the U.S., Indonesia and are under construction that will use Topsoes
a few in Africa has created tremendous price SCR [selective catalytic reduction] technology
pressure in the ammonia market in the west, that limits the NOx emissions to ultra-low lev-
says Viswadeb Ganguly, director of Technol- els below 20 parts per million by volume.
ogy, Ammonia & Syngas, KBR, Inc. (Houston;
www.kbr.com). Meanwhile, the Chinese ex- Diversification
port at a very low price has created the same New requirements for diversification have
impact in urea processes in Asia, he says. increased the interest in Topsoes IMAP (In-
With quite a few new plants expected to tegrated Methanol & Ammonia Process) so-
come onstream in 2017 and 2018, it will take lution for co-producing ammonia and meth-
some time for prices to improve significantly. anol, says Kjul Hoffmann. The IMAP portfolio
In the last 23 years, the market has been of processes provide varying ranges of flex-
characterized by oversupply of urea and de- ibility between ammonia and methanol pro-
clining nitrogen prices, says Merethe Kjul duction tailored to the market needs. The
Hoffmann, technology marketing manager, IMAP process combines state-of-the-art
Haldor Topsoe A/S (Lyngby, Denmark; www. NH3 and methanol technologies in a way
topsoe.com). Producers have reacted by di- that minimize the emissions from the plant,
versifying their production, making specialty because all CO2 generated from the process
fertilizer, and revamping plants to improve ef- feed is converted to either urea or methanol,
ficiency and capacity, she says. Across the and all the process condensate is recycled
board, producers are increasingly interested back to process. Over 24 years, eight IMAP
18 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM APRIL 2017
thyssenkrupp Industrial Solutions
Exhaust
Plant air
Dedusting filter
Storage Scrubber
Ammonium tank Droplet separator
sulfate
solution
Granulation
Water
Scrubbing
PROCESS
additive
Fluidized-bed
granulator
Recycle
conveyor
Screen-
solution tank
PLANTS FOR
ing
Crusher
Steam
Coating
agent Ammonium
Air Coating sulfate
drum granules
Condensate
FIGURE 2. Launched last month, this patented process produces ammonium sulfate granulate using a
fluidized-bed process
plants (both revamps and grassroots for additives to make urea granulate
plants) have been taken into indus- containing sulfur either as elemen-
trial operation. The worlds largest tal S or as sulfate and will commis-
IMAP plant (Figure 1) was commis- sion its first urea-ammonium-sulfate
sioned in 2015 in Tatarstan and was (UAS) plant in Russia this year. As an
the first grassroots fertilizer in the for- alternative to its FB granulation, the
mer Soviet Union in decades. company is also working with pastil-
Margins have become thin for lation technology in collaboration with
many producers, many of which are Sandvik Process Systems (Fellbach,
looking to sell a product with an edge, Germany; www.sandvik.com).
says Stephen Zwart, vice president Meanwhile, Shell Thiogro (www.
licensing, sales and services, Stami- shell.com/sulphur/thiogro) and Uhde
carbon B.V. (Sittard, the Netherlands; Fertilizer Technologies (UFT; www.
www.stamicarbon.com). That means uhde-fertilizer-technology.com), part
not just urea, but urea with other addi-
tives, such as sulfur or sulfate, micro-
of thyssenkrupp Industrial Solutions
AG (tkIS; Essen, Germany; www.
Hydrogenation
nutrients and others, he says. Also, thyssenkrupp-industrial-solutions. Solids blending / drying
applications for urea other than fertil- com), established a partnership to in-
izer are emerging, he says. tegrate UFTs FB granulation technol- Pharma, food, cosmetics
Ten years ago, 90% of the urea ogy with Shells Urea-ES (enhanced
manufactured was used for fertilizer; sulfur) technology, which was intro- Finechemicals
now its dropping to 80%, says Zwart. duced in May 2015. The two com-
This shows the growth of non-fertilizer panies successfully granulated Shell-
applications, he says. For example, developed Urea-ES emulsion in UFTs
the use of urea solutions, known as FB granulation pilot plant in Leuna,
DEF (diesel exhaust fluids), as deNOx Germany. Combining the two tech-
agents for SCR of the exhaust from nologies will enable the largest urea Your fast lane to
diesel-engines is now widespread in plants in the world to produce granu- advanced mixing technology:
the U.S., Europe and Brazil, taking off lated sulfur-containing urea (Chem.
in China, and is expected to grow in Eng., May 2016, p. 8). Phone: +1 201 825 4684
other regions as well, such as South- The advantages of Shells technol- Ext.: 205
east Asia and Russia, says Zwart, ogy have been combined with the fea-
usa@ekato.com
adding that Stamicarbon has applied tures of UFTs FB granulation process,
technologies in urea plants to produce where the granulation mode is accre-
DEF and improve operating margins. tion instead of layering. The elemental
Stamicarbons widely used urea sulfur liquor is finely dispersed in the www.ekato.com
fluidized-bed (FB) granulation tech- urea melt before the solution is fed to
nology appears to be very suitable the granulator. Just as in the normal
Circle 10 on p. 78 or go to adlinks.chemengonline.com/66427-10
COLLECTING DATA
F sors have been used tential
in the chemical pro-
cess industries (CPI)
for many activities, includ-
ing monitoring the health
to change the health and safety paradigm
regarding collection of employee exposure data
DOWNTIME IS COSTLY
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Circle 12 on p. 78 or go to adlinks.chemengonline.com/66427-12
I
f youre in the market to increase facility and employee safety but baths, pipe joints for chemical tanks or fluid levels, the safety applica-
arent ready to don wearable technologies just yet, experts sug- tion is in correcting the issue immediately and reducing the probability
gest looking outside the realm of safety sensors and into sensors of unnecessary future access into the hazard area.
that werent traditionally used for safety applications. Sensors such And, non-traditional sensors can be used in conjunction with safety
as those used for level and leak detection and tunable diode lasers sensors for further improvements. For example, when using machine
(TDLs) are currently being employed in chemical applications to avoid automation controllers, which integrate motion, robotics, safety vision
accidents and prevent processes from going out of control, keeping and sensing along with Omrons SQL database, a date and time stamp
plant and personnel safer than ever before. can be tracked. This information can be used to look for trends and
What were seeing is the application of sensors that were tradition- lead to design improvements, says Hull. For example, the liquid-leak
ally used for other applications being applied and related to the safety sensor may detect leakage on a cleaning device at a consistent time,
of not only the process, but the people around the process, as well, such as 4:00 PM, and the safety devices record that the interlocking
says Gene Cammack, director, System Product Marketing with Yok- safety switch is activated within 30 minutes of detection. Activating the
ogawa Corp. of America (Sugar Land, Texas; www.yokogawa.com). interlocking safety device puts the machine into a safe state. The data
For example, we are applying TDL analyzers into a lot of safety ap- could be a warning that a change elsewhere in the system might be
plications because it gives an open path that scans all the way across needed, she says. Perhaps there is a heating element too close to
the boiler to look for specific gases that may create problems with the cleaning station that either needs to be placed at another location
safety, he says. We hadnt really done that before, but its an excel- or it needs to be insulated. This type of change would then reduce the
lent application and now the TDL technology is having a moment as leakage pattern, and thus reduce the operators need to access the
a safety-related sensor, rather just in its traditional use for measuring hazardous area, and even increase production.
the content of the process. In addition, safety is further promoted because the devices are be-
Because the TDL technology shoots a beam across a space and coming more reliable thanks to self diagnostics, says William Sholette,
scans for specific gases, it is possible to set it to scan for gases such level product business manager for Endress+Hauser, Northeast,
as oxygen, carbon monoxide and hydrocarbons in a boiler. The sen- (Greenwood, Ind.; www.us.endress.com). There are more diagnos-
sor technology allows sight into different areas of a boiler that are tics inside the unit, such as watchdog circuits to make sure the micro-
more susceptible to buildups of gases, which can create fire or ex- processors are all working and communicating with each other, he
plosion hazards. Many of these areas couldnt be measured before, says. This is constantly done in the background and is monitored all
but because TDLs are a non-contact technology, the sensors dont the time so, if it fails or gets into a fault condition, a notification is sent
have to be embedded into the gas stream. So instead of using a point to alert users that something is wrong.
sensor, the TDL provides a broader look at whats happening inside, He adds that some companies, such as E+H, take self diagnostics
all the way across the boiler, making it much more advantageous to a step further in some sensors, such as the companys FTL 81-point
sensing the safety level in boiler, cracker or refinery application where level switch, and add a square wave signal onto the current so that it
explosions occur due to offgas in the electrostatic precipitators. is constantly modulating. The unit makes sure it can actually change
He adds that another bonus of the TDL technology is that the in- current by looking at the square signal. If it is modulating, the cur-
formation is provided in realtime, which traditional safety sensors for rent can obviously change, and therefore, it will change in a situation
these applications cant provide. This is why its a big deal in the where it needs to go into a fault condition, he explains. We are trying
safety world. to make these units, especially those used in personnel and process
Tina Hull, product engineering-safety, with Omron Corp. (Hoffman safety, more reliable and more responsible for themselves so they will
Estates, Ill.; www.omron.com) sees a similar trend. We are learning reliably signal if theres a problem that needs attention.
to apply a lot of non-safety sensors to detect activities or events that Its an interesting and evolving area as we try to figure out how
could potentially send a human into a hazardous area or situation, so to keep people and processes safe, especially as we scale back on
by applying more advanced sensors for things like leak detection and human resources and make things more automated, notes Cam-
motion, we are providing more benefits than safety sensors alone. mack. We have to ensure that safety is built into the systems and
For example, she says, detecting when a leak begins and correcting ensure that we maintain the sensors and other parts of the functioning
it quickly can reduce the probability of a slip or fall. While the sensors safety system. Everyone is trying to do more with less, but they dont
primary purpose is detecting leaks on applications such as measuring want to do it with less safety.
ity element to alert the worker that he that use sensor technology to con- provides critical sensor nodes within
or she may be in a dangerous situa- nect workers to realtime information the visual factory. Glasses and
tion and also gives an alert to some- and to each other (Figure 2). The wearables go everywhere hands-
one if the worker is in trouble. It also fundamental purpose is connecting, on employees go, so a tremendous
provides situational awareness in that keeping safe and providing informa- amount of data is generated by these
the sensors are consistently measur- tion to the hands-on workforce as operators, he says. Those data go
ing exposure limits and warning the they do their work, says Jay Kim, back into the system to make data
workers of danger. Theres a third chief strategy officer with Upskill. analysts and workers even smarter.
benefit around worker productivity, as The benefit of wearable technol- In addition, the wearables allow
the connectivity can be used to pro- ogy, such as smart glasses, is that information sharing. Shared informa-
vide information to the workers with their hands are now free so work- tion could include the actions and
instructions about work flow, says ers can keep their hands and eyes steps of safety procedures, such as
Prabhu Soundarrajan, Connected on the tasks at hand. This provides lock out/tag out. Another safety-en-
Worker leader, with Honeywell. increased productivity, improved hancing example might be the use of
Upskill, formerly known as APX safety and better efficiency in ac- what Kim refers to as a simple see-
Labs, (Herndon, Va.; www.upskill. tivities throughout the facility and in what-I-see scenario in which the
io) provides its Skyline platform, hazardous situations. number of people sent into a hazard-
which powers enterprise wearables Further, says Kim, the technology ous area can be reduced because
24 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM APRIL 2017
Vandrico Solutions
head-mounted displays, make sense
because it goes on the body, which
helps determine the realtime location
of the worker, if needed, and gets the
workers attention, says Gonzalo
Tuleda, CEO with Vandrico. With the
prolific use of smartphones, we all
have notification fatigue and tend to
ignore a lot of notifications. But a vi-
bration on the wrist or a flashing light
under a hard hat will get the workers
attention when needed. By combin-
ing the sensors that are in the mine
with a sensor on wearable technol-
FIGURE 3. Vandrico Solutions is exploring the use of networked sensors coupled with software solutions ogy, you can provide realtime safety
and electronic technologies to increase the safety of miners
alerts in an automated way.
remotely located experts could pro- increase the safety of miners (Figure
vide over-the-shoulder coaching to 3). One of the potential uses here The sum of the parts
an individual completing tasks in a would be to use sensors that are Advanced safety solutions such as
dangerous area using a front-facing able to determine shifts in rock and these are dependent upon several
camera on the smart glasses, rather seismic activity, which are linked to system components. According to
than sending the entire team in to software and wearable devices and Honeywells Soundarrajan, in most
complete the activity. used to send realtime alerts to work- solutions, advanced sensors are
And, Vandrico Solutions (Vancou- ers in an automated way. In min- used to measure the hazard, such as
ver, Canada; www.vandrico.com) ing, its often difficult to get signal a chemical parameter, gas or chemi-
is exploring the use of networked propagation, so one of the theories cal substance. That data gets com-
sensors coupled with software solu- we have is that wearable technology, municated from point A to point B
tions and electronic technologies to such as helmets, smart watches and via a communications infrastructure,
Circle 23 on p. 78 or go to adlinks.chemengonline.com/66427-23
Think Magnetrol .
To meet increasing regulatory,
environmental, social and bottom line
demands, rely on Thermatel TA2 for
your energy management solutions.
Natural Gas
Air Flow
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Visit our new portal at
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management and thermal flow
metering technology.
Circle 19 on p. 78 or go to adlinks.chemengonline.com/66427-19
Focus
The TODO TTMA 4-in. Aluminum Fittings now have Type 316
High productivity solidi cation of
Break-Away Coupling (photo) is de- stainless-steel options
products as di erent as resins, hot
signed to reduce the potential for The T&B Liquidtight Systems family
melts, waxes, fat chemicals and
damage and spillage and product of stainless-steel fittings (photo) for
caprolactam has made Rotoform the
loss during the loading and unloading stainless-steel flexible conduit has granulation system of choice for
of road tankers. The device has been added a new addition: SAE Type chemical processors the world over.
adapted for bottom-loading-arm ap- 316 stainless steel, a marine-grade Whatever your solidi cation
plications, and it can be used on new stainless steel with enhanced resis- requirements, choose Rotoform for
loading arms, or retrofitted into exist- tance to galvanic corrosion in food- reliable, proven performance and a
ing ones that currently use the same and-beverage applications and premium quality end product.
type of TTMA flange in their con- other particularly corrosive settings.
struction. It consists of two identical The design of these fittings has High productivity
halves joined together by a series of also been updated for improved on-stream factor of 96%
3-mm break pins allowing the device protection against liquid ingress. Proven Rotoform technology
to be configured to separate at a de- New features include the dome- nearly 2000 systems installed
fined load. Should an excessive load shaped gland nut that is unique in 30+ years
be placed on the loading arms, the to this family of products, says the Complete process lines or
pins automatically close the internal company, which prevents liquids retro t of existing equipment
valves, to protect the driver and the from pooling in the electric box. Global service / spare parts supply
environment. The device can then be And, the SafeEdge ground cone
reset onsite. Emco Wheaton USA, securely attaches to the conduit for
Houston improved pullout performance that
www.emcowheaton.com exceeds UL requirements, says
the company. Sizes range from
Silicone masterbatch 3/8 to 2 in., and they are available Sandvik Process Systems
Division of Sandvik Materials Technology Deutschland GmbH
improves polyethylene in 45-deg, 90-deg and straight Salierstr. 35, 70736 Fellbach, Germany
Tel: +49 711 5105-0 Fax: +49 711 5105-152
processability configurations. Thomas & Betts, info.spsde@sandvik.com
The MB25-502 silicone mas- Memphis, Tenn. www.processsystems.sandvik.com
terbatch provides processabil- www.tnb.com
Circle 24 on p. 78 or go to adlinks.chemengonline.com/66427-24
Metal-oxide semiconductor (MOS). and Health (NIOSH) as exposure to airborne contaminants that is "likely to cause death or immediate or delayed permanent
adverse health effects or prevent escape from such an environment."
Metal-oxide semiconductors are 2 REL refers to recommended exposure limit, an occupational exposure limit that has been recommended by NIOSH and
based on the principle that gas ad- the Occupational Safety and Health Administration (OSHA) for adoption as a permissible exposure limit.
3 TWA is the time-weighted average, used to indicate the average exposure over a specified time period (usually 8 h,
sorption onto, and desorption from,
unless otherwise indicated)
the surface of a metal oxide changes
the conductivity of the material. When action, and the wiring resistance is of the light between the transmitter
target molecules contact a thin film changed by the temperature rise. and the receiver.
of high-surface-area sensor material, Typically, a bridge circuit is used to
the concentration of charge carriers indicate the resistance change. The Common detectable gases
(electrons or holes) changes, and the increased resistance compared to The table [1] contains information on
conductivity or resistivity is altered in a the resistance in clean air is used possible gas detection targets. n
measurable way. to indicate the gas concentration.
Catalytic. Most sensors of this type Infrared. Infrared sensors work via a References
work by catalytic oxidation, where the system of light transmitters and re- 1. National Institute of Occupational Safety and Health
(NIOSH), NIOSH Pocket Guide to Chemical Hazards, CDC,
combustible gas of interest comes ceivers. When combustible gases of www.cdc.gov/niosh/npg/default, accessed March 2017.
into contact with a catalytic surface interest come within the field of view 2. Fine, G.F. and others, Sensors, 10, pp. 5,4695,502,
(often platinum-treated wire coil) and of the receiver, a portion of the radia- 2010.
is oxidized. This releases heat of re- tion is absorbed, changing the power 3. Figaro Engineering Inc., Gas sensor technology, ac-
cessed March 2017, www.figaro.co.jp
CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM APRIL 2017 33
Technology Profile
Bio-based Adipic Acid Production from Glucose
By Intratec Solutions
A
dipic acid is one of the most
Cyclohexane Two-stage oxidation Fermentation Glucose
commercially important ali-
phatic dicarboxylic acids. It
is produced on a large scale Phenol Hydrogenation + Adipic acid Fermentation Fatty acids
primarily to supply the nylon 6,6 pro- oxidation
FIGURE 1. The production of bio-based adipic acid from glucose via a two-step catalytic process is shown here
34 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM APRIL 2017
3D Level Sensor Visualizes Material in Silo Under Pressure - how to safeguard high
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solids stored in silos. including pres-
Accounts for surface sures up to several
variations in lump thousand bar and
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Dry Screw Vacuum Pumps for Solvent Handling Step up to the Vari-Flow Distribution Valve
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reduced power consumption and lower exhaust tempera- used for balancing ow.
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D
Eberhard rying solids is a de- Filling
Tritschler manding task that
Mixing/recondensing of solvents
Ekato Systems GmbH requires both knowl-
edge of process tech- Evaporation of Evaporation of
Heating free solvent bound solvent Cooling
nology and a sound mechani-
Discharge
cal design of the equipment
IN BRIEF used. This article provides an FIGURE 1. Batch drying processes typically consist of the components and
VACUUM DRYING overview of batch-drying prin- steps shown here
ciples and possible options for vertical vac- material without changing its original chemi-
BATCH DRYING
uum-contact dryers. cal composition. In essence, there must be
PROCESS
Most solids in the chemical process indus- no changes to the molecular structure dur-
EQUIPMENT OVERVIEW tries (CPI) are recovered by precipitation or ing the drying process and no derivatives
VACUUM DRYER DESIGN crystallization. The suspended solids are me- formed due to the drying process.
chanically separated by filtering or centrifug- A vacuum contact dryer is built to evapo-
DUST FILTER
ing in the first instance. In most solid-liquid- rate solvents from a solid by the use of the
SOLVENT-RECOVERY separation processes, thermal evaporation following physical and mechanical param-
SYSTEM does not compare favorably with mechanical eters: temperature; low pressure; and me-
PROCESS CONTROLS
separation by filtration or centrifugation with chanical fluidization by agitation.
respect to energy efficiency. However, when In most cases, vacuum contact dryers are
DRYING PROCESS STEPS it comes to the final moisture content, ther- restricted by the requirement that they not
CONCLUDING REMARKS mal evaporation is often the follow-up step to influence the chemistry of the product. How-
mechanical dewatering methods in order to ever, special processes are possible, where
achieve the desired dryness. the application of high temperature will initi-
The residual moisture content of the solids ate or control a chemical reaction.
after filtration or centrifugation is influenced The degree of residual moisture in the fin-
by the properties of the solids crystal struc- ished product is strictly related to the use
ture. A typical filtration cake can show resid- of the product and its specifications. Ex-
ual moisture content of between 5 and 45%. amples include the following: less than 5%
To dry a wet cake to lower values, thermal moisture for waste material for disposal;
evaporation is an effective way to achieve a less than 3% in foodstuffs for storage con-
true dry solids powder. siderations; less than 1% in herbal extracts;
For some products, continuous drying pro- and less than 0.1% in active pharmaceutical
cesses, such as belt and conveyor drying or ingredients (APIs).
spray drying, are suitable methods to achieve A vacuum contact dryer can achieve these
a dry powder in a single pass. While continu- values for the separation of solids from sol-
ous systems are not a subject of this article, vents and there are cases where the solids,
more information can be found in Part 2 of the solvents or both, are valuable products.
this Feature Report, Optimizing Analysis for
Spray Drying Processes (p. 43). Batch drying process
Almost all batch drying processes consist
Vacuum drying of the process steps mentioned in Figure 1.
During any drying process, all additives and Whether the steps are performed in a non-
solvents have to be removed from the solid agitated tray or in an agitated vessel, the con-
36 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM APRIL 2017
cepts discussed here for evaporation and Dust filter
re-condensing and collecting the solvents are
the same.
Each process step in batch drying has in-
dividual issues that require special attention:
Filling. During filling, factors such as the use
of gravity or force (pumping), as well as the
need for a contamination-free transfer into
the dryer will have to be addressed.
Heating source
Mixing. In order to create an even tem- Solvent recovery system
perature and solvent-concentration dis-
tribution in the bulk material, as well as to
support the outflow, mixing is mandatory in
the dryer. However, the influence of shear
forces created by the mixing action on the
solids needs to be addressed. Vacuum dryer
CIP system
Re-condensing. Whether the purpose of
the drying is to retain the dry power and
discard the solvent, or vice-versa, is deter- Evaporation of bound solvent. Some sol- FIGURE 2. Vacuum drying
mined by the user. Re-condensing and col- vents tend to stick to the solid particles by systems require several
pieces of key equipment
lection of the solvents is a demanding task physical bridging, or to hide in the pores of
in the process. the particle structure, while others dont. In
Evaporation of free solvent. The solvent order to predict required process times, de-
selection dictates the evaporation condi- tailed knowledge of the separation behavior
tions (enthalpy) and the maximum tempera- is critical.
ture limits of the solids dictates the thermal Cooling. For safe discharge, it might be
limitations for the drying system. required to cool the solids to very low tem-
PROTECT PUMPS
DRYRUNNINGCAVITATIONBEARINGFAILUREOVERLOAD
PUMPING
AMPS
Circle 18 on p. 78 or go to adlinks.chemengonline.com/66427-18
Food Ingredients
Size Reduction
Herbicides Minerals
Wet & Dry Size Reduction
Steel & Ceramic Lined Mills Nutraceuticals Pesticides
Jars & Jar Rolling Mills Pharmaceuticals Pigments
Q
U
A
EXCELLENCE
I
T
Y C O R P O R AT I O N
Environmentally Safe VpCI /MCI Technologies
Quality &
Innovation Since 1911
Optimizing Analysis
for Spray-Drying
Precise control over spray-drying processes can be enabled by modern measurement
approaches that provide information on particle size and shape in realtime
Daisuke
Sasakura and
Fumiaki Sato
Malvern Instruments
Hayato Kato,
Shinya Kawaguci
and Yuichi
Misumi
Preci Co. Ltd.
FIGURE 1. Atomization technolgy is critical for spray drying processes. These photos show rotary atomizers (left), two-fluid IN BRIEF
nozzles (middle) and pressure nozzles (right) SPRAY DRYING
ADVANTAGES
T
he process of spray drying is ex- powder; subsequent classification ensures
ATOMIZATION
tremely valuable to a wide range of a closely defined particle size distribution. A TECHNOLOGY
solid-product manufacturers due spray drying process can be operated as ei-
to its ability to produce particles ther an open system, in which filtered air exits PARTICLE SIZE AND
with precisely controlled size and shape. to the atmosphere, or in a closed loop under SHAPE
Cutting-edge spray drying technology is inert gas, with solvent recovery, depending on LASER DIFFRACTION
used in industries ranging from food and the characteristics of the powder being pro-
CONTINUOUS PARTICLE
pharmaceuticals, to industrial materials, duced and of the original slurry or solution.
SIZING
metal powders and chemicals. Spray dry- Spray drying offers a number of significant
ing technology is typically selected for its advantages relative to other powder-produc- INCLUDING PARTICLE
ability to deliver standardized particles, so tion methods that give it broad commercial SHAPE
optimizing analytical strategies for process appeal. First, it produces highly spherical A MODERN APPROACH
monitoring is crucial to its successful imple- particles that consequently tend to have
mentation. Methods for monitoring spray excellent fluidity. It also delivers particles or
drying have developed significantly in re- granules with a sharp, stable and closely
cent years, with new technologies making defined particle-size distribution, offering
it easier to achieve precise control. In this a highly consistent output. Furthermore,
article, we look at those techniques that spray-drying processes can be operated
are proving particularly valuable, focusing continuously, minimizing the manual input
on online particle sizing and automated im- and potential for variability associated with
aging, a technology that quantifies particle batch processing (For more on batch dry-
shape, as well as size. ing, see part 1, Batch Drying with Vacuum
Contact Dryers, p. 36). These benefits bring
Spray drying advantages value in the manufacture of products as di-
Spray drying produces a dry powder from a verse as milk powder, vitamins, antibiotics,
liquid solution or slurry. The liquid is sprayed cosmetics, pigments, ceramics and metal
into a drying chamber in which air, or an inert powders including steel and rare-earth-
gas, drives off the solvent to leave a dried metal-based products.
1.2
providing a continuous stream of analytical
data with no manual intervention. Eliminating 1.0
%
increase in viscosity will result in an increase in droplet size. An alterna- 1.0
0.8
tive way of looking at this is that solutions of higher viscosity require
0.6
greater energy input to achieve successful atomization for an equiva- 0.4
lent droplet size. The example discussed here shows clearly how a 0.2
viscosity change can impact droplet formation and, consequently, can 0.0
0.1 1 10 100 1000 10000
affect the morphology of the resulting powder particles. CE diameter, m
Observing the impact of viscosity on the proper- TABLE 1. MATERIAL DIFFERENCES AND SLURRY VISCOSITY
ties of spray dried particles. Because spray-dried
Batch Dv50, m Slurry viscosity, mPas
materials are prized for their precisely defined proper-
ties, reproducibility is critical to the value of products 1 50 2,200
manufactured. The graph here shows data for two
2 39 350
batches produced under identical spray-drying condi-
tions. The particle size Dv50 for the resulting granules Differences in the material have a significant effect on the slurry viscosity, and the size of the product
for the two batches are 52 and 39 m, respectively.
Investigations into the reason for the observed difference in performance highlighted a marked difference in the viscosity of the slurry used
to produce each batch (Table 1). Though the stock solutions for both batches were produced by milling for identical periods of time using
identically sized balls within the mill, the ball-mill media material and weight were changed between the two runs. This led to a substantial
difference in the viscosity of the two stock solutions. The observed change in particle size is attributed to this difference. Establishing control
over the ball-mill charge conditions corrected this issue and delivered the consistent viscosity required to ensure reproducible manufacture.
50
products. Furthermore, the calculations
40 that underpin laser diffraction analysis
30 assume that the measured particles are
20 spherical, so results can be affected by
10 changes in particle shape. Automated
0 imaging makes it straightforward to
0.7 0.8 0.9 1.0 confirm that samples are adequately
HS circularity
Blue, 12,000 rpm, Dv50 = 36 um: Green; 1,000 rpm, Dv50=32 um dispersed prior to laser diffraction analy-
Black; 8,000 rpm, Dv50 = 53 um: Red; 6,000 rpm, Dv50=56 um sis so that primary particles, rather than
46 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM APRIL 2017
agglomerates, are measured, and detects erating conditions of interest to determine
changes in shape that may skew the particle those required to produce the target Dv50
size data generated. (median particle size) and the time taken for
The following real-world examples illus- the process to stabilize. The target Dv50 in
trate how laser diffraction and imaging in this case was 5565 m, but the level of
combination support the optimization of fines in the product was also a concern. The
spray-drying processes. ability of the on-line system to accurately
Case 1: Optimizing process conditions measure down to around 0.1 m was there-
with respect to particle size and shape. fore an important benefit.
Rotary atomizer technology was selected for Figure 6 shows that as the speed of rota-
the production of alumina particles and tests tion of the disk is stepped down, the particle
were then carried out to determine
the optimum speed of rotation of the
disk. The feed solution for the pro-
cess was a mixture of alumina par-
ticles, water and polyvinyl alcohol
(PVA), which was added as a binder Introducing the improved
within the suspension. In an initial
test series, rotary speed was varied
in the range 6,000 to 12,000 rpm
Sentry Saf-T-Vise
and the size of the resulting particles
was compared to the target speci-
corrosion monitoring
fication, which defined the required
Dv50 as being greater than 50 m.
products and services
From these results, a speed of rota-
tion of either 6,000 or 8,000 rpm was
identified as being suitable (Figure
4). A rotational speed of 6,000 rpm
The safest choice under pressure
is preferable from the perspective
of energy consumption. However,
shape analysis reveals that in fact, Sentry Saf-T-Vise Corrosion Monitoring
these two speeds are not equally products enable chemical engineers and
suitable in terms of the particle mor- field technicians to maximize production,
phology of the resulting particles. mitigate materials failure in pipelines while
Shape data show that the higher optimizing chemical usage. This patented
speed of rotation (8,000 rpm, rather
technology far exceeds the rest for operator
than 6,000 rpm) produces more
safety and ease-of-use even in extreme high
spherical particles that, because of
pressure conditions. The Saf-T-Vise portfolio
their shape, are likely to have su-
perior fluidity (Figure 5). Here then, has been redesigned and economically
shape data provide additional, valu- priced to accommodate pressure ratings
able insight into the liquid breakup up to 10,000 psi without any sacrifice to
process and its result, supporting safety. Its our contribution to the economic
process optimization to a more suit- recovery of the oil & gas industry.
able conclusion.
Case 2: Studying process dynam-
ics to define production condi-
tions. A further study of the impact
of disk-rotation speed on the size
of spray-dried particles produced
using a similar alumina-water-PVA
suspension to the one tested in
Case 1 was carried out using re-
altime size-monitoring technology,
an on-line laser diffraction particle Visit sentry-equip.com /corrosion to learn more.
size analyzer. Here, tests at differ-
2017 Sentry Equipment Corp. All rights reserved. All trademarks are the property of Sentry
ent speeds of rotation were carried
Equipment Corp.
out over a relatively short timescale,
simply by stepping through the op- Circle 25 on p. 78 or go to adlinks.chemengonline.com/66427-25
Authors
11:20 12:20 13:20 14:20 Daisuke Sasakura is a product specialist for
cross-product marketing at Malvern Instru-
ments (Enigma Business Park, Grovewood
FIGURE 6. Realtime measure- size of the resulting droplets increases, as ex- Road, Malvern WR14 1XZ U.K.; Phone: +44
ment makes it possible to pected. However, after each change, it takes 1684 892456; Email: salesinfo@malvern.com;
instantly observe the effect Website: www.malvern.com). Prior to his cur-
of decreasing the speed of a certain amount of time for the particle size rent position Sasakura served as product spe-
rotation of the atomizing to steady at a new a value. The realtime data cialist for analytical imaging at Malvern from
disk and the time taken for accelerate the assessment of different oper- 2011 to 2015. He holds a Ph.D. in analytical
the process to re-establish a science and vibrational spectroscopy from
steady state. (The green line
ating conditions but, at the same time, clearly Showa Pharmaceutical University.
represents Dv10, blue line is highlight the need to run for around 30 min- Fumiaki Sato is a product specialist for pro-
Dv50, orange is Dv90, red is utes to generate robust particle size informa- cess systems at Malvern Instruments. Sato
transmission) tion at each new speed. Equally importantly, has been with the company since 2013.
these data provide information as to when
a process change in a manufacturing plant
will feed through to a changed product that
can be securely collected as in-specification
material. The sweet spot for this process
is found to be a speed of rotation of 8,000 Hayato Kato is the CEO of Preci Co. Ltd. (2-
11-6 Taito, Taito-ku, Tokyo 110-0016 Japan;
rpm, which produces particles with the re- Phone: +81 3-3839-4540; Website: www.
quired Dv50 and an acceptable level of fines preci.co.jp.). Prior to becoming CEO, Kato
as quantified by Dv10 data (Table 2). served as strategic officer at Preci from 2008
to 2012. Kato holds a master's in business
administration in international business from
A modern approach Tsukuba University.
Spray-dried powders are prized for their fluid-
ity, shape and tight particle size distribution. Shinya Kawaguchi is chief of the Powder
Producing standardized, spherical particles is Technical Center at Preci Co Ltd. Prior to that,
Kawaguchi was manager of the sales team for
crucial and relies on exerting effective process the drying machinery department at Preci
control. Timely, relevant particle characterization from 2013 to 2016 and has worked for Preci
is essential. Commercial realtime particle sizing since 2012. Kawaguchi holds a bachelor's
degree from the Tokyo University of Science
technology makes it possible to continuously
monitor the quality of spray-dried powders, as
Yuichi Misumi is an application specialist in
TABLE 2. ATOMIZATION DISK ROTATION SPEEDS AND PARTICLE PROPERTIES powder manufacturing at Preci Co Ltd., and
10,000 rpm 8,000 rpm 6,000 rpm has been with the company since 2011.
Crossflow Membrane
Filtration Essentials
Several aspects of crossflow membrane filtration , including process design, equipment
selection and control, are detailed here
A
membrane, also re- Feed Alan Gabelman
ferred to as a semi- Gabelman Process
Retentate
permeable mem- Solutions
brane, is a thin layer
of material that selectively
passes one or more com-
ponents of a feed solution or IN BRIEF
slurry, while retaining the oth- Permeate ADVANTAGES AND
ers. Biological membranes DISADVANTAGES
have existed since the dawn BATCH PROCESS
of time, but synthetic mem- Circulation pump FLOWSHEET
branes are of greater indus-
MF AND UF BASICS
trial importance. These were
first employed commercially FIGURE 1. Crossflow membrane filtration (CMF) differs from conventional filtration
in that feed flow is parallel to, rather than perpendicular to, the filtration surface
PRESSURE EFFECTS AND
in crossflow filtration opera- POLARIZATION
tions in the 1960s, and growth DESIGN
in the ensuing years was remarkably fast. sion that do lead to retention of dissolved CONSIDERATIONS
Today, crossflow membrane filtration (CMF) species, including adsorption onto the mem-
is a major unit operation that is pervasive in brane surface or the undissolved solids MEMBRANE MATERIALS
numerous industries. themselves. The relatively large pores char- MODULE
The concept is illustrated in Figure 1. Un- acteristic of microfiltration membranes are CONFIGURATIONS
like conventional filtration [1], feed flow is known as macropores. DIAFILTRATION
parallel to, rather than perpendicular to, the Like microfiltration, ultrafiltration (UF) oper-
filtration surface. During a given pass, only ates using traditional size exclusion, but with CONTINUOUS
a small portion of the feed permeates the smaller mesopores rather than macropores. OPERATION
membrane and becomes permeate, while While both UF and MF are used to remove MEMBRANE FOULING
a much larger portion is retained as reten- undissolved solids, UF membranes are also AND CLEANING
tate. Most of the retentate is returned for capable of separating large and small mol-
multiple passes, by the action of the circula- ecules in solution. UF membranes are de-
tion pump. This allows a high linear velocity, scribed by their nominal molecular weight
which imparts a shear to the membrane that (MW) cutoff (NMWC), which is a rough in-
helps to keep the filtration surface clean. The dication of the smallest molecule that the
valuable stream may be the permeate, the membrane will retain. However, because
retentate, or both.
As shown in Table 1, membrane pore size TABLE 1. CROSSFLOW MEMBRANE FILTRATION PROCESSES
varies considerably, with separation capa- Membrane process Separation Separation Transport regime
bilities from angstroms () to several microns mechanism capability
(m) in particle size. The relatively coarse Microfiltration Size exclusion 0.110 m Macropores
microfiltration (MF) membranes are used to Ultrafiltration Size exclusion MW 1,000500,000 Mesopores
g/mol
separate liquids from undissolved solids by Nanofiltration Size exclusion, elec- MW 100-1,000 g/mol Micropores
size exclusion, as in traditional filtration pro- trostatic exclusion
cesses. In principle, the liquid composition Reverse osmosis Solution/diffusion MW <100 g/mol Molecular
does not change, although in some cases Gas separation Solution/diffusion Molecular size Molecular
there are phenomena other than size exclu- ~0.0001 m
Circle 21 on p. 78 or go to adlinks.chemengonline.com/66427-21
Water
www.sturtevantinc.com
FIGURE 12. A sintered stainless-steel module is
fabricated as one solid, highly porous unit Circle 26 on p. 78 or go to adlinks.chemengonline.com/66427-26
Continuous operation
Batch and semi-continuous pro-
Permeate cessing are discussed above, and
these operating modes are impor-
Feed
tant when volumes are relatively
Steam
small. However, as with other chemi-
Water
cal engineering unit operations, con-
tinuous processing is more efficient
Feed tank Stage 1 Stage 2 Stage 3
and cost-effective when volumes
are large. In most cases, continu-
Steam Steam ous membrane filtration processes
CIP
contain multiple stages. This is ad-
solution Water Water vantageous because, for many ap-
plications, flux declines with increas-
CIP
tank ing concentration of the retained
species. Since each stage operates
CIP: clean in place PIC: pressure indicator-controller
FI: flow indicator PSH: high pressure switch Retentate at the flux corresponding to the con-
FIC: flow indicator-controller RC: ratio controller
FIT: flow indicator-transmitter T: steam trap centration of the retentate leaving
PI: pressure indicator TIC: temperature indicator-controller
Diafiltration
that stage, the overall flux is higher
water with multiple stages, and less mem-
FIGURE 14. This example of a flowsheet for a three-stage, continuous crossflow membrane filtration pro- brane area is needed to reach the
cess includes diafiltration added to the third stage targeted productivity. A continuous
58 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM APRIL 2017
TABLE 5. COMMON CLEANING AGENTS nally, a high linear velocity is needed
Type of cleaner Example What it removes to impart sufficient shear at the
Caustic 12% NaOH, pH > 10 Proteins, microorganisms, biological debris membrane surface.
Detergent 0.1% Alconox Particulate matter, miscellaneous organics, Common cleaning agents are
Enzyme-based detergent 0.1% Tergazyme colloidal fouling listed in Table 5. Typically, the clean-
Sodium hypochlorite bleach 2001,000 ppm in water Cleans and sanitizes ing protocol calls for several such
Acid 12% sulfamic acid Inorganic scale
cleaners in sequence. For example,
the following steps may be used
membrane system with an infinite Membrane fouling and cleaning to clean a membrane handling a
number of stages requires the same Because cleaning time is non-pro- stream containing microorganisms
filtration area as a batch unit. How- ductive, productivity is maximized and proteins, such as a fermenta-
ever, addition of stages eventually re- when cleaning is infrequent, fast tion broth:
sults in a diminishing return, because and effective. To minimize the rate Water rinse
the cost of the additional circulation of fouling and specify an effective Detergent or caustic cleaning
pump, piping, controls and other cleaning protocol, fouling mecha- Water rinse
components exceeds the savings nisms must be well understood. Acid cleaning
obtained from the reduced filtration Fouling may be organic, inorganic Water rinse
area. In general, the area needed or microbiological in nature. Usually, A cleaning cycle such as this one
for five stages is within 20% of the the foulants are present as physical may require 3 to 4 hours. Except
batch area. buildup on the membrane surface, when using acids, cleaning is usually
The continuous membrane filtra- but they may also be adsorbed, or more effective at elevated tempera-
tion process shown in Figure 14 has small particulate matter may pene- ture. Acid cleaning is done at room
three stages, with diafiltration water trate the pores. Chemical reactions temperature because the inorganic
added to the third stage. With the on the surface may also contribute scale it is intended to remove (for ex-
control strategy employed, the fee- to fouling. ample, calcium salts) often exhibits
inverse temperature solubility.
Edited by Mary Page Bailey
There are a number of strategies for minimizing the
rate and extent of fouling. Prefiltration to remove large References
1. Gabelman, A., An Overview of Filtration, Chem. Eng.,
particulate matter, using a conventional filter or centrifuge, November 2015, pp. 5058.
is sometimes helpful. Similarly, fouling can sometimes be 2. inGabelman, A., Beyond Gravity: Centrifugal Separations
CPI Operations, Chem. Eng., July 2016, pp. 5259.
reduced by upstream removal of large molecules with a 3. Zydney, A.L., Colton, C.K., A Concentration Polarization
Model for the Filtrate Flux in Cross-flow Microfiltration
tendency to foul, using a UF membrane with a relatively of Particulate Suspensions, Chem. Eng. Comm. 47
(1986) 1-21.
high NMWC. 4. Singh, N., Cheryan, M., Process Design and Economic
Analysis of a Ceramic Membrane System for Microfil-
tration of Corn Starch Hydrolysate, J. Food Engr. 38
drate is set independently, while the There are a number of strategies (1998) 5767.
flowrate of final retentate is modu- for minimizing the rate and extent 5. Finn, A., Gabelman, A., Dewaxing, U.S. Patent
9,422,506, 2016.
lated by ratio control to maintain of fouling. Prefiltration to remove
the desired volume reduction. Ratio large particulate matter, using a
control is also used to regulate the conventional filter or centrifuge, is Author
flow of diafiltration water, based on sometimes helpful. Similarly, fouling Alan Gabelman is president of
the retentate flowrate. Each stage can sometimes be reduced by up- Gabelman Process Solutions, LLC
(6548 Meadowbrook Court, West
has provisions for temperature con- stream removal of large molecules Chester, OH 45069; Phone:
trol by heating or cooling, retentate with a tendency to foul, using a UF 513-919-6797; Email: alan.
back-pressure control and, to pro- membrane with a relatively high gabelman@gabelmanps.com;
Website: www.gabelmanps.com),
tect the module, a high-pressure NMWC. Upstream dilution of feed offering consulting services in pro-
switch that shuts off the circulation can reduce the rate of fouling, with cess engineering. Gabelmans 39
years of experience include nu-
pump when activated. The circula- the downside that a larger volume merous separation processes and other engineering
tion pumps are large, and the fee- needs to be filtered. Judicious se- unit operations, equipment selection, sizing and design,
drate to each stage is only a small lection of the membrane material is process simulation, P&ID development, and process
economics. He holds B.S., M.Ch.E. and Ph.D. degrees in
fraction of the circulation rate. Note crucial to minimize interactions with chemical engineering from Cornell University, the Uni-
that there are no controls regulating the process stream that may lead to versity of Delaware and the University of Cincinnati, re-
the flow of retentate from one stage fouling. In some cases, such inter- spectively. He is a licensed Professional Engineer, as
well as an adjunct instructor in chemical engineering at
to the next. These are not necessary actions can be reduced by chang- the University of Cincinnati. Gabelman has edited a book
because the system is self-adjusting ing processing conditions for on bioprocess flavor production, and he has authored
and stable. example, temperature or pH. Fi- several technical articles and a book chapter.
Gas-Phase Filtration
Media Properties:
What to Know
There are many physical properties that can impact the ultimate performance of
adsorbent media in gas-phase filtration applications
G
Chris Muller as-phase filtra- 1.0
Purafil, Inc. tion media speci-
Ce
fications may list 0.9 C0
= 0.9
numerous physi-
IN BRIEF cal parameters, such as 0.8
MEDIA SHAPE shape, moisture content, B = 0, n = 1, Bi =
MOISTURE CONTENT bulk density, impregnation
C/C 0
0.7
level, size and hardness
BULK DENSITY
(crush strength or abra-
0.6 Legend a Ce/C 0 Shape
ADSORPTION EFFICIENCY sion), as important deter- 1 0.9 planar
minants of final media per- 2 0.9 cylindrical
REMOVAL CAPACITY 3 0.9 spherical Ce
0.5 = 0.5
formance. The way these 1 0.5 planar C0
2 0.5 cylindrical
physical characteristics 3 0.5 spherical
can be controlled and opti- 0.4
105 104 103 102 101 100 101
mized during media manu-
facturing processes can FIGURE 1. The effects of shape factor (a) and concentration on adsorption are shown
ultimately determine media for both theoretical and numerical solutions [1]
performance when installed
into any number of end-use applications, Spherical-shaped media of uniform size pro-
including standalone pressurization or recir- vide the most uniform packing, because with
culation units to prevent corrosion in pulp both planar (flake) and cylinder shapes, the
and paper mills or petrochemical plants, or media could settle upon itself. With spheres,
in deep-bed scrubbers in petroleum refin- one could ideally pack them to take up al-
eries and wastewater treatment plants to most 75% of the available space. However,
contain a release of toxic chemicals. this would only occur with complete pack-
In order to optimize the packing density, ing of the particles in the media container.
whether the media is to be used in dis- It would not be achieved by simply pouring
posable modules or deep-bed scrubbers, them into the container rather, randomiza-
spherical media is generally preferred. It is tion effects will only yield a maximum pack-
also the most favorable shape with regard ing fraction of 6065%.
to the diffusion of contaminants into pellets. With flake and cylindrical shapes, the
This article discusses the physical param- packing density from random packing meth-
eters of media shape, moisture content and ods, such as pouring without tamping or
bulk density specifically as they relate to vibrating, would result in a packing fraction
overall media performance, with some gen- similar to that of spherical media. However,
eral discussion of related parameters. over time, both of these media shapes can
stack upon themselves along their planar
Media shape axes, resulting in a higher packing fraction
The ability of particles to fill space by packing and settling of the media. This leads to by-
together is obviously related to their shape. pass and a reduction in performance of the
60 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM APRIL 2017
air-cleaning system. 0.6 FIGURE 2. Different adsorbent
Spherical shapes allow more ac- geometries are compared for
the same adsorption process.
cess to the external surface of the Here, coverage indicates the
0.5
particle, which is important in ad- fraction of adsorption sites of
sorption and in taking advantage of the surface of the media un-
Sphere available versus the number of
the large internal surface area. When 0.4 Cylinder
1 vacant sites still available for
planar or cylindrical media line up adsorption [2]
Coverage
or stack upon themselves, this effec- 0.3
2
tively blocks access to the external
surfaces in contact with each other.
Proper packing of spherical media 0.2
limits the surface area affected by
particle-to-particle contact and as- 0.1 3
sures access to the maximum num- Plane
ber of adsorption sites.
0.0
Adsorption is usually described
0 1,000 2,000 3,000 4,000
through isotherms the amount Time, s
of adsorbate (contaminants) on the
adsorbent (media) as a function tion (Ce) and initial concentration (C0), to preferentially adsorb water from
of its pressure or concentration at all in kg/m3. Other pertinent terms the air, which occupies adsorptive
constant temperature. The quantity in Figure 1 are the Freundlich coef- sites and reduces the efficiency and
adsorbed is nearly always normal- ficient (n), the dimensionless time () capacity of the carbon. The water
ized by the mass of the adsorbent and the dimensionless Biot number adsorption isotherm for activated
to allow comparison of different ma- (Bi). Figure 1 shows that the rate of carbon (Figure 3) shows that as long
terials. There are basically two well- adsorption will increase as the ad- as the relative humidity (RH) of the
established types of adsorption iso- sorbents shape factor (a) increases airstream remains below 5055%,
therms: the Langmuir and Freundlich in all cases, indicating that there is the carbon performance should not
adsorption isotherms. a minimum of surface energy for be affected. The carbon will equili-
Among numerous studies on ad- the sphere among the three shapes brate with the moisture content of
sorption dynamics of adsorbent of adsorbents. the air. However, this can produce
media, little has been reported on the Figure 2 [2] shows another rep- periods of much lower performance
effect of shape. One study compared resentation of the effect of differ- for a great number of contaminants.
adsorption dynamic processes for ent media geometries (shapes) on This is especially so when the car-
three adsorbent shapes: spherical, adsorption rate. Additional graphs bon is used to clean outdoor air.
planar and cylindrical. The results of could be provided to show the re- Some engineered media can op-
a comparison of both Langmuir and lationships between the rates of erate in a specified RH range of
Freundlich adsorption isotherms and adsorption (or removal) and other 595%, although it is recommended
kinetics showed that the rate of ad- physical parameters, but each has to operate in the range of 2080%
sorption will increase as the shape the same basic shape. The spheri- for optimum performance. Operation
changes from planar to cylindrical cal media is always to the left of the at the extremes of the RH range (for
to spherical, indicating that there cylindrical media, indicating a faster instance, <20% or >80%) can cause
is a minimum of surface energy for adsorption rate. a drop-off in performance due to
the sphere among the three media The real power of the Langmuir the following:
shapes. In other words, the spherical and Freundlich adsorption models is 1. The media drying out, which
geometry is the most favorable for in providing a reference framework causes the chemical impregnant
adsorption, and the planar geometry within which one is able to compare to come out of solution and not be
is the most unfavorable. the adsorption rates of spherical, cy- available for reaction
There are no simple representa- lindrical and planar geometries in a 2. The media becoming soft with
tions of the Langmuir and Freundlich relative scale. Figures 1 and 2 show too much water. Although a soft
adsorption models that can easily ex- this very well. media still retains full functionality
plain the changes in adsorption rates (and even works better in some
between spherical and cylindrical Moisture content applications), this can cause set-
media shapes. The easiest thing to Plain activated carbon used for air fil- tling of the media due to abrasion
do is to provide a graphic that shows tration typically has a moisture speci- loss, leading to bypass through
these differences. fication of 25 wt.%, and as long as the system
Figure 1 [1] compares theoretical the moisture content remains below
and numerical solutions for the rate 810 wt.%, the performance is rela- Bulk density
of adsorption in terms of concentra- tively unaffected. Above a moisture Practically all granular adsorbent or
tion in air (C), equilibrium concentra- content of 10 wt.%, carbon begins chemisorbent media are almost al-
30
air-cleaning system can remove per
unit volume. This provides a truer
comparison of one media to an-
20 other, because differences in bulk
density are taken into account.
Another helpful practice is to list
10
a medias capacity for a single con-
taminant as a minimum value, be-
cause the specific conditions under
which the media would be used
0 cannot be assured. This provides
0 2 40
RH, %
60 80 100 assurance that the media will be
able to remove a certain amount
FIGURE 3. This water adsorption isotherm for activated carbon shows the effect of relative humidity (RH) of contaminants before it has to be
on the adsorption performance replaced. This also allows for the
provision of media life estimates
through the length of the cylinder. cylinder length-to-diameter ratio that do not exceed those experi-
If the cylinders length-to-diameter exceeds 1.2. Many extruded media enced under actual use conditions.
ratio approaches 1, the rate of diffu- have an average length-to-diame- By determining removal capacities
sion approximates that of a sphere, ter ratio of 1.75, based on numer- against individual contaminants
which favors the more efficient ous sample analyses. and by specifying minimum values,
radial diffusion. users can properly account for the
With cylinder-shaped particles, Removal capacity actions of other contaminants that
the random nature of a packed bed To reiterate the statement from might be present in the airsteam
causes both the radial and longitu- above, gas-phase air cleaning against the media.
dinal axes to present themselves. systems using granular adsorbent Edited by Mary Page Bailey
When airflow is hitting the end of media are filled by volume and not
the cylinder, slower longitudinal dif- by weight. Therefore, one needs References
fusion is the result. With increasing to look at the removal capacity of 1. Wang, Z., Effect of adsorbent shape on adsorption dy-
cylinder length, the particles tend a particular media in terms of how namics in a batch adsorber, Chemical Engineering Sci-
ence, 54(23), pp. 5,7875,790, 1999.
to line up along their length. This much contaminant material a given
2. Kankare, J. and Vinokurov, I.A., Kinetics of Langmuirian
can have two results. If the ends volume of media can remove be- Adsorption onto Planar, Spherical, and Cylindrical Sur-
of the cylinders are perpendicu- fore it becomes spent and needs faces, Langmuir, 15, pp. 5,5915,599, 1999.
lar to the air flow, longitudinal dif- to be replaced. 3. Knaebel, K.S., Adsorbent Selection, Adsorption Re-
fusion predominates. If the media Media manufacturers may report search, Inc. Dublin, Ohio, www.adsorption.com/
publications/adsorbentsel1b.pdf.
particles are lined up along their a volumetric removal capacity or 4. Crittenden, B. D. and Thomas, W.J., Adsorption Tech-
length, radial diffusion dominates. as a percent by weight. These val- nology & Design, Butterworth-Heinemann, Woburn,
However, this media configuration ues are determined according to Mass., 1998.
results in a high packing density, the test procedures described in
which reduces the void volume the ASTM International Standard D Author
around the media, increasing the 6646-01, Standard Test Method Chris Muller is the technical di-
pressure drop, and decreasing the for Determination of the Accelerated rector for Purafil, Inc. (2654
Weaver Way, Doraville, GA 30340;
rate of adsorption. Hydrogen Sulfide Breakthrough Email: cmuller@purafil.com), a
Spherical media provides for Capacity of Granular and Pellet- manufacturer of gas-phase air-fil-
more efficient adsorption due to the ized Activated Carbon. Although tration media, filters, equipment
and air monitoring instrumenta-
uniform radial diffusion of contami- the title may suggest that this test tion. He is an expert on environ-
nant gases. The cylindrical shape method has limited use, it is read- mental air quality and gas-phase
air filtration, and has helped de-
of extruded media involves both ra- ily applicable for many different velop many standards on the topic of air filtration. He is
dial and the less efficient longitudi- media types against a wide variety an ASHRAE (American Society of Heating, Refrigerating
nal diffusion. Adsorption efficiency of contaminants. and Air-Conditioning Engineers) Distinguished Lecturer
who has presented over 75 seminars. Muller has written
is significantly reduced when the Breakthrough capacity testing in- over 150 peer-reviewed papers and articles.
C
ooling towers are an impor- stream as the hot water inlet
tant unit operation in chem- stream flows down from the
top of the cooling tower and
ical process industries (CPI) the air stream flows upward Water Tw, out
Cooling-water supply
in = 1.148 kg/m3
design purposes, the worst sce-
nario that is, the summer season Lout = 7,368,000 kg/h
tout = 33oC
wet-bulb temperature needs to 1
be considered. Makeup water Cooling-water flow to
Range (T). The range is the differ- exchanger
Lm = 165,000 kg/h
tm = 33oC Heat load
ence between the water tempera- 2 Q = 105 MW
tures at the inlet and the outlet of the Pump flow Cold blowdown
cooling tower (tin tout). In this case, Hot blowdown
Lp = 7,533,000 kg/h Lp = 33,000 kg/h
the range is 12C. The range does tp = 33 oC tp = 33 oC Lb = 0 kg/h
tin = 45 oC
not represent the cooling tower ca-
pability; rather, the range is based on FIGURE 2. This schematic diagram depicts the parameters of the case study cooling tower system.
the cooling-water circulation flowrate Note: All three cells and three fans are lumped together and shown as a single unit
(Lin), and the sum of the heat loads
taken from the heat exchangers in Use Equation (3) to apply a mass
the process unit (Q), and it is not re- balance for the entire section of (5)
lated to the size or capability of the tower. As shown in Equation (3), the
cooling tower. On the other hand, an amount of water evaporated (eL) in
increase in range will cause an in- the down-pouring liquid is the dif- Solving both mass and heat bal-
crease in approach, if all other con- ference between the inlet liquid flow ance equations [Equations (3) and
ditions are not changed. The range (Lin) and the sum of the outlet liquid (5)] simultaneously, the evaporation
is shown in Equation (1): flow (Lout) and the drift loss (dL). It is
equal to the difference of moisture
content of air across the tower. NOMENCLATURE
(1)
cw = Specific heat of water, kJ/kgK
dL = Drift loss, kg/h
Cooling tower efficiency (). The (3)
eL = Evaporation loss, kg/h
cooling tower efficiency is the ratio of
G = Air flowrate (wet), kg of air/h
actual cooling (range) to the theoreti- Where:
G' = Air flowrate (dry), kg of dry air/h
cally possible maximum cooling (that G' = the quantity of dry air flow
h = Water enthalpy, kJ/kg
is, when the approach is zero), as (which remains the same at the inlet
H = Moist air enthalpy, kJ/kg
shown in Equation (2): and outlet air streams), kg of dry air
L = Liquid flowrate, kg/h
Y = absolute humidity, kg water/kg
OL = Other losses (seal leak, pipe leaking,
dry air/h
and so on) in the system, kg/h
(2) The subscripts in and out refer to the
Q = Heat load, kW
entry and exit locations.
t = Water temperature, C
Theoretically, an approach of The overall energy balance is given
T = Air temperature, C
zero means the tower is 100% ef- by Equation (4):
Y = Air humidity, kg water/kg of dry air
ficient. Industrial cooling towers = Moist air density, kg/m3
typically have an approach tem- o = Latent heat of vaporization of water,
perature between 4 and 8.5C, (4) kJ/kg
and an efficiency between 70 and = Cooling tower efficiency, %
75% [2]; in this case, the efficiency Where: T = Range, C
is 75%. h = the liquid enthalpy, kJ/kg water Subscripts
H = the moist air enthalpy, kJ/kg d = Drift water
Evaporation loss and air needs dry air b = Blowdown
Method 1. The evaporation loss Substituting Lout from Equation (3) in = Inlet location
and air flow requirement through the into Equation (4), and assuming the m = Makeup water
tower can be evaluated by solving enthalpy of the drift water hd is hout, out = Outlet location
the mass and energy balance equa- and simplifying Equation (4), one p = Pump
tions simultaneously. gets Equation (5): w = Wet-bulb temperature
HA
(6)
C YA
A
From Equation (6), eL is calculated
E D YD as 132,000 kg/h. It is to be noted
that in this method, the dry air flow
Sensible heat (G') is not required. Once eL is evalu-
transfer ated, G' is estimated from the mass
balance equation [(Equation (3)]. The
Dry-bulb temperature, oC
split of latent heat transfer and sen-
FIGURE 3. In this psychrometric chart, the relevant process condition from the case history is marked as sible air heating in this case is about
vector AB 85% and 15%, respectively.
loss (eL) and the dry-air require- the inlet air. But in the case of DB, Makeup water and blowdown
ment (G') are estimated as 132,000 the dry-bulb temperature of air is Makeup water (Lm) is added to the
kg/h and G' = 4,699,850 kg dry decreased and thus the air is cooled sump to compensate for the water
air/h, respectively. at the exit. In both cases, the wet- losses in the circuit. The water losses
Method 2. Depending on the tem- bulb temperature of the exit air will include evaporation loss (eL), drift
perature of the inlet air (whether it always be increased compared with loss (dL), blowdown (Lb), and other
is hot or cold), the air can be either that of the inlet air. So, the water leakage losses (OL) in the system,
heated or cooled as it travels along flowing through the cooling tower such as losses from the pump seal,
the height of a cooling tower. In the can be cooled by unsaturated air, ir- piping leak, washdown water and fil-
psychrometric chart shown inFig- respective of whether the air is hot ter backwash.
ure 3, the entering condition of the or cold.
air is denoted by point A, and the In this case study, from the field (7)
exit air (which is completely satu- measurements of DBT and WBT,
rated with water) is denoted by the psychrometric properties, such Drift loss. Small droplets that are
point B. The enthalpy difference of as absolute humidity, saturation hu- entrained by the upward-flowing air
dry air is (HAHB). The vector AB midity and moist air enthalpy for the stream are collected in a mist elimi-
is the sum of the two components. inlet air and the outlet air, could be nator, where they accumulate to
The horizontal component AC rep- evaluated. The inlet air is marked as form larger drops that are eventually
resents the sensible heating of air, point A, and the outlet air is marked returned to the fill. In general, very
and the vertical component CB is as point B in the psychrometric little water in the form of droplets is
the latent heating of air. In a cool- chart. Another hypothetical point C carried along with the air, but those
ing tower, it is also possible to is marked in such a way that it has a droplets do results in water loss,
cool the air if the inlet air condition dry-bulb temperature similar to point called drift loss or windage loss.
is at D [3]. At point D, the air is hot B and absolute humidity similar to This drift water typically contains dis-
and dry, when compared to the air point A. It must be noted that the solved solids and may cause stain,
at point A. point C is a hypothetical and does corrosion or damage to nearby
The component DE is the sensible not correspond to any location in the buildings and structures. Drift loss is
air cooling, and the component EB is cooling tower; the point C is marked usually about 0.10.3% of the circu-
the latent heating of air. The net heat on the chart to see the horizontal lation water rate (Lin).
received by the air is the difference and vertical component of vector To compensate for the evapora-
between the latent air heating and AB. Moist air enthalpy for point C is tion loss and drift loss, additional
the sensible air cooling. calculated. makeup water is added. Since the
In the case of the AB process, the The total heat gained by the air makeup water typically contains dis-
dry-bulb temperature of the air is (HBHA) has two components: the solved solids, these solids are typi-
increased at the exit that is, the latent heat transfer (HBHC), and the cally left behind in the sump water
exit air becomes hot compared to sensible heat transfer (HCHA). The as the water evaporates in the cool-
66 CHEMICAL ENGINEERING WWW.CHEMENGONLINE.COM APRIL 2017
350,000
ing tower. Meanwhile, since the
cooling water is a very effective air Makeup water requirements, kg/h
scrubber, dust and debris present in
300,000
the up-flowing air is washed out by
down-pouring water and collects in
the sump. As solids accumulate in
250,000
the sump, they increase the poten-
tial for scale corrosion and biological
fouling in the cooling-water circuit.
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Send Advertisements Diane Burleson
and Box replies to: Chemical Engineering, 11000 Richmond Ave, Houston, TX 77042
E-mail: dburleson@chemengonline.com Tel: 512-337-7890
(1957-59 = 100) Jan. '17 Dec. '16 Jan. '16 Annual Index:
Prelim. Final Final
2009 = 521.9 600
CE Index ______________________________________________ 553.0 550.9 536.4
Equipment ____________________________________________ 664.1 661.0 640.5 2010 = 550.8
Heat exchangers & tanks _________________________________ 578.3 573.7 551.7
2011 = 585.7 575
Process machinery _____________________________________ 668.6 667.9 649.3
Pipe, valves & fittings ____________________________________ 835.2 833.9 795.0 2012 = 584.6
Process instruments ____________________________________ 398.5 396.9 378.9 2013 = 567.3 550
Pumps & compressors ___________________________________ 971.3 973.5 979.1
Electrical equipment ____________________________________ 512.6 512.1 509.0 2014 = 576.1
Structural supports & misc ________________________________ 722.4 713.9 701.9 2015 = 556.8 525
Construction labor _______________________________________ 324.0 324.4 319.6
Buildings _____________________________________________ 550.0 547.0 537.7 2016 = 541.7
Engineering & supervision _________________________________ 313.9 313.6 316.6 500
J F M A M J J A S O N D
Starting with the April 2007 Final numbers, several of the data series for labor and compressors have been converted to
accommodate series IDs that were discontinued by the U.S. Bureau of Labor Statistics
CPI OUTPUT INDEX (2000 = 100) CPI OUTPUT VALUE ($ BILLIONS) CPI OPERATING RATE (%)
110 2300 80
105
2200 78
100
2100
95 76
2000
90
74
1900
85
72
80 1800
75 1700 70
J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D
*Due to discontinuance, the Index of Industrial Activity has been replaced by the Industrial Production in Manufacturing index from the U.S. Federal Reserve Board.
For the current months CPI output index values, the base year was changed from 2000 to 2012
Current business indicators provided by Global Insight, Inc., Lexington, Mass.
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